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Showing posts sorted by relevance for query baking oven. Sort by date Show all posts
Showing posts sorted by relevance for query baking oven. Sort by date Show all posts

Types Of Baking Oven

Baking ovens are major equipment  for  any bakery process  . Major function of baking oven is to  heat the wet dough ,batter  to  a temperature  where it becomes  baked with desired texture and taste . Baking removes  the moisture which helps in improving shelf life of the baked products plus it kills any microbes  in the dough at a higher temperature .Accessories to baking oven are  circulating fan , steam extraction , chimneys , safety explosion doors , fire tube , burners , drive ,temperature controller and indicators , fuel system with  baking moulds  and wire bands.Bakery ovens selection also take dimensions  into consideration such as height ,width , weight , chimney dimensions , foundation method  , electrical wiring and automation.Types of oven used in bakery are classified on several  factors .

Baking Ovens  are  of various types used for baking breads , cookies , biscuits , cakes ,pizza and cream rolls

Types of oven for baking  can be classified by

indsutrial baking oven s, types of industrial baking ovens , type of baking industrialPhysical  Characteristics



Heating

  • Direct  Heating ovens
  • Indirect  Heating Ovens
  • Hybrid Ovens


Loading

  • Top  Loading Ovens
  • Front Loading


Fuel  Used

  • Diesel  Ovens
  • Gas Ovens
  • Electric Ovens
  • Infra red


Wire Bands



Length or Width

  • 1.5 mtr  Band width Oven
  • 1.2mtr Band width Oven
  • 1.0 mtr Band width Oven
  • 0.8 mtr Band width Oven
  • 4/5/6/7/8 Zone Ovens

As Per Design

  • Mark III Oven
  • TRP   Ovens
  • Mark II  Ovens

Tension  Arrangement
  • Pneumatic
  • Mechanical

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Types of Industrial Biscuit Ovens

Various  types of biscuit ovens  are used in biscuit industry  for production of   varieties of biscuit .  Selection  parameter  for   any biscuit  oven are capacity ( which covers length ,width  and speed ) , products , baking time  and type of fuel  .Normally in bakery parlance  ovens are defined as per  width and no of  baking zones .

Biscuit Oven , Industrial  Biscuit oven , Tunnel Oven , Direct fired oven , Indirect oven Biscuit ovens are mainly  classified  under  following  types

Direct gas fired

 The gas fired  oven is used  for those product  that require  great heating power . They can burn natural gas  or LPG . The gas  is mixed  with air  in a special  mixing pipe  based on  the Venturi tube  principle . In each zone  the heat at  top and bottom  can be  independently set by regulating  the two combustion  air fans which controls  the volume of gas  fed  to the  burners . A bar graph potentiometer  set by operator  can be  used to select the heat ratio between  top and bottom . Each zone is equipped with a suitable humidity  extraction system .


Indirect   radiating  cyclotherm oven

 The Indirect Gas / Diesel fired ovens  also known as  cyclotherm  oven - transfer heat  to the product   by radiation . Each zone consists of  set of tubes  at the top and bottom  of the baking  wire band  through which  the hot air  which has been previously heated  by burner flows .

At the end  of each baking  zone the hot gasses are collected  by a plenum and returned  by blowing  fan to the burner  where they  are heated  up again  to the working  temperature  and sent back  to the tube circuit . The heating  system  is there for  completely  independent  and the products  of combustion   does not  comes in contact with dough being baked . Each zone  has  extraction fan to remove humidity from  baking chambers .

Convection oven 
The convection  oven  is suitable  for baking delicate products  like cookies , wire cut  or sponge . Its baking chamber  is constituted  by a plenum  duct positioned  on the top and bottom  of the baking wire band  where hot air is  gently  blown out of  properly  designed  slats  and comes  in  contact  with the dough . The heat transfer  is mainly by convection . The convection  type of oven can be  direct  or indirect . In those cases  where the available fuel  is natural gas or lpg  and the reduction  of baking time is a necessity the direct convection  is the  correct choice .  In the  In direct   convection type of  oven  the  air is heated  up by passing through  a dedicated  heat exchanger  hence  baking  never comes into contact  with the dough .Humidity  is removed through extraction fans in each zone .

 

Hybrid  Oven

Hybrid ovens are those  ovens which have combination of any of the above types of ovens.  Sections are divided  into different type of heating  systems , depending upon  product and its baking  requirement .
  


Electric  Oven

Electric ovens  are  not so popular with  manufacturers due to low cost of lpg,cng or diesel as compared to  electricity . Oven  consist of electric heater s  which  en capsuled into radiating pipes  . These are then set  for set temperatures by thermostats .

Swing Tray Baking Oven s

In Bread manufacturing process baking oven is the major equipment. There are various baking ovens for bread manufacturing ,for any higher capacities manufacturers often opt for Swing tray baking ovens .Other model for baking oven for higher volumes of bread production is contray ovens .

Swing Trays main drive moves sprockets and chain with which the racks are  hinged with the chain and this tray swings both ways .These racks hold bread moulds  and carry them  to complete the baking cycle

Burners can be of ldo ( diesel type ) or cng ( gas type ) . hot air is circulated through circulating fan in headers either through top and bottom headers or middle and bottom headers .

