CHAPTER - II

B R E A D MAKI NG P R O C E S S
 CHAPTER II

BREAD MAKING PROCESS

2 .1 . 1 . INGREDIENTS

Bakery industry needs a v a rie ty of raw m aterials. The raw m aterial

r e q u ir e m e n t d if fe r with th e d if f e r e n t ite m . Even within th e sam e product,

th e in p u t co m p ositio n varies con siderab ly, and depends on the n u tritio n a l

r e q u ir e m e n ts of th e end p ro d u ct, th e consu m ers t a s t e , and th e pricing

of th e p ro d u c t.

The raw m a te ria ls re q u ir e m e n t for conv entio nal b re a d and biscuits

pro d u ced in m echanised units are well defined . A v a rie ty of raw m aterials

in d if f e r e n t mixes are used for a num ber of tra d itio n a l bakery item s

and also ite m s such as cakes, p a s te rie s , depending upon th e quality,

th e t a s t e re q u ire m e n ts and local p r a c tic e s .

L orna Walkar and 3oyce Hughes hav'fe rightly quo ted th a t "Bread

making is surprisingly sim ple and good re s u lts are c e r ta in if one understands

th e in g re d ie n ts used and follow th e sim ple rules. It is also econom ical

since only sm all q u a n tititie s of more expensive in g red ien ts such as sugar

and f a t a re u sed".^.

Thus large num ber of in g red ien ts a re em ployed in the bakery industry.

D e ta ils of som e of the com m on and widely used in g red ien ts a re as under:-

2 .1 .2 . WHEAT FLO U R

F lo ur, used in b ak eries, is o b ta in ed by milling w h e a t. Flour is the

S o u rce 1 C o m p lite Bread Book, 1977.

 - ; 43 : -

m ost i m p o r ta n t single in gredient, w ith o u t which production of white

b re a d as i t is known in p re s e n t tim es, would n o t be possible.

W heat is classified according to h ard n ess and colour of th e kernal.

W heats v ary in p ro p e rtie s depending on th e v a rity and a r e a w here they

a r e g ro w n . They may be grouped into tw o g e n e ra l headings as hard and

s o ft v a r ie tie s .

The h ard spring and hard w in ter w h e a ts a r e th e typ es most desirable

for b re a d p ro d u ctio n . They mill well and yield good q u a n titie s of flour

t h a t is high in good quality p ro tein and fro m it stro n g , e la stic doughs

can be m ade w ith proper develop m en t. T hese doughs have good toleraince

to bak eshop con dition s w ith r e s p e c t to mixing, for m e n ta tio n , te m p e r a tu r e ,

and h av e e x c e lle n t gas holding p r o p e r tie s and yield, b read w ith good

volum e, and t e x tu r e under a wide ran g e of con dition s. The hard w heat

doughs have high w a te r absorptive c a p a c itie s and gen era lly have e x ce lle n t

dough handling p ro p e rtie s when properly m a tu re d .

The s o f t w h e a ts include soft red and s o f t w h ite w h e a ts . These w heats

are used p rin cipally in th e production of flour fo r cak e s, p asteries, and

cook ies. These w h e a ts a re c h a r a c te r iz e d for th e most p a r t as being

low in p r o te in and th ey yield flours which h av e low w a te r absorption

c a p a c ity and poor to le ra n c e to mixing and f e r m e n ta t io n . They are considered

u n d esirab le for c o m m e rc ia l b read pro d u ctio n , bu t a re highly desirable

for th e p ro d u ctio n of cak e s, p a s te rie s , and cook ies. It would be observed

 - z i -

th at th e quality of w heat is d e te rm in e d by s e v e ra l f a c to r s including

c i lm a t e , v a rie ty of w heat sown and th e soil.

TYPES OF FLOUR

D if f e r e n t ty pes of flour are used for d if f e r e n t types of end p ro ducts.

D if f e r e n t grad es of flour can also be o b ta in e d by milling one p a rtic u la r

typ e of w heat flours should co n tain in ex c e ss of 10.5% good quality

p ro te in and no t more than 0 .^ % ash. Also b re a d flour should have high

a b s o rp tio n and good mixing to le ra n c e which means prolonged mixing

w ith o u t b re a k down of gluten.

C ake flours should contain less th a n 10% p ro tein and G.^% ash,

and should have low absorption. Ash c o n t e n t of a flour is considered

as a m e asu re of th e d eg ree of se p e ra tio n of th e flour fro m a p a rtic u la r

w h e a t blend it is n ot a reliable index of baking qu ality .

L oaf p o te n tia litie s a re d e te rm in e d by g lu ten and q u an tity . Their

p o te n tia litie s a re s e t in the loaf by the s ta r c h during th e baking process.

P ro p e r conditioning of gluten is responsible for th e dough handling c h a r a c -

t e r i s t s t i c and p roper conditioning of s ta r c h is responsible for final bread

c h a r a c te r i s t ic s , as crum b c h a r a c te r is tic s a re p rim arily those of sta rc h

gels. It has been found t h a t th e collapse of som e gluten breads is due

to in s u ffic ie n t s ta r c h for m aintaining th e in te r n a l b read s tru c tu re following

th e baking process.

CHARACTERISTICS OF FLOUR

E very bak er w ants to use flour having th e following 4 c h a ra c te ris tic s

 - : : -

for th e production of quality bread in colour, s tr e n g th , to le re n c e and

high ab sorption c a p a c ity .

Colour Flour should have a tr a c e of c re a m is h colour. O therw ise the

b read will have a dead w hite crum b. In th e c a s e of bread it can be

c o n tro lle d by m odification in th e baking form ula, m echanical t r e a tm e n t

of th e dough, and by addition of ing redients which will a f f e c t th e colour

of flour.

S tr e n g th It is o fte n said t h a t th e flour is s tro n g or th e flour is w e a k .

Such S ta t e m e n t s r e f e r to th e s tre n g th of flour which is ca p a b le of producing

a bold, large volumed, well risen loaf. For th e p ro duction of quality

bread s tro n g flours need a la rg e r f e r m e n ta tio n period than weak flour.

The q u ality of th e flour is decided by th e am o u n t of f e r m e n ta tio n it

will s ta n d . Bread flour should be such th a t th e dough made fro m it

will re ta in its shape a f t e r being moulded.

T o le ra n c e Means the ability of flour to w ith sta n d th e fe rm e n ta tio n

process and to produce a s a tis fa c to ry loaf over a period of tim e, in.

ex cess of w hat norm ally is requ ired to bring a b o u t th e c o r r e c t degree

of rip en ess for t h a t p a r tic u la r process.

HiRh A bsorption C a p a c ity This re fe rs to the ability of flour to take

on and hold th e maxium am o unt of m oisture w ith o u t additional mixing

for full d e v e lo p m e n t of dough. If the dough is not given the required

mixing tim e b ecause of lim ited mixing c a p a c ity , or for any o th e r reasons,

th en th e baked prod uct will lack volume and have a dry crum b .
 STORAGE OF FLOURS

Proper s to ra g e of flour is very e s s e n tia l to s a fe g u a rd it against

any sp oilage. The flour should be piled o ff th e floor on skids. The s to ra g e -

a re a s should be well v e n tila te d . D ire c t sunlight should not e n t e r it.

Too dry air and too higgh r e la tiv e

h u m itd ity a re both d e trim e n ta l to
O 0
th e flo u r. The te m p e r a t u r e and hum idity should be b etw ee n 19 to 25
O O
or 55 F to 65 . Flour has a te n d en cy to pick up foreign odours, hence

ot should be s to re d away fro m any in g re d ie n ts which will im p a rt an

odour e .g . p e tro l, k ero sen ce oil, onions and spices. It should also be

ensu red b e fo re hand t h a t it is f re e from in s e c t co n ta m in a tio n . Under

th e se cond ition s, bleached flour may be s to re d upto 5 months and unbleached

flour u p to 8 months.

2 .1 .3 . SALT

C om m on s a lt or ta b le sa lt is used for bringing out the flavour to

o th e r in g re d ie n ts which a re used in ca k e s, and o th e r pro ducts. Instead

of red u cin g sugar in th e cake form ula, s a lt should be used as an ad ju stm en t

to th e s w e e tn e s s if th e cake is too s w e e t. One of th e functions of sugar

is to r e ta in m oisture in the c a k e . It is th e re f o r e b e t t e r to in crease salt

to to n e down th e ex cessive sw e etn ess. S alt also lowers c a ra m e liz a tio n

t e m p e r a t u r e of cake b a t te r s and aids in o btainin g c ru s t colour.

In b re a d production, salt is mainly added for t a s t e . It brings out

th e ta ste to o th e r ing red ients and helps to im prove th e flavour and

ch ara cteristics of b read . Salt is a th o u g h n e r. Without s a lt th e doughs

a re w e t t y . It th e re f o r e , im proves th e t e x t u r e of th e loaf by stren gth en in g

th e dough, thus in d irectly helping in the colour, grain and te x tu r e .

 -I k7 -

Salt helps to c o n tro l in, raised doughs, th e a c tio n of the y e a s t and

th e re b y co n tro ls th e r a t e of f e r m e n ta tio n . Salt also aids in preventing^

th e fornnation and g ro w th of undesirable b a c t e r ia in y e a s t raised doughs.

A m ount of sa lt to be used depends mainly upon th e type of f l o u r .

Weak flour will ta k e more salt, because s a lt gives stre n g th e n in g e f fe c ts

to p ro te in s. A nother facto r which will d e te r m in e th e am o unt of salt

is th e fo rm u la used. In o rd er to bring out th e flav o u r of additional ingredi-

-e n ts , a rich er fo rm u la will ta k e a higher p e r c e n ta g e of s a lt, as com pared

with a le a n e r fo rm u la.

It is to be no ted t h a t th e Salt for use in th e bak ery should have

th e following c h a r a c te r i s t ic s .

a) It should be c o m p le te ly soluble in w a te r .

b) It should give a c le a r solution.Cloudy solution will in d ic a te presence

of c e r ta in im p u ritie s.

c) It should be f re e f ro m lumps.

d) It should as pure as possible.

e) It should be fr e e fro m a b it te r or biting t a s t e .

2.1 A . YEAST

Y east is a one cell micro organism of th e fungus ty p e . The function

of th e y east in th e bakery mix or dough is to Lighten it and im part

to it, its c h a r a c te r i s t ic flavour and a ro m a . Y east is im p o rta n t prim arily

to bring about f e r m e n ta tio n . It is also a n u tritio u s food, being a rich

source of some im p o r ta n t vitam ins and e n z m e s . Thus y east is of g re a t

im p o rta n c e to th e baker.
 - I 1^2.: -

The fresh y east g en era lly has grey to light brown co lou r. It is springy

to to u c h , breaks easily and has a y easty odour. Usually fresh y east consists

of a b o u t 14% pro tein s, 10% c a rb o h y d ra te s , 0.5% f a t, 23% mineral m a tte r,

68% to 73% m oisture and some en zy m es and vitam ins.

O
F e r m e n ta tio n by yeast was b est at te m p e r a t u r e s b etw ee n 20 C.
o o
Dough ferm ent best b e tw e e n 25 C and 27 C. At te m p eratu re below

th e s e ra n g e , th e f e r m e n ta tio n will be slow. At higher te m p e r a tu r e s ,

th e f e r m e n ta t io n may o u t p ace th e r a te a t which th e dough is conditioned.

USES OF YEAST

Y e a s t suspension should be added to g e th e r w ith th e flour, to the

dough. In mixing a sponge dough, th e y e a s t suspension is added with

p a r t of th e flour and w a te r and the sponge is s e t. Due to lack of salt

in th e sponge dough, f e r m e n ta tio n is rapid. In s w e a t doughs, for rapid

f e r m e n ta t io n more y e a s t has to be added. But it adds to th e c o s t and

th e fav o u r too could be a f f e c t e d . In w a rm moist w e a th e r , y east a c tiv ity

in c re a s e s . In hot w e a th e r, cold w a te r should be used. Richness or leanness

of th e dough also affects th e a m o u n t of y e a s t req u ire d . More yeast

is re q u ire d in rich c o f fe e c ak e dough th a n in th e bun dough, as sugar

r e ta r d s th e a ctio n of y e a s t. Bun doughts, c o n ta in s less sugar. In bread

doughs, sm aller am ounts of y e a s t is req u ire d to ra is e th e dough.

It is to be re m e m b e re d t h a t only th e b est quality y e a s t should be

used b ec a u se th e am ou nt used is sm aller as co m p ared to o th e r ingredients.

