In the world of professional silicone moulds, Flexipan has established itself as a benchmark for many years. However, evolving industrial needs and increasing demands for durability have paved the way for new alternatives. MAE Innovation now offers a French solution that deserves the attention of production managers and decision-makers in the food industry.
This article provides a factual comparative analysis between these two solutions, based on criteria of performance, composition, durability, and profitability.
Mould Composition: Two distinct approaches
SIL035 Silicone from Maé Innovation
Maé Innovation manufactures its moulds using SIL035 silicone, a premium silicone with remarkable mechanical properties. This 100% silicone composition, without composite reinforcement, offers:
- Optimal flexibility for demoulding without excessive mechanical stress
- Increased resistance to intensive cycles reported by industrial clients
- Superior lifespan in high-speed production environments
- An extended thermal range: from -45°C (mechanical cooling) to +280°C, with the possibility of use down to -100°C in cryogenics with specific precautions
Maé Innovation uses 100% high-quality silicone, providing excellent flexibility, optimal thickness for demoulding, and superior long-term durability.
The Flexipan structure: Silicone + Fibreglass
Flexipan has developed a technology combining platinum silicone and integrated glass knit. This composite structure aims to:
- Guarantee increased dimensional stability
- Maintain the shape of the mould even under stress
- Ensure homogeneous thermal distribution
Flexipan moulds initially have a very smooth surface, but this finish tends to degrade after the first few baking cycles.
| Criterion | Maé Innovation | Flexipan |
|---|---|---|
| Main material | 100% premium silicone (SIL035) | Platinum silicone + glass knit |
| Structure | Homogeneous silicone | Silicone reinforced with fibreglass mesh |
| Thermal resistance | -45°C to +280°C (down to -100°C) | -40°C to +240°C (+260°C) |
| Food certification | FR, EU + FDA (USA) | French and European standards |
| BPA/Peroxide free | ✓ | ✓ |
Demoulding and baking performance: Comparable results
Both solutions offer natural non-stick properties, eliminating the need for greasing in most cases.
In the field, tests conducted under real conditions demonstrate that Maé Innovation moulds offer demoulding performance equivalent to those of Flexipan, for both sweet and savoury recipes. Dimensional stability and baking regularity remain constant, even in high-speed industrial environments.
Production lines integrating Maé moulds show high reproducibility, a crucial element for maintaining consistent quality of finished products. The technical design of these moulds guarantees homogeneous thermal distribution, allowing for predictable and measurable results, cycle after cycle.
Versatility of use
| Application | Maé Innovation | Flexipan |
|---|---|---|
| Oven baking | ✓ (+280°C) | ✓ (+240-260°C) |
| Freezing / Deep-freezing | ✓ (-45°C / -100°C) | ✓ (-40°C) |
| Microwave / Bain-marie | ✓ | ✓ |
| Sweet / Savoury recipes | ✓ | ✓ |
Durability and resistance between the moulds
The primary difference between Flexipan and Maé Innovation lies in their material composition. Flexipan uses a structure combining silicone and fibreglass, whereas Maé Innovation has chosen a 100% premium silicone, without composite reinforcement.
This design difference results in increased resistance to intensive cycles for Maé moulds. In industrial environments, where moulds undergo repeated mechanical stress (handling, thermal shock, intensive washing), the full premium silicone composition demonstrates superior longevity. Field reports indicate a prolonged lifespan, reducing replacement frequency and thus optimising the total cost of ownership.
Optimise your production line with adapted moulds
For over 30 years, Maé Innovation has supported food industry professionals with bespoke silicone mould solutions. Premium quality, French manufacturing, resistance from -40°C to +280°C.
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A design engineered for industrial constraints
Maé Innovation developed its moulds by considering the realities of professional production environments. Thicknesses have been optimised to withstand high production speeds while maintaining sufficient flexibility for easy demoulding.
Adaptability to the mechanical constraints of automated lines is a major competitive advantage. Processes become reproducible and reliable, minimising production downtime linked to equipment failures.
A major advantage of the Silmaé range:
- Common dosing centre distances across many models
- Compatibility with automatic dosing machines
- Interoperability facilitating production changes
Client Case Study (United States)
The example of one of our clients, an American producer specialised in cannelés, concretely illustrates the added value of the Maé Innovation approach. This company initially sourced from another manufacturer, using moulds with aluminium fillers to optimise heat transfer. However, the rapid degradation of these moulds led to frequent replacements, significantly impacting operational costs.
