SMART PLANT MANAGEMENT TO IMPROVE THE QUALITY AND SUSTAINABILITY OF BAKERY PRODUCTS

This doctoral thesis explores the integration of digital technologies and sustainable ingredient innovation in the bakery sector, with particular emphasis on gluten-free breadmaking. The work is framed within the evolving paradigm of Food Industry 5.0, which combines technological advancement with human-centricity, sustainability, and system resilience. The first part of the thesis provides a critical review of the transition from Food Industry 4.0 to Food Industry 5.0, highlighting the role of enabling technologies such as the Internet of Things, automation, artificial intelligence, smart sensors, and datadriven decision support in modern agri-food systems. Special attention is given to the opportunities and challenges associated with digitalization in terms of efficiency, traceability, sustainability, and workforce involvement. The second part presents an experimental study focused on the valorization of edible legume grains excluded from commercial markets due to aesthetic non-compliance, specifically through the production of dehulled bean flours derived from local Fagioli di Sarconi PGI ecotypes. Optimized pre-treatments were applied to improve dehulling efficiency, and the resulting flours were incorporated as partial substitutes in commercial gluten-free baking mixes. Breadmaking trials were conducted using a standardized recipe, and technological and physical quality attributes were systematically evaluated. To support process optimization, a low-cost IoT-based monitoring system was developed using an ESP32 microcontroller and environmental sensors to track dough fermentation in real time. This approach enabled objective, continuous monitoring of leavening behavior and demonstrated the potential of smart, accessible technologies to improve process control in both research and small-scale bakery contexts. Overall, the thesis demonstrates how the combined application of digital monitoring and circular raw-material valorization can contribute to improving the quality, sustainability, and resilience of gluten-free bakery products, offering practical tools and conceptual insights aligned with the principles of Food Industry 5.0.