Pies, Pie Machines & Pie Production

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All about Pies, Pie Machines & Pie Production

Making your pastry, and pie manufacturing a breeze. Ever thought that there has to be a better, simpler way of doing things, in particularly making pies?

There most certainly is. We believe in simplicity, working smarter and not harder. We have many years of experience in the aeronautical, automotive, optical and food industries to mention but a few, as well as extensive knowledge of pie manufacturing and all that is related. By combining our experiences and being dedicated in finding and creating solutions, we have been able to revolutionize the way pies are made forever.

Pie manufacturing tips & techniques

1. Stay alive. Probably one of the most important tips we can give you is how to control pastry shrinkage. Remember: pastry is a live entity; it possesses the ability to come alive at the right temperatures. To ensure control of your pastry's growth, add a bit of acidity. lemons_full Pure lemon juice or 100% bottled lemon juice is best. Natural white vinegar works well too. Or purchase a pastry relaxing agent to add to your pastry. Adding just the right amounts will not affect taste or texture, but will have a remarkable effect in reducing the level of shrinkage in your pastry.

The wetter pastry is, the easier it is to work with. But the more water you add, the more gluten is formed, which makes the pastry tough. The Solution? Substitute vodka for some of the water.
Eighty-proof vodka is essentially 40 percent ethanol and 60 percent water. As it happens, gluten cannot form in alcohol, which means that for every tablespoon of vodka one adds, only 60 percent of it contributes to gluten development. Alcohol doesn't completely vaporise in the oven, even with that being so your pastry will not have a boozy flavor.

2. Keep cool. Or cold. For the best results, and always for flaky pastry, refrigerate all ingredients prior to making your dough, even the flour.

3. Chill out. All liquids should be ice cold. The purpose of keeping temperatures down when creating a pastry is to prevent the pastry from "coming alive". The various ingredients start reacting with one another at higher temperatures (from around 16 to 18 degrees C). For instance, puff pastry will start losing its ability to "puff" and will also start becoming hard and tough. The same applies to short pastries, however, short pastry is by far less temperamental.

4. Take it easy. Mix your dough quickly with as little handling as possible. Do not overwork your dough as this could cause it to be tough.

5. Relax. Always let your dough relax in the refrigerator for a minimum of 30 - 60 minutes before using. Depending on pastry type, it is sometimes best to rest your pastry for a few hours, even overnight. Or you can block your lids or tops using Pie Designs' cold blocking system and leave them in the fridge for at least an hour (or overnight for best results). This is to help minimize shrinkage during baking. In pastry that has not been relaxed sufficiently, pies can shrink by as much as 20% in baking.

6. Start right. Start the production day by blocking your bases and using your lids that have already been blocked up and rested overnight. Or, to achieve optimum results, run two blockers, one for lids and one for bases.

7. Use the right stuff. Production is not just determined by equipment and staff. Seamless production is based on many factors which all have to be in place. Yes, equipment is the key. However, everything - from your bakery's layout to cleanliness and a clutter-free environment - plays a major role. For instance, your premises may be more efficient when your team works from right to left, or from left to right. Or you may have the option of both. It's all about working smarter, rather than harder. Every second counts.

8. Check it out. Analyze your production environment carefully. Take the time to watch your staff at work. Time their operations and calculate total production time to produce your product. Pay particular attention to the distances that staff members have to walk or move or stretch to complete a task. For example, assuming your finished product - ready to bake or freeze - is 5 meters away from the oven or fridge and it takes a team member 5 seconds to carry them that distance%u2026 If you make 5 000 pies per day, you're looking at a loss of about 5 minutes productivity each day, which equates to a loss of approximately 75 pies or more if you're using our system.

9. Waste less. This applies to absolutely every dedicated task your staff have to accomplish within a working day to produce your product. Remember that time is money. Staff members who chat while working, is not a bad situation; it could add to a happy environment. However, in extreme cases this will result in great productivity loss. Separate those staffers who tend to chat to much; dedicate them to tasks which are on opposite sides of your bakery. Every 3 seconds wasted (if you are using our pie machine system) is one less pie you'll produce.

10. Cut the clutter. Make sure your bakery is clutter-free. Avoid having staff walk around things to get to their goal or have to constantly move things around to accomplish their tasks. It not only wastes valuable time, but psychologically it messes with the mind. It will tire your staff even if it's something that you or they won't even be aware of. It will slow down your whole production chain and add to staff becoming discouraged. Make it an easy and pleasant environment for them in which to be productive. Possibly even add music to their environment, as this can lift spirits and will most definitely up production and maintain consistency.

11. Do it in bulk. By preparing your pie mixtures/fillings one day ahead of time, and blocking your lids the day before should you only use one cold blocking machine, you can ensure seamless production. If you use our quick fill mixture depositing system , you can bulk up on your fillings a few days before without any risk of your mixtures going off. This due to the unique storage concept we've incorporated in the systems design. This will ensure a dramatic production and profit increase.

