Bakery processing market remains buoyant despite market challenges
pic: Adobestock
The bakery sector is set to witness significant growth in the coming years, with innovation and sustainability key to its evolution. From digital tools to energy-efficient processes, Confectionery Production dives into the latest advancements that are shaping production processes. Daisy Phillipson reports
From the comforting aroma of fresh bread, to the indulgence of a perfectly flaky pastry, baked goods have an enduring appeal. Behind the scenes, the industry is undergoing a huge transformation, reflected in its projected growth. According to market research firm Fortune Business Insights, the global bakery products market, valued at approximately $480.2 billion in 2024, is projected to grow to $731.6 billion by 2032, reflecting a CAGR of 5.45 per cent.
Several key trends are shaping this growth trajectory. The integration of advanced technologies, particularly automation, is revolutionising production processes, enabling faster and more efficient manufacturing. What’s more, there’s a rising consumer demand for health- conscious offerings, artisanal and crafted treats, global flavour fusions, functional ingredients and interactive and experiential products.
These trends are not only contributing to the growth of the sector but also representing significant business opportunities. For manufacturers, it’s important to balance innovation with operational efficiency, while navigating challenges such as fluctuating ingredient costs, supply chain disruptions, and ongoing labour shortages. Sustainability pressures continue to mount, requiring companies to rethink production processes to reduce waste and energy consumption.
Cutting-edge advancements in bakery processing technology are making it possible to address these challenges head-on. From automation-driven efficiency gains to intelligent monitoring systems that enhance precision and reduce waste, machinery and technology developments are helping bakeries streamline operations and maintain consistency in an increasingly complex market.
Puffed to perfection
The Bühler Group continues to push innovation, sustainability, and efficiency in bakery and snack production. With a comprehensive portfolio of advanced processing equipment, its latest move reinforces its commitment to shaping the future of food manufacturing. At the start of 2025, the company acquired puffing technology from Cerex to meet rising demand for products like bars, extruded snacks, nuts, seeds, and plant-based alternatives such as puffed oats.
According to Prophecy Market Insights, the global ready-to-eat snack market is expected to grow at a CAGR of 9.7 per cent from 2024 to 2034. Puffing technology supports manufacturers in adapting to emerging consumer trends, broadening Bühler’s offerings and enabling healthier, more diverse food options.
“The puffing process is a game-changer in how we approach cereal and snack production, offering a broad range of recipe possibilities, including coatings and fillers across many product categories,” says Christoph Vogel, head of business unit human nutrition at Bühler. “The integration of this technology into Bühler’s portfolio strengthens our ability to meet the evolving needs of our customers and fosters continued innovation in recipe development.”
The technology also helps reduce costs and supports sustainability goals by increasing volume and weight while lowering sugar content. As a hydrothermal process, it uses heat and pressure to expand raw materials. It also enhances digestibility, reduces moisture and gives products a lighter, crisper mouthfeel, making them easier to enrich with functional ingredients. Puffed products contain no added ingredients and are being made available as white-label options.
Bühler highlights how Cerex puffing technology boosts grain processing, achieving maximum yields of over 95 per cent while reducing waste and delivering uniform puffing. The system is reported to use 50 per cent less energy than similar systems while ensuring strict food safety compliance.
To support customers in product development, Bühler opened an application and training centre in Uzwil, Switzerland, focused on puffing technology. Here, customers can test recipes with ingredients such as pulses and refine processes.
“By incorporating advanced puffing technology, we are confirming our commitment to innovation, addressing both current market demands and anticipating future consumer trends,” adds Vogel. “Now, we are ready to discuss with our customers the exceptional opportunities for integrating this solution into their plants.”
Innovation in the spotlight
In the evolving bakery landscape, the iba 2025 trade show in Düsseldorf, Germany, is a pivotal event, offering a platform for industry stakeholders to explore innovative solutions and strategies to navigate modern challenges and learn about emerging trends. This year’s fair, taking place between 18 to 22 May 2025, will showcase advancements in bakery processing, highlighting how companies are leveraging technology and innovation to stay competitive.
Attendants can visit the freshly-devised food trends area, as well as the digitalisation area to experience new technologies and test new possibilities. Artisan bakery will also be a top priority, with Hall 13 featuring oven builders who will be demonstrating how residual heat can be utilised using a newly developed heat recovery system, allowing for increased energy efficiency.
At iba 2025, the Koenig Group will showcase its full portfolio by bringing together Koenig, Fortuna and Vulganus in a unified presentation.
Alongside the showcase of its equipment, Koenig is placing emphasis on connecting visitors with the individuals behind its business, featuring experts from various fields to ensure a comprehensive experience.
