What Are Bread Quality Parameters ?

Bread manufacturing process  which involves following  stages in  bread processing  such as

Mixing
Dividing
Moulding
Prooving
Baking
Cooling
Slicing
Packing

Following parameters need to be checked  for better bread quality

Mixing

Quantity of Ingredients as per standard recipe
Quality  of  Ingredients as  per standards
Sieving as per  standards
Sequence of addition of  ingredients
Mixing time
Dough temperature
Temperature of Ingredients
Yeast solution temperature
Quantity of Yeast ( Variable )
Quantity of water addition ( Variable)
Fermentation time

Dividing 

Weight of Dough pieces
No of Dough balls per batch

Moulding 

Moulder roller gaps
Moulder Board gap

Proving
Temperature  of  moulds
Temperature of Prover
Proving Timing
Humidity In Prover

Baking
Baking  time
Baking Temperature
Hot bread weight

Cooling

Cooling Time
Cool Bread weight 
Moisture content of bread before Slicing

Slicing 

Slicing Thickness
Bread Dimensions


Packing

Coding

All these  have set standards with few variables depending on temperature and humidity . Bread Qualtiy Parameters needs to be spelt out /displayed  and recorded  in regular intervals .Other physical features of bread which are important  such as  Texture , Crumbs , Color of crust  etc .

Select Your Laminator s As Per Requirement

Laminators  are  critical component of  any hard dough or  cracker biscuit line  . Laminators  are  required to  create   dough laminates  to be cut  into  sheets  which are further reduced  into  leaner  sheets  in  steps  thus providing bite and texture  to biscuits . Laminator's  can be selected on basis  of 


Capacities  - No of sheets per min or per hour

Dimensions - Length x width  of  dough  sheet

Orientation - Vertical  Or   Horizontal


Vertical  Laminator

Infeed of   dough  is  on the  top rollers  placed  horizontally  with cutting of  sheet  done before small inclined  conveyor   on a small platform .

Horizontal  Laminator
Height  of the  laminator is smaller than the vertical laminator with two sets of roller for lamination of dough sheet . Cutting of sheet is done  on  a reciprocating  platform  larger than the vertical laminator . Horizontal sheet  larger area or space then vertical laminator .But  if we consider maintenance of the laminator . Horizontal laminator are better option than  the vertical laminator .Vertical laminator are installed where space is the contrain plus when  dough feeding is  done from  different floors ie at certain height .

Smaller bakeries have  Dough sheeter instead of  laminators .

Lindstrom Providing Works Wear Services To Bakeries

When it comes to personal hygienic  clothing  for  bakery  manufacturers of   large to medium scale operations the options are

Providing  uniforms  to workers  and maintaining  deptts for collection ,repair  and laundry services.
Providing  works wear   for year to the staff . Maintenance of these uniforms are done by the staff by  themselves.
Engaging  professional  work wear providers to cater for their production  /food handler clothings


All three options are practiced  by medium to large bakery manufacturing units . Uniforms are part of  food safety management  systems  and HACCP  . It helps into reduction of foriegn body  complaints ( FBC ) .

One company  which has  build business out of these needs of  production facilities  where food safety  is of prime importance  is Lindstrom.

Lindstrom works on principle of providing  uniforms  as per the requirement of clients  from coats , aprons  to work wears on rental basis with complete solution

Lindstrom  works wear  services includes

Mapping of needs

courtesy-lindstrom.in

Delivery
Collection
Washing / Repair /Return delivery
Storage facility 

For  bakery manufacturers  who do not want  to handle uniform handling of employees are placing contracts to Lindstrom  for these services . They have started this business since 2007 in India with offices at  Chennai , Delhi , Mumbai  and Hyderabad .

Check  their site  for more info
www.lindstrom.in

List Of Indian Manufacturers Of Horizontal Flow wrap Packing Machine

Horizontal flow wrap packing  ( hfw )machine is the most popular packing machine to be used in bakery industry  due to its versatility to pack   various  bakery products. Following types of hfw packing  machines are available  for packing  bakery products

Single feeder
Double feeder
Pillow pack
On edge pack
Pile pack
Family pack

Other classification is  done  as per   speed of packing  from 25 pkts /min to   150 pkts /min .

courtesy -Multipack systems pvt ltd

Hfw  packing machines  can adopt  1 -2 sku's   through  changeovers . Other solid items  could  also be packed  through  hfw . Wrapping machines pack product in  bopp laminates, opp, poly films  etc .

List of items  which could be packed through  horizontal flow wrap  packing machines

Biscuits/Cookies/Bun/Bread/Cakes/Donuts/Wafer/Rusk/Chocolates/Noodles/Ice creams /Chukkies
Other  non -food items which  could be packed by hfw packing machines are
Bearings/Soaps/Stationery/Disposable syringe/Machine parts/Auto parts/Toys/Cotton Bandages/Pharma products/Cosmetics/Oil seals/Battery

Thus  we can  gauge the application hfw packing machines in the  industry .

List of  horizontal flow wrap packing machine manufacturers .

