Wheat flour is the major ingredient used in manufacturing products . It directly affects Profitability & performance of the product and the units. The performance of the raw material is related to the various constituents in the wheat flour which play a major role and go under various chemical, physical and microbiological changes during processing. Good quality wheat flour helps to manufacture standard and consistent quality product constantly and is directly responsible to the product yield and cost. It is because all the constituents of wheat flour are responsible to achieve excellent quality product, hence it becomes important for all of us to understand the contribution of wheat and wheat flour in general so as be able to implement the same to control the product manufacture and production process.
Wheat grain consists of :
Bran
Endosperm
Germ DTKFCPL Feb 03 2
Varieties of Wheat
Triticum Vulgare Triticum Durum Triticum Compactum
Bulk of wheat is of the Vulgare variety and is used for manufacture of bread and biscuits. The Drum variety of wheat is used to manufacture pasta goods. Very soft wheat is suitable for manufacture of biscuits (compactum)
Wheat mainly consist of three major components 1) Germs 2) Endosperm 3) Bran/Husk.
These constituents exists in wheat in the falling ratios : 1) Germ embryo that produce new plant growth 2% 2) Starchy endosperm -- food for new plant growth 85% 3) Various Coverings Bran/Husk 13%
The chemical composition of these constituents will demonstrate the chemical role of these constituents during manufacturing as well helps the flour mills to manufacture the quality of the flour required by bakery product manufacture.
DTKFCPL Feb 03 3 Chemical Composition of Three Major Constituents of WHEAT
The Wheat composition consists of average composition of all these constituents. Approximate composition of wheat : Moisture 9-18% Starch 60-68% Proteins 815% Cellulose 2-2.5% Fat 1.52% Sugar 2-3% Ash 1.52%
The wheat flour which is used for manufacture of various bakery products mainly constitute of the endosperm.
To understand bakery operation in relation to the constitution of the wheat flour, there are too major elements viz starch and Gluten (Protein) which affect the quality and yield in bakery operation. It is important to understand the chemical composition and their all level effects in the processing.
The profitability of flour mills is dependant upon the extraction rate. High extraction provides better contribution and thereby increases overall profitability. Higher extraction produces wheat flour of poor quality and also varies in the composition. It effects the gluten quality. Higher extraction rates always damage the starch molecules. The variation in composition due to extraction rate is shown below :
Carbohydrate Starch consists of Amylose and amylopectin. Amylose constitutes 23% and consists of straight unbranched chain of glucose 1 : 4 gulcosidic linkage. White amylopectin consists of highly branched short glucose chains.
The significant point here is that these compounds react differently to enzymic (diastatic) attacks.
The analysis converts straight chain to maltose but is unable to attack amylopectin beyond the branch point.
DTKFCPL Feb 03 6 The analyses however can attack linkage at branch point and once this is done amylose can act on amylose and produce maltose with residue from amylopectin position as dextrin
When amylose attack starch , dextrin (gummy) are formed from amylopectin and these are compounds which are harmful during bread manufacture the formation of dextrin makes the product clammy and sticky. During this reaction process , maltose is produced. There has always been correlation between the amount of dextrin and maltose. If one is able to estimate the percentage of maltose it would be possible to derive the extent of starch damage that has taken place and in due course the quantity of dextrin produced.
There are several methods for the estimation of maltose (which is one of the by products of anylase reaction. This subjects has always been a very interesting aspect of cereal chemistry . Rumsey develop a method of estimation and value was represented as maltose figure. The autolysed flour at fixed time at 62 0 C after which a separate meter reading was obtained.
Better physical methods were developed to understand the reaction of amylose on wheat starch. Various equipment were developed and one of the most important techniques presently used is Amylograph.
The process is described below: The mixture is mixed at 75 rpm. The material is heated through bath by increasing temperature at the rate of 1.5 0 C per minute. The shaft operate at the upper end of pen that records the changes in viscosity .
To 50- 80gm flour add 450ml water in smooth suspension. DTKFCPL Feb 03 7
The temperature is allowed to increase to 95 0 C and is held constant and apparatus is allowed for an hour. The graph is recorded as a line at which it runs parallel to horizontal axis but at 70 0 C starts to rise reaching as peak between 88 0 C to 95 0 C usually after 45 to 50 mt. Lower peak shows addition of amylase or excess.
