SUNBAKE BOERSTRA BAKERY TOUR

1. SUNBAKE BOERSTRA BAKERY TOUR 100 Years of Quality and Service in every product. The Best Bake Under the Sun

2. Sunbake Boerstra has all the required flour delivered in bulk tankers of +/- 30 ton per tanker. All our flour comes from our mill in Pta West. The flour is stored in silo’s that can hold 65 Ton each.

3. The flour is pumped by means of air blowers to the holding bins in the bakery. This is the ingredient store room where raw materials are stored for future use. Ingredients are sent from here to the mixing room where they are carefully weighed based on a specific recipe.

4. This is the mixing room where the ingredients are weighed to the specific recipe required by production. The scaled ingredients called premix are put into bins and sent to production. The bins are color coded for different recipes. Shown are premixes for white bread.

5. This is the liquid yeast plant which allows the yeast to be pumped into the mixers allowing for accurate dosage and stock control. The dry ingredients are put into the mixer by hand while the flour, water and liquid yeast are added automatically by the Tweedy mixer control system as per the recipe that the baker is using at the time.

6. The ingredients once they have been placed in the mixer bowl are mixed together to form a dough. The Tweedy mixers pictured here can have 50 different recipes in the automatic memory Pictured here is the mixer after it has tipped the dough into the high tip bowl and is returning to the upright position ready for the next mix.

7. The high tip will drop the dough into the top of the divider which cuts the dough into small individual pieces of a given weight. The dough pieces are then sent to a machine called a rounder seen in the background. The machine seen here is the rounder which rounds up the dough piece. The rounded dough piece is then sent to the intermediate proofer.

8. The dough piece sits in the intermediate proofer for about 10 minutes to allow the dough to rest after all the stress it has endured this far in the process. The intermediate proofer is a series of conveyors which transfers the dough pieces to the moulder.

9. The dough balls are sent to the moulder which is a series of rollers that flattens the dough piece, much like a pizza crust. At the front of the moulder is a curling chain which flips the end of the flat dough piece up and rolls it into a sausage the length of the pan.

10. The dough piece is dropped into the pan and sent onto the final proofer. After the dough piece is panned this machine detects if there has been two dough pieces put into one pan and rejects the pan before it goes into the final proofer.

11. Pictured below are the pans entering the final proofer and the inside of the final proofer. In the final proofer the dough piece is kept at a constant humidity and temperature to ensure that it is ideal for the dough piece to rise at a uniform rate. This usually takes about an hour. The temperature is kept at 42 degrees and the humidity is set at 62% Pans entering the final proofer The inside of the final proofer.

12. Shown here are pans being loaded into the oven. The oven loads five pans at a time automatically. Bakeries use many different types of ovens for baking bread. This is a side view of our tunnel oven which has six temperature zones that can be adjusted independently in order to get the ideal bake based on the type of bread being baked. Our oven has a capacity of 8000 loaves per hour.

13. After the dough is baked, usually between 20 and 30 minutes depending on the type of loaf, it exits the oven to be removed from the pans by the depanner. This is the back of our depanning machine showing the bread exiting the depanner. The depanner removes the bread from the pans by means of vacuum.

14. The depanner is a dual purpose machine as it also removes the lid from the pans if sandwich loaves are baked. This is done automatically and returns the lid to the lid store. Shown here are the lid and pan stores that feed the plant with pans and lids automatically as required.

15. From the depanner the bread goes onto a conveyor which takes the bread into a cooling room that is humidity and temperature controlled. The bread is cooled down to about 30 degrees ready for slicing. It takes about 70 minutes to cool the bread. Shown here is the inside of the cooling room with bread on the conveyor. The cooled bread is then sent to the slicer. This machine is made up of a series of blades which slice the solid loaf into individual slices. These slice sizes can be changed to customer requirements ranging from 11mm to 15mm.

16. Directly after the slicer the bagging machine takes the loaf and automatically places the sliced loaf into the bag. Shown here are the loaves that have already been placed in the bag exiting the slicer. The bagged and sliced loaf is then passed through an automatic bag sealer which puts a sealing clip with the date and production code on the clip onto the bag.

17. The loaf now sliced, bagged and sealed with the appropriate date and information on is then taken to this machine which packs the bread into bread crates that are then sent to the finished goods store.

18. This is the finished goods store where the bread is checked and sorted into loads for each of our delivery vehicles ready for delivery.

19. This is the pride of our modern fleet of 62 vehicles being loaded with product from our rolls finished goods store.

20. The History of Boerstra Bakery. • Boerstra Bakery was originally started by Colonel George Boerstra more than a century ago in Pretoria close to Church Square. The bakery remained a family business until it was bought by Fedfoods in 1992. Fedfoods has changed and the industry has changed but everybody that works at Boerstra Bakery feels a special affinity to our heritage. • Boerstra Bakery now part of the Foodcorp Group of companies has an 8000 per hour state of the art bread plant, as well as one of the most modern roll plants in South Africa capable of baking 24000 pieces an hour. • At Boerstra bakery we strive to maintain the supply of excellent quality and value for money products which is part of Boerstra’s heritage.

21. SUNBAKE Long Term Vision Sunbake will be a globally competitive player in the South African baking industry with operations strategically positioned to access key growth markets. We will offer high quality morning goods and bread products to the wholesale and retail markets through a combination of our own, outsourced and agent distribution channels. The above products will be developed and manufactured in highly mechanized and automated production facilities, with non core activities being outsourced, thereby pursuing the highest standards of efficiency and effectiveness and a service that meets customer needs in a cost effective manner.

22. SUNBAKEMISSION To be the lowest cost producer and most effective and efficient distributor of consistent quality bread, rolls and buns in selected regions within the boundaries of South Africa.