Multipack systems pvt ltd - Baroda
Khosla precision machines - Panchkula
New Indo Packing Machines - Delhi
Durga Packing machine - Faridabad
Sanjivani  Products - Thane
Sahora Impex pvt ltd  - Coimbatore
Rajasthan Packers - Faridabad
Khosla Machines pvt ltd - Mohali
Maa Vaishno machineries  - Hyderabad
Gemp pack entterprise - Chennai
Ultra world wide pvt ltd - Mumbai
Swastik  Packaging - Mumbai
Harshidi Indusries - Faridabad
Super -tech Packing  - Faridabad
Bharat Industries - Noida
All Pack  Industries - Faridabad
Unique Packaging Systems - Faridabad
Qasco Engineers - Faridabad
Shree Chamunda Micro Industries - Ahmedabad
V.K. Engineering & Co - Coimbatore
Packmach Systems - Noida
Excell Pack Machines - Coimbatore
Khushi Engineering Work - Noida
Advance & Autopack Sytems - Mohali
E.C. Packaging Pvt Ltd - Faridabad
Friends Packaging - Faridabad
Sai Dinesh Packaging Systems - Hyderabad
Deepak Engineers - Faridabad
Ganapati Packaging systems - Faridabad
Ovenman Industries Pvt Ltd - Faizabad
Packsol Industries - Thane
Corvette Technologies Pvt Ltd - Delhi
Sara Udyog  - Noida
Interflex Pvt Ltd - Faridabad
S.P Engineers - Mumbai
B.M.Packing Machines - Mohali
Europack Packaging Systems -Chennai
Fill-N-Pack - Faridabad
Durapack - Chennai
Mansi Packaging Machines - Faridabad

Matrix  Packaging Machines- Faridabad
Metro Star Packaging - Faridabad
Shakti Enterprise - Hyderabad
Omshree Enterprise - Nashik
Akash Packtech Pvt Ltd - Faridabad
SVM Wrapping Pvt Ltd - Mumbai
Singh Packaging Industries - Faridabad
S.P Industries  - Faridabad
Uniwrap Systems Pvt Ltd - Vadodara
A.R Enterprise - Mumbai
Aden Ovens - Mumbai
Star Engg Corp  - Faridabd
Gaurishankar Pattern - Mumbai
Robotech Industries -  Faridabad
Trimurti Packaging - Faridabad
ABM Engineering works - Mumbai
Ladecor  Systems - Mohali
Rising Industries - Kolkatta
D-tech Industries - Thane
Mangal Machines Pvt Ltd - Patiala
Indian Packaging Machineries- Faridabad
Deepankar Engineering - Ulhasnagar
Besto  Oven - Mumbai
Benzler Machinery Products - Mumbai
Vijay pouch packaging machines - Faridabad
B.R.Pouch Packing Machines Pvt Ltd - Noida
Sabrish Packaging  Associates - Bengaluru
Jwala Engineering Pvt Ltd - Ballabhgarh
Associate Pack tech  Engineers - Ahmedabad
Shri  Ancillary Industrial Machinery Pvt Ltd - Mumbai
Vishpack Machines - Nashik
Dhansa Engineers  Pvt Ltd - Nashik
Stanzy Oven Equipment - Mumbai
KDR Industries - Mumbai

Basic terms and parts of  horizontal flow wrap packing machine

Indian Cookies Competes With Other Bakery Products

Apart  from popular  biscuits , cookies and bread  which have been originated from  European and  American  countries . Indian do have their own bakery products  such  as 


NAN -KHATAI


KHARI


MATTRI OR MATHRI


PAPPADI 


TEKHUA  


COCONUT COOKIES


It has been  popular items during festival and  were  tried  even by the women folks in their kitchens . Traditionally popular among Gujaratis's, Rajasthani's . 

Few of the manufacturers are  now  trying  to  encash  on the popularity  of these  products, these  are now being  packaged and  being  branded . Frontier Biscuit factory  a major home made cookies manufacturer and few other local manufacturer  have now started marketing these Nan- khatai 's  and Khari 's . Wide range of  variety  are available for  nan -khatais such  as  elaichi,badam etc .

Even  malls , supermarkets and retail chains  have been promoting these Indian cookies through  private labels . Indian cookies which till now have seen mostly with street vendors  is gaining acceptance and are competing well with  common  bakery products .

Major Problems In Bread Production

 Bread manufacturing consists of   various stages and parameters  which  are standardize . Yeast  is the main spoiler which if not handled with in set temperatures and humidity can  impact  Bread quality .


Excessive  Volume (  Over proofed )
Small        Volume       ( Under proofed )
Pale bread            ( Under baked )
Dark  bread           ( Over baked )
Open texture
Closed texture
Holes in crumb
Poor crumb colour 
Coarse patches in crumb
Staling

Following aspects need  to be checked  for  successful trouble shooting
Quality of ingredients as per standards

Quantity of  Ingredients added
Addition of water(  variable )
Mixing time
Standing /fermentation time
Yeast  solution temp
Yeast quantity( variable )
Dough temp
Dividing weight
Moulding setting
Proving time /temp/humidity
Baking time
Baking temperature

Depending  on process / ambient conditions  values are standardize  for  above parameters

It's Coffee War By Biscuit Majors

Taking leaf out of  huge  success  and popularity  of coffee cafes mushrooming in cities , Biscuit major  like  Britannia  and Parle have  introduced  Coffee flavored  biscuits  with   Cappuccino  Bourbon  and  Cafe Mocha   respectively .