Baking Viscosity Diastatic activity of maltose Maltose Per 10 gm
Very Poor 150 540 3.5 Fair 315 395 Good 442 -547 365 352 Very Good 763 1000 + 275 85 5.5
The other method adopted nowadays is Falling No. in milling industry
The sample of wheat is grounded is allowed to pass through 0.8mm screen. The 7 gm of flour is mixed with 25 ml. of water in a tube provided with 20 to 30 shakes. The test tube with a stirrer in position is immediately immersed in a lively boiling water bath. The contents remain in bath for 60 sec. The stirrer is then raised on top and allowed to drop by its own weight to a fixed depth. The time taken for the stirrer to drop is called falling No.
Sprouted wheat would have : Falling No. 150 -300 This provides indication of amylose activity with liquefaction No. DTKFCPL Feb 03 8
Liquefaction No. 6000 Falling No. -50 ( Although starch is insoluble in water the granules swell in hot water and eventually burst. The effect is known a gelatinization of starch.
During the milling process the starch gets damaged due heat produced from rollers during grinding as it is sheared and crushed between roller. A large amount of water added which is around 50% or more in the mix is largely consumed by gluten and small quantity is utilized by starch, which starts swelling. The top of the bread shows preponderances of starch granules that are swollen. This represents first order gelatinization. The inside of the loaf has temperature never more that 95 deg Celsius and water is limited and the gelatinization is not complete.
High viscosity of starch is associated with low volume of baked loaf.
Protein
An Organic Compound where in amino acids are linked together.
Protein in wheat flour is a combination of the following:
Albumin Globulin Protease Prolamin ( Glidnin) Glutelin (glutenin)
The first three are insignificant because of their quantities in wheat flour are approximately 1.7 %. The other two protein are commonly known as gluten and Glidnin . Glutenin gives solidity and gliadnin imparts softness. The estimation of extensity/strechability and strength is estimated by various techniques as below:
1) Alveograph
2.5 % salt solution for making dough at 25 0 C - weigh 250 gm start mixer carefully add calculated qty of salt water taking approximately 15 sec. Allow mixing to proceed for 7 minutes. Stop mixer, raise the shutter A. Extrude the dough cut into four piece . Place the dough in tempering compartment . Relax for 20 min. If a bubble is created, the recording monometer should watch the bubble as it punctures. DTKFCPL Feb 03 10
Area is measured by Planimeter provides strength of the dough P = Height of peak is measured in mm stability L = MM gives stretching ability Stability 45 90 Strength 20 75 Condition Wheat stability 90 Strength 70 -75
Sticky body is responsible for binding. The bran and germane richer in protein contact. It is quality of gluten rather than quantity that influences baking quality. The quality of gluten depends upon chiefly the collidal state of protein.
2) Farino Graph P L DTKFCPL Feb 03 11
0
A= Dough Consistency B = Dough Development D= Elasticity C = Dough Stability C B A E D DTKFCPL Feb 03 12 E= Weakening of dough
Quality Of flour
a) There must be sufficient sugar and enough diastatic activity to produce reserve sugar during fermentation to ensure continuous sufficiency of gas to distant the dough b) Protein must be sufficient in quality to hold sufficient gas c) The dough must be ripe at the time of baking.
B A C Tension D Proportional No D = B/C Time Seconds
Visco elastic behavior of the dough. DTKFCPL Feb 03 13 Fat and lipids
The whole grain contain 2% rather under 4% fat
The oil is present in germ contain : Oleic = 30.0 Linoleic = 44 % Linolenic = 10% Other saturated = 13 14%
Germ oil acidity is very important it is responsible for the oxidation of the product. It is always necessary to check the germoil acidity on a regular basis. It has been observed that more than 20 units is not an acceptable quality for manufacture of biscuits and baked varieties.
The lipids in flour affect both formation of dough as it is influenced by the gluten and also a method to understand the gluten quality and water absorption.
Sugar and Dextrin
Dextrin are responsible to glaze the side / Top of the bread. Excessive dextrin causes heaviness, stickiness in curb which is noticeable with amylose process.
DTKFCPL Feb 03 14 Standards of white flour Moisture Ash Protein PH fat maltose Gluten % min. 14 0.65 10.5 6.0 -6.8 1.5 250 8
Other ingredients
Other important ingredients used in baking operation is yeast which help in proofing the to the required size and volume . It is important to understand the quality of yeast used in manufacturing process. The yeast which is commonly used in bakery operation is called SACCHAROMYCES CEREVISIAE (YEAST).
Yeast is also used a leavening. Yeast converts fermentable sugars such as maltose, glucose, fructose and sucrose into CO 2 and alcohol. Yeast is a living organism and its activity can be influenced by storage practices, dough temperature and PH, availability of water and food supply. Out of these control points, the most important is temperature.
