Unibic forays into wafer biscuit segment

While visiting one of the shopping centre near my residence I can find this unibic wafer biscuit pack promoted with one pack free with one. Wafer biscuit market is  in  nascent  stageIndian market have few players in this segment . Britannia ,Dukes,Tiffany,Nutro are few popular brands in Indian  wafer biscuit segment

Unibic  key  products are wire cut  cookies  and are dominant  player  in cookies segment .Unibic India is a  subsidiary of UNIBIC Australia, UNIBIC India Pvt. Ltd., has its factory and infrastructure in Bangalore with state of the art machines from Italy. 
  

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Provers In Bread Manufacturing

Proofing

Bread, Bun , Pie and Rusk  manufacturing  have unique ingredient yeast which is responsible for texture requires either time or conditions ( humid and  hot ) to act  and release gases which are trapped into dough ( leavening)  or fermentation . Various type of provers are available as per plant layout such as Box type , L type or Type , Gas  or  steam could be used for humidity and heating arrangement .It includes  gas burners , steam heaters or steam injection system .Rack type or Traveling tray type provers  are available for proving/proofing  process.Proofers are thermally insulated enclosures and. vary in size from a small box with shelving to a room. With  space  for  many  portable  bread  racks. Proofer  is  heated  by  steam  coils  or  electric  heating. Elements located inside the enclosure.



Intermediate  Prover
Intermediate provers are provided in bread manufacturing process to allow bread to relieve and recuperate from stress- strain to mechanical action on dough by  dividers and rounder . It also  gives dough to ferment during  this time and make dough soften up for  Final prover  after moulding .Its  also called relaxation prover  where it travels for few minutes in trays .



Final Prover

Dough  are  converted into elongated  cylindrical dough pieces  which are twisted  and re placed into moulds  which are greased  with emulsion or oil  for depanning . Final prover have arrangement for steam  which spread out  uniformly in  the final prover . Temperatures in Final prover  is about 38 deg c - 45 deg c. Humidity level and temperature maintained in such manner  that  yeast activity is maximum  in the final prover . Precautions need to be taken  so as to prevent  dough to rise above moulds . box or inversely the dough is left without rising . Speed of moulds travel in the prover  is either controlled through timers or through manual start and stop . Speed of travel of moulds are  to monitored with respect to rate of  dough yeast activity . Tray movement could be horizontal ( swing tray )  or  vertical ( Contray Oven ) . Approximately time for proving is  60- 75 min as per conditions . Final prover are mostly fabricated at site for large bread manufacturing  with drives and sprockets  to which racks are attached on which mould s are kept .With completion of  cycle in prover  the dough which is risen to 3/4 th mould is  then  transferred to oven for  baking .   Other popular type of prover are retarder prover . Capacities are matched with that of  Oven .

Energy Audits In Bakery

With  ever increasing cost of energy  bakeries  need  to  get their plant audited once in every 3-5 year period for modification and changes in their energy management and technology  to reduce energy cost . Energy  aud
its  can be done  by  experienced  auditors  or through  institution s .

Energy Audit Methodology:

Energy Audit Study is divided into following four steps

a. Historical Data Analysis:

The historical data analysis involves establishment of energyconsumption pattern to establish base line data on
energy consumption and its variation with change in production volumes.

b. Actual measurement and data analysis:

This step involves actual site measurement and field trials using various portable measurement instruments. It
also involves input tooutput analysis to establish actual operating equipment efficiency and finding out losses in
the system.

c. Identification and evaluation of Energy Conservation Opportunities:

This step involves evaluation of energy conservation opportunities identified during the energy audit. It gives potential of energy saving and investment required to implement the proposed modifications with payback period. All recommendations for reducing losses in the system are backed with its cost benefit analysis.


d. Monitoring and Control:

With increasing energy prices, many organizations have incorporated sub-metering systems in their
plants. It is required to identify and monitor parameters for energy consumption per unit of production
or services i.e. Specific Energy Consumption (SEC).SEC monitoring is an important tool for monitoring and
proving of energy conservation measures especially to see the effect of implementation of projects directed towards energy conservation.


Major Area's  for Energy Audits

Baking Oven
Lighting in Plant
Air Compressors
Air conditioning and Refrigeration unit
Packaging Unit
High  rating Motors
Electrical s system including Transformers
Mixers , Grinders , Blenders  and conveyors 


Energy Audits  has been made mandatory  by several countries . Incentives  for  better power factors  in electrical energy usage  are provided through lower bills .Few  easy  to implement plans  are suggested through these energy  audits  and the cost of  conducting such  audits  are insignificant in comparison to the savings generated   through the   suggestions and modification .

Automation in bakeries - Benefits

Bakeries world over are now opting to automate their operations due to shortage s in labour , to increase productivity , save time and safety .This trend is more pronounced in Europe , Middle eastern countries where labour is a problem.
But for many countries bakery manufacturers prefer manual operations as labour cost is low in comparison to their European counter part hence they prefer to have workers performing all the operations . Automation is also very cost intensive hence bakery owners avoid putting money in the automation projects plus the skills to operates these system has a cost .Spares and Inventory is also a problem for these small to medium plants .
Even with these disadvantage automation has benefits for large or big bakery plants which results in better productivity and cost savings

Areas in bakeries operation where Automation can be done

Material handling
Conveyors can be used to load or unload matrials from vehicles to the stores or production hall with minimum requirement of labor .
Pneumatic conveying for Bulk handling and storage of raw material . These can be done with PLC based pneumatic system.

