Much-needed automation for Bakker Ammerlaan.

At Bakker Ammerlaan, the love of baking has been passed down from father to eldest son for over 125 years. Now, the fifth generation is at the helm. To keep up with modern times, robotization is indispensable. Jacques Ammerlaan talks about the cooperation with DERO GROEP.

Jacques started his career in the bakery when he was 15 and is still involved in the business today, 57 years later. At 72, he is no longer officially the owner, but as a consultant, he still enjoys sharing his insights - solicited and unsolicited - as he says himself.

"A bakery is labor intensive: a lot of production and everything fresh. With around 350 employees and only stores of our own, we offer a wide range - from bread and pastries to sausage rolls and croissants," Jacques says. "Automation is crucial to remain competitive. Skilled workers are scarce, labor costs are rising and our products must remain affordable to sell. Efficiency and smart solutions are the key, and automation is essential for that."

Consequently, Bakker Ammerlaan decided early on to explore opportunities for automation. The cooperation between Bakker Ammerlaan and DERO GROEP began in 2002, when the bakery moved to new premises in Bleiswijk. This bakery supplies 32 of Bakker Ammerlaan's own stores with bread and pastries. Jacques explains: "With the help of a consultant, we looked at the layout and possibilities for automation. First we thought about a system with boxes and carts, but the advisor suggested a robot."

Robots in action

Jacques continues: "Baking a loaf of bread takes about three to three and a half hours. First, the dough is kneaded firmly and laid out as a ball to rise slowly. When the dough is ready, we roll it out and give it that characteristic elongated shape."

This is where the robot comes into action. It sends the right kind of baking tins from the central tin storage via a conveyor belt to the dough department, where the dough is automatically placed in the tins. Then the filled tins return and the robot puts them on a cart, which goes to the proofing cabinet. When that is finished, the carts with tins go into the oven. After baking, the carts return to the robot area. The robot removes the tins from the cart and puts them on another lane, where a second robot removes the bread from the tins. The empty tins then return to the first robot, which places them in storage.

Efficiency to the millimeter

The robot also cleans baking trays - something that is usually hard work. Jacques says: "At night the robot is busy with the tins for the bread, and during the day it uses its time to clean baking trays. This requires many different movements from the robot. It is not simply going from A to B, but a complex process with all kinds of directions and tasks. Everything has to be done precisely, down to the millimeter."

Not just hot air

Jacques: "For an artisanal baker, having a robot in house is quite special. After all, we are a small-scale bakery. As an 'early adopter' we did have some start-up problems in the beginning, but now everything works satisfactorily. At the time, Jogchem den Otter, the creator and programmer, got fully involved and made sure everything worked. Meanwhile, we have been working very pleasantly with DERO GROEP for over twenty years. Fortunately, I don't have to call them often - that's a good sign for everyone. But when I need them, they are always there for us. That trust is very valuable."