A new blending system from Buhler for making flour confectionery goods and instant bread mixes for bakers and households allows the Finnish company Fazer Bakeries Ltd. to conquer new markets.
The Finnish company Fazer Bakeries Ltd is one of the most important large–scale bakeries in the Baltic Sea region. In the 21 Fazer operations in Finland, Sweden, Lithuania, Estonia, Latvia, and Russia, 5,500 employees produce bread each day for a market numbering about 140 million people. Alone in Finland, Fazer holds a share of 30 percent of the bread market.
Premix system
One of these bread factories is located in a forest near Lahti in sight of the internationally known ski jump. Beside eight bread lines, the Fazer operation in Lahti also includes a milling system for producing various flours for the Fazer bakeries. Since the autumn of 2004, Fazer has been operating an additional production unit in Lahti: After a 14–month period of planning and construction, the essentially automated and state–of–the–art mixing system for flour confectionary goods plus premixes and ready mixes for bread went into production. With this premix system, Fazer Mills & Mixes Ltd has developed a new market, for in addition to its own operations, the company will also supply caterers, small bakeries, and wholesalers with premixes and ready mixes for various types of bread. For Fazer, the company in Lahti is a platform for unlocking new markets.
Proven partnership
The contract for the new system was awarded to Buhler. Fazer and Buhler have long–standing ties as partners in the bakery business. Buhler bakery lines demonstrate their high performance day in, day out in Fazer companies in Finland, Sweden, and Russia. But there were two other very important reasons for awarding the contract to Buhler: On the one hand, Buhler proved in a number of tests conducted in the laboratory blending system in Uzwil that the quality requirements of Fazer can be satisfied at all times. On the other hand, Buhler offered the customer "one–stop shopping" for the entire plant. In addition to an excellent mixing quality, the new premix system also had to be particularly fast and easy
to clean because of frequent changes in customer orders.
Second mixer
Design and engineering work on the new Fazer premix system started in the summer of 2003 in close collaboration with the customer. The plant was to replace a small mixer with which Fazer had "tested the market". In this phase, it was found that the installation of a second mixer would boost the flexibility of the system, allowing continuously changing third–party products to be mixed. The new premix system enables highly homogeneous mixes to be produced within a very short time.
This requires careful preparation of the ingredients before actual mixing takes place in the two paddle– and chopper–type mixers. The space available for housing the new Buhler system measured about 8,800 cubic meters on a surface area of 400 square meters. It took ten months for the Buhler specialists to design and engineer the facility. The actual construction time itself was four months. The premix system, Finland`s first, went into service in the autumn of 2004.
Output increased by a factor of ten
Each mixer is capable of processing four to ten batches within 60 minutes. Fazer operates the new ready mix system in two work shifts. The complete plant has a high level of automation. This enables Fazer Mills and Mixes Ltd. to produce almost ten times more ready mixes with almost the same manpower than with the smaller predecessor system. The highly motivated personnel operating the new plant received training on site during start–up as well as in two one–week sessions at the Training Center of Buhler in Uzwil.
The mixing process is highly complex, involving a number of mixing stages. In the process, about 15 ingredients per product formula are automatically weighed and transferred to the mixer at just the right moment. The finished products from Fazer have a flour content till 95 percent. Other ingredients include sugar, starches, fat, and specific additives. To this are added other ingredients such as sugar, starches, fat, seeds, and specific additives, either automatically or by hand. After mixing, the product is packed automatically in Big Bags or standard–size bags of 10 and 25 kilograms.
With its new premix system for the production of flour confectionery goods and instant bread mixes, Fazer Bakeries Ltd has a powerful instrument for supplying its own large–scale bakeries with semi finished products to open up new markets.
Fazer Group
Fazer Bakeries Ltd with its 5,500 employees generates sales (turnover) of 340 million euros. The company is only a small part of the entire Fazer Group. In addition to the listed "Oy Karl Fazer AB" company, which evolved from a Franco-Russian confectionery that the Swiss immigrant Karl Fazer set up in 1891, the Group also includes Oy Fazer Amica and Oy Candyking beside its bakery operations. Oy Fazer Amica is a caterer to 1,400 restaurants in six countries with 7,300 employees who produce some 300,000 meals a day. In 2004, it achieved sales of 460 million euros. Candyking is
the Nordic market leader in confectionery and candy.
Its 700 employees generate annual sales of 115 million euros.