With  ever increasing pressure from competition  biscuit manufacturers are now looking for innovative  ideas to differentiate their products from  others  thus came idea of  coffee flavour  to their premium products  such as  Bourbon for Britannia and  Hide Seek  choco chip  for Parle .


Both are targeting youth segment for the success of these coffee flavored  biscuits . Coffee flavored  confectionery have already being tested in Indian market . With MNC eating up the cream segment  these manufacturers have taken lead to present  chocolate variant  with tweak of  coffee flavor . Increasing coffee chain s popularity for brands  like barista , cafe coffee day,costa coffee and starbucks  have  also  made them to take note of these development . Coffee consumption has been on rise among youth  in this country and chocolate - coffee  combination   is established  combination in baked  goods  in other countries .




It  would be interesting  to see whether  other  major player  ITC  , UB  and Cadbury  enters this  race of coffee flavored  biscuits .

Principles of Hot Melt Touch Dry Printing In Bakeries

Hot ink rolls are popular method of printing in bakeries  mostly used by  products which are packed by horizontal flow wrap machines and vertical form fill machines.Ink roll sizes are selected as per the  sizes of characters and space utilised by the labels on the product pack . These ink rolls are placed on coders which makes contact with  brass characters placed on type holders  . Used to create labels such as production date , price and batch codes .Maximum rows could be of three to four  of labels with pre defined size of  alphabet or number . These brass characters  are also of two different type  as per printing arrangement of coders such as  axial  or radial .

Other form of printings include  ink jet printing and thermal tape printing

Principle  of  Hot Melt  Touch Dry  Printing
These ink rolls  are  soaked and dried  with  printing ink  which on  heating releases molten ink which gets stuck  into the brass character  and when deposited on cool packing film solidifies are thus we get printing for packs.
These characters  then  creates prints   on  pre  set  coding  space for  labels . Ink rolls  are of different sizes depending on  application and no of characters needs to be printed some popular sizes are 36 mm x32 mm , 40 x32 mm , 38 x32 mm . Colors of Ink rolls  also varies as per requirement you can get black,green,red and white ink rolls .Quality of Ink rolls are classified as per no of impression or life on ink rolls . Depending on the usage the no of impression for normal ink rolls . On average it should have life of something between 80,000 to 100,000 impression .


Cost saving ideas on Ink Rolls

• Recycle used ink rolls through  dipping these used rolls into ink and then drying it to be ready for re use.
• Cutting the ink rolls in middle are placing  these part with reversed side .

Please check the quality of print before you implement these ideas .

IPEKA Automatic Bread Packaging Machine

Used Bakery Equipment On Sale - Madurai

 Following equipments are available for  sale , Interested  people  can contact   to the below mentioned   details .


NAME = Lakshmi Palanikumar
COMPANY_NAME = Sree chakra hotels private limited
EMAIL = ranipalanikumar@yahoo.com
ADDRESS = 1,vinayagar nagar, madurai 625020
TEL/MOBILE = 9344151600,9843145511
CITY_/COUNTRY = India
TYPE_OF_PRODUCT = Bakery Machinery ....All machineries for sale
BUY_/SELL = SELL
DETAILS = Oven,Spiral Mixture, Cake mixture, work tables, moulds, deep freezers, bread slicers, puff dough sheeter, mini ovens, weighing scales elecronic, weighing scales mechanical, exhaust fans, refrigerated display counters, racks and stands, tables and chairs, pedestal fans, air conditioners, and all related equipments for bakery

Contract Manufacturing In Bakery Industry -Win -Win Arrangement

contract manufacturing in bakery

Have you wondered  that the biscuit pack or the bread in the poly bags  are manufactured by outsourced companies and not  produced by the principal brand or the manufacturer for which you have paid for .This arrangement for contract manufacturing is a win-win arrangement between the large companies with small to medium contract manufacturers . For your information all major bakery brands have their Co Packers ( CP ) or contract manufacturing unit ( CMU ) spread across the geography of country  . CMU could be as large as 50- 60 units affiliated to major brands .This is also the best method to test regional markets by large multinationals in any country thus avoiding large investment and infrastructure and making a quick exit in case of  failure of not making any inroads in the market segment .

Major Advantages of Large Companies  from  engaging Contract Manufacturers  are
1. No large investment in infrastructure
2. No major commitment for labour /workforce
3. No major legal compliances  and liason for legal from their side
4. Can start operations in short span with cmu in any defiecient market
5. Easy exit
6. Can have advantage such as  easy backward integration if possible with facility with the cp
7. Cost saving s in terms of salaries and emoluments
8.  Inventories with cmu
9.  Trials and development can be taken with cmu's


Advantage  for Contract Manufacturers

1. No expense on building brands
2. Steady income and low risk on investment
3. No marketing and brand building investment
4. No need have large sales force
5. No need for procurement department
6. With low investment and various financial arrangement with principals
7. Logistic and transportation inward/outward to be arranged by principals
8. Can build facilities alongwith plant for backward integration and earn additional income.
9. Can promote own brand with idle capacity
10.Consumer and customer issues with principals
11.Gets technical expertise with help of principals
12 .Raw material/packing material  arranged by principals as per their standards


Following entities enter into contract manufacturing

Large manufacturers and brands
Major Super markets and Malls
Private enterpreneurs
New entrant in segments

All Major brands of bakery  have network of contract manufacturers who produce s products as per the principals specification /standards /recipes . Quality is monitored by representatives of principals based at  contract manufacturing units . Technical help and developments are taken care by the principals . Machinery can be leased or supplied on bailment  to cmu's. Principals enters into contract  with certain  conversion rates per unit of product taking into account following cost

Labour cost
Fuel/electricity cost
Maintenance cost

Penalties  or deductions  are  worked out  for negative material variance if cmu or cp  fails to produce as per standard output .