12. Don't "speed bake". Optimum baking temperature for pies is around 180 to 200 degrees C, at a time of 20 to 25 minutes. We've seen how some increase temperature to shorten baking times. What happens is that your pastry dries out prematurely, causing it to become hard or tough. Yes, convection ovens do make a difference, particularly in providing a more even bake. Should you have a normal oven and find you're not getting an even bake, reduce your temperature and space your pies further apart for a better result.

Find out more visit - http://www.piedesigns.co.za/process-and-production-secrets.html

Pie Machines & Pie Production Simplicity

Pie Designs & Solutions

Pie production cannot get any simpler, cheaper or more profitable.

We have permanently eradicated the risks and dramatically reduced the costs of pie manufacturing for small, medium and large enterprises.

Our pie making machines, bakery equipment and innovative solutions eliminate tiresome labor reliant processes. No more water or egg washing of pastry surfaces prior to sealing. No more manually venting your sealed pies. And gone are all those time-consuming labor intensive in between pie making processes.

We are able to assist you in streamlining your process and profits ...

* by removing all the complexities in your pie manufacturing and production process,
* through innovations that entirely eliminate all the labor intensive aspects of pie production,
* by eliminating the high rate of common wastage associated with the process which was a traditional 'given' until till now,
* by massive reductions in your manufacturing costs, such as less flour, less electricity and more,
* by eliminating your product reject rate with pies that split open and leak while being baked,
* by ensuring your staff can't have a bad day and ruin your product,
* by ensuring short and long term growth of your enterprise in assisting you with the confidence to take on more business without the fear of non-delivery. Providing you with the confidence that your production is smooth and profitable, allowing you to focus on running your business more effectively,
* by ensuring customer confidence in having your pies and pastry products look great all the time,
* by providing you with high quality, genuinely affordable equipment as well as consultation solution based services such as production layout and manufacturing best practices,
* by caring about your success and being focused on minimizing your risks,
* by providing solutions that are simple and ergonomically friendly to use, making it easy for you and your staff,
* pie machines that producing high volumes of pies while providing extreme life at the lowest cost with maximum consistency and perfect duplicity,
* by supplying you with pie machines which are maintenance-free and won't put your production at risk and as such giving you peace of mind,
Pie Designs. Pie Machines and Pie Manufacturing
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Pastie or Pasty

Some Pie History

These are basically individual pies filled with meats and vegetables that are cooked together. The identifying feature of the Cornish pasty is really the pastry and it's crimping.

The solid ridge of pastry, hand crimped along the top of the pasty, was so designed that the miner or traveler could grasp the pastie for eating and then throw the crust away. By doing this, he did not run the risk of germs and contamination from dirty hands. The crusts weren't wasted though, as many miners were believers in ghosts or "knockers" that inhabited the mines, and left these crusts to keep the ghosts content. There is some truth to this rumor, because the early Cornish tin mines had large amounts of arsenic, by not eating the corner which the miners held, they kept themselves from consuming large amounts of arsenic.

One end of the pasty would usually contain a sweet filling which the wives would mark or initial so the miner wouldn't eat his dessert first, while the other end would contain meat and vegetables. The true Cornish way to eat a pasty is to hold it in your hands, and begin to eat it from the top down to the opposite end of the initialed part. That way its rightful owner could consume any left over portion later.

Pasties are one of the most ancient methods of cooking and of carrying cooked food. It is said that the early Irish Catholic Priests created them in order to transport food as they walked about the countryside preaching and aiding the people. The dish is mentioned in Shakespeare's Merry Wives of Windsor (1598).

The earliest known reference to the pasty contribute it to the Cornish. From 1150 to 1190, Chretien de Troyes, French poet, wrote several Arthurian romances for the Countess of Champagne. In one of them, Eric and Enide, it mentions pasties:

Next Guivret opened a chest and took out two pasties. "my friend," says he, "now try a little of these cold pasties And you shall drink wine mixed with water...." - Both Guivret and Eric came from various parts of what today is considered Cornwall.

Irish people that migrated to northern England took the art of pastie making with them. Soon every miner in northern England took pasties down into the mine for his noon lunch. Pasties were also called oggies by the miners of Cornwell, England. English sailors even took pastie making as far as the shores of Russia (known as piraski or piragies).

The Cornish people who immigrated to Michigan's Upper Peninsula in the United States in the middle of the 19th century to work in the mines made them. The miners reheated the pasties on shovels held over the candles worn on their hats. In Michigan, May 24th has been declared Michigan Pasty Day. In the Upper Peninsula of Michigan the pasty has gone from an ethnic food to a regional specialty.