O th e rw ise th e c h e a p e r grade of y e a s t may prove to be even co stlier

p r o c tic a lly .
 1^9 : -

2 .1 .5 SUGAR

The prin cip al purpose of using sugar in b ak ed goods is to sw eeten

th e p ro d u c t. By varying th e grades and types of sy g ar. o th e r e ff e c ts

a re also ach ie v e d . As th e sugar c o n te n t in c re ases in b iscu its, th e biscuits

b eco m e h a rd e r u til a hard b r it tle biscuit is o btain ed.

USES OF SUGAR IN BAKERY PRODUCTS

1. It gives th e n e c e s s a ry sw eetn ess.

2. Serves as food for y e a s t in f e r m e n ta tio n .

3. It is used in th e p re p a r a tio n of a v arie ty of icing for baked products.

k It assists in c re a m in g and whipping processes of mixing.

5. It provides good g rain and te x tu r e to th e finished p ro d u c t.

6. It aids in t h e r e te n tio n of m oisture due to its hygroscopic n a tu re ,

and prolongs fresh n ess.

7. It p ro m o te s a good c r u s t colour.

8. It adds n u tritio n a l value to the product.

FUNCTIONS OF SUGAR IN BREAD.

Usually fine grain sugar is used in bakery p ro d u c ts . S u g a rt p erform s

several fu n ctio n s in b re a d . Sugars are th e so urce of en ergy for yeast

a c tiv ity . By addition of sugar, th e flavour of th e b re a d is Improved

and th e c r u s t colour is d ark en e d . The te x tu r e and grain becom es sm oother

and finer with added sugar.

2 .1 .6 WATER

W ater is also an im p o r ta n t raw m a te ria l p a r tic u la r ly for bread.

 - : 50 ; -

W ater has s e v e ra l fun ction s in b read making. It m akes possible the form ation

of g lu te n . G luten as such does not exist in flour. Only when flour proteins

a re h y d ra te d , g luten is fo rm ed . Water c o n tro ls th e co n sisten cy of dough.

W ater ass is ts in th e con trol of dough te m p eratu res. The w arm ing or

cooling of doughs can be re g u la te d throug h w a te r . It dissolves salts,

suspends and d is trib u te s non-flour in g re d ie n ts un iform ly. Water w ets

and swells s ta r c h and renders it d ig e stib le . W ater also makes possible

en zm y a c t iv it y . W ater keeps b read p a la ta b le lo nger, if su ffic ie n t w ater

is allow ed to rem a in in th e finish p ro duct.

F or b read production th e w a te r used, should n e ith e r be too hard

n o t to o s o f t. It should be medium hard. Soft w a te r is low in minerals.

It r e s u lts in lack of gas production during th e f e r m e n ta tio n of dough

and also th e gas r e te n tio n will be poor, resu ltin g in stic k y dough. Addition

of b .2 5 % of dough con dition er or m ineral y e a s t foods, shall e lim in a te

th e h a rm fu l e f f e c t s of using so ft w a te r . S o m etim e s am ou nt of s a lt in

th e dough is also slightly increased .

2 .1 .7 MILK

Milk is a c tu a lly an emulsion of tin y p a r ts of f a ts in a w a te r

solution of p ro tein , Sugar and m inerals. Emulsion may be defined as

a s ta b le solution of f a t, w a te r and o th e r in g red ien ts which will not

s e p e r a t e on standing. The avera g e co m positio n of milk consists of w ater

8 7 .7 5 % and to t a l solids 12.25% . The to tal solids portion may consist

of p ro tein s 3.25 % , F a t 3.50% , m inerals 0 .7 5 % and la c to s e (Milk sugar)

kJ5% .
 - ; 51 : -

FUNCTIONS OF MILK IN BAKING

1. In creases absorp tion of flour in th e dough.

2. In creases volume and im proves te x tu r e .

3. Im proves n u tr itiv e value because of its p ro te in , m inerals and vitam in

c o n t e n t.

4. Im proves crest colour by combining la c to s e w ith protein during

baking.

5. IN creases mixing to le r a n c e .

6. In creases for m e n tatio n to le re n c e i.e., yields a s a tis f a c to r y loaf

of b re a d even when th e dough is under or ov er fe r m e n te d .

7. Supplies liquid to th e dough or cak e mix.

8. Im proves and help in keeping th e quality of th e p ro d u ct.

ADVANTAGES
_
OF USING MILK SOLIDS IN BREADS PRODUCTION

There a r e sev eral a d v a n ta g e s th a t could be d eriv e d fro m adding milk

solids in th e bread dough. These a re -

1. Increased absorptio n and dough s tren g th en in g .

2. In creased mixing to le ra n c e .

3. Longer f e r m e n ta tio n tim e .

k. B e tte r c ru s t colour.

5. B e tte r g r a in and colour.

6. Increased loaf volum e.

7. B e tte r keeping qu ality .

8. B e tte r n u tritio n .
 - : 52 : -

2 .8 . SHORTENINGS

Shortening means fat or oil used to te n d e r iz e baked products or

to fry p ro d u cts. This is one of th e major n u tr itiv e in gredients used in

th e b ak ery industry and may c o n s ti tu te up to 40 % of th e p rod uct w eight.The

type and am o un t of f a t used has d ir e c t bearing on th e c h a ra c te r is tic s

of th e baked p ro d u cts. For e x am p le on bread and cookies, the use of

th e baked p ro d u cts.F o r e x am p le on bread and cookies, the use of shortenings,

im p ro ves th e dough for maching and sh eetin g , c o n tro ls th e flow of biscuits

and en h a n c e s th e ir flavour.

CHARACTERISTICS OF SHORTENING

To ach iev e th e b est p e rfo rm a n c e , f a t should co n fo rm to the p r e d e t e r ­

mined physical and ch em ica l c h a r a c te r i s t ic s . The m elting point, p la sticity

and u n fo rm sm oo th te x tu r e is d ir e c tly r e la te d to th e d eg ree of dispersion

in th e dough. An ideal f a t for baking shQuld have th e following p ro p e rtie s.

1. Short pla stic range.,

2. R e s is ta n c e to exid ation.

3. C onsistency which makes its ready in c o rp o ra tio n into dough.

4. M elting point lower th an human t e m p e r a t u r e .

USE OF SHORTENINGS

C orrect am ou nts of sh ortenings is used to g e t b est resu lts. With

in c o r r e c t am ounts, dense, lean, tough or poor keeping quality cakes,

is o b ta in ed . F a t does not dissolves in w a te r , hen ce on mixing, it only

g e ts dispen ersed through out th e mix. F a t should be well mixed to g et

te n d e rn e ss in th e baked prod uct, p a rtic u la rly in c ak e mixes. When two

types of shortening are to be mixed in, th e h a rd e r one should first worked

 : 53 :

into th e mix, until it b ecom es p la stic and of th e sam e consistency

as th e o th e r f a t, which is also th en mixed in. In a rich s w e et dough,

hard b u t t e r and v eg e ta b le shortenings a r e o fte n m elted b efo re being

added. In the ca s e of le a n e r doughs, th e f a t or v e g e ta b le shortening,

acts as a lu b rican t in developing th e g lu te n . The f a t helps p re v e n t

th e te a r in g of th e g luten during mixing. In rich e r doughs, such as

bun dough, th e f a t is blended and c re a m e d w ith th e sugar.

2 .1 .9 CHEMICAL LEAVENING AGENTS

For many years man has p r e f e r r e d baked p rod ucts which are

leavened beca u se of th e following reasons -

1. Baked prod ucts so made a re light and th e re f o r e easily chew ed.

2. Baked p ro d u cts made with leaving a g e n ts a re more p a la ta b le

and app etizing than those made w ith o u t leavening.

3. Baked p ro d u cts made with leavening have an open of more

porous grains than unleavened p ro d u cts, so the disestive juices

com e in co n tact with the food more readily and digestion

is g re a tly f a c ilita te d .

Any p rocess by which dough is filled w ith holes and which

a re re ta in e d upon baking is a leavening process.A ny m a teria l which

brings this process is called a leavening a g e n ts .

BAKING POWDER

Is a leavening ag e n t produced by mixing an acid r e a c tin g m aterial

and sodium b ic a rb o n a te with or w ith o u t s ta r c h or flour as a filler.

Since all baking powders must consist of baking soda the only way

in which th e se can d iffer is in the type of acid ingredient used.

 : 54 ;

N orm ally ta rtra te , phosphate and s u lp h ate pow ders a re used

as acid in g re d ie n t. A baking powder should re le a s e its gas in the b a t te r

to s a t u r a t e it w ith carbon dioxide gas and then lib e ra te th e gas unformiy

during to hold th e raised b e t t e r intil s e t. This te n d s to give a uniform

c ru m b and p re v e n t shrikage and cakes fro m falling.

AMOUNT OF BAKING POWDER TO BE USED

It depends upon th e ty p e of p ro d u ct, th e c h a r a c t e r and am ount

of in g red ien ts em ployed and th e a t ti t u d e of th e p la c e . It is im p o rtan t

th a t th e exact am oun t of baking req u ire d is used. If th e q uan tity

of baking powder is ex ce ssiv e , th e c ak e will collapse or shrink a fte r

rising in th e oven. The crum b colour of th e cake will be dark and

the t a s t e will be salty . If too littl e is used, th e cak e may not be su ffi-

c e n tly leavened, resultin g in a dense heavy s tr u c t u r e which lacks

volum e and good e atin g q ualities.

2 .1 .1 0 EGG AND EGG PRODUCTS

Eggs a re highly n u tritio u s and th e r e f o r e enrich any recipe

in which they are included. Whole egg consists of yolk and th e w hite
‘ 2*1
p o rtion . They have the following av era g e com position as seen in Table.

Table - 2 ; 1

A verage Com position of an Egg

Sr. C ontent Whole Egg Yolk White

No.

-1 - -2- -3 - -k- -5 -

1 M oisture % 50 U
 : 55

Table 2 : 1 (contd.)

-1- -2 - -3 - -if- -5-

1. P ro te in % 17 11

3. - Fat % la 31 0.2

4, Sugar % T races 0.2 0.^

5. , Asg % I 2.5 1

Source : Bakery technology & M an u factu re, 1980 Ed P .2 5.

Thus yolk co n tain s m ost of th e f a t t y m a te ria l of the egg in

finely em u lsified s t a t e . It im proves c re a m in g and volum e of th e mix.

Only good quality fresh eggs should be used. S tale eggs ruin th e products.

D reid egg pow der is also so m etim e s used in b ak ery p ro d u cts. It

is produced by spray drying. ^ ' ‘ .t ;

USES OF EGGS

A p art fro m ic re asin g th e n u tritio n value, eggs, beacuse of

th e ir album en, help in s tr u c t u r e fo rm a tio n , both in th e dogh form

and when baked. They also im prove crispness, te x tu r e and e a tin g qualities

of biscuits. The yolk gives th e d esirable yellow colour to th e cak e.

When whipped or b e a te n , eggs produce foam , due to e n t ra p m e n t of

air bubbles, this gives som e leavening e f f e c t to th e mix. Whole dried

egg pow der should be soaked w ith 3 tim e s its w eight of w a te r for

one hour b efo re use. In th e ca s e of dried yolks 2.5 tim e s w a te r should

be used for soaking, one hour b efo re use and in th e case of dried

w h ite s, 8 tim es w a te r should be used, 3 hours b efo re use.

 - : 56 : -

2.1.11 FLAVOURS

Flavours is defined as the sensation of snnail and t a s t nningled.

Flavour is an im p o r ta n t in g red ien t and it helps th e baker to add uniqueness

to his p ro d u ct. D oubtless , ap p e a ra n c e is an eye catch in g fa c to r

in th e f ir s t sale of any baked pro du ct, but flav ou r holds to key to

all sub sequent sales. The g en era l a c c e p te d co m p o n en ts of ta s t e are

Sw eetness, sourness, saltin ess, and b itte r n e s s . A ddition of flaovurs

makes th e p ro d u c t more a c c e p ta b le to th e c u s to m e r . Only the best

quality flavour should be used

Flavours is to be sto re d according to s t r i c t in stru c tio n s given

by th e m a n u fa c tu re rs . Flavours should be s to re d ina place where

the am ou nt of light reaching th e flavour m a te ria l is very r e s tr ic te d .

V olatile flavours a re always sto red in coloured galss c o n ta in e rs . A

higer s to ra g e te m p r a t u r e will have an ad v erse e f f e c t on the volatile

flavours, which w eakens th e s tre n g th . Always re p la c e caps and stoppers

during and a f t e r use. It is to be re m e m b e re d t h a t caps and stoppers

the p o ten cy of th e falvour can change consid erably according to the

solvent used and th e length of tim e of s to ra g e .

Some conditions causes for th e disflavouring of the baked

p ro duct are as under : -

(1) Use of in ferio r quality ingredients.

(2) Use of un balanced form ula.

(3) Following fa u lty baking sy ste m or fau lty processing method

{^■) Use of unclean pans.

