Académique Documents
Professionnel Documents
Culture Documents
FOURTH EDITION
Volume I: Fundamentals & Ingredients E.J. Pyler and L.A. Gorton Fourth Edition
BAKING
Science & Technology
E.J. PYLER
AND L.A. GORTON
SOSLAND PUBLISHING COMPANY
ii
Every effort has been made to ascertain the owners of copyrights for the
selections used in this volume and to credit and/or obtain permission to reprint
copyrighted information and graphics. Sosland Publishing Co. expresses
its gratitude for permissions it has received. Sosland Publishing Co. will be
pleased, in subsequent editions, to correct any inadvertent errors or omissions
that may be pointed out.
Foreword
Baking Science & Technology, 3rd edition stayed in print for nearly
20 years, but as the industry approached the 2007 International Baking Industry
Exposition, it became clear that a new edition was needed. Much had happened,
especially on the nutrition side as well as with process automation, and the industry
now encompassed many new aspects not covered in the text. The 4th edition was
announced at that international trade show, and this book is the first of two volumes
comprising the new version.
Baking Science & Technology, was first published in 1952, then again
in 1972 and 1988. That this book stood the test of time and continues to be used
as a textbook by the industrys leading baking schools and as a daily reference
for thousands of bakers worldwide is testament to its original writers insight and
writing ability.
For the 4th edition, Sosland Publishing approached Laurie Gorton,
executive editor of Baking & Snack. She has nearly 35 years experience covering
the technical, scientific and business aspects of the grain-based foods industry.
The grain-based foods industry and baking in particular face as many, if
not more, challenges than 20 years ago. Todays issues involve nutritional content,
food safety and the demands of the health-and-wellness shopper. But every era
brings its own concerns to the table, quite literally.
We intend Baking Science & Technology to move into the future through
this new edition and, later, digital formats. As developments occur, the book will be
updated using emerging electronic technologies. We encourage readers to comment
on this edition and its contents and to recommend topics and changes for future
inclusion.
Mark Sabo
President, Sosland Publishing Co.
August 2008
iii
Table of Contents
Foreword ................................................................................................................ ii
Chapter 1: Basic Food Science ........................................................................... 1
Carbohydrates ........................................................................................................ 2
Sources of carbohydrates used in baking ...................................................... 2
Carbohydrate synthesis ................................................................................... 2
Simple vs. complex......................................................................................... 3
Physical and chemical differentiation............................................................. 4
Monosaccharides ............................................................................................ 4
Sugar: Disaccharides and trisaccharides......................................................... 5
Starch .............................................................................................................. 7
Dextrins ........................................................................................................ 11
Gelatinization of starches ............................................................................. 12
Retrogradation of starch ............................................................................... 14
Acrylamide formation .................................................................................. 15
Glycemic index vs. glycemic response......................................................... 16
Pentosans ............................................................................................................ 17
Sources of pentosans in baking .................................................................... 17
Structure ....................................................................................................... 18
Physical and chemical differentiation........................................................... 18
Functions and effects during baking ............................................................. 18
Fiber ..................................................................................................................... 20
Sources of fiber ............................................................................................. 21
Definition of dietary fiber ............................................................................. 21
Structure ....................................................................................................... 26
Properties of fiber in food ............................................................................. 27
Probiotics, prebiotics and synbiotics ............................................................ 27
Proteins and enzymes .......................................................................................... 28
Proteins ......................................................................................................... 29
Sources of proteins ....................................................................................... 30
Amino acids .................................................................................................. 31
Classification of proteins .............................................................................. 34
Structure of proteins ..................................................................................... 39
Properties of proteins .................................................................................... 41
Proteins of wheat .......................................................................................... 43
Enzymes ....................................................................................................... 47
Sources of enzymes ...................................................................................... 47
Classification and nomenclature of enzymes ............................................... 49
Lock-and-key, induced fit of enzymes .......................................................... 51
vii
viii
Table of Contents
Properties of enzymes...................................................................................
Lipids ...................................................................................................................
Source of lipids .............................................................................................
Nomenclature ...............................................................................................
Chemical composition ..................................................................................
Fatty acids .....................................................................................................
Fatty acid naming protocols .........................................................................
Saturated vs. unsaturated ..............................................................................
Cis vs. trans ..................................................................................................
Short- and medium-chain fatty acids ............................................................