After analysing specific issues (the need to strengthen plate stability and improve heat transfer to obtain perfectly caramelised cannelés), Maé Innovation proposed a bespoke solution:
- Silicone plates dimensioned and thinned with a strategic increase in centre distances between cavities to optimise heat transfer
- Addition of structural reinforcements to ensure increased stability during handling
- Integration of aluminium fillers to maximise thermal conductivity
The results obtained exceeded expectations: better mould stability, considerably increased resistance and durability, and optimal heat transfer allowing for the desired caramelisation. Our client thus reduced their replacement frequency while improving the consistent quality of their production.
Collaboration with Chefs: Co-Creation and Innovation
Maé Innovation’s DNA: Founded by an MOF Chocolatier
Maé Innovation was created under the impetus of Serge Granger, Best Craftsman of France (MOF) Chocolatier. This origin gives the company:
- An in-depth understanding of the requirements of high-level artisans
- A culture of excellence rooted in the company’s DNA
- **Legitimacy** with the most demanding professionals
One of the distinctive assets of Maé Innovation lies in its ability to develop products in close collaboration with professionals. This co-creation approach allows for the design of bespoke shapes perfectly adapted to the specific needs of each client.
Field feedback is systematically integrated into the design process, ensuring that each mould meets the practical requirements of users. This proximity to pastry chefs and production technicians fosters continuous innovation and adaptation to market changes.
Partnership with Jonathan Mougel, MOF Pastry-Confectioner 2019
The most iconic collaboration of Maé Innovation is with Jonathan Mougel, MOF Pastry-Confectioner 2019. Together, we have developed:
The ES-TAMP Range: High-End Decors
Officially launched in 2023, the ES-TAMP range is a collection of 8 silicone decor mats inspired by nature:
- Beech Leaves, Hazelnut, Water Lily, Dragonflies, Almonds, and other natural patterns.
ES-TAMP Technical Specifications:
- Thermal resistance: -45°C to +280°C
- Use: decors in sugar or chocolate
- High ease of use and cleaning
Other collaborations with renowned chefs
Value for Money: Thinking in Total Cost of Ownership
The comparative analysis between Maé Innovation and Flexipan cannot be limited to the initial purchase price. The true indicator of economic performance lies in the TCO (Total Cost of Ownership), which takes into account the effective lifespan of the moulds.
A mould whose acquisition cost is slightly higher but whose durability allows for significantly fewer replacements generates substantial savings in the medium term. Industrial field experience shows that the increased longevity of Maé moulds largely offsets the initial investment, particularly on high-speed lines where wear is intensified.
| TCO Component | Factors to Consider |
|---|---|
| Acquisition cost | Unit price of the mould |
| Lifespan | Number of cycles before replacement |
| Replacement frequency | Resistance to industrial constraints |
| Replacement cost | Price × Frequency |
| Maintenance cost | Cleaning products, washing time |
| Downtime cost | Production losses linked to failures |
This lifespan-oriented financial approach allows production managers to optimise their budgets while maintaining consistent production quality.
Environmental Commitment and Circular Economy
Beyond technical performance, Maé Innovation stands out for its commitment to a sustainable industrial economy. The company has implemented a used mould take-back program in Europe, allowing for their recovery and recycling.
How the program works:
- Take-back of silicone moulds at the end of their life
- Material recovery and recycling
- Contribution to the reduction of industrial waste
- Participation in a circular economy approach
This approach fits into a circular economy logic that meets the growing expectations of industrialists regarding environmental responsibility. Local manufacturing also promotes the reduction of the carbon footprint linked to transport and guarantees optimal product traceability.
Conclusion: Maé Innovation, a credible industrial alternative to Flexipan
The comparative analysis between Maé Innovation and Flexipan reveals two professional-quality solutions, each with its technical specificities. While Flexipan remains an established benchmark, Maé is gradually establishing itself as a credible French alternative, particularly attractive for industrialists seeking durability, performance, and personalised support.
Demoulding and baking performances are equivalent, while the 100% premium silicone composition offers superior longevity in intensive use. Maé Innovation’s ability to develop bespoke solutions in collaboration with professionals, as illustrated by the client case study, constitutes a tangible competitive advantage.
For production managers concerned with optimising their TCO while committing to a sustainable approach, Maé Innovation represents a relevant option that deserves to be evaluated in light of the specific needs of each production line.