(5) Use of ch ea p and wrong type of packaging and wrapping m a teria l.

 - : 57 : -

(5) Use of cheap and wrong type of packaging and wrapping m a teria l.

(6) Improper method of storing of baked p roducts.

(7) D irty and d e fe c tiv e tra n s p o rta tio n method.

2 .1 2 .2 SPICES AND DRIED FRUITS ; -

Spices are veg etable products which may be in the fo rm of ground

bark, roots or whole seeds. They enhance the t a s t e and flavour of the

p ro duct. Spices is to be stored carefu lly. They are to be stored away

fro m h e a t. Mositure and air e x e rts bad influences on spices. Their

aro m a is volatile, so far as possible, fresh supply of spices nneed

to be used. Amount of spice to be added is to be co ntrolled carefully.

If too much is added, it may spoil the product by making it d ista ste fu l.

It would be observed th a t a varie ty of dried fru its and nuts can

be used in baked products to produce d iffe re n t types of flavours.

Dried fru its should be properly washed before use. C are must be

tak en to see th a t the fru it does not becom es so ft due to absroption

t of w a te r . If the fru it absorbs too much w a te r it could break down

during mixing and discololur the dough, besides it also looses its flavour.

A fter washing the fruits, they are dried by means of a dry cloth to

rem ove the excess m oisture. F ruits are always added in th e end to

ensure even distributiort th rpuou t the dough w ith minimum dam age.

2 .1 .1 3 FOOD COLOURS ; -

The use of colour is as im p o rtan t as the use of flavour. The

eyes appeal of the pro duct is enhanced by th e use of colour. C o r r e c t

colour is used to com plim ent th e flavour added in the pro duct. Colour
 - : 58 : -

should n o t be used w here the p ro d u ct re c ip e has am ple ingredients.

F or a colour to be a c c e p ta b le for use in food s tu ffs , the main

con ditio n being t h a t it should be h arm less to th e human h e a lth . T h ere fo re ,

in th e Food A cts of most c o u n tries, c e r t a in colours are p e rm itte d

and th e o th e rs a re to ta lly banned. The o th e r re q u ire m e n ts of colours

are t h a t th e y should be stab le ag a in st th e a c tio n of acids, alkalies,

sulphur dioxide, high te m p r a tu r e s , daylig ht and th e long s to ra g e . Thus

th e b a k e rs re q u ire to s e le c t th e colours which can stan d upto the

above cond itions.

The th r e e p rim ary colours - red , yellow and blue will produce

seco n d ary colours when mixed. Thus yellow w ith blue form s green.

Yellow w ith red form s orange and red w ith blue fo rm s violet, yellow

with red and blue fo rm s c h o c la te or borwn. The shades of the colour

depends upon th e proportions of one colour to a n o th e r. Colours should

alw ays be d e te rm in e d in broad daylight for p rop er e s tim a tio n .

The colouring m a teria ls th a t are av ailab le a re divided into two

- groups - n a t u r a l and a rtific ia l. The n a tu ra l colours are obtained

fro m v e g e ta b le and anim al sources w h ereas th e a r tif ic ia l colours

are o b ta in e d fro m coal ta r .

 - : 59 : -

2 .2 S T A G E S IN T H E M A K IN G O F B R E A D : -

The very first step is t h e m aking of th e dough. The v a r io u s

in g re d ie n ts are c o rre c tly w e ig h e d or m easured as p er th e fo r m u la tio n

and th en th e dough- is p r e p a r e d . The follo w in g c o m p o s itio n as shown

in T a b l e 2 : 2 m a y b e u s e c d f o r a 4 0 0 g m s l o a f o f b r e a d .

T ab le N o. 2 ; 2
C o m p o s i t i o n of i n g r e d i e n t s u s e d f o r a 4 0 0 g r m l o a f o f b r e a d .

S r. N o . P articu lars Q u a n tity

1. F lo u r 2 7 1 .4 2 gm s.

2. Sugar 4 % of f l o u r .

3. S alt 1 .5 % o f f l o u r

4. D ry y e a s t 0 . 7 5 % of f l o u r

5. V e g e t a b l e oil 1 .5 % of f l o u r

6. Mixi 0 .3 3 % of flo u r.

7. B read im p ro v e r 0 .3 2 % of flo u r.

S O U R C E ; B akery T ech n o lo g y and M a n u f a c tu re .

A n o th er fo rm u latio n for p re p ratio n of bread dough fo llo w ed

in g e n e r a l by t h e b a k e r s is s h o w n in T a b l e 2 : 3
 - : 60 ; -

T ab le N o. 2 : 3
C o m p o s i t i o n of i n g r e d i e n t s u s e d f o r p r e p a r a t i o n o f b r e a d dough.

S r . N o. In g red ien ts Q u a n tity

1. F lo u r 1 0 0 K gs

2. W a te r 6^. Kgs

3. Sugar ^ Kgs

4. S alt 2 K gs

5. S h o rten in g s Kgs

6 . F rie d b a k e r's y e a s t 0 . 5 Kgs

OR

7* C om pressed y ea st 1 .2 Kgs

8. S k i m m e d M ilk P o w d e r ^f.O K gs

9. Dough C o n d itio n e r 0 .3 5 0 gms

S O U R C E ; - B ak ery T ech n o lo g y and M a n u f a c tu r e .

2 .2 .1 D O U G H M IX IN G : -

T h is is th e first process in bread m aking. The in g re d ie n ts

as per th e fo rm u la re m ix e d eih ter by hand or by m ach in e calle d '

' K n e a d e r'. For th e b e st re su lts th e in g re d ie n ts s h o u ld b e m ix e d in

ce rtain order th o ro u g h ly . As is e v i d e n t th e re are tw o m etho ds fro

m ix in g V iz.

(A ) S t r a i g h t D o u g h M e t h o d and

(B ) S ponge D ough M eth o d .

 - : 61 : -

(A ) S T R A IG H T D O U G H M ETHOD ; -

T h is m eth o d is m ore com m on in I n d ia . T h is m eth o d co n sists

of m ix in g to g eth er all th e in g red ie n ts at one tim e . The q u ality of

th e bread depends upon th e th o ro u g h m ix in g o f all th e co m p o n en ts

hian d p ro p e r R eading. T h is is c a r r i e d o u t m e c h a n i c a l l y in l a r g e b a k e r i e s

and by hand in sm all b ak e ries. The dry in g re d ie n ts are m ix e d w i t h

th e l i q u id in g re d ie n ts u n til th ro u g h ly d isso lv e d . The flo u r is m ix e d

u n t i l m o s t o f t h e l iq u id h a s b e e n a b s o r b e d a n d a l u m p y m a s s is f o r m e d .

L astly , th e y e a s t so lu tio n prepared sep erately is a d d e d a n d th e dough

m ix in g is c o m p leted . If a sm all am ount of g h e e is a l s o used then

it is a d d e d a fte r th e yeast is m ix e d in a n d th e dough is a l l o w e d to

d ev e lo p . If oil is t o be used, it is t o be added at t h e b e g i n n i n g of

th e m i x in g , w i t h th e w a te r. The m ix in g is c o n t i n u e d u n til th e m a ss

becom es sm o o th and th e back of th e bowl is c l e a r e d of dough. The

m a c h in e s p e e d sh o u ld be m edium . The m ix in g o p e r a t i o n u s u a lly t a k e s

a b o u t 20 to 30 m in u te s . ^

(B ) SPO N G E DOUGH M ETHOD : -

In th is m eth o d , tw o m ix in g p erio d s and tw o n fe rm en tatio n

p e rio d s are used. In th e first m ix in g p e rio d , a s p o n g e is prep ared

w i t h 5 0 % to 7 5 % of th e flo u r to be used, 6 0 % tp 70% of w a te r, p art

of th e sugar and added m in e ra ls. The sponge is p a l c e d in a w arm

p lace to rise. In l a r g e b a k e r i e s a s p e c i a l f e r m e n t a t i o n r o o m is u s e d .

Sponge tim e w ill vary w ith th e w a te r te m p ra tu re , am ont of yeast

and th e ro o m te m p a ra tu re . U su ally , it v a rie s b e tw e e n 3 t o ^.5 h o u r s .

Sponge is ready when it starts fa llin g a fte r m ax im u m rise. A t this

drop p o in t, th e stru c tu re jo f th e sponge, g ets e x ten d e d to such an

 - ; 62 : -

ex ten t, by th e gas p ro d u c e d , d u rin g f e r m e n t a t i o n , th at it b re ak s and

p a rt of th e gas escap es. T h e s p o n g e is t h e n m ix ed w ith th e re m a in in g

in g re d ie n ts in th e K neader and thus th e sponge dough is o b tain ed .

2 .2 .2 FE R M E N T A T IO N : -

The m ix e d dough is placed asid e for allo w in g th e dough to

fe rm en t. The fe rm e n ta tio n room s h o u ld p re fera b ly be a sep rate one

b ein g m ain tain ed at about 30°C and 75% r e la tiv e h u m id ity . In s m a l l

b ak e ries, th is con tro l m ay n o t be p o ssib le , then th e d o u g h s h o u ld be

c o v e r e d c so t h a t e v a p o r a t i o n of m o i s t u r e f r o m t h e d o u g h is e l i m i n a t e d ,

th u s c r u s t f o r m a tio n does n o t ta k e s p la c e .

The dough s h o u ld not be to o w arm to o c o ld and s h o u ld be

p ro tec ted fro m air d ra fts. In co ld w e ath e r, th e am ount of yeast

in th e dough s h o u ld be in cre ased . also ferm en tatio n w ill a ls o have

to be in c re a s e d . In h o t w e a t h e r , y e a s t f e r m e n t a t i o n t i m e a r e r e d u c e d .

D uring fe rm en tatio n , part of sugar g ets co n v erted , to th e fo rm , in

w h ich it can serve as fo o d to th e y e a st. S ta rc h e s are co n v e rtib le

in to sugar th at produce carbon dio x id e gas. T h is e x p a n d s th e dough.

The dough m atu re s until it reach es m ax im u m sp ring and e la stic ity .

W hen th e dough has risen , it is tesed by in se rtin g finger«s

in to i t . If t h e f i n g e r m a r k s c l o s e v e r y s lo w ly t h e d o u g h is r e a d y f o r

p u n ch in g . In p u n c h i n g , t h e e n d s a n d t h e s i d e s o f t h e d o u g h a r e f o l d e d

f r o m o n e s i d e o f t h e t h r o u g h t o t h e o t h e r . T h is e n s u r e s e v e n t e m p e r a t u r e
 63

t h r o u g h o u t t h e d o u g h , p lu s r e l e a s e o f e x c e s s c a r b o b d i o x i d e a n d i n t r o d u c ­

tio n of fresh oxid atio n , re su ltin g in b e tte r ferm en tatio n a m achine

known as "m o u ld er". P re ssu re p u t on t h e d o u g h d u rin g m o u ld in g s h o u ld

n o t b e t o o l i t t l e a n d t o o hig h b e c a u s e i t t e a r s a n d d a m a g e s t h e d o u g h

s t r u c t u r e . T oo m u c h d u s t i n g o f f l o u r s h o u ld n o t b e u s e d in t h i s o p e r a t i o n ,

o th e rw ise , it w ill re su lt in th e sep e ratio n of th e ro lled dough and

w ill l e a d t o o p e n s e a m s , w h ic h w ill o p e n in b a k i n g , r e s u l t i n g in c r i p p l e s

on th e fin ish b re a d .

2 .2 .6 . P A N N IN G

M o u ld e d dough u n its are p ut in to b re ad p a n s w h ich h av e b e e n

su ffic ie n tly , but not ex c e ssiv ely been greased. The seam s id e o f t h e

d o u g h p i e c e s h o u l d b e p l a c e d d o w n so t h a t i t w ill b e c o m e t h e b o t t o m

side o f th e lo a f ^ d t h e d a n g e r o f s e a m o p e n i n g d u r i n g b a k i n g is a v o i d e d .

T h e d o u g h p i e c e s a r e p l a c e d in tf^e c e n t r e o f t h e p a n .