  
Swing tray ovens can be designed for 5000 – 50000 loafs per day capacity.

  
Some of the features in Swing tray Ovens
swing tray oven , st oven , swing tray  bread  ovens

  • Preferred for higher volumes
  • Oven chain can be hand-cranked in an emergency  
  • The tray's movement is intermittent and controlled by a digital timer  
  • Insulated for maximum fuel-efficiency  
  • Flue gas does not come in contact with food item being baked  
  • Imparts solid top and bottom heat to loaves under baking for uniform results across the length of the tray  
  • Lidding and Unlidding is automatic in swing tray ovens  
  • Requires a larger area than other baking oven for the same capacity 
  • Safety Explosion doors are provided as safety against any explosion

Biscuit Production Line

Biscuit production line consists of following equipments with brief  description

Mixers
All  ingredients are mixed into mixers  to prepare  dough  with desired characteristics . Normally two stage mixing is done  in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer .

Dough Elevator or Dough Tipper

Dough bowl  are either taken to tippers where dough is decanted into mixer bowl  which is beneath the tipper at level lower  to the tipper  or  dough bowl is  carried to certain height  and then tilted to decant the bowl into laminator hopper .

Dough Laminator

Laminator main function is to reduce the  mass of dough into uniform sheet or laminate for further reduction in gauge roll . Laminators have sets of roller where this dough is acted upon  and are converted into dough sheet .

Gauge Rolls

biscuit production line , biscuit production
These gauge rolls have set of cylindrical rollers which rotates in reverse direction so as to  give  push to the next gauge rolls . Three stand to four stand of gauge rolls are used in normal biscuit  production line . Speed of rolls ae set as per the baking time and increases  as we proceed further .

Moulding /or  Cutter Unit

These are equipment  which cuts the dough sheet into desired shape and size . Plant out put are calculated as per the design of the moulder or cutter . These cutters or moulders have dies , cups or inserts which are fixed on the cavities or  surface of the moulder or cutter .
Now days engraved moulders and cutters are available . Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cups .

Moulder are used for short dough  where as cutters are used for hard dough variety

Scrap return conveyor

These conveyors  returns the  scrap dough back to mixers which are again used for production thus minimising waste .

Swivel Panner
Swivel panner  is  installed at the feed end of oven where it centres the dough piece entrance on baking oven band  it has swivel arrangement on which it balances the  web or centres the web  so that wet dough pieces enter s oven in straight line .

Baking Oven

Dough pieces then enters oven  and travels on wire band for baking . Burners generates heat which is circulated through ducts or pipelines  to bake wet  dough pieces . length and width of oven are designed as per the capacity required . Oven speed is adjusted as per the standards baking time for particular variety


Stripper Conveyor

Stripper conveyors are provided  at  the delivery end of oven so that  baked biscuit are cooled and doest not come into contact of any surface when hot . Stripper conveyors has wire mesh which carries these hot baked biscuit .


Cooling Conveyor

These conveyors  are provided in biscuit production line to   bring down temperature of   hot biscuits which comes out from oven . normally they 1.5 -2 times of  oven length .


Magnetic Stacker

Stacker are used to  distributes and   arrange biscuits  in a line and are thus could be stacked easily for packing process . These biscuits  are made to pass of plates which acts as guides which makes these biscuits to fall into space between the guides .


Packing Table

Biscuit s travels into guidelines on packing table where either they are fed into  into  packing machine automatically or are fed into feeding chutes  manually by operators .


Packing Machine
Biscuits are fed into packing  machine for packaging   there are various types of biscuit packing such as pile type , on the edge  and cream sandwich type . Horizontal flow wrap machines are  mostly used to pack with flexible packaging .

Biscuit  Process Flow Diagram 
Bread Process  Flow  Diagram 
Accesories & Additional Equipments For  Biscuit Production

Understanding Energy balance of a Biscuit Oven

 energy balance of baking oven , energy balance of biscuit oven
 Under standing Energy balance of biscuit  oven is important   for  energy saving s in baking oven
Input to the oven  is the heat energy from combustion of  fuel  ( lpg , cng , ldo/hsd/ , electrical ) . One must evaluate the fuel options available  for the factors  such as

  • Availability  of fuel
  • Cost per unit
  • Calorific Value of the fuel
  • Maintenance cost on the Burners

Hence the fuel with best value ( calorific value  per unit  x  net cost per unit )  should be  sourced .

Now Oven out put in energy terms  are

Heat Loss during baking of biscuit

Heat  Loss during evaporation of moisture - Flour quality plays important role plus the mixing quality

Heat Loss  through  flue gas - Combustion generates flue  gases which escapes through stacks . Heat recovery system  can be installed recover this heat  .Air to fuel ratio has to be checked  so as to prevent excessive heating going out as flue gas .

Heat Loss through radiation - Biscuit Ovens have either duct s or Pipe s through which hat air circulates . Considerable heat are lost in  these mediums . Good Insulation  can be provided to minimize the loss of heat through  Biscuit Oven body

Heat Loss in Band Heating  - Band re heating s are now days incorporated  by manufactures by providing enclosure at the  bottom  through  which  the bands returns  to the feeding end .

