Fallsdell Machinery Representing AZO LIQUIDS in Australia and New Zealand
Posted on February 26th, 2019 in NewsNuStef Baking Ltd., they call themselves “The Pizzelle Company”, makes mouthwatering pizzelle cookies in Canada. The company was founded by Mr. Ces Nucci. In 1985 he had the idea to start a business making traditional Italian Pizzelle Cookies. In the meantime NuStef is the largest Pizzelle manufacturer in Canada. Nustef serves lots of different markets, even the Italian one, where the Pizzelle Cookie was founded.
When DB Tech Solutions, the sales partner of AZO LIQUIDS in Canada, visited the Nustef plant in 2012, they saw an immediate opportunity for Nustef, to automate their manual batter making process. Nustef Baking Ltd. was using 6 small mixers, that required 2 operators each to operate, between operating the mixer and measuring and preparing batch quantities of raw ingredients. Each mixer needed 45 minutes to an hour to make a 150L batch of batter. The making area was very busy with many operators, measuring tables, part opened bags etc., causing numerous logistical issues. Furthermore the recipe management on the mixers was complete manual and 100% operator dependent, which resulted in differences on the final product due to variations in ingredients, mixing times, dosing rates, etc.
The Solution? – The AZO LIQUIDS Dough Line DL, a single large, automated batter making system that could provide:
- cost savings
- efficiency improvements
- quality improvements
- Reduction in material wastage
NuStef Baking Ltd. was initially apprehensive, since an earlier attempt by NuStef Baking Ltd. to use a larger mixer to make big batches, failed owing to the fact that the batter wouldn’t stay fresh as their cookies were made without any preservatives. However, DB Tech solutions knew this could be tackled and overcome with the competencies of the AZO Group in particular with AZO LIQUIDS’ expertise. If successful, this would provide significant cost savings, reduce oven adjustment time due to variations in multiple small batches, increased throughput, efficiency improvements and reduction in raw material losses due to automatic handling.
Teaming with AZO LIQUIDS’ Mr. Dieter Reischmann, Mr. Balaji at DB Tech solutions, collected necessary process and product information, to recreate the batter. Mr. Leo, Manufacturing Director for NuStef gave a go-ahead to make a sample batch at AZO LIQUIDS lab in Germany.
An identical trial batch was created at AZO LIQUIDS lab, and the batter was evaluated against the strict standards of NuStef Baking Ltd.. NuStef, also sent one of their electric pizzelle baking machine, with which the batter was baked into pizzelle and the resulting pizzelle was compared for various characteristics including sensory, flavor, feel, etc. NuStef Baking Ltd. was very pleased with the effort and result and placed an order for the AZO LIQUIDS system, called Dough Line DL.
In coorperation with our sales partner in Canada, the AZO Group supplied the core system DL with a corresponding powder handling system for a successful installation in 2013. This batter making system helped NuStef Baking Ltd. save operations cost, and increase production many fold.
As business grew, Mr. Nateram Babulal took over the reins of plant operations and engineering at NuStef Baking Ltd.. He realized that a second identical mixer would be needed to further cater to the increased demand for NuStef Pizzelle in the market place. In 2017, NuStef Baking Ltd. ordered a second batter making system from AZO LIQUIDS, and once again in the same manner the system was efficiently installed and commissioned at NuStef Baking Ltd.. Mr. Babulal, mentions, that the arrival of the second mixer in a timely manner took care of the extra batter requirements required for their additional ovens.
A success story that helped Nustef Baking Ltd. expand their manufacturing capability which in turn helps them to reach more and deeper into the market, with their yummy and versatile pizzelle.
For Further information on the AZO liquids range of equipment, contact Fallsdell Machinery on 02 9791 0933, Russell@fallsdell.com.au or visit us at Auspack 2019, Stand F065