SUNBAKE BOERSTRA BAKERY TOUR

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SUNBAKE BOERSTRA BAKERY TOUR

• 100 Years of Quality and Service in every product.

The Best Bake Under the Sun
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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 silos that can hold 65
Ton each.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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This is the finished goods store where the bread
is checked and sorted into loads for each of our
delivery vehicles ready for delivery.
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This is the pride of our modern fleet of 62
vehicles being loaded with product from our rolls
finished goods store.
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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 Boerstras heritage.

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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.

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SUNBAKE MISSION

• 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.