Bakery Products and Rice Milling

8/13/2019 Bakery Products and Rice Milling

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Bakery manufacturing processBread ManufacturingCake ManufacturingWafer Biscuit ManufacturingBiscuit Manufacturing

Rice Milling Process


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Introduction

Dry Bakery Products Biscuits : Soft biscuits, hard biscuits, cookies, crackers, fancy biscuits, cream waferbiscuits.

Moist Bakery Products Bread : Sweet bread, Milk bread, Masala bread, Garlic bread, Fruit bread etc. Buns : Fruit buns, hamburger buns, dinner rolls, crisp bread, pizza. Others : Cakes, pastries, doughnuts, muffins etc.


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MIXING All ingredients are put together in right proportion for dough formation.These ingredients are then fed into Mixers where mixing is done and dough isprepared for moulding/cutting .Major ingredients are flour, fat, sugar and others as per the product one would liketo have.

MOULDINGWe laminate the dough into sheet, which then passes down to gauge rollers, andsheet thickness is achieved for moulder/cutter.As per the cutter/moulder, one gets the shape and sizes of biscuits.

BAKINGHere we pass these moulded wet biscuit into baking oven.The biscuits are baked on desired temperatures.Various type of heating are available now days as per the convenience and cost.Different type of ovens are available.


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COOLINGThese baked biscuits are passed on to cooling conveyors for natural cooling priorto packing .The temperatures are brought down to room temperature.

PACKINGThese biscuit are then stacked and fed into packing machine for packing.Different packing material are available for packing of these biscuit in differentpacks slug packs , pouch pack or family packs etc.These packs are then put into secondary packaging like cartons to be transported.


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Bread manufacturing

PREPARATION OF INGREDIENTS Check and obtain ingredient Sieve and weigh flour Sieve and weigh dry ingredients Check temperature Prepare water

DOUGH MIXINGHere force is applied mechanically or manually on flour, water and all other ingredients,allowing insoluble components of flour to hydrate, forming the structure of the dough andproper hydration of the starch, resulting in a homogeneous mass.

DOUGH DEVELOPMENTHere protein structure is allowed to be stretched and further hydrate to develop into glutenby means of mechanical force or chemical agents or extended fermentation.The dough is developed to the optimum level sufficient for good gas retention.


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Dough Mixing MethodsLOW (SLOW) SPEED

Single and double arm mixers are most common examples.By gentle kneading, stretching & folding the dough develops.

Dough produced by such mixers requires some bulk fermentation or floor-time tomature the dough.MEDIUM SPEED

Dough is developed by mechanical force and generates more friction resulting highdough temperature.Common examples of such mixers are Spiral Mixers, Planetary Mixers and

Horizontal Mixers.HIGH SPEEDDough development is achieved in a very short time and chemical agents are usedfor the purpose. Mixing time is normally 2-3 minutes.Tweedy Mixers and Indian High-Speed mixers are typical examples.

BULK FERMENTATIONSponge Dough

In this method a sponge is first set, by using about one-half of the flour, about four-sevenths of the water, and all the yeast.Then we incorporate all other ingredients in a second operation some time later,when the dough is made.


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Straight DoughIn this method, all of the ingredients are incorporated in one long process of mixingand kneading rather than in two short ones, as in the sponge and dough process.

DIVIDINGDivide the dough into desired weights or as per government regulation.Excess gas formed is expelled.

ROUNDINGSeals the dough pieces to a smooth and overall volume and also ensuresconsistent shape for moulding.

MOULDINGSheet the dough piece flatCurl the flattened dough pieceSeal curled dough piece

Straight, Twisted, 4

Piece or W- Formation shape for dough panning


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PANNING

Desired, Convenient and consistent shapeMeans for surface during final proofing and bakingMeans for movement

Prevents damageEnhance oven performance and heat transfer

BAKINGFormation and expansion of gasTrapping of gas in the gluten network

Change the properties of starchChange the properties of proteinFormation of crust and browning (caramelisation)

Achieve and set desired volumeDevelop flavor and crust charactersGelatinize starch and set crumb structure

Alter properties of proteinStops action of yeast and enzymesControls moisture content of crust and crumbMakes the food microbiologically stable food


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DEPANNING & COOLINGRemove baked products from oven and panCool baked products sufficiently to enable slicing and or wrapping or packagingwithout damaging the product

Reduce contamination or possible microbiological spoilagePACKAGING

Protect baked product from external contamination and damageProvide suitable medium containing, handling, transport and use of productRetains moisture and aroma

Provide suitable method for labeling, identification, promotion and information


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MIXING All ingredients are put together in right proportion for batter formation.