High Altitude Baking

Why getting pastry righty is so difficult

Altitude. One of the BIG reasons Pastry is so difficult to get right.

Do your cookies crumble and your cakes collapse? It may not be your fault. If you live-and bake-2,500 feet or more above sea level, you get to blame everything on the altitude! Often more frustration than fun, baking at high altitude can be a challenge or a total disaster-but at least you are not alone. Professional and home bakers struggle with this in as many as 34 of the 50 United States, parts of Canada, Mexico, South America, and Europe, plus other mountainous regions around the globe. If you have never heard of these problems, you probably live at or near sea level, though you might have wondered why mountain dwellers around the world make flat breads (Mexican tortillas, for example). But ask anyone who has moved from Boston to Boulder how their cakes turn out and, if they are honest, they'll tell you the name of the best bakery in town.

The Science behind High Altitude Baking:

Wherever you cook or bake, results depend on many factors including food chemistry, atmospheric pressure, climate, and elevation. The higher you climb, the thinner the air and therefore, the lower the atmospheric pressure. Beginning 2,500 to 3,000 feet above sea level, altitude starts to affect all cooking, but especially baking, in three significant ways:

1. The higher the elevation, the lower the boiling point of water (212°F at sea level, 206.7°F at 3,000 feet, 203.2°F at 5,000 feet, 199°F at 7,000 feet, 194.7°F at 10,000 feet). When water boils at lower temperatures:

It takes longer for foods to cook in or over water.

Dense moist batter and dough take longer to completely bake in the center.

2. The higher the elevation, the faster moisture evaporates. When moisture evaporates quickly:
The ratio of liquid to solid changes, potentially weakening the overall structure of whatever you're baking.

Flavors tend to be less pronounced because there are fewer moisture molecules to carry aroma to the nose.

Baked goods dry out and go stale at an accelerated rate.

3. The higher the elevation, the faster leavening gases (air, carbon dioxide, and water vapor) expand. When leavening gases expand quickly:

Cakes may rise too far too fast-and will sink in the center or collapse when cooling.

Stiffly beaten egg whites expand quickly until they literally pop during baking, causing a cake to collapse as it cools.

Yeast breads can easily over-proof (rise too much).

Baking Basics:

Almost all recipes are developed for use at sea level and, when used at or above 2,500 to 3,000 feet in elevation they will require adjustments for optimal results. Baking above sea level can be tricky because one set of adjustments emphatically does not fit all situations; each recipe, altitude, and set of atmospheric conditions is unique. However, different kinds of baked goods do tend to follow certain patterns. Below, are general guidelines for baking cakes, pies, cookies, muffins, quick breads, and yeast breads at high altitude.

Cakes

The delicate formulas that make cakes rise and maintain texture are strongly affected by changes in elevation. Some rising problems crop up between 2,500 and 3,000 feet; above 5,000 feet, cakes typically rise during baking, but may fall or cave in; or they may have a heavy, coarse crumb. Batter may be strengthened by reducing sugar, or adding eggs, egg yolks, or slightly more flour. Acidity helps batter set quickly in the oven's heat, so replacing regular milk with buttermilk, sour cream, or yogurt can be helpful. Leavening is usually reduced, while flavoring agents are increased. Oven heat is sometimes increased 25°F or the temperature is kept moderate (350°F) but baking times increased. Boxed cake mixes often include high-altitude adjustments, but beware-they are designed to work up to about 6,000 feet only; above that, cakes crash. Fortunately, many boxed cake mixes can be fixed using the same methods as you would for cakes made from scratch.

Pies

One of the myths of high-altitude baking is that pies need no adjustment. That is not exactly true, though pies are easier to adjust than cakes. Pie crusts are often too dry and need slightly more liquid to become pliable (be careful: too much liquid can develop gluten and toughen crusts). Baking pie fillings all the way through takes longer than it would at sea level. Cover pies loosely with foil during part of the baking time to prevent the top crust from burning before the fruit beneath is completely cooked.

Cookies

Cookie recipes often work without changes up to about 7,000 feet, but they sometimes spread too much or get tough. Some cookie recipes require less sugar, leavening, or fat; others only need a little more liquid and flour (avoid too much flour, it can make them tough), and some need only a slight increase in oven heat (15°F to 25°F).

Muffins & Quick Breads

This category also includes scones, biscuits, and cornbread. For the correct rise at high altitude, baking powder or baking soda must be reduced slightly. Also, you get a better rise and quicker set with an acidic batter, so you can reduce some of the baking soda, which neutralizes acidity-don't omit all of it as some is needed for leavening. To strengthen batter and prevent collapse, sugar is reduced and flour increased. Extra liquid can be added (it is especially good to substitute buttermilk or yogurt for water or milk) to compensate for dry air and drier flour at altitude. Quick breads baked in loaf pans may crust over and start to brown on top before the batter underneath begins to set. To prevent this, sometimes it is helpful to cover the pan loosely with foil after half the baking time or to substitute a tube pan for a loaf pan. To get a better rise between 4,000 and 6,000 feet, increase oven temperature by 15°F to 25°F. At higher elevations, keep original heat and increase baking time slightly.