Pre -Mixing and Mixing
Raw material addition and transfer of liquid s for mixing can be automated with help of Plc based system along with weighing and batching done with automated system . Weighing is done through load cells and electro pneumatic valves which then are integrated with plc s.Mixers with helps of timers and software can adjust mixing timing as per dough consistency .

Forming and Laminating
Tipping of dough can be done through tipping elevators .Change overs in Dividers for bread as well as Cutter and moulders can be done to reduce change over time s.
Speed of Webs for gauge roller can be increased or decreased as per requirement or baking time for biscuit , cookies and cracker lines in a group .( as speed of each web and gauge rollers are linked to each other ) .

Oven
Burner controls are now fully automated where burners starts and stop as per the requirement of heat inside the baking zones .These are done with installation automated system with help of temperature controllers .
Biscuit lines have multiple burners installed and can be controlled with one command through plc .

Tracking of wire bands in biscuit lines are done through sensors installed .

Loading of ovens in bread lines can be automated with mechanical conveyors with timing adjusted through plc based programs .Prooving and baking trays are loaded and loaded with help of automated mechanisms.
Baked breads are taken out from moulds by putting up Depanners hence eliminating manual labor to depan .


Packaging
Most of the automation which have been installed in bakeries is in the packaging section .
Feeding system - feeding of biscuits to packing machine or bread loaves to slicer are automated through chutes/ guidelines for biscuit lines or conveyors for bread plants.

Biscuit Packaging is than done through horizontal wrapping machine with operations like packs , prints and seals .
Automatic Bagger machine are used for bagging or packaging of bread slices .Horizontal flow wrap machines are also used in bread plants for packaging .
Here we can automate forming of cbbs by installing cbbs forming machine . Most the bakery manufacturers prefers preformed cartons to the automated forming of cbbs
Once the packets are placed then entire system of cartoning , palletizing can be done through robotics most of the western countries have installed robotics to handle post packing machine operations till loading .

Automation of any operation uses sensors , controllers , pressure switches , Ac based servodrives ,HMI , pneumatic s or hydraulic, photocells , scanners , AC Drives,PCB cards with their integration to PLC based software .Various companies gives complete package of plc systems such as Allen Bradley , Siemens , Telemechanique ,Schnieder ,Omron , Okuma , Mitsubishi,GEfanuc ,ABB .

Multigrain Cookies From Kothari Foods LLP - Better Bite

 

BETTER  BITE      

Kothari  Foods   llp  a  delhi  based baker  had  launched many healthier    cookies   such as multigrain , oats ,ragi and fruits and nut  available on supermarkets and departmental stores  across Delhi

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Inventory Cost Control In Large to Medium Bakeries

Large to medium bakeries  needs to have inventory  cost  control system in place

What  are  inventory cost 

INVENTORY  PROCUREMENT  COST

• Cost of order processing  from the  purchase indents  stage to accounts  and finally  to the delivery of item to the factory . Cost involves  the stationary , employee and the time spent on
  these activities.

• Cost of transmission of orders  from purchase deptt  to suppliers , fax , telephones  cost of
  postages etc  with advent of internet  and erp  there has been considerable drop in these costs .

• Cost  of  transportation  including freight , octroi , transit insurance  and protective packaging for the same

• Cost of invoice ,book entries  and processing payments

• Cost of  Inspection , handling , receiving

INVENTORY CARRYING  COST

• Space  rent  for the storage  of goods

• Cost of  Working Capital locked in the inventory

• Cost of insurance of goods

• Cost of spoilage of goods  in storage , breakages in handling

• Cost  of  deterioration  and obsolescence of  goods due to passes of time

• Cost of space utilized during the storage of the product

We don't give much of importance to inventory lying in our stores or warehouse . Its when

some consultants points out that we have blocked money in these stocks that we realize that something has to be done to cut cost of inventory . . Its important to monitor inventory of RM/PM/Engg spares and even Finished goods ( FG ) , If not done it can severely impact the bottom line of business . These steps are applicable for  all items used in bakeries which have considerable cost impact 

Inventory  are maintained for following items in large to medium  bakeries

a )  Raw material and ingredients

b) Packing material and consumables

c) Engineering / Plant  Machine spares and consumables 

d) General office and utilities spares  and consumables 

e)  Finished Goods

Reasons why  stores have large inventory  are 

1  Change  in  recipe  

2. Change in packaging due  to several reason such as marketing . price or legal compliance

3.  Rejection  at   any stage in process  after inspection 

4  Slump  in sales  

5. Wrong  specification s  given at  the time of order placement 

6  Due  to  supplies  constrains  one has  to  keep  inventory   of certain critical items 

7 Duplicate Indents 

Inventory  Cost Control  techniques 

 1. Codify all items which are kept as stock in stores or warehouse .Use any inventory management software to track stocks and movement from one center to another. 

2.  Install  ERP software such as  BAAN or SAP   for better control on inventory  if you are  large to medium unit 

3. Classify items by ABC so you know what are high value items and keep a tab on their consumption and procurement . Next focus on low value items .

 4. Examine value of items on basis of return on investment .

 5.Identify high stock out items and then adjust buffer stock on cost trade off basis 

6.Examine all items for safety stocks with respect of lead time , demand , stock out cost , carrying , ordering don't pile up stock intuitively 

6. Do physical stock verification periodically and eliminate dead stocks ,accept obsolescence write off for these items . 