Ingredient are then fed into Planetary Mixers where mixing is done and batter isprepared for panning .Major ingredients are flour, fat, sugar, eggs, emulsifiers, leavening agents andothers additives as per the product.

PANNINGWe put the batter into baking pans/ moulds with different sizes.Baking papers are used on pan to prevent product to stick to the surface of thepans.

BAKINGWe pass these moulds into baking oven .The cakes are baked on desired temperatures.Various type of heating are available now days.Different type ovens are available.Most popular ovens now days are rotary ovens and contray ovens

Cake Manufacturing


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COOLINGBaked are then passed on to cooling chambers for coolingprior to packing.The temperatures are brought down to room temperatures.

DEPANNING After baking the moulds are taken out from oven and cake slabsThe cakes are extracted from moulds either manually or through depanner.

PACKING

Baked cake slab is then taken out of and then passed to slicer. These bars are again passed on to cake slicer for packing.These slices are then packed in horizontal flow wrap machine .Various packing materials are used for packaging.Varieties available are fruit cut, cake milk, cake orange cake, chocolate, plum cakesetc.


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MIXING Batter preparation

Wheat/flour( low gluten type )is mixed with water and other ingredients in battermixer to get thin batter of suitable consistency.Mixing time could be 2- 5 minuteBatter is then transferred to batter storage tank from where it can be transferred tobaking plate.

Cream Preparation

Cream is prepared in mixers where ingredients like flavors, colors, and wheypowder and soya lecithin are added.Cream of suitable consistency is prepared.Various types of creams are popular in wafer biscuit are chocolate s , milk , caramelorange, banana, strawberry, hazelnut and others.Cream preparation takes place between 10- 12 minutes.Cream then can be transferred to reservoir.

BAKINGBatter is then pumped and spread on to baking plate by help spreading nozzles.These plates then moves into baking zone of the oven.Temperature maintained for baking these wafer baking plates is b/w 175-200 C.

Wafer Biscuit Manufacturing


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The baking time kept is 1.75 - 2.0 min.Capacity of oven can be from 50 - 100 plates.Size of plate can also vary from 400 x300 to 300 x 200 mm and thickness ismaintained between 2.5 - 3mm.Most of these wafer ovens are electrical ovens.These plates travel upon guide rail and electrical power is supplied through bus barsinside the oven .Baking plates are in contact with bus bar through carbon brushes.

CREAMINGThese wafer sheets are the allowed to cool down by moving through one or two

arch's .Cooled wafer sheets are then taken to spreading machine.Cream is then spread over wafer sheets at creaming machines.The block of 2/3/4/5 layers of creamed wafer is made.

COOLING TOWER

Wafer sandwich blocks are then cooled to harden and creams get set on waferblock.The cooling block is dehumidified to reduce the moisture absorption by wafersduring cooling.Temperature maintained in cooling block is between 10- 15 C.


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CUTTING AND FEEDINGFully automated cutting is done at cutting machines.Here we cut wafer blocks in different sizes.

PACKINGHorizontal flow are used to pack these fingers.These fingers are packed in heat sealable moisture proof films for good shelf life.These packets are then packed into cartons and sent for dispatch.


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Rice MillingComposition of Rice20% rice hull or husk 11% bran layers,69-% starchy endosperm , TOTAL MILLEDRICE .

Harvesting of rice cropUnmilled rice paddy,Grains have a moisture content of ~ 25 percent .Mostly, harvesting is carried out manually.

ThreshingCarried out within 0-2 days after harvesting.It is removal of chaff from the grain.

MillingIt is removal of the husk and the bran layers.

Harvesting

Threshing

Milling


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Carried out at two different levels1. Village level2. Commercial level

Mills carry out milling by1. Sun dry2. mechanical driers

Milling systems 1. Simple one step process

Husk and bran removal are done in one pass and milled or white rice is produceddirectly out of paddy.

2. Two step processRemoval of husk and bran are done separately, and brown rice is produced as anintermediate product.

3. Multi stage processRice will undergo a number of different processing steps.


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Traditional hand

pounding

Single pass, single

stage rice mill

Single pass,

two stage rice mill

Village milling

Commercial rice mills

Small commercial multi-stage mill State of the art modern multi-stage rice mill


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Rough rice Also called paddy rice.Rice as it comes from the field.Rice kernels are still encased in their inedible, protective hull.

Brown rice, husked rice or cargo rice

Least processed form of rice.It has the outer hull removed, but still retains the bran layers.Characteristic tan color and nut-like flavor.Edible but chewier texture than white rice.Cooking time is longer than milled rice

Milled rice Also called white riceIncludes removing all or part of the bran and germ from the rough rice.

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Bakery Products and Rice Milling