Major bread manufacturer s in India have now opted for tamper proof packaging as popular method of bread packaging . Its interesting to know the fact that this kind of packaging was attempted is early 90's but with little success . Now this kind of packaging has been promoted by bread manufacturers with large retail shops opening up in India like Big bazar , Food bazar , Easy Day , Spencers and many more . Britannia , Harvest Gold , Bonn and Cremica are few major bread manufacturers using these types of tamper proof carry bags .It consists of adhesive tape with or without paper tag.
List Of Wheat Flour Mills In India
Bakeries normally source their flour requirement from local flour millers . Every state has their own local flour millers yet few of the flour brands or mills have grown up in size and operations and are supplying flours across countries . Punjab and Haryana are two major wheat producing states thus having large flour mills in comparison rest of the country . Flour are categorised as bread flour or biscuit flour as per the requirement of bakeries . Some times premium flour varieties for cake and pastries .
Here are few major flour suppliers to bakeries
Rajdhani Flour Mills Ltd
Cargill Foods
Shakti Bhog
Modern Flour Mills Ltd
BTS Flour Mill
Ahaar International
Amar Flour Mills
Delhi Flour Mill Ltd
Sree Vengopal Flour Mills
Shiv Roller Flour Mills
Modi Flour Mills
Rajdhani Roller Flour Mills (p) Ltd
Arti Food and Fats (P) Ltd
Bambino Argo Ind. Ltd
Panchkula Roller Flour Mills (P) Ltd.
Victoria Foods Private Limited
Here are few major flour suppliers to bakeries
Rajdhani Flour Mills Ltd
Cargill Foods
Shakti Bhog
Modern Flour Mills Ltd
BTS Flour Mill
Ahaar International
Amar Flour Mills
Delhi Flour Mill Ltd
Sree Vengopal Flour Mills
Shiv Roller Flour Mills
Modi Flour Mills
Rajdhani Roller Flour Mills (p) Ltd
Arti Food and Fats (P) Ltd
Bambino Argo Ind. Ltd
Panchkula Roller Flour Mills (P) Ltd.
Victoria Foods Private Limited
Bhawani Roller Flour Mills Ltd
Shree Ram Flour Mill
We can get exhaustive list of flour millers on
WhenYour Food Packaging Goes Wrong Or Is this Convenience Packaging ?
Watch this funny video highlighting problems with packaged food products. After its all about convenience packaging
Baker's Yeast Specification & Standards For Bakeries
Yeast is a vital ingredient in bakery process and should have following specifications as per standards of bakery manufacturer and products . Quality of yeast determines the end product .
Standards for Baker yeast
Bakers Yeast : Saccharomyces
Percentage Moisture
Dispersibility
Fermenting Power
Dough Raising Capacity or DRC ( Most critical )
Proteolytic activity
Heavy metals and alfatoxins
Microbiology Aspects
Bacteria microflora other than yeasts/gm
E.coli / gm
Salmonella/gm
Coliform Count/gm
Rope spore count /g
Storage Conditions - 4-7deg c
Storage Time - Not more than 15 days
Standards for Baker yeast
Bakers Yeast : Saccharomyces
Percentage Moisture
Dispersibility
Fermenting Power
Dough Raising Capacity or DRC ( Most critical )
Proteolytic activity
Heavy metals and alfatoxins
Microbiology Aspects
Bacteria microflora other than yeasts/gm
E.coli / gm
Salmonella/gm
Coliform Count/gm
Rope spore count /g
Storage Conditions - 4-7deg c
Storage Time - Not more than 15 days
Why Water Is Critical For Bakery Operations
Water apart from being an important ingredient in all bakery recipe has other functions in bakery to perform in bakery units
Role of water as ingredient
Helps in developing gluten in mixing
Forms emulsion alongwith fat
Forming Solutions for better mixing
Give moisture to end product for better taste
Helps in fermentation
Type of water
Hard
Soft
Alkaline
Source
Treated water from Municipality
Under ground water from bore well
Quantity and Quality of water are critical for better end product . Quantity of water are impacted by quality of flour and other ingredients where as quality can be checked through lab analysis of water characterisitics and adhering of standard water quality prescribed by authorities such as hardness , microbiological counts and heavy metal presence .
For potable water in bakery .Reference has to be BIS standard
Other Usage Of Water In Bakeries
Temperature control
Water is circulated in mixer jackets or added to control dough temperatures
Steam is generated to provide temp and humidity during proving which increases or decreases fermentation time .