2 .2 .7 . PAN PR O O FIN G

The dough p ieces are g iv e n fin al proof in p ro p erly c o n tro lled

room . The re la tiv e h u m id ity and th e te m p e ra tu re of th e room are

O
m ain tain ed at 80-85% and 37 C re sp ectiv ely . T h is pan p ro o fin g step

is n e c e s s a r y t o a l l o w t h e l o a f t o e x p a n d b e f o r e f i n a l b a k i n g . T h e s t r e s s e s

and stra in s im p o se d upon th e stru ctu re of th e lo af d u rin g m o u ld in g ,

are eased d u rin g th is step as e x p a n sio n g o es on, u n til th e lo a f is a t

its d esired m ax iu m , and is r e a d y for th e oven. If t h e room has low

h u m id ity th e dough surface w ill dry re su ltin g in a lo s s o f b l o o m on

t h e c r u s t of t h e b a k e d l o a f . E x c e s s i v e h u m i d i t y a n d h ig h t e m p e r a t u r e s

o f t h e p r o o f i n g r o o m r e s u l t s in t o u g h l e a t h e r y c r u s t s , a w r i n k l e d s u r f a c e

a n d h o l e s u n d e r t h e to p c r u s t o f t h e l o a f .
 63 - A

S T A G E S IN T H E P R E P A R A T I O N O F B R E A D

12. SA LE

11. P A C K IN G

10. S L IC IN G

9. C O O L IN G

8. B A K IN G

7. PAN PR O O FIN G

6. PA N N IN G

5. M O U L D IN G

li. IN T E R M E D IA T E P R O O FIN G

3. S C A L IN G AND D IV ID IN G

2. FE R M E N T A T IO N

1 . DOUGH M IX IN G

F IG U R E - 2:1
 - z 6ii : - ‘ .

In order to d e te rm in e w h e th e r th e lo af is p ro p erly pro o fed ,

th e lo af is p r e s s e d lig h tly w ith fin g e r tip s. If t h e im p ressio n m ade

b y t h e t i p o f t h e f i n g e r r e m i a n s o r fi l l s up v e r y s lo w ly t h e n t h e l o a f

is c o n s i d e r e d to be P ro o fed . If t h e i m p r i n t d o e s n o t r e m a i n a n d fill

o u t , t h e l o a f is s t i l l t o l i g h t a n d c o m p a c t a n d s h o u ld b e f u r t h e r p r o o f e d .

U su ally 60 to 70 m in u te s tim e is s u f f i c i e n t for p ro o fin g . In s m a l l

b a k e rie s ro o m s w ith c o n tro lle d c o n d itio n s a r e n o t a v a ila b le .

2 .2 .8 . B A K IN G ; -

B a k in g is th e fin al stag e in p ro d u c tio n of bread . It changes

th e dough to an ap p e tisin g , d ig e stib le p ro d u c t. The dough u n its in

th e pans are p u t in a n o v e n , w hich has been h e a te d to 225°C . T h is

h e a ts th e dough m ass very q u ickly. Y e ast a c tiv ity in creases ra p id ly

u n t i l i t is d e s t r o y e d a t 6 0 ° C . C a rb o n d io x id e p ro d u c e d d u ring f e r m e n t a t i o n

expands. T h is r a i s e s th e dough to its m ax im u m and th e gas e sc a p e s.

E v ap o ratio n of m o istu re and alco h o l does n o t allo w th e gas escap ed .

E v ap o ratio n of m o istu re and alco h o l does not allo w th e in terio r of

th e dough te m p ra tu re to rise above 100°C . S ugar, s ta rc h and o th e r

in g re d ie n ts of th e exposed dough surface c a ram elises fo rm in g th e

c r u s t an d give it th e re q u ire d c o lo u r. T h is h a p p e n s a t 1 3 5 ° C .

The oven te m p ra tu re and th e tim e re q u ire d to bake a loaf

w ill d e p e n d on t h e s i z e a n d s h a p e o f t h e lo af an d t o t a l su g a r c o n t e n t

in th e dough at b aking tim e . T oo h ig h oven te m p ra tu re w ill form

th e curst t o o q u i c k l y , r e s u l t i n g in a b r e a d o f lo o s e s h a p e , lo o s e c r u s t
 - : 65 : -

and unbaked in terio r. Oven h u m i d i t y is a l s o i m p o r t a n t . If iiu m i d i t y

is t o o higli, th en b read w i t h t o u g h l e a t h e r y c r u s t a n d a g l a z e d is to o

u n a ttra c tiv e sh in e s h a ll be o b tain ed . If h u m id ity is too low , th e n

th e bread o b tain ed sh all be sim ila r to th a t o b tain ed fro m to o hot

oven.

2 .2 .9 . C O O L IN G ; -

A f t e r b a k i n g , t h e b r e a d is c o o l e d so t h a t i t d o e s n o t d r y e x c e s s i v e l y .

The m odern p ra ctice of slicing and w rap p in g m akes th is even m ore

n ecessary . If i t is n o t d o n e , t h e n m o u ld f e r m e n t a t i o n w ill t a k e p l a c e .

On co oling, th e bread becom es stro n g er. S li c e d bread now -a-days

in a g re a te r dem and hence a b read s l i c e r is used fo r th e prupose.

The sliced bread is w rapped eith er in an o rd in a ry paper or w axed

p ^ p e r w h ic h is h e a t s e a l e d .

2 .2 .1 0 S T A G E S IN T H E M A K IN G O F B IS C U ITS : -

B i s c u i ts , coo k ies and crack ers are im p o rtan t bakery item s

and are used a ll day and are not re stric te d to any p a rtic u la r tim e

of th e day. They have a v e r y lo n g s h e l f life as th e y a r e not prone

t o d e s t r u c t i o n by f i n g e r s . T hey a r e q u ite po p u lar.

S ugar, salt, m ilk pow der, and sh o rten in g are b lended i n t o ,a

sm o o th p aste. Eggs are th en added and b len d ed w e ll, fo llo w ed by

ad d itio n of w a te r. F lo u r and baking pow der are added and m ix e d

to a sm o o th dough. B isc u its m ay b e m a d e by hand or on m ach in e s.

W hen m a d e by h a n d , th e d o u g h is r o l l e d in t h e f o r m o f s h e e t a n d c u t

w ith th e h elp of p ro p e rly shaped d ies know n as b is c u it cu tters. T he

 - : 66 : -

scrap is w orked, ro lled and reused. W h en b iscu it m aking m ach in ery

is t o be used, th e dough is f e d t o i t a n d t h e b i s c u i t d o u g h is p u t in

th e greased pans. S ta m p in g or r o ta r y m ach in es m ay be used fo r th is

purpose w ith th e re q u ired e m b o s s i n g d e s i g n on t h e r o t a r y o f f l a t d i e .

The to p of th e b iscu its are w ashed w ith egg w ash, m ilk or m elted

fa t. They are baked at 210°C to 215°C u n til lig h t b ro w n , av o id in g

ov er b ak in g . T ab le 2 : ^ show s a ty p ic a l b is c u it r e c ip e .

T ab le N o. 2 ; »
I n g r e d i e n t s u s e d in a t y p i c a l b i s c u i t

S r . No In g red ien ts Q u a n tity : i

1, F lo u r 56 P arts

% Sugar 8 P arts

S. S alt 0 .5 P a rts

k. S h o rten in g (F a ts ) 8 . p a rts

■1. M ilk P o w d e r k P arts

6. E ggs k P arts

1. B a k in g P o w d e r 3 P arts

i. W a te r 32 P a rts

S O U R C E ; - Ba k e r y t e c h n o l o g y a n d M a n u f a c t u r e

2 .2 .1 1 S T A G E S IN T H E M A K IN G O F C A K E S

The m ix in g stag e of cake m ak in g is very im p o rtan t and be

carried out acco rd in g to th e set p rocedures. P roper m ix in g h elp s in

a c h e i v i n g u n i f o r m m i x t u r e of t h e i n g r e d i e n t s a n d in d e v e l o p i n g d e s i r a b l e

g r a i n a n d t e x t u r e in t h e b a k e d p r o d u c t . S o m e o f t h e v a r i o u s t e c h n i q u e s

o f m ix in g t h e c a k e b a t t e r s a r e : -
 - : 67 : -

fe) Single Stage Mixing ; -

T h is is th e m ost com m onJy used m ix in g p ro cess. It c o n s i s t s

o f d u m p i n g o f a l l t h e i n g r e d i e n t s in t h e m ix in g b o w l a n d b e a t i n g t h e m

w i t h t h e b a t t e r b e a t e r , u n t i l h o m o g e n o u s m a s s is o b t a i n e d . The b a t t e r

is g e n e r a l l y b e a t e n a t lo w s p e e d f o r 1 - 3 m i n u t e s , u n t i l t h e d r y i n g r e d i e n t s

have been w e tte d . Then h ig h speed m ix in g is perform ed for 5 to

8 m in u te s. L eaveners m ay be added n e a rly a t th e end of th e m ix in g

p erio d . The d isad v an ta g e of this sim p le m eth o d are p o orer g ra in ,

te x tu re and v olu m e of th e fin ish ed p r o d u c ts . S av in g of tim e is t h e

g r e a t e s t a d v a n t a g e of t h i s m e t h o d .

(b ) T w o s t a g e m ix in g ; -

In th is m eth o d , b a tte rs are m ix e d by p la c in g a ll of th e d ry

in g re d ie n ts and part of th e liq u id m a te ria ls in to a bowl an d m ix in g

t h e m u n t i l a h o m o g e n o u s m a s s is o b t a i n e d . T h e r e m a i n d e r o f t h e liq u id

is th en added g rad u ally and th e m ix in g is c o m p leted . E g gs m a y be

p a d d e d a t a n y t i m e of t h e m ix in g p e r i o d .

(c ) C r e a m in g M eth o d : -

In th is process, sugar and sh o rten in g s a re m ix e d and b e a te n

until a l i g h t a n d f l u f f y m a s s is o b t a i n e d . W h ile co n tin u in g th e c rea m in g ,

at m ed iu m speed, eggs a re added. Milk a n d flo u r a re added iin s m a l l

p ro p o rtio n s at th e near end of th e m ix in g o p eratio n . T his m eth o d

p ro d u c e s good q a u a lity c a k e s w ith im p ro v e d g ra in t e x t u r e .

 67 - A

STAGES IN THE PR E P A R A T IO N O F CAKES

9. SALES

8. P A C K I N G

7. IC IN G

6. C O O L I N G

5. B A K IN G

P A N N IN G AND C U P PIN G

3. L E A V E N IN G

2. B A T T E R I N G

1. DOUGH M IX IN G

F IG U R E - 2:2
 67 - A

B A T T E R IN G AND MIXING OF MAIDA FOR CAKES

F IL L IN G T H E C A K E S A C H A S W ITH B A T T E R E D MAIDA F O R B A K IN G IN T H E O V E N
 - : 68 : -

(d ) B lending M eth o d

In th is m eth o d flo u r sh o rten in g s a re b lended in th e m ix in g

bowl u n til th e flo u r p a rtic le s are th ro u g h ly c o a te d by t h e fa t. T he

rest of th e dry co n stitu en ts of th e fo rm u latio n are th en added. The

e n t i r e m a s s is m i x e d t o g e t a h o m o g e n o u s b a t t e r . F in a lly th e re m ia n in g

l iq u id is a d d e d in p o r t i o n s a n d t h e m ix in g is c o n t i n u e d f o r a p r e d e t e r m i n e d

p e rio d . T h is m eth o d re q u ire s m ore tim e and e q u ip m e n ts as co m p a re d

to sin g le s ta g e m eth o d . T h e f i n a l c a k e p r o d u c e d is f i n e a n d u n i f o r m .

(e ) S u g a r an d W a te r M eth o d

Sugar and w a te r m eth o d re q u ired th e b e a tin g of sugar and

h a lf of its w e i g h t in w a t e r , in t h e m ix in g b o w l f o r a b o u t 3 0 s e c o n d s

at m ed iu m speed. In t h e next stag e, flo u r, dry m ilk f l o u r , s a l t and

and b ak in g p o w d er a re added and th e c o n te n ts a re b e a te n a t m ed iu m

speed fo r about 5 m in u te s. The c a k e s produced by t h i s m eth o d have

b e t t e r c o lo u r c r u s t and im p ro v e d v o lu m e as c o m p a r e d to c a k e s , p re p a re d

by o th e r m eth o d s.

In g e n e r a l , c a k e s a r e b a k e d a t 3 6 0 ° F t o ^* 0 0 ° ? o v e n t e m p r a t u r e .

C akes baked at low er t e m p r a tu r e s are f l a t on t h e to p and ex h ib it

ex cessiv e sh rin k ag e around th e circ u m fera n ce and are to o ten d er.

H ig h er oven t e m p r a tu r e s p ro d u ces p e a k ed c a k e s w ith c ra c k e d c e n tr e s .

B esid es th e C akes are tough and low in vo lu m e and th e crum b has

h o l e s a n d t u n n e l s d e v e l o p e d in i t .