For majority of the   Baking Ovens it has been seen that it  utilise' s only  40 - 50%  of the Heat Input . Efforts  has to be made  for optimisation  of  heat energy


What Are Different Types Of Baking Bands In Travelling Ovens

Travelling oven Or Conveyor ovens  consist s of Bands which travels  through the oven with the product to complete the baking cycle of the product .These bands are kept on feed end and delivery end drums  and the tension is provided either by weights or pneumatic pressure .Drive is given through motors to the drum .  High Temperature  elongates the band  the tension provided by weight or pneumatic pressure keeps the band from falling .

Several type of Wire bands are  used as per the application


wire mesh bands , tunnel oven bands , z-47 oven bands 1. Articulated Wire Mesh  : These kind   wire mesh  are mostly  are used in biscuit ovens  and biscuit manufacturing . Wire mesh  specifications covers.

Length x Width
SWG : 16/18/22
Mesh Type =  Z -47
Sides Welded Or Open
S.S or M.S

These  Wire Mesh are joined together  with  spiral links  provided by the wire band manufacturers. Good wire band can run for at least 5- 6 years . Most of the  oven manufacturers  source it from wire band manufacturers . Cleaning requires scrubbing band by mechanical means or putting of  bees  wax to melt on the surface of wire mesh which carries  dust along with it .


2. Flat Steel Band :  These are used in traveling ovens which uses  batter  or  viscous  dough for  baking . These flat bands made of  Stainless Steel  mostly used for products like Cookies ,  Swiss Rolls  and Cakes .
Flat bands are ordered as following specs. Costlier than Wire mesh Bands . Cleaning consume large amount water .

Thickness ( SWG)
Length xWidth



3. Modular Type Wire Mesh  :  These are baking band on which  either bread/buns/Rusk  are kept directly on the  modular band . The bands carries these mould or  baking trays through  baking oven . Small bakeries normally opt these kind of traveling oven.


Tracking of band   occurs due to tensioning   and can be adjusted through adjusting feed or delivery drums.

How to select Industrial Bakery Ovens ?



Are you planning to open an bakery unit . Major equipment or you can say heart of any bakery operation is the Oven from where we produce our baked products let it be cake , biscuits , cookies , wafers , buns , puffs , pizza ,pastries ------ so many other form s of bakery products . Baking is done in these ovens . You have to be careful while selecting ovens .

Criteria for selecting Oven


  • Space - Check the dimensions available for the oven which can be installed in your unit . You can check the length and width of the Oven and ask manufacturer to as per our factory layout .Space required for tunnels ovens and travelling ovens are larger than smaller ovens like rack or deck ovens or Rotory oven .
  • Fuel - Burners are now available for different type of fuels -eg gas , diesel oil , electrical .These burners are installed in the Bakery ovens .Check the availability and cost of the fuel before finalising the type of Oven you require
  • Product - Once your have finalised your product you can approach different types of oven manufacturers for your production of cake , biscuit , pizza , biscuit ,cookies and other related products . Versatile oven can be made as per the buyer .
  • Capacities - Plan your capacities for term of say 3- 5 years where you increase your production and need not run for additional ovens . Capacities helps Bakery oven manufacturers to design ovens as per the requirement
  • Method of baking - Various methods of baking are popular in bakery industry eg Direct heating , Indirect heating or Hybrid Oven for combination of direct as well as indirect heating .
  • Automation - Level of automation can be done as per buyers requirement .Automation in respect of burners , safety and temperatures controls can be done by the oven manufacturers.


Different Kind of Industrial Ovens


  • Rack or Deck Ovens
  • Rotary Ovens
  • Contray Ovens
  • Swing Tray Ovens
  • Travelling Oven
  • Tunnel Ovens
  • Direct Heating Ovens
  • Indirect heating Ovens
  • Hybrid Oven
  • Wafer biscuit oven
  • Flat Steel band Oven

Temperature Profile for Biscuits In An Oven

 baking oven , baking oven temperature profile , temperature profile of biscuit oven


 Wire Band Biscuit Oven s have  several  heating zones each zones having specific action on biscuits

Heating  Zones

Maximum Heat energy is utilised here to bake  wet dough pieces  as moisture content is higher here . Fuel consumed at this zone is maximum as  load here is of wet dough pieces .



Baking Zones

Biscuits when partially baked travels  to Baking zones here biscuits are subjected to higher temperatures to  complete the baking  and make it crisp .



Coloring Zones

Coloring Zone s function is to maintain the heat and add color to baked biscuit  the dark brownish color or light brownish colors are achieved here as per the variety of biscuit.

RADIO FREQUENCY - Post baking drying technique


Biscuit manufacturers all across world have following options to increase capacity in existing plant . They have been trying various method to achieve this .


  • Increase the oven length hence increasing moulder /cutting speed .Not all ovens has this advantage you have to check whether another zone can be added to existing biscuit oven or not .



