Into the future without loaves of bread

Modern loaves of bread are baked in bakeries, in food service, and at home (in bread machines, and ovens) and CO2 is released into the atmosphere when baking bread.

 1. Bread baking is the most energy-intensive process in the food industry. 

The baking time for a standard bread loaf weighing 800 grams is approximately 40 minutes. During the baking process, each loaf emits 200 grams of CO2 into the atmosphere and consumes 0.64 kWh of electrical energy.

При производстве  kWh электроэнергии выбрасывается в атмосферу примерно 0,86 фунтов СО2 (0.39 kg.).

 https://www.eia.gov/tools/faqs...

     Attempts to reduce greenhouse gas emissions in bakeries by upgrading equipment do not lead to tangible results.

     In the article "Turn Oven Sustainability into Bakery Profitability" it is written that тow there are only recommendations for the mass production of bread. - It is proposed to increase the length of the ovens or use heat recovery. This will save 4-6% of fuel.

https://www.bakingbusiness.com...

      Another way to reduce greenhouse gas emissions into the atmosphere is to replace gas stoves with electric ones (as part of a project in California). However, the authors of the project do not take into account the fact that the production of electricity for use in bakeries also releases a huge amount of greenhouse gases into the atmosphere.

https://www.bakingbusiness.com...

 2. A huge amount of bread and bread crusts is not eaten and is thrown away.

 [https://www.ecoandbeyond.co/articles/much-bread-waste-uk/];

More than 12.5 million tons of bread, rolls, croissants, and other baked goods go uneaten each year in the US. That wasted food could be worth $161 billion.

Before eating bread, the crust is often cut off from the slices and discarded.

3. Bread cannot be baked for every meal because of its long dough preparation and the long baking time. Although freshly baked bread is the most delicious and aromatic.

 4. As much as one would like to reduce the amount of bread in sandwiches and reduce the thickness of slices of bread in sandwiches - this cannot be done, because a slice of bread is not just a part of a sandwich, it is also a "container" for the filling of the sandwich. Slices of thinner bread are not used in sandwiches, because, firstly, thinner slices 3-5 mm thick cannot be cut - they crumple and crumble due to the soft crumb. Secondly, such thin slices in sandwiches will bend and the filling from such sandwiches will fall out. Therefore, slices of bread thinner than 7-10 are not cut and are not used in sandwiches. As a result, there is more bread in modern sandwiches than is necessary and a person gets extra calories while eating.

 5. Fresh herbs are not used when baking ordinary bread, because their taste and medicinal properties are destroyed due to the long baking time.

 6. We eat pieces of bread every day and consider it quite normal that the cut pieces crumble and, when eaten, contaminate the face, clothes, and surrounding areas with crumbs.

https://drive.google.com/file/...

It has always been this way: they bake a large portion of bread for a long time - a loaf and eat not the loaf, but slices cut from the loaf. In other words, a loaf of bread is an intermediate product. The final product is slices of bread.

       Our solution is to bake slice-thick loaves of bread rather than bake traditionally shaped loaves of bread.

The baking time for such thin loaves of bread is reduced by 5-7 times compared to the baking time for regular loaves of bread. (The loaves have the same weight). Energy consumption is reduced by 5-7 times. Greenhouse gas emissions are reduced by 5-7 times.

The cooling, freezing, and defrosting time is also reduced by 5-7 times. Environmental pollution from food waste from bread is significantly reduced.

       Why does thin bread bake several times faster than a loaf of bread?

The process of heating the dough in different parts of the dough occurs unevenly, at different speeds.

When baking, the surface of the dough heats up quickly, but the center of the dough heats up very slowly. The reason is that the dough has low thermal conductivity. Therefore, about three-quarters of the baking time of loaves of bread is spent heating the center portions of the dough portions. As a result, baking bread takes a lot of time and effort. A lot of greenhouse gases are released into the atmosphere.

      The shorter the distance from the surface of the dough to its center, the faster the center of the dough warms up and the faster the bread is baked.

Slices of bread cut from a loaf of bread have two completely identical and parallel sides.

        Let us recall that for all existing types of bread, the upper surface (crust) is always different from the lower surface (crust), since these surfaces have different baking conditions. When baking, the top surface of the dough is always in contact with hot air, and the bottom surface of the dough is always in contact with the hot horizontal surface on which the dough is placed.

      This project was made possible thanks to a solution that, for the first time, allows bread to be baked with the same top and bottom sides.

     It should be noted that CO2 emissions are reduced not only by reducing the baking time of the loaves of bread but also because thin breads do not have crusts. This means there will be no crusts cut off by consumers and discarded, which rot and release CO2.