(f) C a k e I c in g s

T here is n o th in g h ig h ly te c h n ic a l about th e sk ill n ecessary

f o r t h e i c i n g of c a k e s a n d p a s t e r i e s . It is m a n u a l sk ill in w h i c h d e x t e r i t y

is ac q u ire d by co n stan t p ra ctice. It is s i m p l y a m atter of p r e s s u r e

c o n t r o l a n d f l e x i b i l i t y of t h e w r i s t .
 68 - A

IC IN G A N D D E S IG N IN G O F T H E C A K E S .
 - : 69 : -

Ic in g s a r e sw eat co v erin g s or c o a tin g s in w h ich sugar is th e

m a in co n stitu en t. They add to th e a ttra c tiv e n e ss of th e fin ish ed

p ro d u c ts. A p ro p erly p rep ared and applied icin g s add trem e n d o u sly

to th e sales ap p eal oft h e p ro d u c ts and h ig h er sales are re g iste re d

e v e n w h e n t h e p r o d u c t is o f i n f e r i o r q u a l i t y .

I c in g s a l s o p lay a h elp fu l part in re ta rd in g th e stalen e ss of

th e p r o d u c t . T h is d e p e n d s m ainly upon th e ty p e of icin g used. F la t

icin g s w h ich do not co n tain ap p reciab le am ount of sh o rten in g s w ill

have th e tendency to absorb th e m o istu re from th e cake. C ream ed

icin g are m uch m ore e ffe c tiv e in co n tro llin g th e ra te of sta llin g .

In o r d e r to in c re a se th e a ttra c tiv e n e ss and d elicio u sn ess o fth e

cakes it has been observed th a t 3 0 % of th e c a k e s w e re a lm o s t b eing

iced by t h e D a k e rs . s.The r a t e o f ic i n g c a k e s w a s t h u s th an o rd in ary

u n ic e d c a k e s b e a c u s e of th e a d d itio n a l c o s t of icing e x p e n s e s .

2 .3 . B A K ER Y M A C H IN E R Y A N D EQ U IPM EN TS

The q u estio n of bakery m ach in ery is ra th e r p e c u lia r in th e

sense th a t when one th in k s of a bakery in d u stry , one co u ld V is u a lis e

tw o ex tre m es. E ith er a c o m p lete ly au to m atic and so p h istic a te d p lan t

com es to th e m in d , w h ich is uncom m on here, or a hom e sc a le u n it

w h ere o p eratio n s are carried out to ta lly by hand w ith brick ovens.

T h u s , t h e r e is a c o n t r a d i c t i o n - w h i l e m o d e r n m a c h i n e r y is n o t a v a i l a b l e

in d ig en o u sly , but th ere is su rp lu s c a p acity in th e bakery m ach in ery

i n d u s t r y . T h e r e is no s t a n d a r d i z a t i o n in t h i s f i e l d .
 -:70:r-

T h e v a r io u s m a c h i n e s a n d e q u i p m e n t s u s e d in t h e b a k e r y i n d u s t r y

c a n be b ro a d ly c la s s ifie d as

1. W e ig h in g E q u i p m e n t .

2. M ix in g E q u i p m e n t .

3. M a k e up E q u i p m e n t .

4. B a k in g E q u i p m e n t .

5. S li c in g M a c h i n e s .

6. P a c k a g in g M ac h in e s.

2 . 3 . 1 . W E IG H IN G E Q U I P M E N T

A fte r th e fo r m u la tio n of a p a r ti c u la r ty p e o f p ro d u c t has b ee n

d e c i d e , t h e n e x t s t e p is t h e w e i g h i n g o r m e a s u r i n g o f v a r i o u s i n g r e d i e n t s ,

in d e s i r e d q u a n t i t i e s . T h e e q u i p m e n t s u s e d f o r t h i s p u r p o s e a r e m a n u a l

s c a l e s , o r a u t o m a t i c w e i g h i n g e q u i p m e n t a n d liq u id m e a s u r i n g e q u i p m e n t .

MANUAL SCALES

In sm all bakery estab lish m en ts, v ario u s ty p es of sca le s, for

b a tc h p ro cessin g a re in u s e li k e t h e B e a m a n d P o i s e a n d e v e n B a l a n c e

S cale.

In t h e o p e r a t i o n p r o c e s s , t h e m a t e r i a l t o b e w e i g h e d , is p l a c e d

on th e p la tfo rm and is c o u n ter b alanced w ith th e w e ig h ts. N o rm a lly

an e m p t y c o n t a i n e r is f i r s t w e i g h e d a n d t h e o p e r a t o r s e t s t h e d e s i r e d

i n g r e d i e n t w e i g h t by p l a c i n g w e i g h t s on t h e w e i g h t p l a t t e r a n d p o s i t io n i n g

th e p o ise. The in g red ie n t is p o ured in , un til th e p o in ter reads zero

on t h e e v e n b a l a n c e s c a l e .
 70 - A

W E IG H IN G MAIDA FOR BREAD AND CAKES

 71

T h eje sca le s are av a ila b le in c a p a c i t i e s u p t o 2 0 0 k g s or m ore,

for ca llin g of larg e b atch e s of dough. These la rg e bench sca le s m ay

h a v e dial ty p e o f in d i c a to r and m ay be e q u ip p e d w ith a h an d s e t sto p

p o i n t e r on t h e d i a l .

These m anual sc a le s are satisfac to ry fo r co ttag e and sm all

m ech a n ised u n its. L arge b ak e ries bein g set up th ese days, re q u ire

a m o r e e f f i c i e n t e q u i p m e n t , i n c o r p o r a t i n g s o m e a u t o m a t i o n in w e ig h i n g

te c h n iq u e s .

L IQ U ID M E A S U R I N G E Q U I P M E N T

Some in g re d ie n ts of th e bakery p ro d u c ts can be m easured

v o lu m etrically w ith su ffic ie n t accuracy because of th eir co n stan t

sp ec ific g ra v ity . In sm all u n its, a co n tain e r of p a rtic u la r vo lu m e is

used fo r th is p u rp o se . m o d e r n u n i t s t h e s e i n g r e d i e n t s m a y be m e t e r e d

i n t o t h e m ix e r w i t h t h e h e l p o f s u i t a b l e liq u id b a t c h i n g s y s t e m .

2 .3 .2 M IX IN G E Q U I P M E N T

The v a rio u s ty p es of m ix in g eq u ip m en ts used in th e b akery

in d u stry a re -

1. D ry B l e n d e r s

2. H o riz o n ta l Dough M ix ers.

3. V e rtic a l P la n ta ry M ix ers.

1. DRY BLENDERS

T h ese m ix ers a r e g e n e ra ly used fo r p re -m ix in g of dry in g re d ie n ts

of th e w h o le b atch . P re-m ix in g helps u n ifo rm d istrib u tio n of m icro -

 72

- i n g r e d i e n t s i . e . c o m p o n e n t s w h ic h a r e a d d e d in s m a l l q u a n t i t y c o m p a r a -

-tiv ely . T h is also reduces m u ltip le sc a lin g o p eratio n s in au to m atic

p lan ts. F lo u r, sugar m ilk p o w d e r a n d d r i e d eggs are m o s t l y p r e m ix ed

b e fo re bein g a d d e d to th e fin al b a tc h m i x in g . F o r t h i s p r o c e s s , R ib b o n

B l e n d e r E q u i p m e n t is t h e s t a n d a r d e q u i p m e n t .

The R ib b o n B len d er in its stan d ard fo rm , co n sists of a long

th ro u g h shaped b ow l. The m a te ria l a fte r m ix in g is d isch arg ed from

th e d isch arg e pot situ a te d a t th e b o tto m c e n tre of th e bow J. R ib b o n

B lenders can be so desig n ed to su it all ty p es of pow der in g red ie n ts.

H o w e v e r , t h i s e q u i p m e n t is n o t i n s t a l l e d b y s m a l l b a k e r y u n i t s .

2* H O R I Z O N T A L D O U G H M IX E R

In hand k n ea d in g a d o u g h ly m ate ria l, th e dough is p u lle d o u t ,

flo d ed back on itse lf and pushed down to join th e sep e rated lay ers.

T h is a c tio n is r e p e a t e d until tn e d esire d u n ifo rm ity is o b t a i n e d . The

m e c h a n i c a l d e v i c e w h i c h d o e s t h i s a c t i o n is c a l l e d a k n e a d e r . It c o n s i s t s

of tw o sp e c ia lly shaped b lad es set on p arallel sh a fts, m oun ted w ith

c lo se clea ran c es in a U s lia p e d th rough. The b o tto m of th e th ro u g h

is c u r v e d u p w a r d s t o f o r m a r i d g e b e t w e e n t h e b l a d e s . R e la tiv e p o si-

- t i o n i n g o f t h e b l a d e s a n d s u i t a b l e o v e r l a p p i n g a v o i d b u ild up of s t i c k y

doughs on th e blad es. The d isch arg es m ay be by tiltin g , by a d o u g h

in t h e s i d e o r by a d o o r o r d o o r s in t h e b o t t o m .
 73

3. V E R T IC A L P L A N E T A R Y M IX E R S

T hese are m ost w id ely used m ixers in b ak ery . They can be

used fo r a ll p ro d u c ts li k e bread doughs, pie doughs and s w e e t goods.

They are b e s t su ited fo r cake b atters fo r w h ich th ey are u n iv ersa lly

em p lo y ed . The b e a te r a c tio n of th is v e rtic a l p lan etary change bowl

ty p e m i x e r is d e c r i b e d a s p l a n e t a r y b e c a u s e t h e b e a t e r h a s t w o m o t o r s .

It re v o lv e s on its own v e rtic a l a x is at a re la tiv e ly h ig h speed. Its

axis is ro ta te d around th e in s i d e of th e bowl at a re la tiv e ly low er

s p e e d , in t h e o p p o s i t e d i r e c t i o n . W ith a r u b b e r e d g e d b e a t e r , t h e e n t i r e

in s i d e su rface of th e bowl is w ip e d p ro g ressiv ely , as th e p lan eta ry

c y c l e is m a d e .

2 .3 .3 MAKE UP EQ U IPM E N T

The p rim ary fu n c tio n of m ake up e q u i p m e n t is t o change th e

shape of th e dough pieces, a fte r th e m ix is r e a d y , from fe rm en tatio n

room . The m a k e up e q u i p m e n t f o r b r e a d i n c l u d e s - D i v i d e r s , R o u n d e r ,

In term e d iate P ro o fer and M oulder. H ow ever, it has been seen th at

none of th e b ak eries under stu dy have in stalle d th ese eq u ip m en ts.

1. D IV ID E R S

The dough a f te r f e r m e n t a t i o n is t r a n s p o r t e d to th e d iv id e ra re a .

In p rin cip a le , th e d iv id er is a m achine used to cut th e dough in to

loaf sized p ieces. The c a p acity of d iv id ers can be as h ig h as 2if00

to 5000 lo av es per h our, d e p e n d in g on th e num ber of p o ck e ts and

stro k es per m in u te . To co m p en sa te th e change in th e dough d en sity

and th e v a ria tio n of w e ig h t of th e fin ish ed lo a f, th e vo lu m e of th e

p o c k e ts can be ad ju sted by c h a n g in g th e p isto n to th e le ft sid e, in

each p o c k e t. These dough d iv id ers are fitted w ith sp e c ia l lu b ric a tin g

sy stem s. O il used in th e sy stem lu b ric a te s th e m ech an ical p a rts of

th e m ach in es and also fo rm s a seal b etw een th e dough box and th e

d iv id er head.

ROUNDERS

T h e n e x t o p e r a t i o n a f t e r s c a l i n g o f d o u g h p i e c e is t h e r o u n d i n g ,

w h ich is in fo rm e d in a m ach in e c a lle d ro under. The fu n c tio n of th e

r o u n d e r is t o c l o s e t h e c u t s u r f a c e s a n d t o i m p a r t t o t h e d o u g h p i e c e

a sm ooth and d ry ex terio r. It a l s o h e l p s to m ake a th ick co n tin u o u s

s k in a r o u n d t h e d o u g h p i e c e a n d f i n a l l y t o f o r m t h e d o u g h i n t o a b a ll

fo r ea sie r handling. T h is is done in th e rou n d er by ro llin g th e w e ll

flo u re d dough p iece aro u n d t h e s u r f a c e o f a d r u m o r c o n e , w h ile a l s o

m o v in g it upw ard and dow nw ard along th is su rfa c e ,b y m eans of a

s p i r a l t r a c k . In t h e r o u n d e r , t h e d o u g h p i e c e a s s u m e s a n a p p r o x i m a t e l y

sp h e ric a l shape as it le a v e s it.

% IN T E R M E D I A T E P R O O F E R S

They p erfo rm th e fu n c tio n of re sto rin g th e flex ib le stru ctu re

of th e dough p ieces so th at th ey respo nd w e ll to th e m anip u latio n s

of th e m ou lder. T h ese p ro o f e rs m a y be b e l t o r t r a y t y p e . It h a s b e e n

observed th a t none of th e b ak eries, under study had th ese ty p es of

m ake up eq u ip m en ts. They w ere been in sta lle d o n ly in very large

bak eries.
 75

4, M OULDERS

T h e f u n c t i o n of t h e m o u l d e r in t h e b a k e r y i n d u s t r y is t o s h e e t

c u r l a n d ro ll t h e d o u g h p i e c e i n t o c y l i n d r i c a l l o a v e s r e a d y t o b e p l a c e d

on t h e b a k i n g p a n s a f t e r t h e y c o m e o u t f r o m t h e i n t e r m e d i a t e p r o o f e r .