Mono-, di- and triglycerides .........................................................................
Sterols and stanols ........................................................................................
Other lipids ...................................................................................................
Physical aspects ............................................................................................
Liquid, plastic and solid forms .....................................................................
Melting point ................................................................................................
Crystallinity ..................................................................................................
Hydrogenation and interesterification ..........................................................
Oxidation ......................................................................................................
Autoxidation mechanism ..............................................................................
Antioxidants .................................................................................................
Hydrolysis and polymerization.....................................................................
Physical chemistry ...............................................................................................
Acid-base reactions ......................................................................................
Electrolytes ...................................................................................................
Titration ........................................................................................................
Active acidity ................................................................................................
The pH concept.............................................................................................
Buffers ..........................................................................................................
pH determination ..........................................................................................
Role of pH in baking ....................................................................................
Buffering action of proteins ..........................................................................
pH in chemically leavened product ..............................................................
Oxidation and reduction ...............................................................................
The redox potential .......................................................................................
Estimation of redox potential .......................................................................
Role of oxidation in baking ..........................................................................
Role of pentosans .........................................................................................
Role of thiols and disulfides .........................................................................
Role of flour lipids ........................................................................................
Dough physics: colloids and rheology .................................................................
States of matter .............................................................................................
51
55
55
56
57
57
58
58
62
63
63
64
64
64
64
65
66
66
68
68
69
70
71
71
71
72
73
74
75
76
77
78
79
80
81
81
82
83
84
85
86
87
113
113
114
115
119
136
141
144
145
147
152
152
159
160
165
165
170
175
176
177
183
187
189
191
ix
Table of Contents
191
192
195
197
198
200
210
213
217
223
227
232
236
236
238
238
239
242
247
253
271
272
272
296
303
311
312
312
316
322
324
327
327
329
330
331
337
340
346
348
Starch .................................................................................................................
Wheat starch ...............................................................................................
Supplementary starches ..............................................................................
Properties and functions .............................................................................
Starchs role in bread baking ......................................................................
Cake, cookie, cracker and other applications .............................................
Recent developments ..................................................................................
Fiber ...................................................................................................................
Composition ...............................................................................................
Fiber ingredients and their processing ........................................................
Bakery applications ....................................................................................
Bulking agents ............................................................................................
Prebiotics and probiotics ............................................................................
349
350
351
355
356
359
361
363
364
366
371
375
376
391
394
395
399
401
402
402
403
404
405
412
413
414
415
417
417
418
420
421
423
424
426
427
428
428
429
432
xi
xii
Table of Contents
433
437
438
442
449
452
454
456
459
466
466
477
478
480
483
483
485
486
487
499
500
500
503
509
510
511
514
519
520
521
521
522
526
526
527
533
534
535
536
539
540
541
541
542
545
548
550
551
552
557
560
561
562
562
563
565
567
569
569
571
574
576
577
578
579
581
584
584
585
586
587
587
588
589
589
590
590
590
xiii
xiv
Table of Contents
Olive ..........................................................................................................
Palm ............................................................................................................
Oilseeds ......................................................................................................
Canola (rape) ..............................................................................................
Flax ............................................................................................................
Peanut .........................................................................................................
Poppy ..........................................................................................................
Safflower .....................................................................................................
Sesame ........................................................................................................
Soy ..............................................................................................................
Sunflower ....................................................................................................
Pulses ..........................................................................................................
Lentil...........................................................................................................
Lupin...........................................................................................................
Crop improvement .............................................................................................
591
591
592
592
592
593
593
594
594
595
597
598
598
599
600
613
614
615
616
618
619
621
622
622
623
624
624
625
626
626
626
627
628
629
629
630
631
631
632
632
633
633
634
634
634
636
636
637
638
638
639
639
639
640
640
641
642
642
644
644
645
646
646
646
647
647
648
649
650
651
652
652
652
653
653
653
653
653
653
653
654
654
xv
xvi
Table of Contents
661
662
663
663
664
665
666
666
670
670
671
675
676
677
680
680
682
684
685
685
688
689
689
692
693
694
695
695
696
696
697
701
703
704
705
706
706
707
707
708
708
709
709
710
710
711
711
712
712
713
714
714
715
715
715
715
716
716
716
716
717
717
718
718
719
719
720
721
721
723
724
725
725
xvii
CHAPTER 1
of the science
of carbohydrates,
proteins, lipids and
fibers will help
any practitioner
of the bakers art.