Rusk Manufacturing Process Flow Chart

Rusk  manufacturing  process consists of  two stage baking  where in the first baking stage is more like bread manufacturing  and 2nd stage baking consists of tunnel ovens for large volume or  rack ovens for smaller volumes .

 

Ebook on  - Bakery manufacturing process

Major Indian Bakery Equipment Manufacturers

 Indian  bakery market  is  estimated to be Rs 12000 crore  and is increasing by 10 -15 % per year . Major international brands  have started investing in manufacturing  bases . To cater to this huge surge in  bakery segment  major Indian equipment manufacturers  have also increased  their  production .
Indian bakery equipment manufacturing is in its nascent phase .Investment and R&D inputs are very low .Quality and service level are far below world class. Automation is key  to new technologies  which would help Indian bakeries  to compete with  international players .Still few companies have marked their presence in Bakery Industry. Few of them are listed below

OMORI INDIA PVT LTD ( PREV  MULTIPACK    )
NEW ERA INDUSTRIES
SARLA INDUSTRIES/VIVEK ENGINEERS
NECON
PRIMA ENGINEERING
KAPS ENGINEER
TECHNOFOUR
MIRANDA AUTOMATION
CS AEROTHERM
PRITUL
AIFSO
SEPERATION ENGINEERS
NARI WIRE
ROSHAN INDUSTRIES
APPLE  MACHINERY
SOHAL ENGINEERS

MANGAL  ENGINEERS   

SEPERATION ENGINEERS 

K DHARMALINGM 

There are numerous opportunities for bakery equipment manufacturers to produce
equipments which can compete for international markets .

AMF Bakery Systems - World Major Bakery Equipment Manufacturer

AMF  Bakery Systems  are  world leaders in providing bakery equipments   and  solutions for bread , bun and  soft  rolls  manufacturing units across the globe . Its  also popular  for customer specific packaging solutions . AMF  which is now almost  a century old  organisation  are known for technological  superior products and service . AMF has presence in almost all the continents  such  as  North -South America , Middle East and Africa , Asia , Europe  and  Australia / New Zealand .

The product line includes

Dough Systems
Make up systems
Pan and product handling system
Proofing and Baking system
Product cooling systems
Packaging systems
Basket  and Distribution systems
Automation 

Works with  affiliate companies like  Baketech , Tromp bakery equipments  and IIM .

Head  Office  at
2115, West Laburnun Avenue , Richmond , Virginia 23227 , US
AMF have  regional  head office  at  Canada , UK  , Singapore  and China.

For more info  visit
www.amfbakery.com

IBA Munich 2012

    IBA Munich 2012  - Germany is schedule to open on september 16 - 21 , this year . IBA is one of the largest trade event covering bakery and confectionery business in the world .  This events is hosted every 3 year with help of German bakers confederation and the organisers GHM . Its held alternatively at Munich or Dusseldorf.Around 123,000 sqmtr area would be used to show the best of baking techonology , ingredients , packaging , machinery and equipments at Messe München, Germany.  Bakery s Industry largest trade exhibition of the world is a must for any one related to bakery business or industry . Major equipment and machinery  manufacturers are present with their latest technology . Other related seminars and workshops related to bakery and confectionery are also planned .

IBA s main attraction are


    Huge potential for B2B opportunities
    Innovations and latest technology are displayed
    Energy efficient and environmental freindly technology displayed


    Information on bakery related subjects a s food safety , ingredients , additives , Hygiene , packaging are available in form of workshops , seminars and forums .
    New bakery products and categories ( which includes other confectionery items )
    Main  attraction for IBA  -Munich  would be  the iba- cup  which is presented to the top team of bakers  which bakes the best bakery  or confectionery  product .


Items displayed at IBA trade fair

Ovens , Mixers , packaging machines , bagging machines , bakery and pastry making machines , Confectionery equipments and accessories ,pasta and pizza making machines , Ice cream making machines ,refrigeration , fermenting , air conditioning equipments , coffee making machines ,ice cream manufacturing , hygiene and cleaning equipments , raw material , food additive , IT service and software . Must visit trade fair for people in bakery industry and is highly recommended from us .

Sectors represented are : bakery , catering , hote and restaraunt equipments , hygiene and cleaning equipment , baking craft , confectionery , raw material , technical journals on these subjects

Location
Messe München
Am Messesee 4
81823 Munich, Germany Tel: +49 (0)89 94920720
Fax: +49 (0)89 9499720729




For more  on  IBA -Munich
Visit : www.iba.de

Common Food Allergens In Manufacturing

Food  Allergy  can be defined  as immunological  response to proteins   to which  body release large amount  of  histamines.