7. Determine Economic Order Quantities of all items .thus eliminating chances of excess material  lying in store blocking capital 

8. Shift owner ship  of  storage to vendors /suppliers  with  Annual contracts /Replenishment contract with  fixed quantity order or as and when requirement .

Thus  plant management needs  to  audit and review  stores and warehouses in regular interval to check  inventory levels  of  goods lying in stores .

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Werner and Pfleiderer - World Major Bakery Equipment Manufacturer - A profile

Werner and Pfleiderer are one of the world major bakery equipment supplier known as WP in bakery circles . It has long history of bakery equipment development and innovation in their name . Started in 1875 at London and manufacturing plant at Cannstatt, Stuttgart with patent to develop universal mixer it has come a long way to be world renowned bakery equipment manufacturer. Werner and pfleiderer industrial technologies are part of WB Bakery group which is owned by Horst Mann Group of Industries.



W&P are known for total plant solution for biscuit and freshly baked plants .They install and commission complete plants .So anyone opting for best technology should go for W&P bakery equipments as they make custom made specific equipments .


The merger in the WP BAKERYGROUP offer customers the entire process of baking technology, starting with the dosing and kneading, and work on parts, laminating, cooling and fermentation, through to baking in the floors or rotary rack oven and loading jaws.


In WP BAKERYGROUP get artisan bakers and industrial bakeries perfectly coordinated processes from a single source and with German engineering excellence.




Their equipments are installed across the globe from Europe , Middle East , USA , China , Australia ,South America , Africa and Asian countries .Supported by spares and service division .


Core Business


Biscuit - Plant Engineering and components

Freshly Baked Products – Plant Engineering and components



HQ

Werner & Pfleiderer

Industrial baking technology GmbH

Frankfurter Straße 17

71732 Tamm

Phone: +49 (0) 7141 202 - 0

Fax: +49 (0) 7141 202 - 111

E-mail: info@wpib.de

Website : http://www.wpib.de/

Major National Organisation , Boards Linked To Food Processing

GOVT ORGANISATIONS

Here is the list of major organizations which helps government in policy making , monitoring ,research  and  promote  food industry 

 INTERNATIONAL 

• Food And Agriculture  Organization(FAO) http://www.fao.org
•  International Organization for Standardization(ISO) http://www.iso.ch 
• International Plant Protection Convention http://www.ippc.int/cds_ippc/IPP/En/default.htm Office International des Epizooties (OIE) http://www.oie.int
• World Health Organization(WHO) http://www.who.org 
• World Trade Organization(WTO) http://www.wto.org 

 NATIONAL 

• Ministry of Agriculture 
•  Department of Agricultural Research and Education http://dare.nic.in
•  Indian Council of Agricultural Research http://www.icar.org.in 
•  Department of Agriculture and Cooperation http://www.agri.coop.nic.in
•  Directorate of Marketing and Inspection (DMI) http://agmarknet.nic.in 
•  Directorate of Plant Protection Quarantine and Storage 
• Central Insecticides Board and Registration Committee http://cibrc.nic.in 
•  Department of Animal Husbandry and Dairying http://www.nic.in/dahd/
•  Integrated Fisheries Project http://ifpkochi.nic.in 
•  Department of Atomic Energy http://www.dae.gov.in Bhabha Atomic Research Centre http://www.barc.ernet.in 
•  Ministry of Commerce and Industry http://www.commin.nic.in
•  Department of Commerce http://commin.nic.in/doc Agriculture and Processed Food Products Export Development Authority (APEDA) http://www.apeda.com 
•  APEDA has registered with Food Products Exporters for certain food products  http://www.apeda.com/ecom/scripts/exp_dir_entry.asp 
•  Cashew Export Promotion Council http://www.cashewindia.org
•  Coffee Board http://www.indiacoffee.org 
•  Directorate General of Foreign Trade http://dgft.delhi.nic.in
•  Export Inspection Council (EIC) http://www.eicindia.org Export Inspection Council (EIC) registers exporters for exports of Commodities for which certification is compulsory.
•  1) http://www.eicindia.org/eic/units/rice.htm
•  2) http://www.eicindia.org/eic/units/black_pepper.htm
•  3) http://www.eicindia.org/eic/units/marineproducts_1.htm 
• 4) http://www.eicindia.org/eic/units/milk.htm 
• 5) http://www.eicindia.org/eic/units/egg.htm
•  Marine Produce Export Development Authority http://www.mpeda.com 
•  Spices Board http://www.indianspices.com 
•  Tea Board http://tea.nic.in http://www.teaindia.org
•  Ministry of Consumer Affairs, Food and Public Distribution http://www.fcamin. nic.in
•  Department of Food and Public Distribution http://www.fcamin.nic.in/civil_ind. html 
• Directorate of Sugar http://www.fcamin.nic.in/sugar_ind.htm
•  Directorate of Vanaspati, Vegetable Oils and Fats http://www.fcamin.nic. in/sugar_ind.htm 
•  Department of Consumer Affairs http://www.fcamin.nic.in/cons_ind.htm 
•  Bureau of Indian Standards http://www.bis.org.in 
•  Ministry of Defence http://mod.nic.in
•  Defence Food Research Laboratory (DFRL) http://www.drdo.com/labs/dls 
• Ministry of Environment and Forests http://envfor.nic.in 
•  Ministry of Food Processing Industries http://www.mofpi.nic.in/ Ministry of Food Processing Industries regulates FPO. The list of Licences under FPO. http://www.mofpi.nic.in/venturesetup/licensing/licensing.htm
•  Prevention of Food Adulteration Act http://mohfw.nic.in/pfaact.pdf
•  http://wcd.nic.in Ministry of Science and Technology http://www.mst.nic.in
•  Department of Biotechnology http://www.dbtindia.org 
• Research Institutions Bhabha Atomic Research Centre http://www.barc.ernet.in 
•  Central Food Technological Research Institute (CFTRI) http://www.cftri.com 
•  Defence Food Research Laboratory (DFRL) http://www.drdo.com/labs/dls/dfrl/index.shtml 
•  Industrial Toxicology Research Centre (ITRC) http://www.itrcindia.org 
•  Indian Council for Medical Research (ICMR) http://www.icmr.nic.in
•  National Institute of Nutrition (NIN) http://icmr.nic.in/000229/nin.htm 
•  National Dairy Research Institute http://www.ndri.nic.in Industry 
• Associations Confederation of Indian Industry (CII) http://www.ciionline.org 
•  All India Food Processors' Association (AIFPA) http://www.aifpa.com 
•  Confederation of Indian Food Trade and Industry (CIFTI) http://www.cifti.com
•  Consumers Organizations (Members of NCC) 
• Consumer Education and Research Centre (CERC) http://www.indiatrade. com/cerc Voluntary Organization in Interest of Consumer Education (VOICE) http://www.consumer-voice.org Consumer Unity and Trust Society (CUTS) http://www.cuts.india.org
• Niftem  http://iifpt.edu.in