Yeast is available in two forms: Compressed yeast Dried yeast
DTKFCPL Feb 03 15 The compressed yeast needs to be stored at refrigerated conditions. Active dry yeast must be pre hydrated 5-to 15 mins before adding to dough at 95 110 o F water. Instant Dry yeast can be added directly without pre-hydrating.
Average quantity requirements : 1.5 lb 280. lb per sack 4 lb per sack Addition Salt
The fermentation by yeast depends on Quality flour and process parameters used in manufacturing. It has been observed that good quality of flour shows an over jump of approximately 1.7cm. This is achieved by ability to produce co 2 while entering the oven and gluten able to extend to encompass the gas which qualified as over jump.
These are various method for manufacture of bread and commonly used are sponge and dough and straight dough methods. Sponge and dough process is commonly used in Europe, straight dough process has been adopted as common manufacturing process. Both these processes have advantages and disadvantage and produce quality bread . In American countries sliced bread and soft buns are mostly consumed hence the adoption of soft spong process allows them to achieve better texture for soft bread. In the European market French bread, Italian bread etc are available from straight dough method. Bread obtained by such a method provides quality bread and shows better performance.
The spong dough process is carried out by using half of the flour in formation process and half the flour is later added to achieve complete dough. While as in straight dough method all ingredients are mixed at one time and dough is straight taken for manufacturing process
DTKFCPL Feb 03 16 In the spong dough process the flour quality has to be good otherwise during fermentation process amylose activity is likely produce more dextrin. So if the quality of starch is poor it is always recommended to use straight dough process for manufacture of bread/ bun etc.
For soft flour some oxidsing and reducing agents have been recommended. Oxidsing agents help to achieve good volume and provide strength to the flour while reducing agents help gluten to achieve the ability to extend / stretch by breaking down the protein structure. Oxidizing agents - Ascorbic acid. KBro 3
S Di Sulphide bands OXIDIZING AGENTS DehyoAscorbicacid KBo 3
SH DTKFCPL Feb 03 17
There are many theories on how oxidizing agents work. We know that oxiding agents strengthen the dough. Oxidizing agents have the ability to form disulphide band which like protein, chain together. It also allows the dough to recover from mixing faster. This may be due to disulphidethiol interchange. Another theory suggests that oxidizing agents promote protein aggregation through ionic and hydrogen bonding. When dough is under oxidized the dough tends to be over sticky and with poor gas retention properties. A dough that is over oxidized will be too tight and stiff and the resulting product usually is low in volume( except for over usage of ascorbic acid and KBro 3 ) and grain is dense with holes.
Our strategy is to give longer fermentation time. As the fermentationt time increases, the oxidation requirements are reduced. Another strategy is to reduce proofing temperature. The only problem in reducing the proofing temperature is , it extends the proofing time. This can be overcome by adding additional quantities of yeast.
The oxidizing agents: Strengthens dough structure by creating bond between proteins Improves dough handling Increases product volume Produces tigular grain
DTKFCPL Feb 03 18
S
S HS-X REDUCING AGENTS Free L-cystine S
S SH S-S-X Disulphide bands Break band between protein chain Reducing Agents : Wakens dough structure by breaking bonds between proteins Allows shorter mixing time Improves machine reliability HS X DTKFCPL Feb 03 19
Changes During Baking
Mai Lard reaction/ broconing 121/350 Alpha Amylose Starch Gelitinization Slow Begins starch geletinization Protien Thermal death point of yeast CO2 liberated expanding cell Mixing Makeup Proofing baking Cooling
200
180
160
140
120
100
80 93 o C 79-80 o
60 0
49 o
DTKFCPL Feb 03 20
Some of the reducing agents and emulsifiers performance in bakery operations
The reducing agents reacts during the mixing cycle and has infinite and limited reaction. It should always be balanced with oxidizing agents. It helps to achieve proper mixing and flour time.
Usage in rays for same important Ascobric acid 100200 ppm Cystaine 10-90 ppm Sodium bisulphate (bakery) 20- 100 mm (Pie, crackers)
DTKFCPL Feb 03 21
Dough strengtheners/ Crumb softeners are also called emulsifiers or surface active agents or surfacetants. They help to change surface tension. These emulsifiers have both strengthening and softening effect upon the product. The most common softeners are mono and triglycerides. They also help to increase shelf life. For breads, we need hard monoglycerides and for cakes we need soft monoglycerides are used. The percentage of alpha alpha monoglycerides is important as it has better dispersibility. Softeners flows down starch retrogradation thereby inhibiting the staling process. It also slows moisture migration and improves moistures retention.