 The thin film that forms after a few minutes of baking is as soft as the middle of the slice and prevents the bread slice from crumbling. By increasing the baking time, you can achieve a crust on thin bread that is similar to the crust on existing loaves of bread.

     Thin bread can be quickly baked for every meal. This reduces the emissions of stale bread slices and therefore also reduces CO2 generation.

We believe that the project should be successful because, in this project, the implementation of environmental requirements will be stimulated by market requirements.

     Thin loaves of bread suddenly revealed many new properties and capabilities that will be in demand by both consumers and bread producers.

Clients

1. Consumers of bread. Fast food lovers. Vegetarians. Children. They especially like the delicious, thin, crustless

bread that doesn't crumble or bend, and you can add a lot of different toppings. The bread for therapeutic nutrition.

2. Consumers and food service who want to bake thin bread at home in a few minutes.  Such a consumer needs household baking equipment and industrial devices, utensils, and tools. For quick baking, such a consumer also needs semi-finished products and dough frozen after proofing.

3. Bakeries. They need automatic lines and other equipment to bake thin bread quickly and reduce environmental pollution many times over.

Why consumers will buy thin bread?

1.  Our devices for the first time allow baked bread for a few minutes to eat with every dish. Convenient, simple, and fast. Freshly baked bread is much tastier and more aromatic than bread baked a few hours ago.

2. The slices of our bread are thinner than slices cut from a loaf. This allows you to eat less bread and get fewer calories at mealtimes.

3. New slices of bread do not crumble. The face, hands, and clothes of the consumer remain clean, there are no crumbs on them.

4. Due to the short baking time, thin bread does not have a crust. This means that there is no need to cut and discard the peel from the slices, as there is no peel on the slices. No need to throw away two heels of a loaf of bread. You can buy less bread.

 5. The sizes and shapes of the slices will be more varied than slices of bread in modern loaves.

 6. Packages will have varying numbers of thin slices. This will allow you to buy less bread and throw less of it.

 7. A new product - bread envelopes of different sizes. These will replace bread slices for making school sandwiches and provide convenience for tourists and those on the road.

Why consumers and bakeries will buy equipment and appliances for baking thin bread?

Bakeries.

 - energy costs are reduced;

- the number of employees is decreasing;

- not significant costs for the purchase of new equipment;

 - reduced emissions of greenhouse gases into the atmosphere;

- reduced production area;

- еquipment for baking thin bread will be much cheaper than the existing one;

- оverhead costs are reduced.

Another use for thin bread.

Thin bread solves all the problems associated with baking on spaceships. The surface of the baked thin bread in space is without crust and does not crumble. Thin bread can be baked quickly in sunny kitchens in large quantities.

It should be noted that the solutions found in the project and innovations became possible only because highly qualified specialists - physicists and mechanics - engineers and doctors of sciences - took up the development of the project. Each member of the team has a large amount of knowledge in various fields of science and technology. This combination allowed us to find unique solutions. Team members are relatives. They were able to use all their free time and enthusiasm to develop the project.

The stage of research and making fundamental decisions in the project has been passed.   The engineering stage begins - the development of industrial models of machines and devices is required. It is necessary to organize the development and production of equipment and its sale to bakeries, retail outlets, and consumers in different countries. 

To achieve these goals, the team must be significantly expanded.

The project developed a large number of MVPs, including devices, tools, and forms. These are tools and devices for proofing and baking in mini-bakeries, catering, and at home. The advantages are a simple and cheap design, high productivity, and fast changeover. Prototypes were made and tested in mini-bakeries, home ovens, and our equipment. These devices produce thin bread with equal and parallel top and bottom surfaces and bake thin bread weighing up to 800 grams in a few minutes. Such devices will allow you to bake bread from frozen dough or a baked loaf of semi-finished product at home before each meal in a few minutes. We use several of these devices to bake thin bread throughout the year. An analysis of promising designs of automatic lines for the production of thin bread of various capacities was carried out. https://drive.google.com/file/...

We want to find partners and start working more actively on the project.

In Israel, most bakeries are mini bakeries.

And this project needs contact with a large bread manufacturer.

An important task is also the need to change the stereotype about a loaf of bread since bakers are quite conservative. An example of this.

In 1928 American inventor and engineer Otto Frederick Rohwedder in the city Davenport, Iowa invented the bread-slicing machine. https://www.onthisday.com/peop...

The baking industry cast off Rohwedder as a crackpot. https://www.foxnews.com/lifest...