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Food Handling Gloves In Bakeries

Food handlers or operators in bakeries  more often comes into manual contact to perform activity in  pre mixing ( addition of ingredients & chemicals) ,mixing ( check dough consistency) , baking ( remove defectives ) , stacking ( packing) .Manufacturers provide workers with protective gloves to prevent cross contamination ,microbes and bacteria from handlers hand .Wearing gloves is not mandatory in most countries but still as per good manufacturing practices manufacturers provide their workers  with food handling gloves


Conventional method which most of the bakeries still use is  to provide wash basins  near to working areas  with potassium permanganate solution  to wash their hands in frequent intervals .


PVC  thin clear transparent disposable  gloves

These gloves are preferred gloves for  food handlers as its cheap in comparison to latex or vinyl gloves .Even while wearing these gloves workers should be trained to switch over to new pairs in case of damage or high perspiration in hands .One has to wash his hands and use dryer  before putting up new gloves  . These types of gloves are mostly used  where glove changing is frequently required .


Latex  disposable gloves

These gloves are required for handling of hot objects  such hot cookies while at baking section or removing defective biscuits from oven or depaning  operations , oven loading or unloading  in bakery manufacturing process.Its also used in area where workers have to handle chemicals .Latex gloves are costlier than PVC poly gloves  hence it is used only where you cannot  replace it withpvc poly gloves.These have to be washed and sanitised for multiple use .These gloves could sometimes results in rashes and itching.

Guidelines for Gloves
 

•      Wash hands properly before and after wearing or changing to a new pair of gloves
•      Use gloves that fit properly and that are designed for the task at hand
•      Change gloves whenever tasks change or whenever an employee leaves his/her workstation
•     Sneezing, coughing or touching one's hair or face with a gloved hand all require hand washing and a   new  pair of gloves
•     Because perspiration and bacteria buildup under gloves, wash hands and switch to a fresh pair periodically

Few experts  are  of the view that  gloves  are as harmful as manual contact . These gloves develops  pinholes when damaged which may not be visible by naked eyes , this may then results in bacterial contamination of hands.Workers never remove these gloves as often as required.Expert still believes the  conventional method of hand washing  to gloves

Local Bakery Equipment Manufacturers Draws Huge Crowd At Techmart2010

  
Techmart 2010 organised  by NSIC  has  wide representation of small scale industries  from areas like bakery , textiles , dairy , leather and handicraft .Its  held  along with annual Indian trade fair at Pragati Maidan ,New Delhi.

Major  attractions has been   live  demonstration  of  manufacturing process  by these small  bakery equipment manufacturers  where  one can see cookies preparation and baking .Products were offered to visitors  fresh from oven .Capacities displayed were from  30kg-50kg/hr  of production .

Some of the bakery equipment suppliers were

Pritul Machines: Mixers , Rotary  Ovens ,

Growthway Technologies: Mixer , Rotary  Ovens , Depositors

Ever Bake :  Rotary Ovens

Goodlife  :  Rotary Oven , Mixers and Depositors

In addition to  bakery equipment manufactures One can visit packaging machinery section which  could be used in cookies , cakes  and biscuit packagin

Companies present were

Jawla Engineering Pvt Ltd  -  HFW  , Vertical form fill machine

Shri Vinayak Packaging Machine  P ltd - Shrink wrap , Sealers , Vertical form fill machines


Entrepreneurs  looking for  starting small bakeries   could visit   these manufacturers /Suppliers  in Hall No-14  at TechMart 2010 .

Health risks in Bakeries

Bakeries are not known for Major occupational health risk yet precautions should be taken to protect workers , employees acquiring disease related to their work in bakery plant . manufacturing units should go for OSHA 18000 & ISO 14001 for better work environment and productivity .Consumer should also encourage with their preference for product s which are produced with companies having such certification .

