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Showing posts with label bread manufacturing. Show all posts
Showing posts with label bread manufacturing. Show all posts

Bread Improvers

Improvers  are  critical  ingredients of  mass  bread manufacturing  process . Bread Improvers performs  multipurpose function during production process  which impact the  texture of the  final product . The two most important function of an improver  are to  co2 generation during fermentation and gas  retention  during no time production method .These improvers are basically amylase enzymes which helps in breaking starch into  sugar  thus providing  food for better yeast activity during fermentation


Following are the major bread improvers

Ammonium persulphate
Potassium bromate
Potassium Iodate
Calcium carbonate
Acid calcium phosphate
Calcium  phosphate
L-cystiene  hydochloride
Guar gum

 Please check the permissible limits for the bread improver's from pfa act .

Few of  the  major bread improver manufacturers are
Puratos
AB Mauri  Pvt Ltd
Helios Food Additives Pvt Ltd
Enzymes India Pvt Ltd 

Roles of  bakery ingredients

Untold Truth About Super Market Breads

 Modern day bread manufacturing involves many ingredients and chemicals .Limits are arrived for these additives by govt agencies but even then these additives may cause health problems which we are not aware . Andrew Whitley  shares his  thoughts on these issues.


Excerpts from article by Andrew Whitley
The Biggest change of all occurred when the Chorleywood Bread Process was invented in the Sixties. This is the way most British bread is made to this day. It dramatically speeded up the process.
Its method was high-speed mixing, using intense energy (about six times as much as a craft baker uses to mix his dough), a plethora of additives, greatly increased yeast quantities and no fermentation time.
Before Chorleywood - indeed, for all of man’s bread-making history - bakers took time to let their dough rise (or ferment). That way, the small amount of yeast they put in could multiply and react with the flour to produce enough gas to aerate the bread.
Most bread was made in a two-stage process over 12 to 16 hours. Time ripened the dough, making it easier for the baker to handle and tastier to eat.
But advances in molecular science have revealed an even more significant role of time in bread-making.
As you allow dough to ferment, it neutralises some of the bits of wheat protein that are most likely to trigger bowel disease and other auto-immune and inflammatory reactions to gluten.
Unfortunately, almost all British bread is now made from ‘no time dough’. Which is bad news for our bowels.
Chorleywood was a triumph of efficiency: you could get from raw flour to wrapped loaf in under three hours.
But there were also the additives. Quite a few of them, in fact. Potassium bromate (now banned in the UK as a possible cancer producer), azodicarbonamide (also banned), L-cysteine hydrochloride, sodium stearoyl-2-lactylate and so on — the list was long.
To avoid too many frightening chemical names, bread labels were allowed to group the nasties under bland headings such as ‘flour treatment agent’ and ‘emulsifier’.
Some additives were belatedly banned (including the bleaching of flour with chlorine gas in 1999), but new ones filled the gap and, if anything, the list is longer today than 30 years ago.

Bread Dough Divider

dough dividers , bread dough dividers , dough divders , volumetric dough divdiders , pneumatic dough dividers

Bread dough divider is one of the critical equipment in bread automated manufacturing . Its main function is to  divide dough into number of equal  dough pieces.
Mostly  Bread Dough dividers are mechanical  devices  with manual adjustment but we can opt  for more automated dividers  with HMI  integrated to its operation where operators can  change variables from pre programmed software.Basic design are either Crank driven  divider or Hydraulic systems which operates  the ejector , ram ,knife , collector  controlled   by hydraulic directional  valves .
Most used Divider with medium to small bakery are  Crank type mechanical dividers . Its a  device which uses common crank to cut , push and drop  dough piece into equal pieces on the conveyor.
Volume adjustment can be done to correct the weight of these dough piece . Screw along with L –link which change the volume of cylinders to fine tune weights of the dough piece .
Dividers  are rated  by
Capacity  = Strokes /Min  Or   Dough Pieces Per Minutes
We can get bread dough  dividers   which can cut and drop  2,3,4,5,6,7,8,9  dough pieces  and are called tandem dividers .
It has been observed that  initially  the dough is less extensible  but as the time lapses it becomes softer  which affects the weight of dough pieces at bread dough dividers . Hence operator to continuously  adjust  and monitor the  volume of the  cylinder.

Features to  check  for Hydraulic  Bread Dividers
  • HMI  to be integrated with hydraulic system of bread divider
  • Automatic lubrication system
  • Cleaning arrangements for ram , ejector , knife and collector box
  • Knife made up of Stainless Steel
  • Remote weight control arrangement
  • Water wash down to clean entire bread divider
  • Cross and inclined conveyor
  • Flour duster

Major bakery equipment manufacturers are
  • Baker Perkins
  • Werner and Pfliederer
  • The Peerless group 
Other equipments
De panner
Dough Tilter

Plant layout for an automated bread plant

Schematic diagram of  bread plant layout

 automated bread plant layout , bread plant layout , bread factory layout

Bread Manufacturing Process - Video



Bread Manufacturing process - which involves
Mixing
Dividing
Molding
Paning
Proofing
Baking
Depanning
Cooling
Slicing
Packing

How to control dough temperature during bread/biscuit manufacturing process



Temperature plays a vital role in dough consistency which in turn impact the quality of bread or biscuit . Bakers have to maintain the dough temperature after mixing for better results after baking . Ambient temperature varies as per the season s a expert bakers has to arrange various method to maintain dough temperature . Average temperature maintained could be different in different locations .However temperature ranging from 28 –32 deg c provides better results at this part of the world .


