Bread is a staple food consumed daily across the world. While consumption is high, its perishability often leads to food waste. Extending shelf life not only helps consumers keep the bread bin full and the waste bin empty, but demonstrates an investment into sustainability.

Why extend the shelf life of bread?

Nearly a fifth of all food produced each year is squandered or lost before it can be consumed(1). In many countries, food waste happens in the kitchen, where food is prepared or left to spoil. Food loss and waste generates up to 10 per cent of global greenhouse gas emissions(1), significantly more than even the aviation sector.

Bread waste accounts for a sizeable proportion of this waste and bakery businesses can support the reduction of this waste by considering shelf-life solutions, which is good for the planet and their profits.

Shelf life is a product attribute which influences the bread purchase decision for 21 per cent of consumers globally(2). As well as sustainability advantages, shelf life improvement ensures consistent product quality and satisfies the 49 per cent of consumers seeking freshness from their bread (2).

Why does bread spoil?

Bread spoils due to two main processes: mould growth and staling:

Mould growth

  • Fungi: Bread can become contaminated by mould spores present in the air. These spores are microscopic fungi that thrive in moist, warm environments with a food source – like bread.
  • Moisture: Bread naturally contains moisture, and if stored improperly (e.g., in a plastic bag at room temperature), this moisture can create a humid environment that encourages mould growth.
  • Nutrients: Bread is rich in carbohydrates, which serve as a food source for mould.
  • Lack of Preservatives: Homemade bread and some artisanal or clean label store-bought breads lack the preservatives found in many commercial loaves, making them more susceptible to mould.
  • Spores: The fuzzy, coloured spots you see on mouldy bread are colonies of spores, which the fungus uses to reproduce and spread. These spores can travel within the packaging and contaminate other parts of the bread.
  • Mycotoxins: Some moulds produce harmful toxins called mycotoxins. These toxins can spread throughout the loaf, even if you only see a small spot of mould.

Staling

Staling is a separate process from spoilage by microorganisms, although it can make bread less appealing and eventually lead to it being discarded.

  • Starch Retrogradation is the primary cause of staling. When bread is baked, the starch molecules absorb water and swell (gelatinisation). Gelatinisation of starch gives the bread it’s soft and springy crumb qualities. As the bread ages, these starch molecules begin to recrystallise (or retrograde) and rearrange themselves, causing it to lose these fresh qualities. This results in a firmer, drier, and more crumbly texture.
  • Moisture Migration: Water within the bread also redistributes itself. It moves from the crumb (the soft interior) to the crust, making the crust tougher and the crumb drier.
  • Gluten Changes: The gluten proteins in bread also undergo changes over time, contributing to the hardening of the texture.
  • Temperature: Interestingly, staling occurs most rapidly at temperatures just above freezing, which is why storing bread in the refrigerator can actually make it go stale faster.
  • Chemical changes to some of the molecules in bread can lead to oxidative rancidity, especially products containing high levels of butter. This type of staling, just like starch retrogradation, is harmless but reduces the palatability of the bread.

While staling doesn’t make bread unsafe to eat on its own, it significantly affects its texture and palatability. Mould growth, on the other hand, does make bread unsafe to eat due to potential health risks from the mould and mycotoxins.

To solve these issues, bakers can utilise a combination of traditional techniques and innovative solutions. Let’s explore a few.

Shelf life by bread type and storage method

Pre-packaged/commercial breads – These types of bread typically have a shelf life of 2-5 days at room temperature or up to two weeks in the refrigerator.

Gluten-free breads -These often have a higher moisture content, which require freezing for preservation.

Dense/coarser breads – Sourdough and rye for instance naturally last longer due to their acidity and antimicrobial properties.

How can you extend shelf life of bread and baked goods

Packaging Solutions

Packaging type is an important factor in extending the shelf life of bread or any baked good. By choosing the appropriate packaging, bakery businesses can ensure their products stay fresh and appealing for longer.

Plastic Bags – The most popular mainstream packaging type and often the lowest cost, plastic bags preserve moisture which keeps bread fresher for longer. Monomaterials like polyethylene or polypropylene bags are often preferred as they are made from a single type of material and subsequently better for recyclability.

Composite Packaging – A type of packaging made by combining two or more different materials that are bonded together and offers enhanced characteristics that a single material could not provide on its own.

Key characteristics of composite packaging includes:

  • Multiple Materials: It consists of at least two distinct materials (eg, plastic and aluminum, paper and plastic, cardboard and polyethylene).
  • Inseparable Layers: The different materials are bonded together inseparably, forming a single, integral unit. This distinguishes it from combination packaging where inner and outer packs can be separated.
  • Enhanced Properties: The combination aims to achieve superior properties such as increased durability and improved barrier properties (against moisture, oxygen, light).

Recyclable packaging made from monomaterials maintain freshness and at the same align to sustainability priorities. For smaller, artisanal bakeries offering premium sourdough for instance and for when short-term storage is acceptable, coated paper bags enable these types of bread to maintain their crispy crust texture.

Enzymes and Natural Preservatives

Natural preservatives, like lactic acid bacteria or vinegar-based additives, can help extend the shelf life of bread without compromising its clean-label appeal. The topic of clean label is an important one for consumers, with 64 per cent now actively choosing foods made with natural ingredients (3) .

Enzymes like amylase, specifically certain types like maltogenic alpha-amylase, play a significant role in improving the shelf life of bread, primarily by delaying the process of staling. Combining enzymes with natural acidifiers, such as sourdough starters or vinegar, can also enhance bread’s longevity.

Bakels offer other convenient ingredients to help bakers extend the shelf life of their bread products. As well as improvers which deliver performance attributes such as stability and volume, these modular ingredients optimise the freshness of bakery products for a shelf life of up to two weeks. 

Implement strict hygiene practices

Maintaining high hygiene standards is paramount in bread making to prevent foodborne illnesses, ensure the quality of the final product, and comply with food safety regulations. Contamination can occur during the cooling, slicing or packaging stages and greatly reduces freshness.

There are simple ways bakeries can prevent contamination, including:

  • Reinforcing staff hygiene practices – Regular handwashing, protective clothing, no jewellery and wound management.
  • Enhance cleaning and sanitation procedures – Implement a cleaning schedule, use of effective cleaning agents, thorough cleaning techniques and sanitisation after cleaning.
  • Prevention of cross-contamination – Separate storage, designated equipment, handwashing between tasks and allergen control.
  • Optimise food storage and temperature control – Temperature monitoring, effective stock rotation, covered storage and clear labelling.
  • Conduct regular audits and reviews – Internal/external audits, procedures.

Extend your bread’s shelf life with Bakels

Whether you’re an artisan bakery or a large-scale manufacturer, Bakels is here to support your journey to achieving extended shelf life in bread products, boosting your profits, reducing your waste and positively contributing to a sustainable future.

Contact your local Bakels representative to discover how we can support you.