Bakery products

INTRODUCTION:
Baking is a process by which the food is cooked in hot air
in a close oven. The action of dry heat is modified by the stream by the
stream which arises from the food during cooking. Bread, cakes,
pastry, pudding, vegetable and potatoes may during this method.
Whether baked in primitive or modern ways wheat is to be first ground
to flour. In baking for each purpose flour of a particular quality is
required for bread making hard wheat flour containing a high level of
protein is required. For biscuits wheat flour with a low protein content
is desirable . According to modern specifications the flour should also
contain levels of nutrient such as vitamin and minerals or other
ingredients.
Home baking is one of the easiest ways of cooking and
nothing is more rewarding than delicious home made cakes or cookies.
The virtues of baked products are many . They are easy to make and
are economical too. They pose no problem while packing as they are
light and could be easily carried. They are nutritious and are easily
digestible. The retention of nutrient is better in baked products than
that in fried products. Baked foods are suitable for any occasion and
they suit the palate of the old and young alike. Incorporation of baked
products in our daily diet is a must, not only for nutritional
improvement but also for enhancing the palatability and relieving the
monotony of any food or diet.
Bakery industry in India is one of the most important
processed food industry and also the fastest growing one. Every year
nearly 0.35 million tones of cookies are produced and sold in Indian
market. Baked products are popularly consumed as snacks by people
of all classes and of all age groups. As such these products may be
considered as ideal carriers for the supply of nutrient to vulnerable
groups like growing children, pregnant mother and convalescents.
Baked products even play a vital role in popularizing wheat in
traditionally non wheat consuming regions of the world.
Successful bakery production is connected with efficient use
of bakery machinery. Machine can work more efficiently, speedily and
at a cheaper rate ( depending on the labour cost) hence in large scale
bakery unit machines are preferred for most of the work. Therefore
mechanical as well as technical knowledge is essential for the baker.
The machines used in bakery units can be divided into four
parts:
Ingredient handling equipments: It includes
• Storage bins
• Weighing balance,
• Sifter conveyer system etc.
• Storage Bin
• Ingredient conveying system
• Unloading system
• Dump bin and Blender
• Flour sifter
• Centrifugal machine
• Weighing machine
Dough processing machines :
It includes
• Mixer
• Divider,
• Rounder
• Prover
• Horizontal mixer
• Double Arm/ Reciprocating arm mixer
 • Vertical mixer
• Liquid ferment equipment
• Dough divider
• Intermediate proover
• Moulder