Cleaning
Used in large quantity to clean floors and utensils in bakeries . CIP are done for liquid handling systems .Plastic trays and pallets are washed and cleaned by water .
Utility functions
Boiler
Hot water generators
Chilling Plants
Cooling towers
Water treating plants
To get water of desired properties bakeries do install water treatment plant such as RO systems . Filters can be used at end use of water in process to prevent contamination.
Role of water as ingredient
Helps in developing gluten in mixing
Forms emulsion alongwith fat
Forming Solutions for better mixing
Give moisture to end product for better taste
Helps in fermentation
Type of water
Hard
Soft
Alkaline
Source
Treated water from Municipality
Under ground water from bore well
Quantity and Quality of water are critical for better end product . Quantity of water are impacted by quality of flour and other ingredients where as quality can be checked through lab analysis of water characterisitics and adhering of standard water quality prescribed by authorities such as hardness , microbiological counts and heavy metal presence .
For potable water in bakery .Reference has to be BIS standard
Other Usage Of Water In Bakeries
Temperature control
Water is circulated in mixer jackets or added to control dough temperatures
Steam is generated to provide temp and humidity during proving which increases or decreases fermentation time .
Cleaning
Used in large quantity to clean floors and utensils in bakeries . CIP are done for liquid handling systems .Plastic trays and pallets are washed and cleaned by water .
Utility functions
Boiler
Hot water generators
Chilling Plants
Cooling towers
Water treating plants
To get water of desired properties bakeries do install water treatment plant such as RO systems . Filters can be used at end use of water in process to prevent contamination.
Does Your Bakery Have Food Safety Measures ?
Food safety needs to be the top priority for any bakery business owner . Here are following food safety measures for small to large bakeries .
Visitor Policy
Jewellery Policy
Plastic Policy
Glass Policy
Personal Hygiene Checks
Pest Control Management
Uniform Management
Sanitation Management
Building Maintenance
Food safety management system
Food safety Audit s
Storage system for raw material
Proper Drainage system
Maintenance system -Lubrication
Material Construction of equipments
Water Management
Solid Waste management
Training for work force
Equipments like - Air curtains/ Pvc strips/ Insect Killers/ Pallets /Rodent Boxes
Metal Detection systems
Filters / Sieves
Hazard Analysis done for HACCP
CCP's( Critical Control Points ) Identified
PRP ( Pre -requisite programs ) and OPRP ( Operational Pre requisite programs ) monitored ,updated
Visitor Policy
Jewellery Policy
Plastic Policy
Glass Policy
Personal Hygiene Checks
Pest Control Management
Uniform Management
Sanitation Management
Building Maintenance
Food safety management system
Food safety Audit s
Storage system for raw material
Proper Drainage system
Maintenance system -Lubrication
Material Construction of equipments
Water Management
Solid Waste management
Training for work force
Equipments like - Air curtains/ Pvc strips/ Insect Killers/ Pallets /Rodent Boxes
Metal Detection systems
Filters / Sieves
Hazard Analysis done for HACCP
CCP's( Critical Control Points ) Identified
PRP ( Pre -requisite programs ) and OPRP ( Operational Pre requisite programs ) monitored ,updated
PPE''s
Types Of Dough Tipping Device
Several types of Dough Tilters or Dough Tipping device can be used for dough feeding systems in bakeries . Dough tilting is required to transfer dough from Dough bowl after mixing to next stage , it could be Diving for Bread or Laminating for biscuits or Depositors in cookies production .Major mechanism for dough tilters is either hydraulic , screw and chain type.
Following Different Types Dough Tilters
Combination of mixer alongwith Dough Tilter
Inclined chain types dough tilters
Straight Lead Screw types tilters
Inclinded Lead Screw type tilters
Moving type -on the wheel dough tilters
Following Different Types Dough Tilters
Combination of mixer alongwith Dough Tilter
Inclined chain types dough tilters
Straight Lead Screw types tilters
Inclinded Lead Screw type tilters
Moving type -on the wheel dough tilters
Pest Birds Control In Bakeries
Some times bakeries have to face problem from birds entering into production hall . Pest bird control measures becomes important to prevent such occurence . Bakeries being food factory are attraction for these birds as they have different kinds of food available for them .
Bird can enters production hall through entrances , roof , damaged windows and gaps or holes in the wall s. . Normally birds which can be seen are crows , pigeon , doves,sparrows ,maina and even bats in some cases .