Few are regular allergens which results into common allergies in   masses and every food manufacturers have to identify  these allergens so as to take preventive measure against these allergens being passed out the consumers .


Peanut and derivatives, (e.g. protein, oil)
Tree nuts  and derivatives, (e.g. protein, oil)
Milk and derivatives (lactose, milk protein, etc.)
Egg and derivatives
Fish and derivatives
Shellfish and crustacean (shrimp, lobster,prawns..)
Cereals (wheat, rye, oats, barley)
Soy and derivatives, (e.g. lecithin, protein, oil)
Sesame seeds and derivatives, (e.g. protein, oil)
Sulphites > 10 mg/kg (in the ready to eat product)
Peas and derivatives only for Nordic
Mustard

Even  small dosage of allergen  such as 5-7ppm  could trigger allergic reactions  and  result  into  following reactions

Rash, hives, cough, shortness of breath,tightening of throat, wheezing, swelling, nausea, stomach cramps in some serious cases sudden drop of blood pressure ,unconciousness and death

Hence its important that manufacturers /suppliers  understand the importance of  labeling

Sieves Sizes For Wire Mesh Used In Bakeries

Most  of the bakeries have installed FSMS in one form or the other,  most  of these companies have opted  for  ISO 22000 , HACCP , BRC   and others . Sieving of  ingredients have been declared by most of the bakeries  as the  most critical control point ( CCP ) . I  have just  tried  to give you  few mesh sizes  which are used  in various plants . Every plants has its own standards .
Given are the most estblasihed  sizes of  wire mesh  used in  bakeries.

Flour  -  30 -40

Sugar  - 10-14

Chemicals  - 24 mesh

Palm oil   - 40 mesh

Ingredient s -  12-16 mesh

Water  -  100 mesh

Butter -   30-40 mesh

Cocoa / Chocolate powder - 12-16 mesh

SMP  -  30-40  mesh

Yeast  Powder  - 24 mesh

GMS powder  -  24 mesh

Liquid  Glucose  - 14 -16 mesh

Pepsico Launches New Bakery Products

With initial success of  Aliva  snacks Pepsico India  has  launched new variant  of  baked snacks

Multigrain Waves
Milk Minis

Thus  challenging competitors like Parle and Britannia

Cakes From Winkies

Winkies  have  now launched  numerous  cake variants available  at super and hypermarkets .

Bauli Croissant In Delhi

Popularity  of  Bakery products   could  be gauged  by the  variety and types of  products now available in shelf in Indian super markets  and hyper markets . One  such  example  is  availability  of  Italian major brand  Bauli   .  Croissants  with  cocoa  cream  packed in attractive packs .

Cracker Biscuit From Britannia

Crackers  are popular segment in salty  biscuits world  wide   loved by  people  who prefers low sugar  and low fat  snacks . Britannia brings these crackers under  Nutri choice  brand .

Winkies Swiss Roll

Winkies  Swiss Rolls  are  now available  off the shelf in Delhi market .Swiss  Rolls  are available  on local bakeries  but to  produce and market it nation wide is another game all together  however  this company  "Dream Bake  Pvt  Ltd"  has  launched  swiss rolls  by the name " Winkies ", packed in cardboard tubes.

Swiss  Rolls were tried  by Britannia  in 1995 -1997   but  not with success and was called off . Swiss Rolls  are popular abroad .

Read  more swiss rolls in India .
http://bakerybazar.blogspot.in/2009/07/britannia-s-failed-brands-and-products.html

Top 10 Baking Blogs

I  just  wanted  to compile  top  10  baking blogs  on internet   for which I  surfed major search engines  and  blog  ranking sites

Here  are  the   top 10 blogs   on baking

David Lebovitz

The Fresh Loaf

Baking Bites

Cake Journal

Cupcakes Take The Cake

Recipegirl.com

Bake or Break

Cake Spy

CupCake Project

Savory Sweet Life 

Other popular  websites  on baking

Joyofbaking.com

epicurious.com

allrecipes.com


verybestbaking.com


veganbaking.net

Check  them out  for  tasty , mouth watering and refreshing recipes

Bergen Cookies

Apetite  for  imported biscuits  has not died even  with onslaught of  international biscuits flooding Indian markets  such as  Oreo , Mcvities , Munchies  , Tiffany   etc .

Bergen  cookies  are  all over   the malls , super market  and  retailers  in Delhi  . Wrapped in attractive packaging  with cookies in trays .  What  attracts  the consumer  is the  size  of the ring shaped  with sugar sprinkled on top of  cookies  and   laced with  exotic  designs . The packs were  made in Poland.