Regarding its machinery on show, Koenig’s Industrie Rex V AW EC dough divider and rounder will be exhibited for the first time at a trade show. The company notes that it is the largest dough divider and rounder in its portfolio, and is made with its Easy Clean design for optimised cleaning and maintenance. Additionally, Fortuna’s newly launched dough divider and rounder Novus will be presented, said to combine gentle dough handling with high capacities.
Koenig highlights the need for increasing investment in areas such as digitisation and automation to overcome challenges such as labour shortages, and to help meet sustainability goals. Using robotic solutions, such as scoring or automatic tray handling, enables customers to automate production while raising the product quality at a consistently high level, another topic its experts will be on hand to discuss at iba 2025.
Bakery equipment specialist WP Bakery Group, which will be showcasing innovative solutions at iba 2025, continues to address modern industry challenges through its extensive portfolio of bakery processing equipment. The company focuses on enhancing efficiency, sustainability and automation, ensuring that manufacturers can optimise production while maintaining high-quality standards.
One example of WP Bakery’s commitment to sustainable solutions is its WP Retherm heat recovery system powered by Ganzenmüller (below). This technology allows bakeries to optimise oven performance on existing or new systems, essentially allowing users to reuse heat generated by baking ovens for a second time, resulting in the recovery of a quarter of the energy used.
The overall solution consists of a smooth tube heat exchanger, control unit, storage tank, fresh air supply, flue and a connection to heating and hot water installations. The technology is also said to minimise odour emissions. The firm’s systems are easy to operate thanks to a clear Siemens touch screen control unit, which will be accessible via the web with a large touch display from mid-2025.
Similarly, bakery machinery group Mecatherm continues to innovate with a focus on sustainability, including energy transition. Scheduled as an exhibitor at iba 2025, the company emphasises the importance of controlled hygrometry for energy efficiency and reduced baking waste.
Hygrometry in the baking chamber affects product characteristics such as crust thickness, water loss, and softness. It results from the quantity of steam injected into the oven, steam generated by product evaporation, outside air intake, and humid air extracted by dampers.
The firm notes how hygrometry in industrial ovens is typically managed empirically, but this often leads to overconsumption of energy when dampers are incorrectly adjusted. To address this, Mecatherm developed the Hygro Control System. This system regulates the inflow and outflow of air, maintaining product quality while minimising waste from non-conforming products.
It ensures regular baking and optimal energy efficiency by reaching the minimum amount of humid air needed to extract and control the fresh air admission necessary for baking ovens. This innovation is one of several designed to meet sustainability goals without compromising quality.
For its part, Corbion has worked on applications for the bakery market, noting that optimising every stage, from ingredient preparation to packaging, with careful attention to both efficiency and product quality is vital to succes.
As the company noted, one key challenge is achieving consistent dough handling and performance. Factors like ingredient variability, temperature fluctuations, and mixing times can significantly impact the final product.
Corbion’s dough conditioning solutions help bakers maintain uniformity, ensuring optimal performance in diverse production environments. Another consideration is extending shelf life without compromising sensory qualities. Corbion’s Verdad and Purac portfolios offer natural mold inhibitors and lactic acid-based solutions. These support clean-label requirements, enabling products to meet consumer demands and reducing food waste.
Furthermore, as the company observed, effective moisture management is equally important. Controlling water activity helps preserve texture and prevent spoilage, especially in cakes and sweet goods. Corbion offers solutions that balance moisture levels, protect against microbial growth, and maintain quality throughout the product’s shelf life.
Advances in predictive modeling tools, such as the Corbion Natural Mold Inhibition Model (CNMIM), are transforming bakery processing. This tool predicts mold growth in specific formulations, allowing bakers to choose the best solutions while minimizing costly trial-and-error testing.
Automation is also reshaping the industry. From mixing to proofing and baking, automated systems improve precision, reduce manual intervention, and increase production capacity. Combined with Corbion’s expert support and tailored solutions, automation ensures both efficiency and quality.
Green baking
For its part, wafer equipment specialist Walterwerk Kiel has been placing sustainability at the centre of its business, including efforts in the design of its baking oven concept to reduce gas consumption. “To counter the current uncertainties regarding future energy sources, Walter has developed a retrofit for today’s gas-fired ovens,” says Markus Bartels, general manager, Walterwerk Kiel.
“As soon as the supply of green electricity increases, our customers can switch their fleet of ovens to electricity. In this way, Walter customers can be sure that their current investment will last into the future. The Elektra oven concept enables energy consumption to be reduced by at least 26 per cent compared to our systems with gas heating.
“For our development department it is a continuous process to find new solutions regarding less energy consumption,” Bartels continues. “The latest improvements have been the optimisation of the heating control to ideally adjust the baking temperature to the baking process and the revision of the burners to reduce the power loss of the oven.”