  • Run plant at maximum speed with increased temperatures in different biscuit oven zones resulting in reduced baking time .This has disadvantage that the quality of biscuit gets affected.


  • Using Radio frequency dryers at the delivery end of biscuit ovens ,this helps in reducing moisture further by 10 - 11% hence we can increase the speed of moulder/cutter resulting higher output .


Principle on which radio frequency dryer work s is that as water has As product exiting the baking oven enters the RF post-baking dryer, it passes through an electrode array having an alternating electric field which reverses its polarity at a rate of 40.68 million times per second.
Water is comprised of "polar molecules" which can be likened to each molecule having a north and south pole. When passing through an alternating electric field, polar molecules react similar to the way bar magnets behave in an alternating magnetic field, constantly realigning themselves to face the opposite pole. At a frequency of 40MHz, friction caused by this rapid movement causes the polar molecules of water to quickly heat, wherever moisture is present, throughout the entire thickness of the product.

Nonpolar materials such as fat, oil, and dry ingredients do not react and, therefore, are not directly heated by RF energy. In the case of bakery products, this means an RF dryer will preferentially heat and dry the wettest area of a product without heating the areas already dry. Typically, there is greater moisture in the interior of a product as it exits a conventional oven. Therefore, this moist area will preferentially absorb more of the RF energy.



Developed for high-volume cookie production Post-Baking Dryers quickly and efficiently remove residual moisture trapped within the center of the product, permitting conventional ovens to run at the maximum speed that a product can be produced with the correct loft, crumb structure, and color. These RF dryers are available in different band widths



Advantages of RF heating
Increased Throughput - Up to 30% increase for crackers and often up to 40% for cookies.

Elimination of Checking - By greatly reducing the moisture variation throughout the thickness of the product, checking caused by differential shrinkage is eliminated.

Excellent Control of Final Moisture Content - Final moisture is controlled to approximately +/-0.25%.


Independent Color Control - Since moisture is controlled in the RF dryer, color development in the oven can be done without concern for final moisture content
Refer radiofrequency.com for more details on RF technology

Rotary Ovens For Bakery

Rotary oven are suitable for uniform and perfect baking of various products like bread, buns, cakes and cookie. Widely popular among small to medium bakery businesses and is best suited for bakeries producing  number of varieties .
Rotary oven are with turntable and has stainless steel, body and baking chamber for easy maintenance. It has one-piece door with heat reflecting glass, specially designed gasket that gives complete sealing of doors. It has large steel heat exchanger that ensures lower fuel, consumption and fully indirect heating, from cold to 250°c in 20mts. It has pictorial indicating plate with electronic digital display. The machine also has steam generators on feed wall for better steaming. It has an excellent air distribution system for optimum baking performance. Illuminating elements outside main heating chamber with off facility to reduce electricity bills.
Rotary oven are designed to be easy and safe to use. The thick, overlaping insulation keeps the heat where it should be,inside the oven ,and forbid to transfer heat to the working environment;.  It can be heated by electricity ,oil,gas or coal. the control panel can be used for either by hook or rotating plantform. the large window in the door incorporating heat-reflecting double glazed glass and the effective internal light permits close observation of the baking process inside the oven. ,toast,biscuit,cake,etc.

Rotary  Ovens  have  anti  explosion safety installed for  any explosion inside  the chamber . Trolleys as per the dimensions of the products are provided or could be fabricated by the bakery manufacturers  . Trolley once loaded with  dough is placed onto  the rotating platform on which this trolley is stationed .Rotary  oven  thus gives uniform heating  to  the product .Main components are  Burners , Extracting Fan , Controls and Rotating base

Specification for  Rotary  Oven

Capacity : Varies from 50kg -200kg
Type :  Convection  Oven / Turbo Oven
Fuel :  Electric /Gas/Diesel
Trolleys : Single or Double
Tray :32trays/trolley or 64trays/trolley
Power : 2.0-5.0 kw
Controls : Manual /Automated


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Wiesheu Dibas 64 Oven Wins Prestigious International Forum Design Award 2011

International  design forum ( IF  ) conducted by IF GmbH has  given Weisheu  Dibas 64 convection for  best design in product design category  for year 2011. IF  awards  are given to best design in product categories  for engineering , architecture and  other categories .



Wiesheu  ovens  are  popular ovens  in European market mainly in smaller bakery  category . Its German design and features makes it s  leading oven for bakeries . Unique  features of Dibas 64 that  it is the only baking oven in the world with the door disappearing into the oven casing at the side and furthermore convinces with its elegant, clear and timeless design unique in the industry.

With features like   double glass doors , removable racks ,halogen bulbs and complete S.S constructions  with  compact modular design makes it perfect for smaller bakeries .







The baking oven Dibas 64 in all its three sizes is a visual highlight in every store and perfectly emphasises the surrounding store concept and baking competence ( source : www.worldbakers.com)

for more on Wiesheu  Ovens  

Are hybrid oven better than any other type of biscuit ovens



I had opportunity to work with different type ovens in biscuit factory . They have direct fired ovens and indirect fired ovens . Basically Oven types are selected with following parameters .