Following factors effects dough temperature



  • Mixing duration

  • Water temperature

  • Ingredients temperature


Jacketed Mixers


All Mixers Manufacturers have Mixers with jackets around the mixer body . Operators can feed this jackets with cold or hot water as per requirement . Cold water is circulated through chilling plants .Hot water generally circulated by boilers or hot water generators .


Ingredient Temperature


Dough temperatures get impacted by ingredients temperatures.Ingredients with low temperature can be fed into mixers to maintain dough temperatures . Areas where ambient temperature reached 45 – 40 deg c its important to store this ingredients in cold storages or air conditioned places.


Ice Addition


Some places Ice is added manually to maintain dough temperatures or for certain varieties like choco chips ice is added to maintain the dough temperatures so as chips does not starts melting during the process.


Other methods used in most advanced bakeries are



  • CO2 Injection in mixing bowl

  • Flour cooling

  • Breaker bars and Agitator in mixers

Gelantinization and Dexterization - Bakery Glossary


Bread manufacturing have two important process in baking which are related to starch these are
Gelantinization
Dexterinization

Gelantinization is the process where starch is heated in presence of water .This process occurs inside the bread crumb which is soft and starch is in molten state . When the temperature reaches about 85° C, a colloidalsolution is obtained in which the amylose and amylospectin molecules arecompletely dispersed in the water. This sequence of events is known as
geíatinization.When bread is cooled then this starch remains in semi solid -semi liquid gel.

Dexterinization is the process where starch is heated in absence of water .It results into solid crust formation at the top of the bread .Temperature required for dexterinization is 225 deg c and above

Bakery Equipments - Bread Manufacturing

Bread manufacturing requires certain specific equipments and machinery to produce bread . Listed are equipments required for bread manufacturing in very large volumes .

Premixing

Flour Handling system
Sugar Grinders

Mixing
Mixers - Spiral

Prooving and Forming

Divider
Hander Up
Inter Proover and final proover
Moulder
Mould trays
Boilers

Baking
Ovens
Depanner
Cooling Racks

Packing

Slicer
Packing Machine
Printing Machine

With other material handling equipments and utility

Harvest Gold -Success story retold

It  all began  1993  In capital  city  of  Delhi  . A brand  called  Harvest Gold  was created  with  objective  to provide  quality  bread  to  consumers . Earlier  we had monopoly of two bread manufacturers  Britannia  and Modern . Demand was high  and  supply  short   hence  what ever was produced was bought without  any choice .Bread  where  sold in wax  papers .People used  to  stand in line for hours  for  delivery vans to get  their loaves  such was the  dominance  of  Britannia  and Modern  breads.Other  competitors  like Bakeman  and Tazza Bread  were non -existent .

The team of  Adil  Hassan  and Taab Siddiqui   then  commissioned  their plant at Bhiwadi  in Year 1993  with  the name  of  Harvest gold foods  India pvt ltd. The product  was instant  hit . This was a case  where  a local player  has  taken on  Big brand  and  was leader  in the market  within span of one - two  year of  launch .


What  differentiated  Harvest  gold from other  brands  was

1. Quality  of Bread  : All varieties  from 400gm  to 800gm pack  had uniform ,well sliced  bread neatly packed in  transparent packaging .With  new baking  technology  they  produced  better and uniformed  baked breads .


2. Packaging : Harvest  gold  pioneered   transparent  packaging  where consumer can  have a look  on product quality  without  opening  the pack . Where as  competitors where  using wax paper  for packaging .

3.  Advertising : Harvest  gold  experimented with English plus punjabi  slang for  its  advertising  which made  connection with  common man .

4. Transportation  and Distribution channels  where  such that  bread  where  delivered  on time and without much damage to product . Plastic trays where introduced  to carry breads instead of  metallic  crates .

Who says  that you cannot beat  the  big players  . Harvest  gold has shown the world  that  it can be done . Today  they  cater  for  65% of  NCR  market .


HO Address:

Company Name : Harvest Gold Foods India Pvt Ltd


Address : RZ- 167/1, Road No. 4, Block-A, Mahipalpur Ext.

Level of Office : Head Office

Phone No : (11) 26784573 26784572

What makes bakery product popular


bakery product are becoming more popular now days because of varieties available due to technological advancement and packaging certain categories of bakery product has distinct advantage of shelf life , it has been found that baked goods have shelf life of minimum of six months .
Long Shelf of bakery product like biscuits and cookies had made them popular to armed forces /sailors in earlier days .

Other advantages are that it can be fortified and other ingredients can be topped or mixed it with it . Cakes and breads can easily be prepared in homes in micro oven . The basic raw material the flour is easily available in grocery also the other products like sugar , salts ,baking soda etc .


Bakery products are all weather , all gender , all classes and any time snacks .
Thus its makes them best food category in entire range

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