Major areas which may cause certain health risks in bakery are


Flour Dust ,Sugar dust ,Biscuit dust
Flour handling , loading and unloading areas , Vibratory sieves , Manual Dusting during process.Prolonged exposure to flour dust may cause asthma , bronchitis .Similarly in case of biscuit dust and sugar dust while grinding or manual addition of these ingredients .Mask and spillages should be avoided . Automated system for flour handling to be installed to reduce flour dust .


Noise level
Noise level at certain area may cause deafness if workers are exposed to higher decibel levels for longer duration .As per factory act decibels should be lower than 70.0 db .Ear buds or rotation of workers after every 4 hours can help reducing exposure to sound. Periodic maintenance and monitoring of sound level should be implemented .


Odour
Odours of chemical and additives can be harmful for human. These chemicals should be kept in closed container. Worker s can use face mask and gloves while performing task with chemicals


Ammonia
Ammonia is most common ingredients for bakery product but is harm full if inhaled in larger dose . Pungent smell come out the moment ammonia comes in contact ambient temp. Even if presence ammonia vapours are within permissible level in most of the cases it does not mean that we don't take precautionary measures .


Heat
Oven operators have risk of skin disease , breathlessness and other diseases in case of prolonged stay without any precaution .Temperatures are around 50 -55deg centigrade around oven or baking area . Sufficient ventilation system should be installed like exhaust fan , natural ventilation through roof etc .



Silos and Tanks
Raw material silos or sugar or liquid tanks or fuel storage tanks these needs to be cleaned periodically . Workers should take proper precaution while performing this task as toxic gases are formed in these tanks which effects health .



Insulation

Precaution should be taken while handling insulation in bakery plant as these can lead to allergies and skin disease. Workers can wear protective coveralls or boiler suite with gloves while handling insulation . Ointments are also available to remove itching while working with insulation's .

Other areas are related to stress on body part while performing feeding for packing machines or loading and unloading heavier loads in Factory . Proper material handling should be provided for movement from one place to another . Mechanical means should be provided for lifting and moving heavier items in bakery plants .ie trolleys , pallet trucks , electric chain hoist , titling devices etc

Read Article on Health risk in bakery

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

Taste of Singapore: The Irresistible Singaporean Bread Roll

Introduction

When it comes to culinary delights, Singapore has a rich and diverse food scene that's hard to beat. While the city-state is renowned for its hawker stalls serving up mouthwatering dishes like Hainanese chicken rice and chili crab, there's one lesser-known gem that deserves its time in the spotlight – the Singaporean bread roll. In this article, we'll take you on a delectable journey to discover this unique and irresistible treat.

A Slice of Singaporean History

Singaporean bread rolls, often lovingly referred to as "kaya buns," have a history intertwined with the multicultural tapestry of the island. They are a delightful fusion of Chinese, Malay, Indian, and Western influences, reflecting Singapore's diverse population.

The key element that sets Singaporean bread rolls apart is the kaya spread, a fragrant and sweet jam made from coconut milk, eggs, sugar, and pandan leaves. This green-hued jam is a beloved local delicacy and serves as the star ingredient in these rolls.

Ingredients and Preparation

Singaporean bread rolls typically consist of soft, slightly sweet, and fluffy buns that encase a generous layer of kaya jam and a thick slice of butter. Here's how they are prepared:

Buns: The buns are often made using a combination of ingredients such as bread flour, sugar, milk, yeast, and a dash of salt. They are kneaded until the dough is soft and elastic, then left to rise until it doubles in size. Afterward, the dough is shaped into individual buns and baked until golden brown.


Kaya Jam: The kaya jam, with its rich and aromatic flavor, is a labor of love. It requires constant stirring over low heat, as it slowly thickens to the desired consistency. Pandan leaves are used to infuse the jam with their distinctive fragrance, giving it a unique taste that's hard to replicate.


Butter: A slice of cold, creamy butter is often added to complement the sweetness of the kaya jam, creating a perfect balance of flavors.

Enjoying the Singaporean Bread Roll

The best way to savor a Singaporean bread roll is when it's fresh out of the oven. The warm, slightly crispy exterior of the bun contrasts beautifully with the cool, creamy butter and the sweet, fragrant kaya jam inside.

These rolls are perfect for breakfast, as a snack, or even as a dessert. They pair wonderfully with a cup of local kopi (coffee) or teh (tea), creating a harmonious blend of flavors that Singaporeans have cherished for generations.

Beyond Breakfast: Modern Variations

While traditionally enjoyed at breakfast or tea time, the Singaporean bread roll has evolved to suit contemporary tastes. You can now find variations that incorporate ingredients like cheese, chocolate, or even luncheon meat, adding a twist to this classic treat.

Conclusion

The Singaporean bread roll is more than just a delightful snack; it's a piece of Singapore's culinary heritage that represents the nation's diverse culture and love for food. Its unique combination of flavors and textures offers a delicious escape into the heart of this vibrant city-state.

So, the next time you find yourself in Singapore or come across a bakery offering these delectable creations, be sure to indulge in the sweet, comforting embrace of a Singaporean bread roll. It's a taste of Singapore that you won't soon forget, and it's a testament to the culinary magic that can happen when cultures and flavors come together in harmony.