Type of Product
Speed
Capacity

Hybrid oven , direct fired ovens , indirect fired ovens , biscuit ovensBoth direct and indirect ovens have few disadvantages and advantages as far as biscuit production is concerned .Direct ovens are generally used with cracker variety
As greater heating is required during baking stage . It has got numerous burners at bottom and top of the oven band .Direct fired operates generally on gas . Controls are less in direct oven .Less energy is consumed in direct oven .

Indirect ovens uses circulating fans to heat pipes or plenum in different zones . Used generally for moulding variety of biscuit as gradual heating is preferred for such type of oven . Control are more in indirect ovens . Energy is consumed more in Indirect oven .

Hybrid Oven combines benefits of direct as well as indirect ovens . Hybrid ovens are most versatile ovens for multi product usage you can have moulded variety as well as cutting variety with higher speed hence with more production .Ratio of direct part to Indirect part are generally 20-30% ( direct ) to 70%-80% ( indirect ).

Main  advantage  of Hybrid ovens  are

  • Flexibility  of the baking process - different  products  requiring  different  baking profiles  can easily  and successfully  be processed  in the same oven .
  • Much better  fine tuned  control  of the final  moisture  content  of the products  with  consequent  reduced risk  of  checking effects  on biscuit .
  • Improved crispness  and improved  general  texture  of  the product
  • More uniform  colour  of all  the baked products  across the width 
  • Higher output can  be obtained

The Art of Gluten-Free Baking: When Health Matters !



Lets first understand what is gluten and how does it effects our health

Gluten is a protein found in certain grains, primarily wheat, barley, rye, and their derivatives. It plays a crucial role in giving dough its elasticity and helps bread and other baked goods maintain their shape and texture. Gluten is also used in various processed foods as a stabilizing or thickening agent.

For most people, gluten is a harmless component of their diet. However, some individuals may experience adverse health effects when they consume gluten. There are three main conditions related to gluten intolerance or sensitivity:

Celiac Disease: Celiac disease is an autoimmune disorder in which the ingestion of gluten triggers an immune response that damages the lining of the small intestine. This damage can lead to various gastrointestinal symptoms such as diarrhea, abdominal pain, and malabsorption of nutrients. Over time, untreated celiac disease can result in nutritional deficiencies and other complications.


Non-Celiac Gluten Sensitivity: Some individuals experience symptoms similar to those of celiac disease when they consume gluten, but they do not test positive for celiac disease or wheat allergy. This condition is known as non-celiac gluten sensitivity (NCGS). Symptoms may include gastrointestinal discomfort, fatigue, headaches, and mood changes. The exact mechanism behind NCGS is not well understood, and it is a diagnosis of exclusion.


Wheat Allergy: Wheat allergy is an allergic reaction to proteins found in wheat, including but not limited to gluten. Symptoms can range from mild hives and digestive upset to severe anaphylaxis. Unlike celiac disease and NCGS, wheat allergy is an immune response to specific wheat proteins and can be diagnosed through allergy testing.

It's important to note that only a small percentage of the population has celiac disease or wheat allergy, while non-celiac gluten sensitivity is less common. For the vast majority of people, gluten consumption is safe and does not cause adverse health effects.



For those with celiac disease or gluten sensitivity, adhering to a strict gluten-free diet is essential to manage symptoms and prevent long-term health complications. This diet excludes all sources of gluten, including wheat, barley, rye, and products derived from these grains. Fortunately, there is now a wide range of gluten-free alternatives available, allowing individuals with gluten-related conditions to enjoy a varied and balanced diet while maintaining their health.

Baking is a universal language of love, comfort, and celebration. The aroma of freshly baked bread, the warmth of a just-out-of-the-oven cookie, and the joy of sharing a homemade cake with loved ones are experiences that transcend culture and time. But what happens when you remove a fundamental ingredient from this culinary equation—gluten? Enter the enchanting world of gluten-free baking, where passion meets precision, and every recipe is an opportunity to create magic.
gluten free  baking


The Challenge of Going Gluten-Free

For many, the decision to embrace gluten-free baking is not a choice but a necessity. Individuals with celiac disease or gluten sensitivity must avoid gluten—a protein found in wheat, barley, rye, and their derivatives. Consuming gluten can lead to digestive distress and long-term health issues. Yet, these challenges have birthed a new era of baking creativity that defies limits and redefines flavor.

Mastering the Flour Palette

In gluten-free baking, traditional wheat flour takes a backseat, giving rise to a diverse palette of alternative flours. Each flour brings its unique texture, flavor, and nutritional profile to the table. Almond flour adds richness, coconut flour lends moisture, rice flour contributes neutrality, and sorghum flour infuses a subtle nuttiness. Gluten-free baking becomes an art of flour blending, where precise combinations mimic the structure and versatility of wheat flour.

The Xanthan Gum Enigma

The absence of gluten calls for the introduction of binders and leaveners. Xanthan gum, a common ingredient in gluten-free baking, steps in as the mystical binder that adds elasticity to dough and prevents baked goods from crumbling into despair. Baking powder and baking soda become leavening wizards, ensuring that bread rises and cakes achieve their heavenly fluffiness.