In manufacturing process several bread softness have been used. This help to develop the linkage with starch molecules and also provide help in retaining better moisture which in togetherness give rise to very soft brand.
The Common Softners - Monoglycerides, starch glycerids
During baking process the flour and other constituents go under various changes. It is important to understand these changes so as to be able take appropriate steps to achieve better quality products.
The flour will affect the handling qualities of dough and all the quality factors that will be evaluated in the product.
Water : The second largest ingredient in bakery operation is water. The main function is hyderation. Gluten must be hydrated and for gelatinization of starch water is essential . It also serves as dispersing agent and a medium for fermentation. Water is used to control dough temperature. The total level of water in a bread dough is normally in the DTKFCPL Feb 03 22 range of 55 to 65%. Water is the best cereal softener. Higher quantity of water can dilute an otherwise good product.
Salt : The main function of salt is to bring out the flavor of the baked product. Its usage levels range from 1.75to2.25%. Bread made out of 1.75% of salt, tastes bland and bread made out of 2.25% of salt tastes very brackish. Salt also inhibits fermentation due to osmatic pressure effect and it also toughens gluten . Salt lengthens mixing time. Therefore addition of salt should be delayed to have proper mixing.
Bacterial analyses (180) 0 F Temperature at which these enzymes get destroyed in baking operation Fungal at (150) 0 F (Cereal amylose) 170 0 F
In baking operation other than mixing other parameters like proof time, weight loss, P, are responsible for loaf volume. Tables are provided to explain the correlation o these parameter which is self-explanatory.
Effect of proofing Temperature on proof time loaf volume
Temp OC Time (min) Volume Lb Ml 21.1 120 2200 30.0 60 2280 35.0 50 2270 40.0 47 2290 46.1 41 2260 DTKFCPL Feb 03 23
Effect of proofing time on loaf volume PH of bread and loss of weight in baking.
Proof line Volume lb PH of Bread Loss in baking (g) of bread (ml) 0 1270 5.49 46 15 1610 5.46 52 30 1980 5.41 61 60 2640 5.34 72 75 2780 5.31 73 90 3030 5.26 80 120 3550 5.16 88 150 4090 5.13 89
Effect of humidity during proofing on proof time , loaf volume and yield.
RH Proof Loss in Volume / lb % Time Proofing + of bread (min) Baking 35 57 74 2230 50 52 72 2320 60 54 71 2230 80 49 64 2150 90 46 64 2270 DTKFCPL Feb 03 24
Average Proof condition
Straight dough dry bulbs wet bulb RH F C 100 - 110 37.8-43.3 5-8 2.8-4.5 75 -80 Continuous Process 115 -120 46.1 48.9 3-5 1.7 -2.8 80 -90
Correlation between time and Temperature is shown to help bakers to achieve better product quality.
Effect Baking rolls
a) Rigid in 10 mts. But danger In crest coloration
b) Rigid in 14min no coloration Considered
c) Roll Rigid should have been Removal at 17 min.
d) Barely rigid difficult to remove From pan
e) No rigid rolls collapsed dough or doughy
0 5 10 15 20 210
170
150 Rigid roll 225 o F 200 o F 275 o F 280 o F 250 o F 1 2 3 4 5 Minutes of baking DTKFCPL Feb 03 25 Some of the bread rolls characteristics are presented below to draw our attention to their uniqueness..
Hard Rolls : American Hard Jewish Kaiser or crown rolls Italian or French All are made almost from same type of dough . the dough is left until is light enough to be flattened by Shimmy Machine Flour Water Yeast KBro 3 Diastatic moulten 60 33 36 2 -3 -0.0375 0-2
Italian Bread : Lean Formula (Normal Composition Flour, Water, yeast, salt, V. less sugar) Incorporate Old Dough. Proof bread is provided with smell certs. To appear shell like bread different shapes, twist S, must have hard, thick crust with dry crumb. Sometimes the bread is proofed in oven so that it will be crusted when it goes to oven thus producing heavier crust on the baked loaf.
French Bread : Made from old fermented dough, it is thick, hard crust and characteristic taste. Fermentation line 3/4 to 1 1/2 hrs. Molding should be tight with tight skin without tearing. Gain character is open. Proofing should be just to the point where it will receive cut and open slightly not over proofed should be baked with low pressure steam. Steam should be left in the oven for sometime (5mt.) No definite temp and time of baking is recommended. slow baking produces better results.