Types Of Popular Bread Rolls




1. French Baguette

The French baguette is a culinary icon known for its crisp, golden-brown crust and soft, airy interior. Its elongated shape makes it perfect for tearing off bite-sized portions, and it's a quintessential accompaniment to cheese, pâté, and wine. The baguette's simplicity belies the skill required to achieve its perfect balance of texture and flavor.

2. Japanese Melonpan

Melonpan, or melon bread, hails from Japan and is a delightful fusion of cultures. The sweet, crispy top resembles a melon's rind, while the soft interior is rich and buttery. Often enjoyed as a snack or dessert, melonpan comes in various flavors and fillings, making it a beloved treat for people of all ages.

3. Italian Focaccia

Focaccia, the pride of Italian baking, is a versatile bread that has gained international acclaim. Its dimpled surface is often adorned with aromatic herbs, olive oil, and sea salt. Focaccia can be enjoyed as an accompaniment to meals, sliced for sandwiches, or used as a canvas for a variety of toppings and flavors.

4. Mexican Bolillo

In Mexico, the bolillo is a ubiquitous and cherished bread roll. With a crusty exterior and a soft interior, it's a perfect vessel for hearty sandwiches like tortas and the famous "torta de jamón" (ham sandwich). Bolillos are often made fresh daily and enjoyed warm.

5. Turkish Pide

Pide, a Turkish flatbread, is a cousin of the more well-known Italian pizza. It features a boat-like shape and is typically topped with an array of ingredients, from ground meat and vegetables to cheese and herbs. Pide is a popular street food and a staple in Turkish cuisine.

6. Portuguese Pão de Deus

Pão de Deus, or "Bread of God," is a sweet bread roll from Portugal that is often enjoyed during festive occasions. It's adorned with a sweet coconut topping, which not only adds a delightful crunch but also gives the roll its heavenly name.

7. American Biscuit

In the United States, the biscuit is a beloved bread roll that's soft, fluffy, and buttery. Biscuits can be served alongside breakfast dishes, used for making sandwiches, or even enjoyed as a side with savory stews and gravies.

8. Indian Pav

Pav, a soft and slightly sweet bread roll, is a staple in India, particularly in the western state of Maharashtra. It's an essential component of the famous "vada pav" and "pav bhaji," both popular street foods in India. The pav's ability to absorb the flavors of spicy curries and chutneys makes it a favorite among food enthusiasts.

9. German Pretzel Roll

The pretzel roll, or "Brezelbrötchen" in German, is a delightful twist on the classic pretzel. With its characteristic knot shape and a rich, salty crust, this roll is a hearty accompaniment to sausages and beer. It's equally delicious on its own or with a dollop of mustard.

10. Spanish Pan de Leche

Pan de leche, or "milk bread," is a soft, sweet bread roll popular in Spain and other Spanish-speaking countries. Its tender crumb and subtle sweetness make it a versatile choice for breakfast or snacks. It's often enjoyed with a cup of coffee or hot chocolate.

These popular bread rolls showcase the incredible diversity and creativity of bread-making traditions from around the world. Each roll tells a story of culture, flavor, and craftsmanship, offering a taste of the unique culinary heritage of its region. Whether enjoyed fresh from the bakery or incorporated into a favorite dish, bread rolls have an enduring place in the hearts and palates of people everywhere, reminding us that the art of bread making is a global celebration of taste and tradition.

Cremica Got Listed At Stock Exchange

  "Cremica"  , Mrs Bector  Foods Specialties  Ltd   which has recently launched  IPO  for    public   to get funds  was recently  listed  at  Stock exchanges . Got bumper response from investor  and has opened with premium of    Rs 624 .00- It was offered at price band of Rs 286.00-  Rs 288.00  .   It IPO  has  198 times   subscriotion from market  which  is  highest  this  season . The response shows  the  confidence of public in food industry sector and the promoter  Mrs Bector Foods Specialities Ltd and its management .

Request  of  IPO was pending  with SEBI for  long  and was delayed  due  to COVID  and  market crash since march2020.Major  QSR major  BURGER KING has  also got listed alongwith Mrs Bector Foods Specialities Ltd . 

"Cremica   " brand   comes from  business  house  of  Mrs Bector Food  Specialties  Ltd .   A women  entreperneur   with   interest in  baking  started  a  small entity   from home ,  making   cakes  and ice creams  from  house backyard  . Mrs  Rajani Bectors   now   manages   Cremica  brand  with turnover  around  Rs 600 crore  making  it  one  of the fastest  growing  bakery  business group  .  Cremica  has also   diversified into  ready  to eat  categories  such  as sauces , Bread spread s etc . Its Head Office  based at  Phillaur  near  Ludhiana - Punjab .


Cremica  brand   has now wide range  of products  such as  biscuits . bread   sauces  ice cream  and Buns .It caters  to  all kind of biscuit categories  such as   Cream , Bourbon , Crackers , Cookies , Marie and  Choco varities .

Bread  s are sold  by the  brand  " English Oven "with  all kind of  varities  such  Atta , Brown  and multi grain bread  

Biscuits and  Bread   operation are largest  in this group  with unit  located   at  Phillaur - Punjab , Tahliwal - Himachal Pradesh  ,  Noida- UP , Mumbai- Maharashtra   and Banguluru  .- Karnataka 

Recent addition being Rajpura  factory in Punjab   with state of the art  machineries   and it produces cookies and biscuits .

