croissants_closeup

Waterjet pastries? Edelweiss Patisserie Plant Visit (April 2015)

Reading Time: 3 minutes
Did you know your trader joe’s brownies in Boston are cut with a waterjet?brownies

first, youtube

On the internet, I watched a video about waterjets containing a shot of a waterjet cutting pastries.
A few more (well, a lot) youtube links later,
Inline image 1
Inline image 1
turns out that right in Medford, MA there is a waterjet being used in production at a bakery called “Edelweiss Patisserie”.
Inline image 1
Based on their website, they are essentially a contract manufacturer for baked goods. So cool!

        We produce more than products that fit your business needs—we create pastries that enhance your product line.

Our customers are category leaders in the food industry, including supermarket and club store chains, restaurants and cafes. They demand innovative, unique products to meet the needs of their sophisticated consumers and their own margin and turn standards.

We invest in product development and have the manufacturing flexibility to create almost any dessert our customers could imagine. Our business is driven by what our customers want, and we deliver! When we say we offer only the highest quality products, we mean it.

I emailed the contact email, and lo and behold, a few weeks later, the very kind owner of the place replied! He was held up by the Easter holidays.

plant visit

Thus, one spring day we drove over to Edelweiss.
edelweiss_outside
We got a sweet tour of the place by the owner himself. The place is gigantic (the pictures don’t do it justice). Here, the owner talks a little about the supply chain and inventory management needed to run the place.
tour
There was a recycling machine that crushed boxes
recyclemachine
into neat cubes, WALL-E style :)
recycle
Industrial quantities of strawberries
strawberries
and trash bins full of tapioca starch put the batch ingredients we use for putz’s (where I lived during undergrad) liquid nitrogen ice cream event (cryofac) to shame.
tapiocastarch
Vat of oil half as tall as me.
oil
There were horizontal bandsaws used to plane pastries
planars
horizontal_bandsaws
Here’s just a few croissants
croissants
croissants_closeup
The ovens were pretty cool because
oven
they had this mechanism inside that would lift an entire rack of pastries up so that they could be rotated and evenly heated while baking. Sort of like an industrial version of the toy vending machines with the claw you use to try to grab plushies.
ovenmechanism
 Giant chocolate machine, chocoma (I think the name is funny)
chocoma

waterjet machine for baked goods

Note: This waterjet uses water only (at 60kpsi), no garnet (it’d get all over your cake! :P)

Finally we came to the highlight, a waterjet from ?Spain? that cuts baked goods (and is in use all the time when the plant is running).

waterjet

machine_side

Here’s a closeup of the interface.
bats
The designs are pre-programmed, there’s a simple shape editor, and then other designs are emailed in to the manufacturer to be converted into DXF or whatever

video of it cutting

in more detail

what was cut:

hearts

filters

filters

right side (pump?)machine_rightside

left side (intensifier?)machine_leftside

They told this awesome story of the seal on one of the components breaking, and then they cut it themselves on the machine. Secretly, they are engineers now too :)
Here’s the part they fixed (maybe a water trap??), which is to the rear of the machine on the left side:
watertrap
chiller
chiller

 

The mechanism

waterjet_mechanism

mechanism

The grille
grille
The grille was a little worn!
worn_grille

misc. technology

 face detector for a high-tech version of punching in and out
 face_detector
labelmaker
labelmaker
wrapping
wrapping
all ready to be shipped!
croissants_shipready

and our going away present

brownies

The end.

edelweiss_box

gallery

same pictures in more modern webdesign look (idk what is google doing with all their photo services):
https://photos.google.com/album/AF1QipP4l6DjOm33q_sNXtFdvoF0heVceXYI27uKR_BQ