1.A. Carbohydrates
1.A.1. Sources
Of all the compounds composing baked foods, carbohydrates predominate by sheer
quantity, typically accounting for 67% of wheat flour. Qualities that consumers associate
with freshness such as keeping quality, crust and crumb texture, along with firmness,
result from the condition of the carbohydrates in the product.
In nature, plants store much of the energy supply for their seeds in the form
of carbohydrates and also warehouse these compounds in their stems and roots.
Carbohydrates make up the bulk of the white, starchy material found in the interior
content of seeds and roots.
Typical sources for the carbohydrates in baked foods include wheat kernels, of course,
but also corn and other cereal grains and legumes, along with sugar cane and sugar
beets. When considering complex carbohydrates and fiber, sources become even more
diverse, including tree exudates, seaweed colloids and fruit pectin as well as root and
stem materials from a wide variety of plants.
Glucose, the simple sugar that forms the basis of all carbohydrates, is fundamentally
important to life. While mammals derive energy from the glucose they consume, plants
put it to additional use. They can transform carbohydrates into lipid substances, and
when making proteins, plants combine the hydrogen, carbon and oxygen from its glucose
stores with the nitrogen, occasionally sulfur and sometimes phosphorus that it gets from
the soil in the form of inorganic salts. The results are complex protein molecules.
three molecules
CO2
1C
three molecules
ribulose
5-phosphate
six molecules
5C
3-phosphoglycerate
3C
3 ADP
3 ATP
6 ATP
6 ADP
three molecules
ribulose
5-phosphate
six molecules
5C
1,3-diphosphoglycerate
3C
6 NADPH
2 Pi
6 NADP *
five molecules
glyceraldehyde
3-phosphate
three molecules of
CO2 fixed give a net
yeild of one molecule
of glyceraldehyde
3-phosphate at a net
cost of nine molecules
of ATP and six
molecules of NADPH
6 Pi
six molecules
glyceraldehyde
3-phosphate
3C
one molecule
glyceraldehyde
3-phosphate
3C
OH
CH2O Pi
3C
CHAPTER 2
Bakery Ingredients
Part A: Major Ingredients
INTRODUCTION
In practice, bakers tend to group ingredients into three categories based on their
level of usage in formulations: major, minor and micro. Major, also termed bulk,
ingredients make up the majority of the formulation. Flour, for example, constitutes
around 55 to 60% (formula weight) or more of breads raw materials. Minor ingredients
typically range from 5 to 10% (formula weight), and micro ingredients are those added
at 5% or less.
High-quality
baked foods
demand use
of high-quality
ingredients.
113
114
BAKERY INGREDIENTS
This classification came about when bakeries started installing automated ingredient
handling systems. Return on investment came rapidly for capital spent on the silos,
scales, sifters and control systems suitable for storing, portioning and dispensing bulk
ingredients. The payout for automating the handling of ingredients used at lower rates
was not as fast, so installation tended to lag. Manual scaling and hand-add delivery
usually characterize the handling of minor and micro ingredients. A good number of
large bakeries do automate their ingredient systems through the micro level, but it is far
more common to find only the bulk materials dispensed through computerized systems.
For this reason, the discussion of bakery ingredients will follow a major, minor,
micro format. Also presented will be coverage of characterizing ingredients, and
ingredient systems such as bases, concentrates and mixes.
Hard white
Soft white
Durum
(Atwell 2001)
General characteristics
High protein,
strong gluten,
high water absorption
Low protein,
weak gluten,
low water absorption
Very high protein,
strong gluten,
high water absorption
High protein,
Strong gluten,
high water absorption,
bran lacks pigments
Low protein,
weak gluten,
low water absorption,
bran lacks pigments
High protein,
strong gluten,
high water absorption
Principal uses
Bread and related products
Pasta
271
CHAPTER 2
Bakery Ingredients
Part B: Minor Ingredients
Ranging from 5 to
10% on a formula
weight basis, minor
ingredients encompass
Although minor ingredients typically range from 5 to 10% (or sometimes less) on a
formula weight basis, they can make or break product success. Within this category, we
nd leavening systems microbial cultures of yeast and/or bacteria, chemical leavening,
air and steam. Other ingredients used at this level include dairy products and eggs, added
starches and ber enhancement ingredients.
leavening systems,
dairy, eggs, starch,
fiber and other
components.