"Few people in the industry believed that bread could be automatically sliced as it came off the assembly line," Aaron Bobrow-Strain wrote in his 2012 book, "White Bread: A Social History of the Store-Bought Loaf." Most bakers actively opposed factory slicing." Rohwedder "found no takers for the idea and had almost given up hope," the author added. ….The bread-slicing machine revolutionized the baking industry and meant sliced bread became commercially available throughout the world.

We hope that with the help Solve our thin bread will become popular.

The process of heating the dough in different parts of the dough is not uniform, at different speeds. The surface of the dough during baking heats up quickly, while the center of the dough heats up very slowly.

The reason is that the dough has low thermal conductivity. Therefore, about three-quarters of the baking time for loaves of bread is spent on heating the central part of the portions of the dough. It still takes about a quarter of the time for the dough to turn into bread.
As a result, baking bread takes a lot of time and energy.
A lot of greenhouse gases are released into the atmosphere.
The smaller the distance from the surface of the dough to its center, the faster the center of the dough warms up and the bread bakes faster.
To speed up the baking of loaves of bread several times, it was decided to reduce the thickness of the loaf to a thickness approximately equal to the thickness of the slices of bread cut from the loaf.
Slices of bread cut from a loaf of bread have two completely identical and parallel sides.
In all existing types of bread, the top surface is always different from the bottom surface, since these surfaces have different baking conditions. The top surface of the dough during baking is always in contact with hot air, and the bottom surface of the dough is always in contact with the hot horizontal surface on which the dough is placed. 
And we have found a solution that, for the first time, allows bread to be baked with the same top and bottom sides.
Thin bread has no crust at all. The thin film formed after a few minutes of baking is as soft as the middle of the slice and does not allow the slice of bread to crumble. By increasing the baking time, you can get a crust on thin bread that is similar to the crust on existing loaves of bread.

Industrial equipment that will be developed to implement this technology will also contain innovative solutions.

Experimental works have shown that baking a thin 800-gram loaf of bread occurs 5-7 times faster than baking a regular loaf of bread of the same weight.

From this, the following follows:
- energy costs for baking are reduced by 5-7 times;
- greenhouse gas emissions are reduced by 5-7 times:
- the time of cooling, freezing, and defrosting is also reduced by 5-7 times.
Eating thin bread will reduce food waste and environmental pollution many times over.
This follows from the fact that thin bread does not have crusts. This means they don’t need to be cut off and thrown away.
According to our calculations, each device will save the equivalent of CO2 per year: - for home use 15-20 kilograms; - for public catering points 8-15 tons; for mini-bakeries – 120-200 tons. 

We want to propose the production and consumption of new bread under SDG goals 2,3,9,11,12,13. For bread consumers - a fundamentally new bread that has many advantages over existing bread. Bread producers will receive fundamentally new equipment and tools for its production. 

The process of heating the dough in different parts of the dough is not uniform, at different speeds. The surface of the dough during baking heats up quickly, while the center of the dough heats up very slowly.

The reason is that the dough has low thermal conductivity. Therefore, about three-quarters of the

baking time for loaves of bread is spent on heating the central part of the portions of the dough. It still

takes about a quarter of the time for the dough to turn into bread.

As a result, baking bread takes a lot of time and energy.

A lot of greenhouse gases are released into the atmosphere.

The smaller the distance from the surface of the dough to its center, the faster the center of the dough warms up and the bread bakes faster.

To speed up the baking of loaves of bread several times, it was decided to reduce the thickness of the loaf to a thickness approximately equal to the thickness of the slices of bread cut from the loaf.

Slices of bread cut from a loaf of bread have two completely identical and parallel sides.
In all existing types of bread, the top surface is always different from the bottom surface, since these surfaces have different baking conditions. The top surface of the dough
during baking is always in contact with hot air, and the bottom surface of the dough is always in contact with the hot horizontal surface on which the dough is placed. 
And we have found a solution that, for the first time, allows bread to be baked with the same top and
bottom sides.
Thin bread has no crust at all. The thin film formed after a few minutes of baking is as soft as the
middle of the slice and does not allow the slice of bread to crumble. By increasing the baking time, you can
get a crust on thin bread that is similar to the crust on existing loaves of bread.

Thus, with our method and our equipment, we learned for the first time to bake thin bread, similar to slices of bread cut from loaves.
The constructed WVP shows the possibility of producing thin bread in all types of production.
Equipment based on new technology is also patentable.

We have developed a large number of experimental devices on which experiments were carried out.
You can read more details here.

https://drive.google.com/file/...

Previously, 5 people worked on the project. Due to the lack of funding, one person is working on the project part-time.
Several temporary contractors were used to make devices and tools for baking thin bread according to our drawings.