2 .3 .4 . B A K IN G E Q U I P M E N T - O V EN S

An oven is an ex trem ely im p o rtan t and in d isp en sib le item in

a b a k e r y u n i t . As r e g a r d s i t s s i z e , c o s t a n d i m p o r t a n c e i t is t h e m a in

e q jip m en t in a bakery u n it. S electio n of a p a rtic u la r ty p e of even

and its proper use, b o th are im p o rtan t, D ifferen t ty p es of oven a r e

a v a ila b le v iz . b rick oven, D iesel oven, e le c tric oven and soon. The

m ed ium of h e a tin g i.e. fuel co u ld be eith er wood, d iesel o il, gas,

c o a l a n d e l e c t r i c i t y , o u t o f t h e s e t y p e s , t h e b r i c k o v e n is a s t h e m ost

po p u lar o n e.

1. B R IC K OVEN

T h is is th e o ld est ty p e of even, still used in a l m o s t all th e

bak eries, sp ec ia lly in sm all b ak eries. It is dom e shaped oven w ith

one o p en in g door and w ith a flat b o tto m . The fuel used usu ally is

wood, w h ich is fed through th is o p en ing and allo w ed to burn for a

lo n g tim e. D uring this b u rn in g p erio d , th e door also serves as s t a c k .

A fte r th e p roper tem p eratu re in th e oven is reached, th e em bers

are racked out and th e oven is a l l o w e d to soak fo r a b o u t one h our,

so t h a t i t a t t a i n s u n i f o r m d i s t r i b u t i o n o f h e a t . L o a v e s a r e in d i v id u a ll y

lo ad ed in to th e oven by m eans of a lo n g w ooden shovel also c a lle d

p ee l.

It is c o m m o n p ra ctice to s t a r t th e b aking sc h e d u le w ith th e p ro d u c ts

re q u irin g th e h ig h e st te m p eratu re. The m a in draw back of su c h o v e n

 76

is th at th e loaves w hich are loaded first have to be rem o v ed last

and so it not p o ssib le to produce bread of u n ifo rm c h a ra c te ristic s.

It a l s o re q u ire s a h ig h ly sk ille d o p e r a to r , if f i n e q u ality p ro d u c ts are

to be b ak e d .

If i t is d e s i r e d to steam th e p ro d u c ts fo r b e tte r app earan ces,

a re q u ire d am ount of w a te r is t h r o w n in th e oven a fte r th e fire is

p u lled o u t, so th a t an e n v e lo p e of s te a m is f o r m e d in th e hig h d o m e

of th e oven. Good ste a m in g c h a ra c te ristic is o n e of th e a d v a n ta g e s

of th is ty p e of o ven.

2 .3 .5 . SL IC IN G M A C H IN E

S li c in g is th e process of red u cin g a lo af of bread in to sm all

w e ll fin ish ed p iece , w ith o u t cru sh in g of th e b read lo af. T here is a

g r e a t d e m a n d f o r s l i c e d b r e a d t h e s e d a y s . S li c in g b y h a n d is la b o u r i o u s

and tim e co n su m in g . H ence bread slicers are used. T hree ty p es of

slin cer m ach in e s are a v a ila b le usin g circ u lar b la d e s, straig h t b lad es

and co n tin u o u s band b la d e s. C ircu lar b lad e slicers are su itab le for

ro lls a n d b u n s . T h e o t h e r t w o t y p e s of m a c h i n e s a r e s u i t a b l e fo r b r e a d ,

slicin g .

1. S T R A I G H T B L A D E S L IC E R S

The stratig h t b lad e slicers are q u ite co m m o n ly used due to

th e low c o s t , and tro u b le f r e e o p e ra tio n s. The m ach in e has a num ber

of b la d e i held out by t h e force ex e rte d by a h e a v y s p r i n g . D i f f e r e n t

fram es are used for e a c h slice th ic k n e s s . The fram e a s w e ll a s t h e

fe w b l a d e s c a n b e r e p l a c e d in a f e w m i n u t e s . T h e s e s l i c e r s h a v e u s u a lly

2 0 t o UO l o a v e s p e r m i n u t e c a p a c i t y .
 77

2 .3 .6 . P A C K A G I N G M A C H IN E

The bak ery p ro d u c ts, a fte r co o lin g are w rapped in su itab le

w ra p p e rs w ith th e help of h an d o p e r a t o r s or sem i a u t o m a t i c or a u t o m a t i c

m ah in es.

1. B REA D P A C K A G IN G

The sim p le st way of p ack ag in g b r e a d is t h a t o f h a n d w r a p p i n g

m ach in es, in w h ich th e loaves passes th rough a re c ip ip D c a tin g slicer

a n d t h e n is d e l i v e r e d t o t h e h a n d s p f t h e o p e r a t o r , w h o u s e s a f o l d e r

jig a n d h o t s e a le r p la te s to p ac k ag e th e b re ad . The m a c h i n e is f i t t e d

w i t h h e a t e r , s w i t c h e t c f o r s e a l i n g t h e w a x p a p e r a n d no g u m is r e q u i r e d ,

t h e c a p a c i t y o f s u c h m a c h i n e is a b o u t 15 l o a v e s p e r m i n u t e .

2. BUN P A C K A G IN G

N o w -a-d ay s buns a r e packed in p o u c h p a c k s . T h is c a n b e d o n e

m an u ally or w ith m ach in e s. In m anual o p eratio n s a bag o f p o ly th e n e ,

\

open at one end and of exact sixe in t a k e n . The buns a r e p ackedin

i t a n d t h e o p e n e n d is h e a t s e a l e d w i t h t h e h e l p o f a n e l e c t r i c a l s e a l i n g

m ach in e. In sem i au to m atic p a c k in g m ach in e , one o p erato r p u ts th e

buns b etw e en th e tw o lay ers by p o iy th y le n e film , w h ich are heat

s e a l e d on a ll s i d e s , f o r m i n g a p illo w t y p e o f p o u c h p a c k .

3. A U T O M A T IC BREAD S L IC IN G AND W R A P P IN G M A C H IN E

T h is t y p e of m a c h i n e is u s e d o n ly by l a r g e b a k e r i e s . T his t y p e

of m ach in e is co m b in ed v ersio n of slicer, w rapper and se a lin g u n it.

A part from b ein g a com pact u n it, it also reduces floor space, saves

labour and e lim in a te s th e re q u ire m e n t of co nveyors in b etw een th e

u n i t s t h u s c o m b i n e d . It c a n s l i c e , w r a p a n d s e a l m any ty p e s and s iz e s

of b re a d .T h is c o m p letely a d ju stab le m ach in e has a self m e a su rin g

 77 - A

SL IC IN G OF BREAD BEFORE P A C K IN G

■ '' ' V - : ' ■

. .t

LADY WORKERS IN THE P A C K IN G DEPARTMENT

 78

p a p e r f e e d r e s u l t i n g in t h e e c o n o m y o f t h e w r a p p i n g p a p e r .

2AA. P R E C A U T I O N S T O BE T A K E N IN B R E A D M A K IN G

W hile m a k i n g b r e a d s a n d r o l l s a n d o t h e r y e a s t l e a v e d p r o d u c t s .

C e rta in d efects so m etim e s occur in th e p ro d u c t. Som e of th e m ajo r

d efects and th e ir re m e d ies p e rta in in g to th e p re p a ra tio n of bread

and ro lls, h a v e b e e n a n a ly s e d as u n d er

1. DEFECTS OF CRUST

The crust co lo u r is due to re actio n of n itro g en o u s com pounds

w ith th e red u cin g su b stan ce s in t h e surface of th e dough p ie c e . The

t e m p e r a t u r e o f t h e o v e n h a s a g r e a t e f f e c t on t h e c r u s t c o l o u r . L i g h t

c r u s t c o l o u r i n d i c a t e s t o o low t e m p e r a t u r e a n d v i c e v e r s a . T h e d e f i c i e n c y

red u cin g su g ars (sw e e tn e ss) m ay be d u e t o t h e i m b a l a n c e in t h e y e a s t

a c ti v i t y . To c o r r e c t it, L a c to s e m ay b e i n c r e a s e d by a d d i n g s k i m m ilk

so lid s or d rie d w h e y .

2. D E FE C T S O F VOLUME

T h e v o l u m e of t h e l o a f m a y b e e ith e r to o m uch or t o o lo w .T h i s

is d u e t o t h e g a s , p a r t i c u l a r l y c a r b o n d i o x i d e , im b alan ce.Gas is evolv ed

by th e yeast a c tiv ity . The gas im b alan ce m ay be due to im proper

p ro o fin g co n d itio n s, or im p ro p er am o u n t or q u ality of th e y e a st, etc *

The reaso n for th e defect m ay be asc ertain ed and co rre c te d . F lo u r

co n tain in g m ore g lu ten g iv es b e tte r lo af v o lu m e, w h ile lean e r flo u r

du e to w e a k dough s tr u c tu r e , re s u lts in e s c a p e o f s o m e g a s , t h u s poor

v o l u m e . T h is d e f e c t m a y b e c o r r e c t e d by b l e n d i n g o f f l o u r .
 79

3. DEFECTS IN FLAVOUR

F l o u r , s h o r t e n i n g s , w a t e r e t c a b s o r b odo^urs f r o m t h e s u r r o u n d i n g s ,

r e s u l t i n g in o f f f l a v o u r . T h e s e o d o u r s m a y b e t h a t o f p a i n t s , d i s i n f e c t a n t s ,

e t c an d m ay b e p ick ed up d u ring tr a n s p o r t or s to r a g e . The ra w m a te r ia l

m ay a lso b e h a v i n g o f f f l a v o u r s d u e t o t h e i r low q u a l i t y . A p p r o p r i a t e

raw m a te r ia l ch e ck in g , sto rag e and tra n s p o rta tio n s h o u ld b e e u n s u r e d .

If lack of flav o u r is due to , in ad eq u a te ferm en tatio n tim e so th e n

th e tem p era tu re of f e r m e n ta tio n m ay b e i n c r e a s e d . If l a c k o f f l a v o u r

is d u e t o lo w s a l t c o n t e n t o f t h e d o u g h , so i t m a y b e i n c r e a s e d . S o u r

flav o u r is due to to o m uch fe rm en tatio n and ap p ro p riate rem ed ial

a c tio n m ust be ta k e n .

4. DEFECTS OF GRAIN AND CRUMB

G r a i n d e f e c t s li k e h o l e s o r l u m p s e t c a r e u s u a l l y d u e t o i n a d e q u a t e

se a lin g of th e dough lay ers by th e m oulder of ex cessiv e dustin g of

flo u r. H eavy crust fo rm a tio n durin g in term ed iate p ro o fin g causes

a gum m y strea k in t h e baked p ro d u c t. Thus th e tim in g and h u m id ity

o f t h e i n t e r m e d i a t e p r o o f e r s h o u ld b e p r o p e r l y c o n t r o l l e d . O v e r p r o o f i n g

or to o law oven te m p eratu re o r t o o o ld o r s l a c k d o u g h s o r t o o l a r g e

o r t o o s m a l l p a n s r e s u l t in c o a r s e g r a i n s . U n d e r p r o o f i n g o r o v e r m ix in g

r e s u l t s in t i g h t g r a i n s . W e ak f l o u r a n d i m p r o p e r f o r m u l a t i o n also leads

to g ra in d efects. Some em u lsifiers give th ick c e ll w a lls. S m a ll c e ll

size re su lts in w h ite c ru m b .G re y ish or d a rk ish crum b m ay be due

to th e p re s e n c e of bran fra g m e n ts .

% DEFECTS IN SHAPE

T he lo af sh ap e m ay no t be u n ifo rm due to im p ro p e r c o m p re ssio n

du ring m o u l d in g or im p ro p er, p an n in g . If th e m o u ld er com presses

 - : 80 : -

th e dough cy lin d er to o m uch, th e lo af sh all have en larg ed ends o rif th e

c o m p re ssio n is to o lig h t, th e lo af w ill have peaked c e n tre . Doughs of

w e a k f l o u r o r o v e r p r o o f i n g w ill g i v e l o a v e s w i t h d e f e c t i v e s h a p e .

6. D e fe c ts of Texture ; -

T h e t e x t u r e o f t h e b r e a d is r e l a t e d to th e g ra in size, its u n ifo rm ity ,

elasticity and re sista n c e . D o u g h in ess of th e c ru m b m ay b e d u e t o e x c e s s

a b so rp tio n , w ro n g sh o rten in g or to o lo w bak in g tim e and te m p ra tu re .