272
BAKERY INGREDIENTS
2.B.1. Leavening
Leavening lightens doughs, enhancing the volume, texture, eating quality and often
the avor of baked foods. The word leaven can be tracked through Middle Englishs
levain to the Latin levare, meaning to raise. The function of leavening agents is
to aerate the dough or batter and make it light and porous. When baked, the porosity
translates into the crumb of the nished product. Leavening, thus, also tenderizes the
crumb and contributes to the esthetic enjoyment of the nal product by giving it uniform
cell structure, bright crumb color, soft texture and enhanced palatability.
The process of leavening involves creating and enlarging the gas cells in dough or
batter, cells that expand under the in uence of time and heat to increase the overall
size of the dough piece before its starch-and-protein matrix gelatinizes and sets. Mixing
incorporates air into the dough mass, thus nucleating the bubbles essential to every style
of leavening. Batters cannot create their own cells, only mixing does. Without the bubble
nuclii, any gas generated by biological or chemical means would merely dissolve in the
free water of the dough. The tiny air bubbles formed during mixing collect the gaseous
products of leavening. The more the nucleation sites, the ner the texture of the nished
product. While such air bubbles are enough to leaven angel food cakes, nearly every
other formulation requires additional leavening gases. The ingredients that contribute
leavening effects often provide other functional properties and add to, or detract from,
the products nal texture, avor and appearance.
Leavens such as bakers yeast, barm or a portion of fermenting sponge consist of living
microbes that generate carbon dioxide, ethanol and other volatile organic compounds
that ll and in ate the air cells created by mixing. Another category of ingredients
leavens by chemical action. This
process combines alkaline baking
soda with an acid material such
Table 2.B.01. Leavening Action of Yeast and Baking Powder
as buttermilk or leavening acids
Yeast
Baking powder*
Leavener based on flour
2.5%
6.0%
to generate carbon dioxide, which
Leavener based on dough weight
1.47%
3.42%
aerates and expands the batters
CO2 evolved per g leavener
volume before the heat of the oven
0.5 g**
0.15g***
CO2 evolved per 100 g dough
0.735 g**
0.513 g***
sets its structure.
CO2 evolved per 100 g dough
350 ml**
214 ml***
Not all leaveners are alike in their
gassing power, as noted in Table
* A double-acting baking powder containing 30% NaHCO3
2.B.01. While chemical leavening
** CO2 evolution per hour
*** Total CO2 evolution
releases its gas relatively quickly,
(Reed and Nagodawithana 1991)
there is no further leavening action
as with yeast. But yeast may not be
ef cient in all baked foods.
2.B.1.a. Yeast
Biological processes interact with physical and chemical reactions during baking in
a highly complex fashion. Of these, fermentation is the most fundamental, in uencing
avor, texture and organoleptic qualities of the nished product, as well as its leavening
performance. Most bakery fermentation processes are initiated and sustained by the life
forces of a unicellular plant, a fungus actually: the microscopically small yeast. A number
of bene cial lactic and acetic acid bacteria also contribute their lives and by-products to
the fermentation of baked foods.
391
CHAPTER 2
Bakery Ingredients
When formulation quantities and weighments enter the realm of parts per million
(ppm), you know you have reached the micro-ingredient category. Typically used at 5%
or less and usually at 0.1% or less, these materials can be difficult to measure accurately
and so are often combined with other ingredients in packets or as ingredient systems
such as bases and concentrates. Some oxidation and fortification ingredients, which are
important to achieving proper baking activity and nutritional quality, are added at the
flour mill, using specialized equipment that streams the ingredient at a controlled rate
directly into the flour.
With all micro ingredients, accuracy is essential. Consider the example of fortification
392
BAKERY INGREDIENTS
Bakery application
Frozen and refrigerated
doughs; batters
Frozen and refrigerated doughs;
batters
Soft pretzels
Tortillas
Leavening phosphates
Salt
Fumaric acid
General use
General use
Reason
Prevent premature release
Prevent premature release
Prevent premature dissolution
Prevent premature carbon dioxide
release; prevent formation of
translucent spots
Prevent off-flavors and loss of viability
Prevent sticky doughs during mixing
Prevent inhibition of yeast
Prevent softening of dough during
processing; mask strong odors
during storage
Prevent premature release;
prevent graying of dough during
storage
Prevent fading
Prevent dusting and exposure of
allergens to workers during scaling
and addition
ingredients. Calcium and folic acid illustrate the physical conundrum of dosing. The US
Recommended Daily Allowance (RDA) for calcium is 1,000 mg, but for folic acid, it is
0.4 mg. A slight miscue in dosing will not affect calcium, but it can really throw off the
delivery of folic acid.