For more information, please contact Mr. Hansjörg Haldner, Bakery Project Manager at:
Buhler News
Opening up new markets
A new blending system from Buhler for making flour confectionery goods and instant bread mixes for bakers and households allows the Finnish company Fazer Bakeries Ltd. to conquer new markets.
The Finnish company Fazer Bakeries Ltd is one of the most important large–scale bakeries in the Baltic Sea region. In the 21 Fazer operations in Finland, Sweden, Lithuania, Estonia, Latvia, and Russia, 5,500 employees produce bread each day for a market numbering about 140 million people. Alone in Finland, Fazer holds a share of 30 percent of the bread market.
Premix system
One of these bread factories is located in a forest near Lahti in sight of the internationally known ski jump. Beside eight bread lines, the Fazer operation in Lahti also includes a milling system for producing various flours for the Fazer bakeries. Since the autumn of 2004, Fazer has been operating an additional production unit in Lahti: After a 14–month period of planning and construction, the essentially automated and state–of–the–art mixing system for flour confectionary goods plus premixes and ready mixes for bread went into production. With this premix system, Fazer Mills & Mixes Ltd has developed a new market, for in addition to its own operations, the company will also supply caterers, small bakeries, and wholesalers with premixes and ready mixes for various types of bread. For Fazer, the company in Lahti is a platform for unlocking new markets.
Proven partnership
The contract for the new system was awarded to Buhler. Fazer and Buhler have long–standing ties as partners in the bakery business. Buhler bakery lines demonstrate their high performance day in, day out in Fazer companies in Finland, Sweden, and Russia. But there were two other very important reasons for awarding the contract to Buhler: On the one hand, Buhler proved in a number of tests conducted in the laboratory blending system in Uzwil that the quality requirements of Fazer can be satisfied at all times. On the other hand, Buhler offered the customer "one–stop shopping" for the entire plant. In addition to an excellent mixing quality, the new premix system also had to be particularly fast and easy
to clean because of frequent changes in customer orders.
Second mixer
Design and engineering work on the new Fazer premix system started in the summer of 2003 in close collaboration with the customer. The plant was to replace a small mixer with which Fazer had "tested the market". In this phase, it was found that the installation of a second mixer would boost the flexibility of the system, allowing continuously changing third–party products to be mixed. The new premix system enables highly homogeneous mixes to be produced within a very short time.
This requires careful preparation of the ingredients before actual mixing takes place in the two paddle– and chopper–type mixers. The space available for housing the new Buhler system measured about 8,800 cubic meters on a surface area of 400 square meters. It took ten months for the Buhler specialists to design and engineer the facility. The actual construction time itself was four months. The premix system, Finland`s first, went into service in the autumn of 2004.
Output increased by a factor of ten
Each mixer is capable of processing four to ten batches within 60 minutes. Fazer operates the new ready mix system in two work shifts. The complete plant has a high level of automation. This enables Fazer Mills and Mixes Ltd. to produce almost ten times more ready mixes with almost the same manpower than with the smaller predecessor system. The highly motivated personnel operating the new plant received training on site during start–up as well as in two one–week sessions at the Training Center of Buhler in Uzwil.
The mixing process is highly complex, involving a number of mixing stages. In the process, about 15 ingredients per product formula are automatically weighed and transferred to the mixer at just the right moment. The finished products from Fazer have a flour content till 95 percent. Other ingredients include sugar, starches, fat, and specific additives. To this are added other ingredients such as sugar, starches, fat, seeds, and specific additives, either automatically or by hand. After mixing, the product is packed automatically in Big Bags or standard–size bags of 10 and 25 kilograms.
With its new premix system for the production of flour confectionery goods and instant bread mixes, Fazer Bakeries Ltd has a powerful instrument for supplying its own large–scale bakeries with semi finished products to open up new markets.
Fazer Group
Fazer Bakeries Ltd with its 5,500 employees generates sales (turnover) of 340 million euros. The company is only a small part of the entire Fazer Group. In addition to the listed "Oy Karl Fazer AB" company, which evolved from a Franco-Russian confectionery that the Swiss immigrant Karl Fazer set up in 1891, the Group also includes Oy Fazer Amica and Oy Candyking beside its bakery operations. Oy Fazer Amica is a caterer to 1,400 restaurants in six countries with 7,300 employees who produce some 300,000 meals a day. In 2004, it achieved sales of 460 million euros. Candyking is
the Nordic market leader in confectionery and candy.
Its 700 employees generate annual sales of 115 million euros.
For more information, please contact Mr. Hansjörg Haldner, Bakery Project Manager at:
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