Flavor Symphony

Gluten-free baking allows for the exploration of diverse flavors. Nut flours like almond and hazelnut impart a delightful richness. Coconut flour introduces a tropical twist, while chickpea flour offers a savory edge. Embrace these flavors and let them dance harmoniously in your recipes.

The Sweet Balance

Sweeteners become essential partners in gluten-free baking, not only for sweetness but also for moisture and texture. Sugar, honey, maple syrup, and their counterparts join the alchemical dance, infusing creations with delightful sweetness. Experiment with different sweeteners to find the perfect balance for your taste buds.

Reimagining Classics

Gluten-free baking is a realm of endless creativity. Classic recipes like chocolate chip cookies, apple pie, and banana bread are ripe for reinvention. Swap wheat flour for a blend of gluten-free flours, and you'll be amazed at the delicious transformations that take place.

Global Inspirations

Why limit your culinary horizons? Gluten-free baking invites you to explore the world's diverse cuisines. Discover Mexican corn tortillas, Indian chickpea flour flatbreads (besan chilla), or Italian polenta. Each culture offers gluten-free gems waiting to be savored.

The Future of Flour Magic

Gluten-free baking has come a long way, evolving from a necessity to an art form. With an expanding array of gluten-free products and resources, the possibilities are endless. The future holds tantalizing discoveries, pushing the boundaries of taste and texture.

Conclusion: Where Magic and Mastery Unite

In the enchanting world of gluten-free baking, every recipe is an incantation, every flour blend a potion, and every bite a taste of triumph. Whether you embrace gluten-free baking out of necessity or curiosity, one thing is certain: it's a journey that leads to a realm of culinary wonders, where taste knows no bounds. Don your apron, gather your gluten-free flours, and embark on an adventure where every creation is a testament to your passion, precision, and the magic of gluten-free baking.

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How Do We Calculate Biscuit Plant Output

When ever people think of putting up  a new biscuit plant  , the first question which come s in mind is the plant output or  capacity . This  is important for  design and  project  of new biscuit plant .Unit could be tons /hr or kg /hr of  production . Biscuit output  is required for  material planning and plant specifications .

There  different methods  to calculate  biscuit plant output  as mentioned below


a .  Baking time   x  with  rows x columns  in  one minute from cutter /molder  rpm. moulder and cutter have dies or cups  as per biscuit shape and size .

b.   Oven  band surface  area  x baking time of biscuit oven .( tunnel oven )
Oven length and width depends upon  the volume of biscuit to be produced 

On the basis of capacity ,  Mixers  and Packing machine  are  selected  for line  balancing

c.   Mixing  time with   batch size processed in  unit  time
 
d.   Number of packing machine  used to pack with  packet per minute  for calculation .


Oven capacity (lbs/hr) = R x N x L 1/C x60/T
R = rows of goods per foot of band length
N = rows of goods across the band width
L = baking chamber length in ft.
C = count of baked biscuits per lb.
T = baking time in mins.maximum baked size of the coojie

To determine N & R.
Let W = actual product width in inches
D = maximum baked size of the cookie
S = spacing from centre to centre of adjacent rows
X = clear band space at each edge
Then, W = ( N x S ) - S + D +2X
or, N = W + S - D - 2X / S and R + 12 / S
Capacities of other machinery prior to the oven can be referenced to the oven capacity
Published May 1967 Cookie & Cracker Technology
Samual A Matz and Theresa D Matz

How to increase biscuit oven output


Biscuit manufacturers have many options to increase their oven output with few changes in their existing set up . These steps are applicable for big or medium biscuit plants which have traveling ovens .

Following steps can be implemented
Increasing moulders /cutters rows and columns.
Increasing the rows and columns in the moulder or cutter to for better utilisation of oven band surface area .Its has been observe that moulder and cutters does not utilise the entire surface area and margins are left on sides on the oven band .

Increasing the moulder/cutter speed ie low baking time
Temperatures of oven zone can be adjusted so that the baking time is reduced and the speed of band can be increased in tandem with gauge roll and cutter /moulder speed .

Adding additional oven zone ( Increasing the biscuit oven length )
Increasing the oven length is another options where we can increase the output of biscuit plant . This requires oven manufacturers to add another section at delivery end and adjusting cooling conveyors and calculating the packing machines capacities to cater increase in biscuit oven output .If required additional packing machines can be installed .

Installing Radio Frequency Dryers at the delivery end of the biscuit oven .
RF Dryers can be installed at the delivery end which reduces the moisture content of the biscuit coming out from the oven hence allowing operators to increase the oven band speed .

One has to calculate the packing machines capacities to handle these increased output and check whether packing machines can pack these biscuits or not ,If not then additional packing machine can be installed . In semi automatic plants the feeding process of the machine has to be checked whether feeders can handle this increased volumes as this operation is manual.Speeds of biscuit plant are interlinked with each other .Hence one has to see whether speeds can be achieved through adjustment in the frequency drives or other combination of gear box and sprockets are required .

Mixers capacities and Ingredients automation too have to checked whether increase speed matches with mixers capacities .