In a certain sense, micro ingredients represent the baking industrys equivalent to
applied nanotechnology. The definition of nanotechnology pegs it as the applied science
and technology of controlling matter at the atomic and molecular physical level and
employs chemistry, engineering, physics and microfabrication techniques. It involves
scales of 100 nanometers or less. (A nanometer is one-billionth of a meter, or 10-9 m.
In comparison, a micron, or micrometer, is one-millionth of a meter, or 10-6 m. Thus,
100 nm equals 1 mcm, or 1 .) Although bakers do not measure ingredients to parts per
billion (ppb), the concept is being studied.
Food nanotechnology is attracting increasing attention among formulators (Tarver
2006), and the Institute of Food Technology issued a Scientific Summary on the topic
(Weiss et al. 2006). The authors noted that foods carbohydrate, protein and fat molecules
interact through nano-scale participation of their sugar, amino acid and fatty acid
components. They suggested the future may see use of nanotechnology for biosensors
and functional improvements such as association colloids, nano-emulsions, biopolymers
and controlled-release delivery systems.
Controlled release is the whole point of micro-encapsulation, a method of
managing ingredient functionality. Encapsulation is the general term covering
the enrobing of one material in another at the microscopic scale, and microencapsulation describes an even finer degree. Ingredient suppliers can count the
CHAPTER 2
Bakery Ingredients
Part D: Characterizing Ingredients
Baked foods appeal to consumers in far more ways than as simple remedies for hunger.
The influences leading a person to select one food over another involve the senses of
taste, smell, sight and touch. Even an auditory crunch sends signals to the part of the
brain that controls appetite.
Some foods we eat to assuage hunger, but others we consume to satisfy a craving
for specific taste sensations. In this more or less discretionary consumption, food
selection usually ranges beyond staple products and follows more freely the dictates
of hedonism.
Characterizing ingredients provide numerous attractive attributes. The appeal of many
baked foods is enhanced by this class of ingredients. Prominent among the group of
discretionary foods are items such as sweet goods, cakes, cookies, confections and pies.
Because the appeal of many of these foods is to a large measure determined by their
499
500
BAKERY INGREDIENTS
highly flavored ingredients, the nature and selection of these ingredients play a significant
role in determining the level of the acceptability of these foods. In other words: fruits,
nuts, spices, flavors, colors, cocoa, chocolate and other such ingredients add value to
baked foods.
2.D.1. Fruits
Fruits are the jewels in the bakers crown. Their bright colors
and pleasing flavors make them natural partners for the more subtle
taste of grain-based ingredients. Bakers can avail themselves of an
encyclopedias worth of fruits in fresh, frozen and processed forms.
While this discussion looks at several of the most economically
important fruits used by bakers, lately several new fruits have found
a home in the bakery formulary, including acai, banana, guava, mango
and pomegranate (Berry 2006). They are worth exploring for their
emerging appeal to consumers.
Growers federations, boards and councils manage marketing
and promotion of many fruit and nut crops grown in the US. These
groups generally provide a wealth of information and application
resources concerning their crops. They often sponsor research into crop
improvement as well as consumer preferences, and some offer grants
to support academic-level research about the dietary, nutritional and
physiological effects and benefits of consuming these crops as food.
The most recent edition of Dietary Guidelines for Americans,
released in 2005, recommends that adults eat 2 cups of fruits and
2 cups of vegetables every day. Bakery foods can contribute to this.
557
CHAPTER 2
Bakery Ingredients
Part E: Ingredient Systems
The inefficiencies
of hand-weighing
ingredients, some in
quantities measured
in milligrams, prompts
bakers to use bases,
concentrates and
mixes.
558
BAKERY INGREDIENTS
the necessity for weighing out a large number of ingredients for a product and warehousing and handling many ingredients in relatively small quantities. To overcome
these inef ciencies, bakers turn to the ingredient systems known as complete mixes,
half-and-half mixes, bases, concentrates and pre-mixes.