Chances of bird feces , feathers and debris contaminating the products are very high if these birds are not stopped from frequenting the production area .It has been observed that the feces could even damage the exterior paints of wall with their stains . Huge cost are incurred while doing re -painting in such area s . Arches and chajja s are best places for birds to build their nest s.
Here are few Pest Bird control measures
Bird Netting
Nets could be placed under the trusses of building to avoid birds resting places .
Bird s glue
Audio and lights
Bird Spikes
Spikes are placed on area frequented by the birds so as to prevent them from landing and then entering into bakery production halls
Bird mist
Mist of certain chemicals prevent these birds to come inside the production hall.
other articles
Pest control in bakeries
Bird can enters production hall through entrances , roof , damaged windows and gaps or holes in the wall s. . Normally birds which can be seen are crows , pigeon , doves,sparrows ,maina and even bats in some cases .
Chances of bird feces , feathers and debris contaminating the products are very high if these birds are not stopped from frequenting the production area .It has been observed that the feces could even damage the exterior paints of wall with their stains . Huge cost are incurred while doing re -painting in such area s . Arches and chajja s are best places for birds to build their nest s.
Here are few Pest Bird control measures
Bird Netting
Nets could be placed under the trusses of building to avoid birds resting places .
Bird s glue
Audio and lights
Bird Spikes
Spikes are placed on area frequented by the birds so as to prevent them from landing and then entering into bakery production halls
Bird mist
Mist of certain chemicals prevent these birds to come inside the production hall.
other articles
Pest control in bakeries
Why Cheap Labor Is Not Cheap For Bakeries
What drive these big companies in bakery industry for contract manufacturing and co -packer arrangement is low cost labor and cheap labor . The Co-packers ( CP ) or CMU ( Contract manufacturing units ) employs several contractors to get workers at very low salaries mostly unskilled and with low literacy rates . As workers are not aware of the legal wages these small companies make huge money out of these worker .
This is how companies cut over head cost of workers in these units as they don't pay for
No ESI ( Employee contribution from contractors or companies
No PF ( Provident Fund )deduction and contribution from the contractors or companies
No Gratuity for the workers who worked for more than five years
No Earned Leave for these workers
No Standard Over time payment
No Incentives or Bonus linked with production
No Medical or Insurance for the worker
No Uniform and Clothing Allowances .
Deduction in salaries for flimsy ground or absence
( Will State agencies look into these malpractices which are rampant in such units some of which mandatory by law payable to the workers ? )
As these workers are paid less there fore the rate of attrition is very high thus impacting the product quality and the process . Also as these workers starts searching for better opportunities or work part time doing extra jobs, which negates what ever efforts these companies have put to train them thus entering into vicious cycle of training unskilled labour all the time
Cheap labor has its own cost which companies are aware of but for profits they try to run the production with these workers .
Here are few negative results from cheap labor
Production inefficiency
High Maintenance cost due to break downs
High number of foriegn body complaints
High cost on continuous training ( few opts for no training )
More Product recalls
More consumer complaints due to defective s
Stress on supervisory personnel .
Major Accidents & Cuts
Hence it can be concluded that cheap labor is actually costlier than skilled and qualified labor . Companies should recognize this and aim for building effective and productive labor in longer run
This is how companies cut over head cost of workers in these units as they don't pay for
No ESI ( Employee contribution from contractors or companies
No PF ( Provident Fund )deduction and contribution from the contractors or companies
No Gratuity for the workers who worked for more than five years
No Earned Leave for these workers
No Standard Over time payment
No Incentives or Bonus linked with production
No Medical or Insurance for the worker
No Uniform and Clothing Allowances .
Deduction in salaries for flimsy ground or absence
( Will State agencies look into these malpractices which are rampant in such units some of which mandatory by law payable to the workers ? )
As these workers are paid less there fore the rate of attrition is very high thus impacting the product quality and the process . Also as these workers starts searching for better opportunities or work part time doing extra jobs, which negates what ever efforts these companies have put to train them thus entering into vicious cycle of training unskilled labour all the time
Cheap labor has its own cost which companies are aware of but for profits they try to run the production with these workers .
Here are few negative results from cheap labor
Production inefficiency
High Maintenance cost due to break downs
High number of foriegn body complaints
High cost on continuous training ( few opts for no training )
More Product recalls
More consumer complaints due to defective s
Stress on supervisory personnel .
Major Accidents & Cuts
Hence it can be concluded that cheap labor is actually costlier than skilled and qualified labor . Companies should recognize this and aim for building effective and productive labor in longer run
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