Lighter Oven Bands Could Result In Energy Saving

Energy  savings   strategies for bakeries  includes  oven  band heating   .  Oven bands are of various types  which are used to convey  wet  products  to the oven  for baking . Normally this type of oven bands are required in biscuits , cookies , pizza , Swiss rolls  manufacturing using tunnels oven with length varying from 150 ft - 300 ft  . Heat   balance of oven   shows that  product itself requires 30- 40%  for its own heating , 10 - 20 %  is required for  oven heating and balance heat  used for heating of  make up air ,oven  and losses. Oven band  have repeated cycle of heating and cooling .


Heavier Belt  requires more heating  than the lighter belt .Type of belt used in oven  impacts the energy cost of the product. So  any reduction  in the thickness  of band  would result is less energy  required for band heating .
Many  manufacturers have  switched to  lighter oven bands for energy savings .



Report by Reading bakery Systems

The Soulful Craft of Artisan Baking


In our fast-paced world, where convenience often takes precedence over quality, artisan baking emerges as a beacon of tradition, craftsmanship, and soulful sustenance. This age-old practice transcends the ordinary and immerses us in a world of unique flavors, profound connections, and a glimpse into the heart of our shared human history.

A Return to Authenticity

Artisan baking is a gentle rebellion against the mass-produced, preservative-laden bread that lines supermarket shelves. It harkens back to a time when baking was an art and a science, not a rushed industrial process. The artisan baker doesn't rush; they savor the journey from flour to loaf.

The ingredients chosen in artisan baking are a testament to its commitment to authenticity. Organic, locally-sourced grains, natural leavening agents, and pure water are the building blocks of this craft. Each ingredient, handpicked, reflects the terroir of its region, giving each loaf a unique flavor that cannot be replicated by any factory.



The Symphony of Sourdough
Artisan baking
Sourdough, the darling of artisan baking, is the perfect embodiment of this craft. It's a living, breathing entity, a symbiotic culture of yeast and bacteria. Sourdough takes time, patience, and a watchful eye. The reward? A loaf that's not only delicious but also easier to digest and packed with nutrients. This is bread as it once was – the staff of life.

The beauty of sourdough lies in its natural fermentation process. As the dough ferments, it undergoes a transformation, producing complex flavors and aromas that tease the senses. It's a symphony of microbes, each contributing its unique notes to the final masterpiece. Artisan bakers are the conductors, nurturing this symphony and creating something truly extraordinary.

Community and Connection

Artisan baking is not just about flour and water; it's about connecting with our community and our roots. Artisan bakers are often deeply embedded in their local ecosystems, sourcing ingredients from nearby farms and mills, and fostering relationships with their customers. The bakery becomes a hub of connection, where people come not only for bread but for conversation, a sense of belonging, and the comfort of familiar faces.

In a world increasingly defined by impersonal transactions, artisan baking reminds us of the importance of human interaction. There's a deep sense of fulfillment in buying a loaf from a baker who knows your name and your preferences, who shares the story of each batch, and who takes pride in their craft.

The Imperfect Beauty

Artisan bread, with its imperfect crust and uneven crumb, embodies the idea that beauty lies in imperfection. It's a tactile and sensory experience, with each loaf boasting its unique character, just like the hands that shaped it. The artisan baker's touch, the slash of the blade, and the uneven distribution of air pockets all tell a story of the bread's journey from mixing bowl to oven.

Artisan bread invites us to embrace the imperfections in life, reminding us that in the cracks and crevices, there's room for authenticity, growth, and the beauty of the unexpected.

A Delicious Legacy

Artisan baking isn't just a momentary trend; it's a delicious legacy passed down through generations. The knowledge and techniques are shared, not patented or locked behind factory doors. Each loaf is a testament to the wisdom of our ancestors and the potential for us to carry this tradition forward.

In conclusion, artisan baking is a celebration of the simple things in life, a reconnection with the past, and a reminder that the human touch can transform the mundane into the extraordinary. It's a powerful testament to our capacity for creating, sharing, and nurturing. So, the next time you savor a slice of artisan bread, take a moment to appreciate the soulful craft behind it – a craft that brings us back to our roots and connects us to the heart of humanity.




List Of Popular Industrial Baking Ovens

Various  types   of  Commercial /Industrial  baking  ovens are  available  to manufacturers  for  their  specific  requirements .

Selection of  ovens are done  on the basis  of  following
     product
     space
     fuel
     volumes/capacities
     heating


Following are different type of  commercial /industrial baking oven


    Pretzel-baking ovens
    Steam ovens
    Continuous-feed ovens
    Electric ovens
    Multiple-deck ovens
    Gas ovens
    Wood-fired ovens
    Infrared high-frequency ovens
    Swing tray ovens
    Contray  ovens
    Confectioner ovens
    Shop ovens
    Thermo-oil oven
    Pizza ovens
    Rotary Rack ovens
    Tunnel ovens

 Also  visit : types of  oven 

A visit to a Biscuit Factory


A Day in a Biscuit Factory


Have you ever wondered what goes inside a biscuit factory and how do you get such delicious biscuit made. A visit to biscuit factory has been detailed below in brief so that ones get s an idea of biscuit manufacturing, process and people. Biscuit factory has it own ways, lingo and people who manage the production. I would tell you more about people who are directly involved in the production process or activities on the shop floor.