Final proover:
After moulding and panning the dough loaves are carried to a
steam box, which is just like a steam room. The accurate control
system for temperature and is established as it may change the quality
of products. The final proover are made up of
1. Stainless steel..
2. Manual
3. Automatic
4. Tray proover
5. Rack proofer
Oven
1. Reel oven
2. Traveling tray oven
3. Tunnel oven
4. Conveyerized oven
5. Rack oven
Product handling machine
1. Bread cooler
2. Continuous belt cooler
3. Tray cooler
4. Rack cooler
5. Vacuum cooler
6. Slicer
7. Packing machine
Ingredients
Depending upon the nature of the baked products, different types
of flours are milled.
The types of flour made for baking are the following:
Bread flour
Bread flour should form good gluten when mixed with water and for
bread with a good volume when baked. Thus bread flours should have
a high protein content. They are milled from blends of hard winter and
spring wheat and then moisture content, protein content, ash content,
starch quality protein quality and particle size are all controlled.
Self rising flour.
This flour is used domestically for making pudding, cakes, pastries
etc. This is made from milling weak wheat of low protein content . Hard
wheat up to 20 % can be used. The moisture content of the flour
should not exceed 13.5% to prevent premature reaction between the
chemicals present in the flour. Sodium bicarbonate and acid calcium
phosphate or some other acid ingredients are the chemicals used in
the ratio of 1.16 % bicarbonate and 1.61 % acid calcium phosphate on
flour weight. A slight excess of bicarbonate gives to an unpleasant
odour and a brownish yellow coloration.
All purpose flour is made from hard wheat or a blend of hard
and soft wheat and has a moderate protein content. It does not contain
self raising agents. It is suitable for use in yeast and quick breads ,
biscuits, pastries and cakes. A variation of this flour is instant flour – an
instant blending flour. This is made by a special agglomerating
procedure where by a number of individual flour particles are
combined.
Biscuit flour
 This flour is made from weak wheat of low protein content.
Depending on the type of biscuit, special types of flour are made. The
flour should make a dough having more extensibility but less spring
than bread dough. Dough pieces should retain their size and shape
after being stamped out. The extensibility of biscuit flour dough may
be increased by treatment with a proteolytic enzyme or with the
reducing agent sulphur dioxide or by the addition of sodium meta bi
sulphite to the dough.
Cake flour
Cake flour is a medium strength flour ground from soft low protein
wheat of low a – amylase activity and is very fine in structure. The
purpose of flour in cakes is to allow an aerated structure to be retained
after the cake has been made. The stability of the final cake depends
largely on the presence of uniformly swollen starch granules. Hence
the starch granules should be undamaged during milling free from
adherent protein and attached by amylolytic enzyme.
Pastry flour
Pastry flours similar to cake flour are made of soft wheat and are
fairly low protein. They are finely ground and they can be used for all
baked products other than breads.
Water
Water makes possible the formation of gluten. Gluten as such
does not exist in flour. Only when flour proteins are hydrated gluten is
formed. Water assist in the control of dough temperature. Water also
makes possible enzyme activity.
Leavening agents
A leavening agent aerates the mixture and there by lightens it.
Leavening action may be produced by physical, chemical or biological
means. The common leavening agents are air , steam and carbon di
oxide
Air
 Air is incorporated into flour mixtures by beating eggs, folding and
rolling dough, creaming fat and sugar together sifting the dry
ingredients and beating batters.
Steam
A team is probably produced in all flour mixtures to a certain
degree since all flour mixtures contain water and are usually heated to
the vapouration temperature of water. Although the steam produced
during baking causes the mixture to expand steam alone cannot
leaven a mixture . Its action must be combined with that of air or CO2.
Carbon di oxide
The principle means of leavening flour mixture is by the formation
of carbon di oxide generated by the action of chemical leaveners or
produced from sugar by the action of yeast , microorganisms ,
chemical leaveners include baking powder, baking soda and
ammonium carbonate.
Baking powder
It is defined as the leaving agent produced by mixing of an acid
reacting material and sodium bicarbonate with or without the addition
of starch or flour. Baking powders are classified according to their
action rates. Fast acting ones give off most of their gas volume during
the first few minutes of contact with liquid. When such powders are
added to a mixture the mixture must be handled quickly to avoid loss
of carbon di oxide and volume . Slow acting powders gives up very
little of their gas volume at low temperature they require the heat of
the oven to react completely. Double acting baking powders begin to
act at low temperatures and give viscosity and smoothness to the
batter but they do not go into complete reaction until they are exposed
too high temperatures.
Baking soda
The reaction of baking soda is similar to the baking powder as
a leavening agent. Carbon di oxide is released when the baking soda
comes into contact with the liquid in the dough . The amount of baking
soda must be only one fourth of the amount used for baking powder in
any recipe.
Yeast helps in fermenting the dough carbon di oxide is
produced as a result and thus it helps in leavening. Yeast a
microscopic unicellular plant reproduces rapidly under suitable
conditions of food warmth and moisture .
Bread improver
The finest bread improver is a good craftman. Flour is always of
variable quality depending on the grade. Bread improver may be
divided into three main classes
• Those of a mineral nature mainly used by main classes.
• Those of an organic nature mainly enriching agents.
• Those which while coming under categories 1 & 2 are also
valuable yeast foods , helping the yeast to work more vigorously.
Bread
Bread industry in India is growing rapidly to meet the increasing
demand of bread which has gained popularly in the Indian diet because
of its availability at reasonable cheaper rate . A good bread can be
preparaed from four basic essential ingredients i.e wheat flour, yeast ,
salt and water. Maida quality plays an important role in the production
of bread. Many additives are used during mixing the dough which
within limit corrects dough strength by conferring stability to the
gluten to form a fine network and quality of bread.
The common procedures for bread making is

