Material balance and Costing Bread making

Submitted by : Apoorva Gupta M.Tech Food Biotechnology (I)

 Baking of bread: Heat transfer by convection and conduction Reactions during baking : caramelization & Maillard reaction Methods of yeast bread production 1. Straight-dough process : all ingredients are combined and mixed together at one time. Then the dough may be allowed to sit for fermentation in bulk prior to dividing 2. Sponge and dough process : a batter is produced first by mixing yeast-dispersed water with part of the flour.The batter is allowed to rise in a warm environment until it becomes spongy and foamy. This can take considerable time, ranging from 4 to 16 hours. Then the remaining ingredients are mixed with the sponge to produce dough, which is allowed to rise as in the straight-dough process

Generic ingredients
Ingredients Whole wheat Flour Water Salt Yeast Sugar Shortening ( vegetable oil ) GMS Calcium propionate Milk solids Total Bakers Percentage 100 % 58 % 1.5 % 2.5 % 2.5 % 1.5 % 0.5 % 0.5 % 0.5 % 167.5%

Formulation
Step - I : Determine the amount of dough needed to produce desired number of loaves [ No. of units scaling rates ] X [ Fermentation loss 1.02] = Dough weight Assuming 100 loaves have to be made, each weighing 400gm: 100 X 0.40 X 1.02 = 40.8 kg Step - II : Determine amount of flour needed to produce desired dough. (Total dough weight/ Total formula % )100 Kg of flour i.e. (40.8/167.5)*100 = 24.35 Kg of flour

Step III : Determine the weight of each ingredient

Ingredient
Whole wheat Flour Water Salt Yeast Sugar Shortening (vegetable oil ) GMS Calcium propionate Milk solids Total 0.5 % X 24.35 0.5 % X 24.35 0.5 % X 24.35 0.12 kg 0.12 kg 0.12 kg 40.80 kg Rs.50 Rs.200 Negligible Rs.6 Rs.24 Rs. 1085 Bakers percentage Amount in dough Price per Kg. Price for amount used in product 100% X 24.35 58 % X 24.35 1.5 % X 24.35 2.5 % X24.35 2.5 % X 24.35 1.5 % X 24.35 24.35 kg 14.12 kg 0.36 kg 0.60 kg 0.60 kg 0.36 kg Rs. 40 Rs.15 Rs. 60 Rs.30 Rs.60 Rs.974 Rs.5.4 Rs.36 Rs.18 Rs.21.6

Manufacturing details /Flow sheet with process parameters

Procurement of ingredients Weighing of ingredients Flour Kneading Dough (40.8 kg) Bulk fermentation (temp. 75-85oF, humidity 70-75%) for 1 hr.

Scaling and dividing Rounding and intermediate proofing (5 - 30 min, temp. 80-85OF) Moulding (Sheeting) (90OF) Panning Baking (temp. 475OF, 20-30 min) Cooling (Room Temp.) Slicing Packing in LDPE
40 Kg. Bread ( 100 loaves of 400 gm each )

 In the given example, 100 loaves each of 400 gm are made, i.e. 100 x 0.40 kg = 40 kg bread is made. Dough weight = 40.8 kg.

Hence, loss = 40.8-40.0 = 0.8 kg or 800 gm loss during fermentation and baking due to water evaporation.
Yield = (40/40.8) * 100 = 98.03 % Costing on the basis of raw material Rs.1085 for 40 kg. bread, i.e for each loaf of 400gm, price = (Rs.1085/40,000)*400 = Rs. 10.85 per loaf (based only on raw material input and not energy consumption, packaging and transportation cost) Retail price of whole wheat bread (400gm) in market is Rs.24