2. Baking Equation Ingredients + Equipment + Baking Process =
Perfect Baking Process Golden Penny Products A promise of
quality
3. Baking Ingredients - Major Flour 100% Water 50-55% Yeast
1.5% Salt 1.8% - Optional Sugar 8-10% Fat 1.6% Improvers 1% (malt
extract, egg, milk, conditioners etc.) Cassava/Maize/Rice/Rye flour
Soya bean flour Malt flour Preservatives Flavourings Colourings
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4. Functions of Ingredients - Flour water absorption An
important quality factor in bread baking is the degree to which the
flour absorbs water. The amount of water which can be absorbed and
carried by a flour varies with the type of flour, its age,
treatment and stability. Generally, for bread making, high water
absorption values are preferred because it increases production
yield and also influences favourably the shelf life of bread.
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5. Functions of Ingredients Water Water to be used for all food
processing operations in Nigeria must be clean. Hard water may also
create a tight dough or slightly slow the yeast fermentation.
Bakers therefore need to know the composition of the water to be
able to adjust recipes and process conditions when developing new
products. If the water content is insufficient, a tight dough is
produced, and the bread lacks volume and has a heavy texture. Hard
water may also create a tight dough or slightly slow the yeast
fermentation. Water constitutes the second largest ingredient in a
typical baked product as bread. The first function water is in the
mixing process to produce a homogenous mass (dough) and in the
development of the gluten network in the dough. Golden Penny
Products A promise of quality
6. Functions of Ingredients - Yeast Yeast cells ferment sugars
in the dough to produce carbon dioxide gas and alcohol. In baking,
it is the gas that is important, and the small amounts of alcohol
are evaporated by heat in the oven Compressed yeast requires
refrigerated storage. It loses its activity more quickly than dried
yeast. Dried active yeast can be activated before use by mixing it
in five times its weight of warm water with little sugar and
leaving it to stand until the water becomes cloudy and gas bubbles
are visible, before adding it to other ingredients. Instant Dry
Yeast is added directly to the dry ingredients without the need for
activation because it is easier to store and has a longer shelf
life. The other factors that affect the rate of dough fermentation
are: 1. Temperature and water content of the dough 2. Time of
fermentation 3. Quality of the flour 4. Amounts and types of other
ingredients The temperature of fermentation also affects the amount
of yeast that is needed and/or the time of fermentation. As a
general rule, a change in temperature of about 1oC requires a
change in fermentation time of 10% Golden Penny Products A promise
of quality
7. Functions of Ingredients - Salt Salt (sodium chloride)
should be pure white crystals Salt is hygroscopic (easily absorbs
moisture from the air) and should be stored in a dry place off the
floor. In regions of high humidity, it should be stored in
moisture-proof containers. Salt has three main functions in bread
making: 1. It controls the yeast fermentation rate which in turn
affects the crust and crumb colour. Too little salt will cause the
yeast to work quickly and use up all its food before it is actually
required. Too much salt will slow down yeast function too much and
this will slow down the production process and may lead to many
different product faults 2. It stabilises and strengthens the
gluten. It helps retain moisture and so reduces staling. The water
retaining properties of salt cause the gluten strands to become
tougher and thus aids the mixing and processing (handling) proper
ties of the dough. A dough prepared with no salt will feel sticky
and soft and a first reaction by impulse may be to add flour to
stiffen the dough; but when salt is blended in, the dough reaches
the required consistency. 3. It gives taste to the baked product.
Salt must be distributed evenly throughout the dough to prevent it
coming into direct contact with the yeast and killing it. This can
be done either by dissolving the salt in water before adding it to
the flour, or by sieving the salt into the flour before mixing.
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8. Functions of Ingredients - Sugar Sugar such as sucrose,
glucose, fructose, maltose and lactose not only have nutritional
value but also function as plasticizers, colour and flavour
producers through the browning reaction, flavour-binding agents and
sweeteners. Nutritionally, sugar supply 4kcal/gram of energy in the
diet. Microorganisms can ferment sugars to CO2 and alcohol, thus
providing the basis for leavening action and alcohol production.