Ingredient
↓
Mixer
↓
 Fermentation room
↓
Trough hoist
↓
Mixer
↓
Tough hoist
↓
Divider
↓
Rounder
↓
Proofer
↓
Moulder
↓
To proof

Process of sponge bread making

50% flour + yeast water

↓
The batter is kept aside sponge stage for 3 -4 hr  Sponge stage
↓
Add remaining 50% flour , salt , sugar and fat
↓
Sponge like appearance
↓
Dough formation
 ↓
Kneading and fermenting dough stage for short period  Dough stage
↓
Proofing and baking

The common method of preparation of bread using

various ingredients is

Ingredient Normal straight No time dough Tin bread

dough
Maida 300g 300g 200g
Fat 8g 10g 6.6g
Salt 5g 5g 3.3g
Sugar 10g 15g 10g
Fresh dry 6g 6g 8g
yeast
Water 180ml 180ml 180ml

Method :-
• Mix yeast in lukewarm water and keepside . Add a teaspoon of
sugar
• Dissolve salt and sugar in remaining water and strain
• Sieve the flour . Mix water in which salt and sugar have been
dissolved with the flour roughly.
• Add yeast mixture to the flour and knead to a smooth and soft
dough add more water if necessary
• Cream the fat and knead it to form the dough
• Keep the dough in the dry prover at 27 7 C for 1 hr 30 min . to 2
hr
 • Pun ch the dough and again keep in dry proof for 55 min . at 27
7C
• Divide and scale the dough into bvalls
• Keep these balls under a dry cloth at room tenmperature for
about 15 – 20 min.
• Roll the mold either by machine or by hand
• Pour in greased bread tin
• Keep tin wet prover at 35 C or under a wet cloth about 1 hr or till
it fills the tin
• Spray water on the bread surface before putting into the oven.
• Injectg sream into the oven or put a pan with hot water inside.
• Bake bread at 204 .4 C for 30 - 35 min.
• Remove and brush over with oil.
Types of bread:-
Whole meal bread (brown bread ); wheat germ bread; gluten
bread high protein bread; high fiber bread ; Granary bread ; banaqna
bread ; bread rolls ; short bread ; white bread ; dinner rolls;
Baking process involves heat transfer and it is by conduction,
convection and radiation. Various source of energy are direct fire ,
indirect fire and steam.
Common defects in bread:-
The defects could be in external appearance or internal load
External defects:
The external defects are
• General insufficient or excessive loaf volume,
• Light or dark crust color
• Blisters on excessive crust thickness and
• Absence of break and shed.
Internal defects:
The internal defects are :
 • Gray crumb colour ,
• Streaky crumb, cores (dense spots in the crumb ),
• Holes in crumb ,
• Poor flavor andrapid staling and
• Poor keeping quality.
Biscuits:-
The biscuit industry has made rapid progress in recent years in
India and several other developing countries. Successful attempts have
been made to enrich biscuits with proteins, vitamins and minerals.
Various formulations are given
Ingredient Salt Sweet Fruit Coconut
Flour 260 170 115 200
Fat 100 85 100 100
Sugar 50 85 30 100
Egg 50 - 20 50
Ammoniumbicarbonat 4 - - -
e
Baking powder 3 2 3 3

Milk - 70-100ml - -
Essence - Few drops Few Few drops
drops
Water 25ml - - -
Coconut - - - 50
Tuity fruity - - 30 -
Cashew nuts - - 25 -

Method:
• Sift flour with baking powder thrice
• Cream butter and sugar till light and fluffy adding essence
• Add flour to make playable dough
• Roll out into 0.31 cm thickness and cut with a biscuit cutter
• Separate the biscuits Bake at 195 C for 15 min.
Important points to remember in making different types of
biscuits.

Salt biscuits : Add baking powder, salt and ammonium

bicarbonate to the creamed mixture. Coat with egg before baking.
Fruit Biscuits : Add desiccated coconut to the flour and some at
the time of rolling.
Masala biscuits : Add 10g Masala powder in the flour sieve twice.
Tricolor biscuits : Sandwich a plain a plain biscuit with one hole using
a thin layer of jam. Sprinkle with icing sugar and fill each
hole different colored jam in each hole.