V e ry w e a k f l o u r , e x c e s s i v e o r t o o lo w b a k i n g t i m e a n d t e m p r a t u r e , i n s u f f i c i e n t

f e r m e n t a t i o n a n d a b s o r p t i o n m a y l e a d t o t h e c r u m b l i n e s s of t h e l o a f .

7. D e fe c ts o f Bread or shred

E x c e s s i v e p a n p r o o f i n g , e x c e s s i v e p r o o f i n g h u m i d i t y , t o o o ld o r y o u n g

dough, too little steam in th e oven, lead to th e lack of sh red. A very

^ r a g g e d b r e a k o r s h e ll t o p m a y b e d u e t o s l i g h t l y y o u n g o r o ld d o u g h c r u s t i n g

d u rin g pan p ro o fin g . A p p ro p r ia te c o r r e c ti v e a c tio n m ay be ta k e n .

2A .2. PRECAUTIONS TO BE TAKEN IN CAKE MAKING ; -

V a rio u s ty p es of cakes m ay su ffer from th e fo llo w in g 5 d efects;-

1. D e fe c t o f volume ; -

C a k e s m ay h a v e t o o lo w v o l u m e . T h is m ay b e c a u s e d by i n s u f f i c i e n t

a m o u n t of leav n in g a g e n ts . In s u c h c a s e s l e a v e n i n g a g e n t s m a y b e i n c r e a s e d .

S o m e t i m e s b a t t e r s m ay b e a l l o w e d t o s t a n d t o o long a t t o o h ig h t e m p r a t u r e s ,

re su ltin g in p r e m a t u r e leav n in g . T h is s h o u ld b e a v o i d e d . O ver and under

h e a tin g of egg w h ite s , sh o u ld b e a v o id e d . Under m ix in g w ll r e s u l t in lo w

ev o lu m e due to le s s ae ratio n . E x ce ssiv e ly high o v e n te m p ra tu re re su lts

in settin g of th e cake stru ctu re befo re fu ll leav e n in g ta k e s p lace, th u s

 - ; 81 : -

th e c a k e v o lu m e re m a in s low . H e n c e , t h e o v e n t e m p r a t u r e s h o u ld b e e q u a ll y

re g u la te d . If t h e cakes are under baked, then t h o r o u g h b a k i n g s h o u ld be

ensured. T h e f o r m u l a o f t h e c a k e m ix s h o u ld b e p r o p e r l y b a l a n c e d p a r t i c u l a r l y

as reg ard s sugar, flo u r and sh o rten in g . Low volu m e m ay re su lt from th e

to o soon re m o v a l fro m th e pans a f t e r bak in g . H e n c e c a k e s s h o u ld b e a l l o w e d

to co o l, b e f o re re m o v in g t h e m f r o m th e ir tin s .

2. D e fe c ts o f Crusts ; -

The cakes cru st m ay becom e to o dark due to th e ex cessiv e oven

t e m p r a tu r e or due to o v e r b aking o r e x c e s s iv e su g ar c o n te n t. On t h e o t h e r

hand, th e lig h t crust c o lo u r m ay be due to th e cool .o v e n , or o v e r m ix in g

o f u n d er b ak in g . To re m e d y th e s e d e f e c ts , th e b ak in g tim e and te m p r a tu r e

and also th e m ix in g and th e fo rm u latio n s h o u ld be c a re fu lly re g u la te d .

T h ick an d hard c ru s t m ay re su lt due to o v e r b a k i n g a n d c o l d o v e n , w h ile

tough crust m ay fo rm due to to o hot oven or to o h ig h s u g a r c o n t e n t o r

im p ro p er m ix in g . S p o tte d c ru sts can be due to non hom ogenous b atter

or b u b b les in t h e c ru st. The fo rm e r m ay b e c o r r e c t e d by . m o d ify in g t h e

m ix in g sch e d u le , w h ile in th e latter case, su itab le le a v e n e r m ay have to

be used.

3. D e fe c ts of Texture :

U n d er baking of im p ro p e r cooling of th e c a k e b e f o r e p a c k a g i n g will

r e s u l t in g u m m i n e s s , d o u g h n e s s o r c h e w i n e s s . T h e s e d e f e c t s m ay b e r e m o v e d

by s l i g h t l y i n c r e a s i n g t h e b a k i n g t i m e a n d by t h o r o u g h c o o l i n g b e f r o e w r a p p i n g .

T hese d e fe c ts m ay also ta k e p lace due to th e a m o u n t of w a te r and type

of or q u an tity of sh o rten in g in t h e fo rm u latio n , w h i c h s h o u ld b e p r o p e r l y

 - : 82 : -

checked and c o rre c te d . C akes m ay b e c o m e tough if o v e r m ix in g , e x c e s s

sugar, too h o t oven, to o m uch flo u r, or to o s tro n g flo u r a r e used. S tr o n g

f l o u r a n d t o o m u c h m ix in g r e s u l t s in e x c e s i v e g l u t e n d e v e l o p m e n t , r e s u l t i n g

in t o u g h n e s . W e a k f l o u r m a y b e u s e d a n d m ix in g , f o r m u l a t i o n a n d t e m p e r a t u r e

s h o u ld b e p r o p e r l y r e g u a l t e d a n d c o n t r o l l e d .

D e fe c ts o f grain : -

T u n n els and larg e h o les at th e b o tto m of th e cake m ay b e d u e t o

excess b o tto m h e a t, d u rin g b a k in g . T o o c o l d o v e n s w ill a l s o r e s u l t in o p e n

g ra in s. W et s tre a k s m ay occour due to u n d er b ak in g , u n d i s s o lv e d s p o t s

of m a t e r i a l s in t h e crum b m ay b e d u e to u n d er m i x in g . C o ld o v e n , o v e r

b e a te n w h ites and in su ffic ie n tly m ix e d b a rte r w ill a l s o g i v e coarse g ra in .

H ence, te m p ra tu re should be re g u la te d , eggs s h o u ld be w hip p ed to w et

p eak and b a tte r s h o u ld b e fo ld ed until s m o o th . O ver b e a te n or u n b e a te n

egg, over m ix in g a f t e r th e ad d itio n of flo u r, to o m u c h s u g a r a n d t o o h igh

o v e n t e m p r a t u r e , r e s u l t s in h e a v y c a k e s .

5. D e fe c ts of flavour : -

As u su al, strong o ff flav o u r m ay be due to im p ro p er sto rag e and

tra n s p o rta tio n of raw m a te ria ls and th e ir bad q u ality . Lack of flav o u r

m a y b e d u e t o i n s u f f i c i e n t s a l t in t h e f o r m u l a o r p o o r f l a v o u r c o m b i n a t i o n .

In th ese cases, salt co n ten t m ay be in creased and proper flav o u r blends

s h o u ld b e u s e d . L ack of fla v o u r or s tro n g flav o u r m a y a l s o b e d u e t o low

q u ality of th e fla v o u rin g m a te ria l, in w h ich case, to p q u ality fla v o u rin g

m a te ria l s h o u ld be used. S tro n g fa lv o u rs m ay re su lt from over b a k in g

or b u r n i n g of c a k e , h e n c e , p r o p e r c a r e s h o u ld b e e x c e r c i s e d du rin g baking.
 - : 83 : -

2 .5 . STALING WASTAGE AND RELEVANT PROBLEMS IN BREAD.

CAKES AND COOKIES MAKING ; -

S ta lin g can be d e fin e d as th e lo s s of p a la ta b ility durin g sto rag e

caused by c h a n g e s o th e r th an those o cco u rin g fro m th e a c tio n of sp o ilag e
o rg a n ism s. S ta lin g is a very im p o rta n g t phenom enon, from th e p o in t of
view of sto rag e and tra n sp o rta tio n . R etailers and w h o le sa le rs are a ls o
co ncerned about it, ap art from th e u ltim a te consum ers. S ta lin g re su lts
b in s i g n i f i c a n t m a te ria l lo sses and m ay m e a su re s a h v e b e e n ta k e n by b o th
sm all and larg e b ak eries to overcom e th e lo s s e s re su ltin g from stalin g .
For econom y and g re ater consum er ac cep tan c e stalin g has to be k e p t to
th e m in im u m .

B a k e r y p r o d u c t s a r e u s u a l l y s o f t a n d sp o n g y a n d a l s o c o n t i a n s m o i s t u r e .
Thus, th ey are very su sc e p tib le to stalin g . P ro d u cts c o n tain in g m orer
m o istu re stale fa ste r, u n less th e m o istu re c o n te n t can be kept at alm o st
th e sam e lev el as at th e tim e of b ak in g . M ain ten an ce of m o istu re lev el
a s c o n s t a n t a s p o s s i b le k e e p s t h e r a t e o f s t a l i n g t o t h e m i n im u m .

2 .5 .1 . STALING OF BREAD ; -
f
The sta lin g p ro c e ss of b re a d invo lves b o th th e c r u s t and th e c ru m b .
T h e c r u s t o f t h e f r e s h b r e a d is c r i s p w h ic h on s t a l i n g b e c o m e s s o f t , t o u g h
and leath e ry . T h is is c a u s e d by t h e a b so rp tio n of m o istu re w h ich c o m e s
fro m th e m o is t c r u m b a n d also from th e surro u n d in g air, if t h e h u m id ity
is h i g h . T h is r e s u l t s in lo s s o f f l a v o u r a n d t a s t e . P a c k a g in g b re a d o fte n
ac ce le ra te s th e ra te of stalin g , beacuse th e excess m o i s t u r e in t h e crust
ca n n o t be ev a p o rated .

T h e s t a l i n g o f t h e i n s i d e o f a l o a f o f b r e a d c r u m b is d i f f e r e n t .f r o m
th e stalin g of th e c ru st. The c ru m b of bread stales if i t b e c o m e s d rier
and le s s elastic re su ltin g in th e lo s s of fresh flav o u r and arom a, m a k in g
t h e b r e a d le s s p a l a t a b l e . T h e s t a l i n g o f t h e c r u m b is d u e t o d r y i n g . S ta l in g
b eg in s as soon as th e p ro d u ct co o ls a fte r leav in g th e oven. It is m ost

r a p i d w h e n t h e p r o d u c t is f r e s h . S ta lin g b e c o m e s m o re ra p id as th e t e m p r a t u r e

o f s t o r a g e is l o w e r e d f r o m r o o m t e m p r a t u r e .

F r e s h n e s s o r s o f t n e s s o f t h e b r e a d c r u m b c a n b e p r o l o n g e d by p a c k a g i n g

in m o istu re proof w rap p ers, as it reduces th e d rying ra te . F resh ness is

usu ally m easured by s o f t n e s s , by t o u c h of th e b re a d , and it in d ic a te s th e

ac ce p ta b ility of th e b read . Good p a c k a g in g e n s u re b e t t e r flav o u r re te n tio n ,

b u t does n o t d elay th e c h e m ic a l stalin g . B read p ro d u c ts m ade fro m lean

doughs have open g ra in stru c tu re and co n tain less m o istu re a fte r b ak in g .

H ence, th ey sh o w m ore pronounced d rying ju st b e lo w th e bread c ru st,

r e s u l t i n g in q u i c k e r s t a l i n g .

Method o f Reducing Staling of Bread ; -

U se of in g re d ie n ts of in fe rio r q u a lity c a n n o t p ro d u c e a b read of p re m iu m

q u ality , so use of good q u ality in g re d ie n ts is very e sse n tid . The p ro p e r

am ount of a b so rp tio n of w a te r s h o u ld be strictly adhered to th e use of

m ilk a l s o a i d s in m a i n t a i n i n g f r e s h n e s s o f b r e a d .
 - : 85 : -

P ro p er p ro cessin g w ill h e l p in i n c r e a s i n g t h e s h e l f l i f e o f t h e b r e a d .

C are s h o u ld be ta k e n a g a in st over m i x in g . .A s a re su lt of over m ix in g ,

dough ten d s to becom e to o w arm re su ltin g in stick y dough. D uring th e

S u m m e r m o n t h s , i t is e s s e n t i a l t o u s e i c e t o c o n t r o l t h e f i n i s h e d t e m p r a t u r e

d u r i n g m ix in g .

The m ain ten an c e of vig o ro u s and h e a lth y fe rm en tatio n and m atu rin g

of th e dough, b rought about by th e co rrect q u an tity of y e a s t a n d a fu ll

am ount of salt, w ill d e fin ite ly produce bread of good k ee p in g q u ality .

O v e r r a g i n g of t h e d o u g h s h o u ld b e a v o i d e d t o o . O v e r p r o o f i n g w ill p r o d u c e

b r e a d o f c o a r s e g r a i n , w h i c h in t u r n w ill lo s e m o istu re m o r e r a p id l y th an

th e p ro p erly p ro o fed lo af.