White granulated sugar is suitable for most bakery use In bread
making, natural, granulated sugar has three major functions in
dough stage, during baking and in finished product. 1. Sugar is
food substrate for yeast for the fermentation process 2. Sugar aids
crust colour development during baking. The shiny, light brown
crust of baked products is largely due to the reaction of sugar in
or near the crust with the heat of the oven (caramelisation) and
the sugar-protein reaction (maillard browning). Without sugar, it
would be difficult to or impossible to achieve the same crust
colour. 3. The third and obvious function of sugar in the final
baked product is that it provides taste. However, the taste
contribution depends on the sugar level in the product. Note Sugar
first serves as (potential) food for yeast and as such only the
sugar that is left when the yeast stops working contributes to
crust colour and to taste. In No-Time (Straight Dough) Bread Making
Process, the time for the yeast to convert added sugar to gas and
alcohol is limited and very little or none of the added sugar is
converted by yeast. Only when there are delays in the no-time dough
process in bulk/during resting/over proofing; or when the yeast
activity is too high does yeast convert the added sugar.
9. Functions of Ingredients Fat In theory, fat is not
compulsory in bread making but the addition of fat at 0.5 1.0% of
weight of flour increases loaf volume and gives a more tender and
thinner crust, a better crust colour, a softer crumb and an
improved flavour. The primary function of fat in baked bread is
that it gives it a specific eating quality characteristic known as
short bite, which literally means that the product can be bitten in
one bite and that it is not chewy or tough. Baked products with a
low or no fat content can become very tough, especially the crust.