Parameters For Sugar In Bakery

Sugar  is among  the major ingredients of  all  bakery products . Important parameters  which   bakers  should check  about the  sugar   are

Particle  size
extraneous matter 
color
moisture
sucrose
water insolubes
sulphated ash
heavy metals

preferably manufactured  by vacuum  pan process

Daily Production Report In Bakery

So you  are  handling bakery operations  then you need to have daily production report  first thing you look for on your desk . Now days  most the bakeries rely  on ERP  software which  collects all the vital information for daily production . Smaller  or  conventional  bakeries still  have report  presented  in  excel sheets from their executives

Here  are the important elements  which makes  a complete daily  bakery production  report

Production -  ( loaves / numbers/cbbs/ kgs / tonnes )
Mixings   - Number of mixings
Labour  - Numbers / labour hours/overtimes/ Labour efficiency
Fuel   -   Ltrs / unit of production
Electricity - Kwh Units 
Defective or wastages  - %
Dispatch or sales
Dividing  Weights
Packet  Weights
Quality  Index Score
Stocks - Opening and Closing for important raw material
Finished Good Stock
Available hours
Break downs  - %
Gaps  - In hours

Above are few important  elements of any bakery production report  .These could provide  the complete picture of operations and on which deviations and shortfalls  can be discussed and means to achieve the target production in bakeries .

Softwares like SAP  and Oracle  helps in getting information on  mouse click .

Good Day - Brand Going Strong

Good Day  Cookies   from  Britannia  Industries  is  second largest  brand of biscuit  sold in India   the sales turnover is estimated to be Rs 1500 crore . This  single brand of biscuit  is second most popular brand after  Parle - G   and is still growing with  new set s of packaging and flavor . It started the concept of Indulgence in biscuit  industry .

It all started with   Britannia  team  launching  indulgence  biscuits market in 1986  where people were  either have been  fed with glucose varieties  or  some  type of cream biscuit  from  local bakeries . Good  day  bridged the gap of  these two varieties . Cookies were only available with local bakers Britannia grabed this opportunity  and launched nation wide  packed cookies and aptly named it  Good day .  The butter variety hit  the bulls eyes and was instant hit  with the masses . Later  it had new avatars  with  pista , cashew and chocolate version .

Crispy and crunchy   cookies was  lapped by all  and rest  is the story .  Britannia under  pressure from high cost of ingredients  have changed its  recipe and prices but  still  Good Day  cookies are favorite for  every one .


Read more on  Good Day  brand  as told  by   Mr  Alagh  former CEO of Britannia -The  man responsible for the success of  Good Day  Brand

Indulgence over 25 years- news story in the hindu

 

Sandwich Biscuit In Single Pouch

Strolling in suburban  area  of   Bangalore   I  could lay my hand on  single sandwich biscuit packed in pouches similar  to  snack pouches  displayed  at various  retail  shop . The concept  was selling bigger size cookies  or single serving for  the consumer on go should have  a  market , its  just reverse of companies promoting smaller pouches  with  2-3 biscuits  for  price tag of Rs 5/-.

The product has  been  marketed by INBISCO India Pvt Ltd , Chennai  with parent company  INBISCO  PT MAYORA INDAH  Tbk , Indonesia . Its being marketed by the brand name "  Danisa"   with Choco Milk Flavor  and  with attractive packaging .

Automation In Bread Plant

Indian bread  plants  in majority  are labour  dependent with most of the process done manually  its high time that  manufacturers think of   automating  the whole proces or  in parts to eliminate

dependence on labour
eliminate waste
have consistent quality
to eliminate human errors
increase productivity
safety 



In ingredient section automatic feeding  to mixer  with help  of  bulk handling , load cell based weigh hoppers  and pneumatic or screw conveyors ( flour , fat, chemicals  and sugar )

Auto greasing of moulds 

Direct feeding   of dough sticks  from  moulder to moulds

Auto  stamping of  dough sticks .

Auto  Lidding  and  De lidding  for  prover  and  baking  oven

Auto  loading  and unloading  of  moulds  into prover  and oven

Auto depanning of   breads from  moulds

Direct feeding to  slicers   from  spiral conveyors

Control  cooling 

Automatic  packing  with  direct feeding  to packing machine

Automatic  twist n tie  or wrapping  in packing

Automatic  loading of packed bread in  plastic  trays .

Direct loading to  containers  with conveyors

Grinding  for  sliced  bread waste to recycle

Metallic Conveyors In Bakery

Conveyors   are  life line  of bakeries ,  these conveyors performs numerous  functions right from  material handling to , transfer , process , loading and unloading . Conveyors  in bakery  could be of two basic  categories  web conveyors or  metallic conveyors

Major  metallic  conveyors are

Chain  conveyor

 Basic  conveyor  made of  simplex , duplex  , triplex  chains  as per  the load  on it  . These are simplest form of material handling conveyors  in bakeries   where moulds  are being transferred  from  different section s such as  proving  to  baking and return . Consists of chain , sprockets , supporting guides and drive rollers  with motors





Slat conveyor

Slat  conveyor  are  improved  version of these chain  conveyors  where   slat elements  are joined together with  pins  and the sprockets  drives these conveyors through  links  . basic elements are  sprockets , slats , sprocket and drive . Used to transfer moulds  from proving to baking and return .



 



Wire mesh conveyor

Used  in tunnel  ovens across the bakery  units   made up of mesh  with different   widths  and mesh sizes  as per product  requirements . Biscuit Industry are the major consumers  for  wire mesh type of conveyors . 




Flat   steel  bands 

Few items  requires  complete  flat surface  for movement and baking  simultaneously  in bakery unit for such  products   flat  steel bands  are used  as conveyors   for e.g  cakes , swiss rolls and  cookies .

