Innovative smart bakery

1. COSMOPOLITAN CUISINE
Dubai embraces bistro culture
Customer Service evolves
achieving after-sales
excellence
TRUE TO FORM
Getting the correct balance
of form and function in design
THE ALI GROUP MAGAZINE ISSUE 3 | OCTOBER 2014
All systems go
Cutting-edge meal
delivery innovation

2. 76 77
EsmachLab
and the future
of artisan bread
Esmach combines the best of both worlds: tradition and quality
with a contemporary business model, says Donna Brown
INNOVATION
Luciano Delpozzo, the CEO of Esmach, is dynamic,
focused and passionate about bread and bakers.
“Coming from a completely different background
in heavy industry, I wanted to understand the work
of an artisan baker,” he says. “I want to learn about
the hours, the challenges, why there are fewer
small bakeries, how they can become more
competitive and what role Esmach can play to
encourage bakers and to maintain the tradition
and future of artisan bread.”
Esmach has considered many different factors in
its study of the market, including workflow, hours,
production, quality and profitability says Delpozzo.
“What emerged from this study is that many small
bakeries are closing because of the difficulties
involved with the lifestyle and revenues. It became
evident that, in order to be a company that partners
EsmachLab is the result of this in-depth study - a
small footprint, highly profitable, flexible and
productive artisan bread laboratory. The concept
itself is innovative and the first of its kind. It brings
the world of artisan bread-making into a daytime job
and makes it accessible to non-professional bakers.
Existing Esmach appliances have been adapted to
this new concept, making it possible to produce
high-quality artisan breads throughout the day
and avoid the night shift that puts such a strain on
personnel and their families.
The components of EsmachLab
EsmachLab consists of five different appliances
that can be sized to meet the production needs of
the customer and guarantee the very best quality
an artisan baker can provide.
The Mother Yeast Generator makes sure that you
have perfectly maintained mother yeast ready at any
time. This means that bread is of the highest quality,
easy to digest and full of natural flavor. There is no
need for artificial raising agents or improvers.
The Automatic Spiral Mixer is a workhorse ready
to mix each dough to its desired consistency easily
and reliably. When the dough is ready it goes into
the intermediate proofer for the necessary time.
It is suitable for short proofs as well as for long,
slow proofs of up to 72 hours. In its controlled
bakers rather than just sells their products, we
needed to work on modernizing
the business model of bakeries and making
them relevant and successful.”
Esmach also looked closely at consumer habits and
how they have changed. “They are fundamentally
looking for one of two things,” says Delpozzo.
“Either the convenience of one-stop shopping with a
reasonable level of quality or a complete customer
experience with exceptional quality products and a
high level of personalized service. Consumers have
become more aware of what they eat and are willing
to invest more time and resources in their health.
This fits perfectly with the objectives of EsmachLab:
to offer extremely high-quality pizza, focaccia, pies
and bread with the inimitable, evocative fragrance
that only freshly baked goods have.”
Esmach wants to encourage
bakers and maintain
the tradition and future
of artisan bread
Clients can increase their
revenues with sandwiches,
snacks and other finished
products made with
their baked goods
A full range of pizzas, pies,
breads and rolls can be made
in an EsmachLab
INNOVATIONINNOVATION

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environment, the yeast will work its magic and each
bread or pastry will rise perfectly as it develops its
flavor. The baker is able to add gourmet ingredients
at this stage: olives, tomatoes and roasted vegetables
to name a few.
While it is obviously possible to shape by hand, a
specific moulder does the work for you, quickly,
professionally and with no flour in the environment,
making the workplace safer and more pleasant.
Various forming dies allow the baker to express his
creativity to the fullest and create many different
shapes without stressing or degassing the dough. The
shaped dough may be baked directly or stored in a
chiller, ready to be baked off when needed.
There is a wide range of ovens: rotary, rack, deck
ovens and modular ovens for all your baking needs.
Pizza, pastry and bread will all be baked to perfection.
Esmach’s research and development department has
perfected existing products to reflect the changes in
this business model for daytime baking. Each of these
appliances has been fine-tuned and are high-quality,
sturdy, reliable, easy to maintain and energy efficient.
Who is Esmach for?
The true test of a company is how it moves with the
times, how it interprets, predicts and even shapes
them. By studying consumer trends, EsmachLab is
designed to enable small businesses and high-volume,
fast turnover customers to produce quality pizza,
focaccia and bread on demand throughout the day.
On a practical level, this means that the appliances
required to bake the goods can be much smaller,
saving costs on valuable retail space and increasing
profitability per square metre.
EsmachLab is accessible to professional and non-
professional bakers. This means that other businesses,
such as bistros, restaurants and small hotels can
expand their business and offer freshly baked pizza
and bread to their customers.
Learn the art of baking at the Esmach Academy
In order to partner future clients and to encourage
the culture of artisan pizza and bread-making,
Esmach has opened its Academy in its brand new
showroom in Vicenza, Italy. Everyone is welcome
to learn the art of pizza and bread-making in
their four one-week courses. They may be taken
individually, and even after the first course, the
participants will be able to make breads, pizza and
pies on their own. Each level is designed to give
the baker more autonomy and confidence in
creating their own recipes as well as using the ones
studied especially for this format by the research
and development department.
“Esmach is a partner, not merely a supplier,” says
Delpozzo. “In understanding our clients and their
needs and by researching consumer trends, we are
able to look at the market from many different points
of view and come up with innovative ideas and
winning strategies for today’s bakers.”
www.esmach.com
Esmach appliances are high-
quality, sturdy, reliable, easy
to maintain and energy efficient
A fully functional bakery can be set up in less than
30 square meteRs
The production capacity is up to
400 kg
of products per day
The initial investment is approximately
70,000-120,000 €
for appliances, training and commissioning
Profitability of approximately
25-40%
Revenues: roughly
40,000 €
per square meter per year
Facts and Figures
The strengths of EsmachLab
• Baking becomes a daytime occupation
• Esmach helps new talents to emerge and express their creativity
• Multi-sensorial experience for the customer
• EsmachLab changes the ratio of footprint: production and profitability
• Delivery of healthy and digestible pizzas and bread
• Makes quality products an everyday, accessible experience
• No waste products when the shop closes for the day
Esmach’s R&D department has
fine-tuned products to reflect
the changes in daytime baking
INNOVATION
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