This project has existed for more than three years.

  It should be noted that the solutions found in the project and innovations became possible only because highly qualified specialists - physicists and mechanics - engineers and doctors of sciences - took up the development of the project. Each member of the team has a large amount of knowledge in various fields of science and technology. This combination allowed us to find unique solutions. Team members are relatives. They were able to use all their free time and enthusiasm to develop the project.

This project can be implemented in countries where loaves of bread are baked. 

 We want to offer: - fundamentally new thin bread for the consumer and quick baking; - for bread producers in bakeries and at home, fundamentally new equipment and devices for its production. 

The main feature of our project is that the economic incentives of our project will contribute to the solution of environmental problems. 

Clients
1. Consumers of bread. Fast food lovers. Vegetarians. Children. They especially like the delicious, thin, crustless
bread that doesn't crumble or bend, and you can add a lot of different toppings. The bread for therapeutic nutrition.
2. Consumers who want to bake thin bread at home in a few minutes and Food service.  Such a consumer needs household baking equipment and industrial devices, utensils, and tools. For quick baking, such a consumer also needs semi-finished products and dough frozen after proofing.
3. Bakeries. They need automatic lines and other equipment to bake thin bread quickly and reduce environmental pollution many times over.

Why consumers will buy thin bread?
1. The slices of thin bread are thinner than slices cut from a loaf. This allows you to eat less bread and get fewer calories at mealtimes.
2. Due to the short baking time, thin bread does not have a crust. This means that there is no need to cut and discard the peel from the slices, as there is no peel on the slices. No need to throw away two heels of a loaf of bread. You can buy less bread.
3. New slices of bread do not crumble. The face, hands, and clothes of the consumer remain clean, there are no crumbs on them. This bread can also be useful for astronauts. Since the main problem when eating is the presence of crumbs.
  4.  For the first time, it became possible to have freshly baked bread for every meal. This bread is much tastier and more aromatic than pre-baked bread.
5. Slices of thin bread are tastier than slices cut from a loaf. They have a rich taste and a more intense aroma. 
6. It became possible to bake thin bread for therapeutic nutrition with fresh herbs.
 7. Sandwiches made from thin bread are soggy to a much lesser extent than sandwiches with regular slices of bread. 
8. A new product - bread envelopes of different sizes. These will replace bread slices for making school sandwiches and provide convenience for tourists and those on the road. 
9. A new product - Bread bars as snacks, and bread energy bars. They can have different fillings.
10. A new product - Slices of bread with a ledge. The filling from such slices does not fall.

Why will bakeries buy equipment?

Reduced by 5-7 times:
- baking time;
-performance;
- electricity costs;
- greenhouse gas emissions.
-The number of employees is being reduced.
Overhead costs.
No significant costs for purchasing new equipment;
The production area is reduced.
  Overhead costs are reduced.

The stage of research and making fundamental decisions in the project has been passed.  
The engineering stage begins - the development of industrial models of machines and devices is required. It is necessary to organize the development and production of equipment and its sale to bakeries, retail outlets, and consumers in different countries. 
 Main directions of project development.
It is planned to continue work in three directions.
. The first direction will allow the launching of the production and sale of thin bread in several bakeries a few months after the start of funding. This direction includes the development and manufacture of 5-10 sets of equipment. Checking the reliability and durability of the equipment. 
The second direction includes the development of universal bakery equipment. Organization of
production and sales. 
The third direction is the development of automatic lines for the mass production of thin bread. It will begin to generate income only two years after the start of project financing. 

The main stages of work. 
1. Design and manufacture equipment for baking thin loaves in a mini-bakery.
 2. Together with one of the bakeries, master baking, cutting, and packaging slices from thin loaves. 
3. Design and manufacture industrial samples of devices for proofing and baking new slices for homes, cafes, and restaurants. 
4. To complete the development of a prototype of an automatic line for proofing and baking a continuous belt of bread with a thickness of 0.4-1.2 cm. Productivity - 10-100 kg per hour.
 5. Test the automatic line, make the necessary adjustments, and prepare documentation for creating an industrial design. 

 During the project, new variants of thin bread will be constantly developed and its production will increase. We plan to develop industrial samples of equipment for baking thin bread ourselves. Organize the production of equipment at existing industrial enterprises or build a separate plant. 
In a year, we will be able to produce a small batch of machines for baking thin bread for mini-bakeries, catering establishments, and for home use. Each device will save the equivalent of CO2 per year: - for home use 15-20 kilograms; - for public catering points 8-15 tons;
For mini-bakeries – 120-200 tons.