'Snackuits' Britannia s answer to healthy snacks

Britannia Industries one of the largest bakery manufacturer  in  India  is trying to increase its share  in snacking business  which has market turnover  of  Rs  7000/ - 10000 /crores . Early entrant to this market have been  Pepsi co with Aviva  and  Parle  Hippo .

Britannia  has launched  new  variants  to its  power brand 50-50  with  flavors  like " Swiss Cheese & Chilly", "Chinese Hot & Sweet" and " Italiano Pizza". These variants are mainly targted  towards indian housewives  for their penchants for snacks . Britannia would offer these baked snacks with healthy tag  of  zero transfat  product. Media and tvc have been planned would be released soon .Snackuits  aptly  reminds consumers for snacks which are baked as biscuits.Other product which  Britannia has launched in this category are  "Time pass"  and  "Nutrichoice" . "Time pass"  poppable  spicy snacks  are  being tested in  different regions .  "Maska - chaska "was instant hit with youth  for its unique flavours which was extension of  brand 50 -50. Snackuits are being marketed in North , East and West  region at present . Price tags for snackuits are being kept  as Rs10/- for 30 gm pack and Rs 20/- for 50gm pack .

Its worth to note that  snacking market  is  being estimated to be 20%   for coming years . Britannia with increasing competition has made moves to diversify into other popular food segments-.Ready- to- eat , dairy  and snacking .

Parameters For Fat As Ingredient In Bakery

One of the major ingredients  in bakery product is fat  . Fat could be used as palm oil , palmolien , hydrogenated  vegetable oil  and others

To use fat and oils   following parameters  are to be checked  it varies from  product to product and countries to countries .

moisture percentage

peroxide value

butryo refractometer reading or refractive index

Iodine value

saponification value

 oelic acid

unsaponification  matter

Flash Point

argemone oil   - negative
 
anti toxidant TBHQ

lead ( Pb )

New Standard Pack Size To Be Introduced Soon

Indian  Fmcg  would  have to  implement  standard pack sizes  which were  offloaded since  2004  where fmcg manufacturers were allowed  to  have non  standard  weights  such as  18 g , 36g , 89g  etc. which has made consumers confused  while relating  and calculating   the price comparisons with  quantity of different brands .

Maximum impact  would  be on  confectionery  , soaps , coffee and edible oil  manufacturers   companies  which  would have impact would be Britannia ,Parle , ITC , Hindustan  lever , Nestle and Cadburys .

Manufacturers have to  exhaust  inventories of existing packing  and change over to  new weights  , which may lead to  price increase in most of the  skus  and  product  availability in market .Packaging cost would  hit  the profit margins as well it might also results in lowering of demand for few products . Reduction of grammage has been major  cost reduction drive for many fmcgs  , keeping margins thru  lower weights at same price without any hike in the price .

Finally its the consumer which would gain  from rationalization  of packet weights giving them a clear picture of price comparison vis-a-vis  weight .

The  law  states that the packet weight which are  below 100g  to  label their products in terms of  25g, 50g,75g,100g  above 100g to 300g it would be  100g, 150g,200g ,250g  and above it would be in multiples of 100g  such as 200g ,300g,400g etc . Ministry  of Consumer affairs  has shortlisted 19 categories of product to start with new norms  applicable  from  1st , July 2012 .Earlier law enacted was under  standards of weights and measure ( Packaged Commodities) Rule , 1977.

here  are  the  new  standard weights  norms under  Indian Legal Metrology Packaged Commodities Rules


 Product  category              New weight as per  proposed amendments 

Baby food	100g,200g,300g,400g,500g,600,g, 700 g,800 g, 900g,1 kg, 2 kg, 5 kg and 10 kg
Weaning food	100g,200g,300g,400g,500g,600,g, 700 g,800 g, 900g,1 kg, 2 kg, 5 kg and 10 kg
Biscuits	25g, 50g, 75g, 100g, 150g, 200g, 250g, 300g and thereafter in multiples of 100g up to 1 kg
Bread including brown bread but excluding bun.	100g and thereafter in of multiples 100g
Un-canned packages of butter and margarine	25 g, 50 g, 100 g, 200 g, 500 g, 1 kg, 2 kg, 5 kg, and thereafter in multiples of 5 kg
Cereals and Pulses	100g, 200g, 500g, 1 kg, 2 kg, 5 kg and thereafter multiples of 5 kg
Coffee	25g, 50g, 100g, 200g, 250g, 500g, 1kg and thereafter in multiples of 1kg
Tea	25g, 50g, 100g, 125g 250g, 500g, 1kg and thereafter in multiples of 1kg
Edible Oils Vanaspati, ghee, butter oil	50 g, 100 g, 200 g, 500 g, 1 kg, 2 kg, 3 kg, 5 kg and thereafter in multiples of 5 kg
Milk Powder	Below 50g no restriction, 50 g, 100g, 200g, 500 g, 1 kg and thereafter in multiples of 500 g
Non-soapy detergents (powder)	Below 50 g no restriction, 50g, 100g, 200g, 500g, 700g, 1kg, 1.5 kg, 2 kg and thereafter, in multiples of 1 kg.
Rice(powdered), flour, atta, rawa and suji	100g, 200g, 500g, 1kg, 2kg, 5 kg and thereafter in multiples of 5 kg.
Salt	Below 50g in multiples of 10g, 50g, 100g, 200g, 500g, 750g, 1 kg, 2 kg, 5 kg and thereafter in multiples of 5 kg
Soaps	25g, 50g, 75g, 100g, 125g, 150g, the multiples of 50g
Aerated soft drinks, non-alcoholic beverages	65 ml (fruit based drinks only), 100 ml, 125ml(fruit based drinks only), 150 ml, 200 ml, 250 ml, 300 ml, 330ml(in cans only), 500 ml, 750 ml, 1 litre, 1.5 litre, 2 litre, 3 litre, 4 litre and 5 litre
Mineral water and drinking water	100 ml, 130 ml, 150 ml, 200 ml, 250 ml, 300 ml, 330 ml, 500 ml, 600 ml 750 ml, 1 litre, 1.2 litre, 1.5 litre, 2 litre, 3 litre, 4 litre and 5 litre