Premixing area

Operators checks the variety and weighs ingredient as per the recipes waits for mixers operators signals .Once he gets the signal , starts putting up all ingredients manually or in case system is automated he starts the discharge options. Automated additions could be flour , butter , sugar solution , milk , water etc . Food Additives which are in very small quantities are added manually. Pre mixing area have storage tanks, pumps, votators , sifter and in many cases dough truck tilters . Operators has to get the material arranged from the stores for the days production . In case of cracker varieties the preparation s starts as early as 18 – 20 hrs . Gets stocks for sugar , flour ,hvo and other ingredients .Does cleaning operations at the end of the shift .Sifts Flour , Ammonia and Sugar .

Mixing Area

Mixer Operators gets the Ingredients from pre mixing area, cleans the mixer and checks the timers setting on the mixer for mixing process. Gets following material for addition such as biscuit powder from biscuit grinding room and dough in case of any left out in earlier process . Mixing operators does the mixing in stages . Checks the dough consistency , temperature and forwards the dough in a dough truck to tilting device .Operator has to be careful about the quality of flour take certain corrective measures in case he does under mixing or over mixing .


Forming Area

Operator checks the variety of product whether it is a molding variety or cutting variety . Check the cutter or the molder as per variety of the biscuit. Changes the speed and pressure of the molding or cutting as required .Install accessories like milk spray or salt or sugar spray units if required . Adjust speed of forming units like laminator, gauge rolls . Changes conveyors if required. In case of change over from one variety to other he selects the moulder or the cutter and install it on the biscuit production line .Add flour dust to the flour duster in case of sticky dough . Checks the wetness of the cutting web .Drops deformed biscuits . Return scrap dough to the


Baking Area

Oven operators checks the variety and adjust the oven zones temperature , adjusts the dampers as per the requirement .Adjust burner setting as per temperature requirement .

Increase or decrease speed of the traveling oven band as per the requirement . Simultaneously instruct forming section operator to adjust the speed of the forming unit . Drops burnt biscuits . Checks the tracking of oven band, make a note of damaged band area . Important roles comes into picture in case of power failure when he has to get the biscuit trapped in the oven zone out with help of manual arrangement .This is very important as any delay by him can result in fire in the oven .Checks the safety sheets of the oven .Hence oven operator has big role in baking quality of the product .


Packing Area

Packing area can be most populated in case of semi – automatic packaging but for automated area one or two operators are sufficient per machine .Biscuits are fed into feeding chutes manually by feeder s . Packaging operators checks the date , labels and product setting on the packing machine . Checks the wrapper and adjust the setting of the machine . Adjust the speed of the packing machine as per incoming quantity of biscuit. Checks temperature of sealers to avoid any defective packaging .Does the change over of the packing machine as per the product. Then ensure that cartons are taped and then passed on to the finished good ware house.

All operators has been provided with pre formatted form to be filled in . Each section fills these form s to be submitted to the shift supervisors who then send it to the production manager who checks for the data , outputs , break down , wastage etc and log it on the ERP software .

Other functions

Store – Receives and inspect incoming material . Updates stock position, Store these material at predefined place .

Purchase – They are responsible for arranging material for production On request generated by production planning they release orders for vendors to deliver the material on time .

Production planning- Gets sales requirement from sales deptt . Plan production accordingly with taking view of raw material, plants availability, personnel and packing material .

Dispatch- Co ordinate with sales dept and dispatches material to the destination in time .Has to follow up with transporter for dispatches .

Quality team - Responsible for quality of the ingredients , packing material and standards of the process , product and keep monitoring on critical control points , Maintain documents for

Maintenance team - Responsible for break down maintenance and upkeep of the plant and machinery.

Hygiene team - Maintains the hygienic and cleanliness of the factory .

learn more  on bakery business 

Bakery Equipments - Rusk Manufacturing Equipments

Rusk , Rusk Manufacturing , Rusk  manufacturing equipments
Rusk s  are bread baked twice . This toasted  bread are popular in many countries  and people prefer to have it as tea time snacks  as well as  nourishing food for children .

Rusk has advantage of shelf life  as it can stored for longer time . Rusk are available in many shape and sizes  and flavours .

The Process of Rusk manufacturing starts  with  dough preparation in spiral mixer or kneader . followed by  dough feed and moulding . The dough is then  proofed  and baked in tin moulds .Once the baking is completed then these bread bars are cooled and then cut into slices .These slices are then  toasted  in a secondary baking process  and conveyed for packaging .

Following equipments  are used in Rusk Manufacturing

  • Spiral Mixers
  • Dough Divider
  • Hander Up ( coned shaped moulder )
  • Inter prover
  • Moulding
  • Final Prover
  • Baking oven  or Tunnel oven
  • Bread Depanner
  • Bread Cooling
  • Bread Slicer
  • Toast Oven
  • Product stacking
  • Packing Machine
More on  bakery  production  equipments

Biscuit  production line
Bread production line 
Cookies  production line
Wafer biscuit production line

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