Fat in dough makes it more machinable and gives more process
tolerance and stability and allows the dough to be worked using
modern machinery with relative ease. Products containing fat, such
as bread, have a longer shelf life because the fat keeps the
product softer for longer. Golden Penny Products A promise of
quality
10. Functions of Ingredients Improvers The functions of
chemical improvers (oxidizing and reducing agents) are that they
help to: Shorten dough resting time Increase bread volume Increase
gas retention Speed up proofing time Improve crumb texture Improve
shelf life Oxidizing Agents Ascorbic Acid (Vitamin C) Usage: 75 100
ppm Azodicarbonamide (ADA) Usage : 10 25 ppm Reducing Agents
L-Cysteine (Amino acid) Usage: 25 35 ppm Sodium Metabisulphite
Usage: 10 20 ppm Golden Penny Products A promise of quality
11. Bread Production Flow Chart Flour and Other Ingredients
Weighing Mixing Resting Kneading Dividing/Moulding Proofing Baking
Cooling Slicing Packaging Golden Penny Products A promise of
quality
12. Stages in Bread Production Weighing/Recipe Formulation
Accurate weighing of the ingredients is an obvious requirement in
the baking process This is the first right step in ensuring that
the product is good and perfect Golden Penny Products A promise of
quality
13. Stages in Bread Production Mixing Ingredients are put into
the mixer according to their group specifications on the recipe and
properly mixed with correct Speed and Time There are two types of
mixing 1. Manual 2. Machine with mixers Mixers are of different
types - Non spiral mixers - Two speed spiral mixers *** The best is
the two speed spiral mixers Golden Penny Products A promise of
quality
14. Mixing (Local Mixing)
15. Mixing (Spiral Mixing)
16. Spiral Mixing contd.
17. Stages in Bread Production Objective of Mixing Mixing
distribute the ingredients evenly and create structure of air
bubbles capable of expansion within the dough Mixing produce a
dough of good machinability Mixing must produce dough with
temperature between 28C 31C Mixing must produce dough with properly
developed gluten network that is able to retain gas produced during
fermentation Golden Penny Products A promise of quality
18. Stages in Bread Production Spiral Mixers Spiral mixers have
two stages: 1. Slow stage mixing ingredients dispensing 2. Fast
stage mixing dough development Slow stage Slow mixing stage is
2mins during which all ingredients are blended together Fast stage
optimum dough development Take a small piece of the dough and
stretch it between your hands until thin film can be formed. If the
dough tears easily, it is not yet well developed. The dough in the
mixer will appear smooth and soft and start forming a flow in the
spiral mixer. Golden Penny Products A promise of quality
19. Stages in Bread Production Optimum Dough Development After
mixing, the dough may be dusted with a very thin layer of flour and
must be removed from the mixer immediately. The temperature of the
dough should be taken at the end of mixing by inserting the
thermometer deep into the centre of the dough. Development time of
the dough should be fairly standard for each bakery and product
type based on recipes used. Differences in flour, water and
temperature changes may influence optimum development time. Each
bakery is expected to and should test dough development time to be
able to adjust accordingly when the need arises. Golden Penny
Products A promise of quality
20. Stages in Bread Production Resting Resting step or time
depends on the production method used. It could be immediately
after mixing in the bulk fermentation process or after dividing and
rounding in the Straight dough method. As the dough is allowed to
rest for the predetermined duration, the fermentation process
relaxes the dough and makes it more extensible and allows shaping
or moulding of the dough into a loaf or other product without
tearing or shrinking. Note: During resting time, if the dough is
dusted lightly and covered with a plastic sheet during resting, it
prevents skinning of the dough and ensures a better final product.
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21. Stages in Bread Production Dividing The dough is divided
into small weights. This is done by using scales Rounding The dough
is rounded into smooth even surface and placed inside the pans .
The purpose of smoothing is to have even surface final product. The
process is also to eliminate excess air trapped inside the dough
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22. Stages in Bread Production Moulding During moulding the
rounded dough that has rested is shaped, rolled into final shape
Moulding is done by hand or automatic moulder which is faster and
produce more uniform products Stages of Moulding 1. Flattening of
dough to release excess carbon dioxide 2. Dough rolled into
cylindrical shape 3. This is rolled again under pressure to ensure
that it sealed tightly Golden Penny Products A promise of
quality
23. Stages in Bread Production Panning In panning stage, the
moulded dough is placed in the pan (previously oiled) in which it
will go into the prover/proofing chamber. Bread dough pieces are
placed centrally in the bread pan with the moulding seam at the
bottom and as straight as possible. Other products are placed on
baking trays or pans. The basic principle is to leave as much space
so that the products can proof and be baked without touching or
interfering with adjacent products; but the space should be
utilised as efficiently as possible since oven space is limited and
expensive. Golden Penny Products A promise of quality
24. Stages in Bread Production Proofing Proofing is the stage
or time necessary for the yeast to produce adequate supply of gas
to increase the volume, add flavour, and condition the dough prior
to baking or frying. Optimum proofing conditions depend on the type
of products and formulation used. For example, yeast-raised
doughnuts are typically proofed under dryer conditions than breads.
The prover gives the yeast the ideal environment to achieve the
optimum fermentation rate and the dough piece the right conditions
to expand during fermentation. Golden Penny Products A promise of
quality
25. Stages in Bread Production Baking The bread is fully baked
when the core temperature reaches about 97oC. Moisture loss from
the dough during baking is approximately 10% but varies depending
on the recipe, dough moisture, baking temperature, time and size of
loaf. It is important during baking to use the right temperature
and the required temperature should be reached before loading the
oven. Bread baking temperature ranges from 200 230oC although
baking at 180 200oC for a longer time is also done in traditional
bakeries using earthen (mud) ovens. Golden Penny Products A promise
of quality
26. Stages in Bread Production De-Panning, Cooling and Wrapping
After baking, the products are removed from the pan or baking tray
and allowed to cool before wrapping or packaging. For bread, the
loaf is de-panned almost immediately after removal from the oven to
prevent sweating and becoming soggy. Products on baking trays (e.g.
bread rolls, meat pies) also tend to sweat on the bottom but are
generally left on the baking trays. Bread must be allowed to cool
down to room temperature before wrapping otherwise it will sweat
and this will accelerate spoilage. Golden Penny Products A promise
of quality
27. Bread Making in Action (Local Kneading with Rollers)
28. Bread Faults Identification Causes Solutions at the Bakery
level