A fter m ix in g and fe rm en tatio n , th e b ak in g tem p ra tu re of th e oven

a l s o v p la y s an im p o rtan t p a rt. Ovens h aving a tem p ra tu re w h ic h is to o

lo w w ill g i v e a v e r y h ig h o v e n sp rin g and t h e e f f e c t is t h e s a m e a s t h a t

o f o v e r p r o o f i n g . If t h e l a o f s t a n d s t o o lo n g in t h e o v e n f o r w a n t o f s u f f i c i e n t

h e a t, it a c tu a lly d ries out d u rin g b a k in g . D u rin g co o lin g of th e bread,

th e bread s h o u ld be stack e d in s u c h a way as to a v o id t h e c r u s h i n g of

th e la o f c e l l s . W ra p p in g of bread in m o i s t u r e p r o o f f i l m s is a ls o h e l p f u l .

2 .5 .2 STALLING OF CAKES AND COOKIES ; -

C akes and co o k ies c o n ta in m o is tu re re ta in in g in g re d ie n ts and c o n ta in

lo w er p e rc e n ta g e of starc h , thus p re v en tin g re tro g ra d a tio n . F a t q u an tity

is also h ig h er, w h ich in c re a se ric h n e ss and h o ld s th e m o is tu re lo nger.

THus cakes of clo se g ra in stru ctu rean d rich in fa t, stale co m p ra tiv le y

s lo w ly .
 - ; 86 : -

In c a s e o f c o o k i e s , t h e f a t c o n t e n t is h ig h , w h i l e t h e liq u id s a r e l e s s e r .

So th e short dough co o k ies keep longer than co o k ies th a t co n tain liq u id

in th e form of m ilk a n d e g g s . C o o k ies m ade w ith on ly t h e liq u id eggs)si

su ffer from ra p id d ryin g and consequent stalin g . S h e lf life of th e rich

co o k ies depends upon m ore on th e sta b ility of th e fa t, th an th e effect

of sta lin g .

Means o f Reducing Staling o f C akes and C ookies ; -

The use of Paper lin e rs h elp s to re ta in th e fre s h n e s s of c a k e s and

o th e r b ak ery p ro d u c ts. A cake baked in a p a p e r l i n e r w ill lo se m o istu re

v e r y s lo w ly , a s c o m p a r e d t o t h e o n e b a k e d in a p a n a n d r e m o v e d s u b s e q u e n t l y .

The later w ill dry fa ste r due to e x p o su re and stale fa ste r. L arge cakes

w h i c h a r e c u t a n d t h e n s o ld in p i e c e s , d r y f a s t e r a n d h e n c e s t a l e q u i c k l y .

Thus, th ese cake p ieces sh o u ld be encased in w axed paper or in a fin e

th in w rap. A good and p ro p erly s e le c te d icin g , also re ta rd s stalin g of

th e cake. F la t icin g d o es n o t h elp m u c h ., b u t f l a t a r e f o n d a n t icin g w ith

th in coat or b u tter cream is th e b est, sim p le flat i c in g not c o n tain in g

any fat m ay itself absorb m o istu re from th e cake and m ay peel of th e

c a k e a f t e r a few h ours.

2 .3 .3 . LOSSES IN BAKING : -

T here a r e m any b ak in g losses w h ich c a n be checked th ro u g h proper

c o n tro l and e ffic ie n t m an ag e m en t. B ut t h e s e lo sses c a n n o t co m p letely

Ibe e l i m i n a t e d . T h e e f f i c i e n t b a k e r is a l w a y s on a n a l e r t f o r a n y o f t h o s e

fa cto rs b ec o m in g ex c essiv e. Some of th e co n tro llab le fa cto rs and as to

how t h e y c o u l d b e c o n t r o l l e d a r e a s u n d e r : -
 - : 87 : -

1. INVISIBLE LOSS : -

T h e i n v i s i b l e loss o f m a t e r i a l , is t h e d i f f e r e n c e b e t w e e n t h e an n o u n t

of m a t e r i a l a c t u a l l y r e c e i v e d a n d t h a t a c c o u n t e d f o r , d u r in g b a k i n g p r o c e s s

S o m e of th e s e re a so n s fo r in v sib le lo sses a r e : -

F lo u r b eing th e b u lk am o n g th e to ta l i n g r e d i e n t s u s e d , is l i a b l e f o r

th e g re atest a m o n t of i n v i s i b l e loss, w h ich occours m a in ly d u rin g s t o r a g e .

T h is is due to th e lo s s o f m o istu re th ro u g h ev a p o ratio n , tearin g of scks

a n d f a i l u r e t o r e m o v e a ll t h e f i o u r f r o m t h e s a c k , w h e n d u m p i n g t f o r m ix in g .

b) F a i l u r e t o r e m v e a ll th e m a te r ia l f o r m th e c o n ta in e r s such as sy ru p s,

sh o rten in g s, e tc .

c) In a ccu rate w e ig h in g of th e in g r e d ie n ts fo r th e dough b a tc h e s .

d) S p o il a g e o f m a t e r i a l s

e) T h e f t s of m a t e r i a l s .

A b s e n c e o f s t o r e r e c o r d s of m a t e r i a l u s e d .

A lt h o u g h th e above lo s s e s lo o k very in sig n ific a n t, th e sum to tal

of th ese ac cu m u lated lo s s s h o u ld be co n sid erab le over a p erio d of tim e .

It is s e e n t h a t in v i s ib l e lo s r a n g e s b e t w e e n 1 % a n d 2 % .

2, MIXING LOSS : -

The m ix in g loss re p re se n ts th e to tsl am ount of in g re d ie n ts dum ped

fo r k n e a d in g , eith e r by hand or by m ach in e, an d th e fin ish ed dough o u t.

T h is lo s s m ay be u n im p o rtan t in te rm s of m oney, b u t it se rv e s to m ake

t h e m ix in g o p e r a t i o n p e r s o n n e l m o r e e f f i c i e n t . The to tal loss s h o u ld be

c a lc u la te d at th e end of th e e n tire sh ifto r d a y ’s run. The lo ss o c c o u r s

 - : 88 : -

when th e w o rk e r fa ils to clean th e m ix in g d o u g h s e f f i c i e n t l y . In a ccu rate

se a lin g of m a te ria ls, sp ec ia lly flo u r and w a te r, a c c o u n t fo r th e g re atest.

3. FERMENTATION LOSS t -

F e rm e n ta tio n losss a f f e c t s th e b ak er in t w o w ays. F irstly , i t is t h e

eco n o m ic lo s s due to less y eild and sec o n d ly , it a ffe c ts th e q u ality of

th e fin ish ed p ro d u c ts. The to ta l fe rm en tatio n tim e of th e doughs and th e

h u m id ity of th e dough ro o m w ill have a d e fin ite b ea rin g over th e rang e

of to ta l fe rm en tatio n loss. The lo n g er th e fe rm en tatio n tim e, th e m o re

w ill be th e fe rm en tatio n lo s s . Even if th e proper h u m id ity is m ain tain ed

t h e r e is b o u n d t o b e a l i t t l e f e r m e n t a t i o n loss d u e t o t h e c o n v e r s i o n o f t h e

sugars in to carbon d io x id e and alco h o l. N orm al fe rm en tatio n lo ss sho u ld

be average about 0 .7 5 % p ro v id ed th a b aking o p eratio n s are co n tro lled .

U n c o n tro lle d o p eratio n s w o u ld in crease th e lo ss and m ay go as h igh as

\
3 . 5 % f i n i s h e d d o u g h t e m p e r a t u r e is o n e o f t h e o t h e r f a c t o r s t o b e w a t c h e d ,

t o a v o i d e x c e s s i v e f e r r r i e n t a t i o n lo s s , d u e t o c o n v e r s i o n o f s u g a r s .

It. TROUGH GREASE ; -

A v o id ex c essiv e use fo sh o rten in g s or oil for g reasin g th e tr o u g h s

or th e m ix in g tab le to p s, b efore th e dough is a l l o w e d to r e s t , f o r i n i ti a l

fe rm en tatio n . T h e c a r e l e s s a n d i n e f f i c i e n t w o r k e r is l i k e l y t o u s e an e x c e s s i v e

am ount and th e dough m ay turn e a sly as w e ll as slid e o u t, w ith o u t m u ch

e ffo rt. T h is facto r is to be co n tro lled not o n ly from th e eco n o m ic p o in t

of v ie w b u t i t a l s o a f f e c t s t h e q u a l i t y of t h e f i n a l f i n i s h e d p r o d u c t . When

used in excess, sh o rten in g s or o ils will cause h o les and strea k es in the

fin ish ed p ro d u c t. T h is is also tru e in th e case of bread pan g reasin g .

E x c e s s i v e a m o u n t s w ill c a u s e a p o r o u s c r u s t on t h e f i n i s h e d p r o d u c t .
 - ; 89 : -

5. DUSTING FLOUR LOSS ; -

T h is fa cto r s h o u ld also be co n tro lled , for to o m uch d u stin g causes

lum ps, streak s, dark c irc le s and a harsh tex tu re on th e fin ish ed p ro d u c t.

It a l s o a m o u n t s t h e a d d i t i o n a l c o s t d u e t o w a s t a g e . F l o u r d u s t i n g is d o n e

to prevent th e dough fro m stick in g , so o n ly su ffic ie n t am ount m ust be

used. D u stin g flo u r, w h ich re m a in s unused a fte r th e d iv id in g ,.and

m o u ld in g o p e r a t i o n s , s h o u l d b e r e u s e d a f t e r s e i v i n g . T h e a m o u n t o f d u s t i n g

f l o u r u s e d s h o u ld n o t e x c e e d o n e p e r c e n t .

6. DIVIDER LOSS OR GAIN : -

B a k in g u n i t s w h ich are u s in g dough d iv id ers s h o u ld be very careful

ab o u t th eir o p eratio n s. The p ro fita b le o p eratio n w ill d e p e n d u p o n a c c u r a t e

u n ifo rm s c a lin g w ith c o r r e c t yield . O v e r s c a l i n g w ill r e s u l t in a n e t lo s s .

U nder sc a lin g of th e dough w ill not o n ly be a v io latio n of th e law , b u t

\
th is p artic u la rly b akery w ill lo s e th e m uch needed cu sto m er co n fid e n ce,

if th e facts becom e known. The norm al d iv id er loss s h o u ld not exceed

0 . 2 5 % . D o u g h s c o m i n g o u t o f t h e d i v i d e r s h o u ld o f t e n be c h e c k e d m anually

to e n s u re th e u n ifo rm s c a lin g o p e r a tio n s.

7. CRIPPLES ; -

D o u g h l o a v e s a r e s o m e t i m e s c r i p p l e d d u r i n g p a n n i n g or d u r i n g d i v i d in g

and sc a lin g if due c a u tio n is not e x c e rc ise d . M O reover, if porper care

is not ta k e n d u ring th e tra n sfe rrin g of th e dough lo av es into th e oven,

so m e of th e m m ay be k n o c k e d dow n an d c r ip p le d . L o av es a re o f te n c rip p le d

d u rin g b aking eith er by ex c essiv e heat w h ich re su lts in b urnt loaves or

by w ild i r r e g u l a r b u r s t s in t h e o v e n w h i c h r e s u l t in d e f o r m e d , u n s y m m e t r i c a l
 - ; 90 : -

lo a v e s, w hich are u n salea b le. O ven c rip p le s can be avoid ed by proper

re g u la tio n d u rin g pan p ro o fin g . U n sale ab le c r i p p l e s r e s u l t in a t o t a l loss

o c m a t e r i a l a s w e ll a s m a n u f a c t u r i n g c o s t s .

I. FUEL, POWER AND LIGHT ; -

These th re e item s of expenses usually play an im p o rtan t part in

th e general cost of p ro d u c tio n . C are s h o u ld be ta k e n th at th e oven is

fire d w ith no, unnecessary w a ste of fu e l. All m ach in es s h o u ld be kept

in g o o d c o n d i t i o n a n s w e ll l u b r i c a t e d . T h e y a r e t o b e o p e r a t e d o n ly w h e n

in a c t u a l use. The lig h tin g sy stem of th e bakery s h o u ld be arranged in

such a fa sh io n so th a t it g iv es e ffic ie n t re su lts and l i g h t s s h o u ld not be

used w hen n o t re q u ired .

It w o u ld be observed th at no ba)<ery is cent percent efficien t and

som e of th ese losses are bound t o o c c o u r in t h e best re g u alted b ak e ries.

The i m p o r t a n t p o i n t is t o d i s c o v e r all such losses, d e te r m in e th e ir causes

and t a k e s te p s to m in im iz e t h e s e lo sses.