Yeast Breads

At high altitude, bread tends to rise much more rapidly than at sea level and changes in ingredients or technique are needed to slow down this action. Some bakers reduce their yeast slightly or use ice water instead of warm water, while others punch down their dough more often, then add extra rises or one overnight rise in the refrigerator. Beware of dough that has risen too much or "over-proofed" before baking; it may warp, droop, or collapse in the oven. To prevent over-proofing at high altitude, only allow dough to rise about a third-not double in bulk-before baking. Never omit salt: At high altitudes, salt is essential not only for flavor, but also to slow down the growth of yeast and the expansion of gases. To achieve good rise and a crisp crust at high altitude, begin baking bread with a pan of boiling water on the bottom of the oven, then remove the water for the final 15 minutes of baking.

Ingredients:

The previous section discusses the way several categories of baked goods react above sea level and what to do to eliminate problems. Below is an outline of what to expect from various ingredients at altitude and how to make adjustments for successful baking. Remember that every recipe is different and will often require several tries to get it just right for your elevation.

Liquids

Because liquid evaporates more quickly at altitude and mountain air can dry out flour, adding more liquid (two to four tablespoons, depending on the elevation) to a recipe is often very helpful.

Flour

Increasing the amount of flour (one to four tablespoons, depending on the elevation) in recipes can improve the structural strength of a batter. However, flour's protein content is the most important factor governing liquid-to-flour ratios: Bread flour absorbs more liquid than all-purpose flour, which in turn absorbs more than cake or pastry flour. At high altitude, all-purpose flour is preferred over cake or pastry flour because it is stronger, has more protein, and helps baked goods maintain their shape as they cool.

Leavening

Because of the rapid expansion of leavening gases, you usually need to decrease the amount of baking powder or baking soda as elevation increases (decrease each teaspoon of leavening by 1/8 to 2/3 teaspoon, depending on altitude). Whipped whole eggs are sometimes used as leavening; they should be slightly under-whipped at high altitude. Whipped egg whites are often used as leavening. A sea-level recipe may call for whites whipped to stiff peaks (air cells are fully expanded), but above 3,000 feet elevation egg whites must be whipped only until they form soft peaks, leaving room in the air cells so they can expand while baking and remain stable when cool.

Eggs

Eggs add liquid as well as fat and protein to baked goods. Occasionally you can adjust a sea-level cake recipe for altitude simply by adding one more large egg. The egg white contributes strength and the yolk contains a natural emulsifier that allows batter to hold extra sugar without weakening the overall structure. Yolks also contribute richness and tenderness, which can counteract the drying effects of baking at altitude.

Fats

Fat weakens the gluten in flour and thereby creates tender baked products; this is good at sea level, but at high altitude, when fats are concentrated because of moisture loss, excess fat can weaken cell structure too much. In very rich cakes and some cookies, you need to decrease fat by a tablespoon or two to maintain structural strength.

Sugar

Sugar also weakens the gluten in flour. Excess sugar (or other sweetener) can weaken a cake's structure and hasten its collapse. The fix: In many recipes, reduce the amount of sugar by one to four tablespoons as altitude increases.

Acidity

Acidic batters tend to set more quickly than others. In addition, acidic ingredients hold moisture in batter when reacting with baking soda.

Continued here http://www.piedesigns.co.za/hot-news-topics/high-altitude-baking.html

Pie Production. Costing and Calculations

The critical process of accurately costing every aspect of your pie making process

Click to Calculate your Profits

Get free, accurate costing analysis of your pie production by clicking on the image.

Costs vs Profits in pie production. Getting this right is critical to your business. Bakers often tend to forget to include important variables in their costings such as electricity, which could be detrimental to your bakery profits.

Your costs are influenced by many factors such as your raw materials, their quality & the wisdom in managing them, the effectiveness of your staff & the quality of their skills as well as their training. Your bakery equipment as well as the production processes themselves & how you set them out, also ones effectiveness in dealing with the variables that you're sure to encounter.

New Guestbook

  • kathysart Jan 25, 2012 @ 11:08 am | delete
    btw, you can delete the message from the guy who posted all that spam ya know. That same person did that to a couple of my lenses too.
  • Pie_Designs Jan 26, 2012 @ 1:09 am | delete
    Thank you very much:)
  • kathysart Jan 25, 2012 @ 11:07 am | delete
    How cool is this!? Love all your interesting facts. Angel blessed lens.

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