Cremica  almost dominate  northern region  market   such as    Punjab ,  Himachal , Jammu and Kashmir  alongwith  significant  presence in Delhi , UP  and Haryana 

Major characteristic  of  Cremica  is that   it is    making  product  for major   players   in food industry  such  as   ITC ,  Kraft  Foods   and McDonalds .Thus  getting  expertise  working with  these giants .  Cremica  has now started  getting professional to strengthen  its   team through hiring  professional  from various fields  and hiring  new  recruits   from  best  institutes  across India .


Cremica  has  also got  foot hold  in  oversea markets  with   exports   to various countries . It export s to almost 60 countries  with majority  going out for  African countries.

  It also have   bulk orders from CSD s  and Railways . Covid-19  has impacted 


 Cremica  is thus  becoming leading  bakery product  manufacturers  with other players like   Bonn ,  Biskfarm , Anmol , Duke  and Priya Gold .

The  other  major   bakery  manufacturers  listed   at stock exchange is    Britannia Industries Ltd  . 

The last price for  Cremica  share  is  Rs 502.70. Investor  can think of  long term investment  as  growing  brand  of  food industry

Benefit of HACCP in bakeries

HACCP (Hazard Analysis and Critical Control Points) is a system, which identifies specific hazards and preventative measures for their control to minimise the risk of producing defective products and services for the each step of the food chain. HACCP has been adopted by all major food companies and are mandatory for exports to certain countries . Bakery manufacturers would gain by implementing HACCP .
HACCP determines the critical limits in the critical control points (CCPs) in the process and determines the critical limits by monitoring and applying amendatory and inhibiting factors. It is very difficult to determine the source of the fault when there is a problem with the end product in the factories where in HACCP is not applied.
In brief, HACCP is a proactive risk management system that contain all steps of food chain, from raw material manufacturer to end product and analyse possible dangers and guard. In industry, for successful HACCP system, a successful team is required.Pre-requisite programs and Standard Sanitation Operation Procedures (SSOP) are also required for HACCP.

How do we implement HACCP ?

As described its s analysis of hazard in a given environment and declaring critical control points . We start with going through entire process of production right from raw material unloading to finished good dispatch. We take entire inputs and actions in process which might effect process . After that we rank them on a scale of severity .Those which get maximum severity scale are declared critical points hence controls are devised to minimise the impact
Factors taken could be hazards , impact on brand , legal compliance's , damage to health of consumers, etc . SOP are documented with logs and records for any deviation from standard procedures . Areas are marked numbered and highlighted so that every one knows what is the critical control point .Internal audits and external audits are conducted for compliance.

What Are The Pre-Requisite Programs?
(GAP) Good Agriculture Practice
(GVP) Good Veterinary Practice
(GMP Good Manufacturing Practice
(GHP) Good Hygiene Practice
(GPP) Good Production Practice
(GDP) Good Distribution Practice
(GTP) Good Trade Practice

What Are The Benefits of HACCP?
Preventing possible hazards and supplying safe products
Minimising risks of food poisoning
Making increase consumer confidence
Making increase industry authenticity
Supplying active auto-control system
Minimizing product cost
Maximising advantageous
Making easier marketing
Increasing products’ shelf life
Making solve product problems systematically
Making product export easy, due to it international acceptability.
Increasing food safety and hygiene conscious of food industry stuff.

CCP in bakeries could be : Haccp in bakery industry  have its own features which includes identifying  critical control points  which have significant  impact on the business .Haccp  for  bakery  industry  is the most potent tool in food safety management systems which also includes prp( prerequisite programs ,oprp (operational requisite programs) and ccp's .

Oven burners
Baking temperatures
Storage temperatures 
Metal detectors
Sieves
Filters
Conveyors

learn more  on bakery business 

Macadams International -World Major Bakery Equipment Manufacturer- A Profile

Macadams  International  is  a  major  bakery  equipment manufacturer  from South Africa .It has strong presence in African continent and has establsihed  a prominent place in  other countries for retail bakery equipment segment .

Established in  1904   Macadams  have  been  manufacturing  bakery equipments , packing machines  and bake ware. Macadams International  is wholly owned subsdiary of Universal Industries . It  is based at Capetown , Blackheath , South Africa .

Here  are range of equipment  manufactured  by them

Baking Systems
        Rack Ovens
        Deck Ovens
        Convection Ovens
        Provers
        Kneaders,Mixers,Bowl Hoists and Bulk Hoppers
        Moulders
        Dividers
        Bread/Cake Slices
        Pastry Sheeters
        Industrial Frying Pan
        Doughnut Fryer
        Biscuit Machines
        Water Chillers
        Specialised Solutions

    Food Service Solutions
        Combi Oven
        Chicken Grillers
        Slicers
        Foodwaste Disposers
        Meal Merchandisers
        Ice Cubers and Flakers
        Fryers
        Fridges,Freezers and Blast Chillers
        Packaging
        Dishwashers & Utensil Washers
        Ovens
        Premier Ranges
        Oil Filtration Systems

    Packaging Solutions
        Macadams MacPak Automatic Packaging Machine
        Macadams MacPak Horizontal Packaging Machine
        Macadams MacPak Multiple Packaging Machine

 

HQ &  Address

Head Office & Exports
Macadams Business Park
School Street
Blackheath
Cape Town
75811
Phone: +27 (0) 21 907-1000
Fax: +27 (0) 21 907-1111
Email: info@macadams.co.za

Website : www.macadams.co.za

Cremica - A Regional Power Brand

"Cremica   " brand   comes from  business  house  of  Mrs Bector Food  Specialties  Ltd .   A women  entreperneur   with   interest in  baking  started  a  small entity   from home ,  making   cakes  and ice creams  from  house backyard  . Mrs  Rajani Bectors   now   manages   Cremica  brand  with turnover  around  Rs 600 crore  making  it  one  of the fastest  growing  bakery  business group  .  Cremica  has also   diversified into  ready  to eat  categories  such  as sauces , Bread spread s etc . Its Head Office  based at  Phillaur  near  Ludhiana - Punjab .