DTKFCPL Feb 03 26
Bread Faults
Deviations from the normal bread quality standards, whether perceived subjectively or determined by objective measurements, are designed by the collective terms bread faults. They arise from two principal sources : inferior ingredients and improper processing. in many instances bread faults result from a combination of various factors so that it is more convenient to classify them into broad categories and indicate the possible causes that may be involved in each.
Pelshenke has made the very succinct observation that every bakery encounters as many bread faults as it deserves. This implies that bread faults can be held to a minimum by paying close attention to the quality of the ingredients and by accurate control of the production process. It is often quite difficult to the correct diagnose the immediate cause of a given bread fault and to apply the appropriate remedial action. However , bread faults will manifest themselves less frequently and their effect will generally be less serve if an adequate quality control program is adopted and effectively implemented .Adequate Quality assurance implies that proper steps are taken at all times to ensure that only ingredients of satisfactory quality are used, that errors in formulation are avoided, that proper environmental conditions are consistently maintained. That proper time temperature and humidity requirements are satisfied without fail at all stages of dough processing and baking , and that the equipment us maintained in optional operating condition at all times.
DTKFCPL Feb 03 27 The table below is a list broad classes of common bread faults, together with their probable causes.
Bread Faults
External Faults Lack of Loaf Volume Immature or green Flour Wrong type of flour. Insufficient absorption Insufficient Yeast Poor quality or mishandled yeast. Excess salt Excessive diastatic activity Lack of shortening Improper mixing over or under termented dough Over mentioned or under fermented dough Dough temperature too low. Insufficient pan proof. Insufficient dough weigh for size Hot Oven Excessive Loaf Volume Overaged Dough Insufficient salt Over proofing Overscaling for pan size Cool oven Pale crust colour DTKFCPL Feb 03 28 Insufficient residual sugar Deficiency in diastatics activity Excessive mineral yeast food. Fermentation temperature too high Old dough Insufficient humidity in final proof Cool oven Low top heat in oven Under baking Dark Crush Colour Excessive sugar in formula Immature milk Products in formula Excessive milk products in formula Hot oven High top heat in oven Over baking Blisters Under Crust Undermixing Young dough Careless moulding Excessive steam in final proof Over proofing Rough handling at oven Excessive oven steam ( condensation) Excessive vacuum at depanner (separation)
DTKFCPL Feb 03 29
Thick Crust Insufficient sugar and shortening in formula Insufficient milk in formula Deficient diastatic activity Old Dough Insufficient humidity in final proof Low oven temperature Over baking Shell Tops Immature Flour Deficient diastatics activity Inadequate oxidation Young dough Insufficient humidity in final proof Too tight moulding (low pressure board) Excessive to heat in oven Insufficient Oven Wild Break and Shred Slightly overaged dough Overmixing Inadequate oxidation Insufficient STEAM IN OVEN Improper moulding (low Pressure Board)
DTKFCPL Feb 03 30
Absences of break and Shred Weak Flour Undermixing Excessively diastatic activity Over oxidation Excessive final proof Excessively hot Oven Internal Faults
Gray Dull Crumb Color Excessive diastatics Overmixing or undermixing Young Dough (round , thick, cells) Old dough (open Cell structure) Improper sheeting and moulding Underweight dough for pan size. Excessive proof Low oven temperature Streaked Crumb Improper dough mixing Excessive dusting flour. Too much trough grease or divider oil. Insufficient shortening Dough crushing during termination and final proof
DTKFCPL Feb 03 31
Improper use of rework dough Excessive pan grease Poor Gain Weak flour Overly stiff dough Overly slack dough Overmixing Young dough Improper moulding Insufficient dough weight for pan size Low oven temperatures Poor Texture : Overly stiff dough Improper mixing Excessive diastatic activity Insufficient Shortening Old Dough Crushing of sponge or dough fermentation Crushing of sponge or dough during fermentation Over Proofing Insufficient dough weigh for pan size Low over heat.
DTKFCPL Feb 03 32 Holes in breads Immature or weak flour Unbalanced formula Improper mixing either over or under mixed Old dough, young dough Crusting of sponge or dough during fermentation Excessive dusting four or divider oil. Improper moulding High final proof temperature Insufficient Oven steam Poor Flavor Poor quality ingredients Improper storage of ingredients Unbalanced formula Insufficient salt Old dough , young dough Insanitary plant conditions Old trough and pan grease Over or underbaking Poor Keeping Quality Unbalanced formula Lean formula Poor quality ingredients Improper mixing Overfermentation Under proofing Low oven temperature Excessive cooling before wrapping.