A complete mix contains everything needed to make a product except water, yeast and
sometimes liquid eggs. This is handy in retail shops, where the product may require a
special type of our not readily available to the baker. Many wholesale bakers also use
complete mixes for certain products, especially cake doughnuts and Danish pastry.
Half-and-half products are mixes that contain all the additive ingredients required
plus part of the formulas our, usually a specialty our such as rye, rice, oat, corn
or whole-wheat. The baker supplies the rest of the our from the bakerys own bulk
our stores.
Bases incorporate all formula ingredients except those readily available in bulk to
the baker usually bread or cake our, sugar, yeast and water. Bases are offered in
liquid (Figure 2.E.01), paste, plastic (Figure 2.E.02) or powdered form. For example,
a roll base may look like shortening, while a sourdough base is often liquid.
Concentrates resemble bases but contain fewer ingredients. The active ingredients
are blended onto a base ( our, soy, dry milk solids, etc.) for a dry concentrate or
creamed into a shortening or oil carrier creating a paste or plastic material. Usage is
generally low: 1 to 5 lb per 100 lb of our.
Pre-mixes, which contain blends of oxidants, yeast foods, enzymes, enrichment vitamins and minerals and/or additive ingredients, nd wide acceptance. Formulation
accuracy improves tremendously because the addition of such micro ingredients is no
longer a matter of many weighments but the addition of a single packet or pouch to
Flour (spring)
Flour (winter)
Sugar
Salt
Nonfat dry milk solids
Mineral yeast food
Shortening
Emulsifier
Calcium propionate
Vital wheat gluten
Whey
Potato flour
Soy flour
Blend weight
Scratch
(lb)
70.00
30.00
8.00
2.00
3.00
0.50
4.00
0.25
0.25
118.00
Mix
(lb)
73.00
27.00
5.00
2.00
0.35
4.00
0.50
0.15
1.00
2.00
2.00
1.00
118.00
Base (1:1)
(lb)
41.00
5.00
2.00
0.35
4.00
0.50
0.15
1.00
2.00
2.00
1.00
59.00
Base (2:1)
(lb)
21.00
5.00
2.00
0.35
4.00
0.50
0.15
1.00
2.00
2.00
1.00
39.00
Yeast
Water
Flour
Total dough weight
3.00
65.00
186.00
3.00
65.00
186.00
3.00
65.00
59.00
186.00
3.00
65.00
79.0
186.00
(Smith 1991)
567
CHAPTER 3
INTRODUCTION
In addition to the ubiquitous wheat ours, bakers use many other grains and seeds in
their baked foods. They add them not only for ingredient functionality but also for avor,
texture, appearance and a healthy image. Strictly speaking, a grain means the seed
of the botanical family Gramineae (now renamed Poaceae), usually called the grasses
(Morrison and Wrigley 2004). These are the principal cereal grains. In practice, there are
several other plant seeds with similar properties that are used by bakers and considered
by them as grains also and sometimes referred to as pseudocereals. And nally, there
A thorough
understanding of the
grains suitable for
baked foods is critical
for formulation and
nutrient claims.
568
are seeds that do not resemble the cereal grains but that are added to provide unique
characteristics (Table 3.01). In addition to incorporating these other grains and seeds
into the main dough or batter, they are frequently used as toppings and llings.
This chapter provides a listing of the grains and seeds most commonly used by bakers.
For simplicity, we will use the term grain for all items discussed. They are listed in
alphabetical order, and each in turn is discussed, providing information on the basic grain
Table 3.01. Principal Cereal Grains and Oilseeds of World Importance
Worldwide grain production (2006-07 July/June crop year)
Grain
Worldwide
rank
Corn (maize) 1
Wheat
2
Rice
3
Barley
4
Sorghum
5
Oats
6
Rye
7
Production
Top producing
(mmt*)
country and share
704.28
US 37.9%
593.19
EU** 21.0%
418.24
China 30.6%
137.35
EU 40.9%
56.99
Nigeria 18.4%
23.11
EU 33.4%
12.38
EU 52.8%
US share
37.9%
8.3%
1.5%
2.8%
12.3%
5.9%
1.5%
36.6%
27.0%
30.4%
44.8%
45.3%
22.4%
Palm kernel
Copra
43.3%
41.6%
7
8
US
China
China
Indonesia
China
Russian
Federation
10.27 Indonesia
5.28 Philippines
properties, where and how it is produced, and how and why it is used by bakers. References
are provided to lead the reader to more detailed discussions on each of the grains.