Cremica  brand   has now wide range  of products  such as  biscuits . bread   sauces  ice cream  and Buns .It caters  to  all kind of biscuit categories  such as   Cream , Bourbon , Crackers , Cookies , Marie and  Choco varities

Bread  s are sold  by the  brand   English Oven with  all kind of  varities  such  Atta , Brown  and multi grain bread 

Biscuits and  Bread   operation are largest  in this group  with unit  located   at  Phillaur - Punjab , Tahliwal - Himachal Pradesh  ,  Noida- UP , Mumbai- Maharashtra   and Banguluru  .- Karnataka

Cremica  almost dominate  northern region  market   such as    Punjab ,  Himachal , Jammu and Kashmir  alongwith  significant  presence in Delhi , UP  and Haryana

Major characterisitic  of  Cremica  is that   it is    making  product  for major   players   in food industry  such  as   ITC ,  Kraft  Foods   and McDonalds .Thus  getting  expertise  working with  these giants .  Cremica  has now started  getting professional to strenthen  its   team through hiring  professional  from various fields  and hiring  new  recruits   from  best  institutes  across India .


Cremica  has  also got  foot hold  in  oversea markets  with   exports   to various countries .  It also have   bulk orders from CSD s  and Railways .


 Cremica  is thus  becoming leading  bakery product  manufacturers  in the league  of   Bonn ,  Biskfarm , Anmol , Duke  and Priya Gold .

Career options in Bakery

With ever increasing demand for bakery products , speciality products . Burgeoning bakery chains , live bakeries ,hotels and restraunts , demand for bakery professionals have increased many folds

With traditional functions required to run a bakery business still present like
Accounts
Sales and marketing
Procurement
Human Resources
Stores or Warehouse
Production Planning

Following are the Skilled roles for bakery

Bakers ( Operators /Chefs)
In earlier days bakers used get trained under senior or experienced bakers .They used to get expertise through years of trials and errors . At present any one can get the skills and theoretical knowledge through Culinary ,hotel and catering schools or Specifically Bakery schools . It could be six month or two year course . Baker has a prime role in a small , retail , hotel or restruant type of bakery as he control s process from mixing to baking . Prime role of baker can be identified as .
Checking the right ingredients or raw material for the desired recipe .
Knowledge of roles and properties of ingredient added
Quality of the ingredients added
Get the quantities right as per the recipe of the product
Mixing Properties of the dough
Dough Consistency
Trouble shooting in case mixing is not proper
Check sanitation and hygiene requirement at working area
Record process parameters and other documents
Highlight safety or hygiene issues to the manager or supervisior



Food technologist
Role for foodd technologist are multi task . Most important is
Quality Control and Inspection
Product development
Reaserch and Development
Production supervsion


Engineers
Engineers are required for maintenance , new technology for process and Break down trouble shooting. Specifically for material handling equipments , Oven , Packing machines. Due to automation done in almost all bakery plants Instrumentation has gained importance .
Mechanical
Electrical/Electronics
Instrumentation

Cookies Production Line Equipments And Process

Cookies  production line  process  uses  different configuration  for variety of products  with  following  equipments  apart from ovens , mixers and packing machines .

Major  process used in cookie production line are  -  wire cutting , depositing  and rotary moulding

Wire  Cutting  have several  different method  of cookies production . These categories  of products can be manufactured  starting from  a single machine .The basic machine  consists  of  two grooved rolls which extrude  the dough  through sets  of dies in order  to give  the dough pieces their shape .  A filler block  is inserted  between the  rolls  and  the die plate  in order to equalise  dough distribution  across the width  and provide the optimum  weight control . A wire cut mechanism  can be added  for the production  of plain wire cuts or products with inclusions. Rout Press products  are cut by means  of a guillotine  cutter positioned  before or after the oven ,depending upon the type of final product .By adding the crimping device  soft centred cookies can  be formed  where the centre filling  can be jam or cream .

Options in wire cutting

Plain wire cut
Wire cut with inclusion
Two  color dough
Soft centre
Fruit Bars

Depositing  consist of head  which have  pair of grooved  rolls which evenly  feed the  dough to set of dosing  pumps positioned underneath. The one pump one nozzle  concept ensure  uniformity of weight across the width .The machine is fully servo controlled  movement of heads are driven independent motors . Depositors can have wire cut mechanism  attached  or  a rotating nozzle mechanism can be added  in order to produce swirl or twisted dough piece. Jam depositor can also fitted for  cookies product flexibility.

Rotary Moulding  consists  of  set of moulder , pressure roller  and   extraction  roller  which  releases the cookies with help of knife . Moulder s can have  cups of  different shapes  and size . Moulding process are suitable for high volume production with low baking time .Most of the manufacturers integrate moulding with  hard dough   cutter variety .


Biscuit 

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