source : Legal Metrology Packaged  Commodities  Rule .

latest news on standard pack rule
http://bakerybazar.blogspot.in/2012/06/standard-pack-size-rules-postponed-till.html

Happy Happy From Parle

Parle  has recently  launched  a new  chocochip cookie  named - Happy  Happy   to  cater  for lower segment of  premium biscuit  which could be bought by  common  man  with price tag  of  Rs 5/- . Premium segment of chocochip variant is catered by its  Hide -seek and Milano  brands.Competition comes from  Britannia s  Tiger  & Choconut varieties .

Britannia's " Good Day " Completes 25 years

Britannia  's power  brand  Good day  completes  its  25 years of existence launched in 1986   and is worth more  than  Rs 100 crore brand   rightly placed  as one of the power brand from Britannia .which includes Marie , Milk bikkis, Bourbon , Fifty - Fifty ,  Nutri choice

Good Day  complete 25 years 

Its origin can  be attributed to the  Britannia  R & D which bridged  the  gap  of biscuit and cookies . Good Day  is the major  product  as far as market leaders  from Britannia is concerned . Good Day  biscuits could not be replicated by competitors  like Parle , ITC and now  United Biscuits . Of course  Unibic  has come closer by creating a cookies niche  in biscuit segment successfully .

Rich  in recipe  the  Good Day  has  been popular among masses  with its  bite and taste . In addition Britannia   has used  ingredients like  cashew , pistacchio  and  chocolate  to add spice to it brand .



Good Day  biscuit  has now many variants  such  as   Butter , Cashew , Pista ,Chocochips, Choconuts . Britannia has planned to showcase Good Day  with human touch in its tvc and media campaign .

Industrial Sewing Machine For Conveyors

Most of Indian biscuit manufacturer use  cotton conveyors  for their   conveyor  requirements  and with  time these  cotton conveyors  get worn out and start  tearing   apart  at various places  , thus  conveyor web related break down  are  very  high  in  such  biscuit  unit. Stitching  of web  is time consuming if done manually .

Solution  to these  problem   have been  tackled by  following steps .

Preventive maintenance method  where by a dedicated  web inspection team is formed to monitor the health of conveyors and immediate action is taken to prevent further  damage

Replacement  done irrespective  of  cotton web condition  after  deciding  the life of conveyor .ie  12 months, 18 months etc.

To reduce the time taken to  repair the damaged cotton web , industrial sewing machines are now being introduced to stitch the worn out  cotton conveyors  as  manual stitching takes more time . Industrial sewing machines are motorised and  need  a platform  to perform the operations in less time . The quality of job obtained from  these machines  is  good in comparison to manual stitching as the threads generally do not come out in  case of job done through  industrial sewing machine.

One of the most popular industrial sewing machine  which have found application in biscuit industry is  "JUKI"  sewing machines , it has wide range of industrial sewing machine to cater various application in biscuit industry .

Parameters For Bakery Ingredients - Flour

In series  of  parameters  used  for major  ingredients  in bakery industry . we  would explore parameters  for flour .


Moisture
Total  Ash
Acid Insoluble
Wheat germ oil acidity
Alcoholic  acidity
Gluten %
Water absorption % ( WAP)
Sedimentation value (  SV )
Ageging ( Millers  end )
Maltose  Value
Granularity
Falling No
Alfa toxins
Heavy Metals

Each parameter  is important with different  values  or  standards  for  different  bakery products . Hence a professional baker or  bakery  needs to  evaluate  flour  quality  with above mentioned parameters .

Bisk Farm Comes Up with RUSKIT

courtesy-biskfarm.com

Rusk s  have  been  now under   the lense   with  big  bakery players . Only branded rusk are  being manufactured by Britannia  under  the brand  premium rusk  . Bisk farm has now entered the rusk  segment with media blitz and advertisement  promoting its  rusk  as  Ruskit .

Biskfarm  a regional power brand in biscuit segment   especially  in  eastern sector of India.  Rusk is pre dominatly  liked by  elderly  people and  workers  for   source of  break fast  alternative  and  people have liking of  dunking  bread  into  tea. It would be interesting to see how Bisk farm   captures customers  preference in rusk . Variant  which are popular are butter rusk , sooji rusk  and milk rusk .