It has been suggested that the habit of nomadic peoples to gather seeds from wild
grasses led to the establishment of permanent settlements, agriculture and civilization
(Ziehr 1987). At any rate, cereal grains today provide a major portion of our calorie
needs, either directly or through feeding them to animals. There are eight cereal grains
that are usually listed as widely used for food and feed. They are, in order of world-wide
production: corn (maize), wheat, rice, barley, sorghum, oats, rye and the millets.
The naked kernels, or caryopses of the cereal grains with the hull removed, have many similar
characteristics in their structure and composition (Figure 3.01). The lengths (diameters) for the
various species will vary from about 1 mm to about 10 mm and their individual seed weights from
about 1 mg to about 350 mg. Their structures and compositions all share many characteristics.
613
CHAPTER 4
Quality Laboratory
Bakery laboratories
well as instrumentation,
INTRODUCTION
documentation to
accomplish their tasks.
From specifying the our, to mixing the dough and through nishing the loaf of bread
or any other baked product, it is wise to use objective data to validate consistency and
quality to assist production and product development. Maintaining adequate control
over composition and functional properties of the ingredients used in the process is an
important requisite for producing any type of baked food.
614
Quality Laboratory
Change is inevitable. Analytical procedures and methods can detect, monitor and
track small changes, unseen by the human eye, over time. Maintaining a history of
these changes can help make sure you are receiving the quality you are paying for from
your ingredient suppliers. But this data can also assist in an investigation to validate a
complaint or document a decline in product quality.
Typically, our is the main ingredient on the ingredient legend of any baked food. This
key ingredient deserves more attention than simply documenting limits or ranges on an
ingredient speci cation to be recorded in a database or stored in le drawer. Flours from
different wheat blends, mills and geographic origins can uctuate considerably in their
content of protein, ash, moisture, absorption, mix time and functionality. It is essential
for the baker to be aware of any changes that may occur in these characteristics before
using the our in production. In the automated bakery today, knowing the consistency of
our functionality before the mixing process is essential. If the mix time and absorption
of each lot of our is not optimized, then the resulting product will not achieve the
consistent high-quality product consumers deserve.
Evaluating and approving test methods pertaining to our and other ingredients
used by the baking and other cereal-based industries has historically been taken on by
AACC International (previously American Association of Cereal Chemists) and AOAC
International (previously Association of Of cial Analytical Chemists). Both organizations
publish their approved methods in volumes titled, respectively, Approved Methods of
the AACC, whose 10th edition appeared in 2000 and was updated as of September
2004, and Of cial Methods of Analysis (AOAC Methods), whose 18th edition was
published in 2004-05.
This chapter will attempt to survey the more pertinent tests relating to our and dough
evaluation as they appear in these volumes. Methods that are gaining acceptance in
cereal and baking laboratories will also be described brie y even though they may not
have gained of cial status.
All laboratory work requires precision, especially when handling such a naturally
variable ingredient as our. Timing and technique must be impeccable and reproducible.
For this to happen, however, temperature and humidity conditions within the laboratory
and its storage areas must be consistent. Whether lab tests support production or product
development, reproducibility is critical, and that precision cannot occur when the labs
ambient conditions vary day-to-day. Climate control is essential.
Remember a short pencil beats a long memory any day. Maintain records of your test
results. Data and facts will provide the information needed to run a successful grainbased food company.
661
CHAPTER 5
Bakery Sanitation
and Regulations
By Richard F. Stier
Consulting Food Scientist
Phone (707) 935-2829; e-mail Rickstier4@aol.com.
A complete
understanding of
INTRODUCTION
sanitation its
There are some people who equate sanitation with a bakery looking, smelling and
feeling clean. Sanitation is more than that. It is a state of mind and a means of ensuring
the products that come out of each and every bakery, whether breads, cookies, cakes,
meat pies, pizzas or any one of the myriad of specialty products, are safe, wholesome and
t for human consumption. Commitment to good sanitation starts with management and
ows down through the plant hierarchy. Management must provide the tools, nancial
support and leadership to establish and sustain such commitment. Sanitation is an integral
part of the whole quality system, which consists of every operation needed to ensure the
program, procedures,
systems and tools is
required to maintain a
safe and secure bakery
operation.
662