The water that is being absorbed by the starches is released by the gluten, which causes them to bind. A gas permeable gluten network is created, allowing the CO 2 to escape without changing the structure of the bread.
During the baking process the outside of the bread dries sooner than the inside also referred to as crumb. Maillard reactions are very desirable when baking bread; it gives the bread the brown colour and provides a specific smell.
The browning can also occur when the starch-dextrins combust. After baking, the loaves of bread are lightly sprayed with water, which makes, along with the pyrodextrins incineration residue the crust of the bread shine. The bread needs to cool down before it is cut and packed. Packing it before the bread is cooled down will lead to condensation in the bag.
The production process of bake-off bread is similar to that of regular bread. However, the baking time of bake-off bread is shorter, ensuring that the bread is not fully baked and no brown coloration has occurred yet. The outside crust of the bread is lightly baked, this way the bread becomes slightly more firm and retains its shape. Usually, pre-baked breads are frozen giving them an extended shelf life and making them easier to distribute.
The frozen pre-baked loaves can be placed directly into the oven to continue the baking process. The final baking takes place together with the browning of the bread. This type of vacuum packaging, in which oxygen is partially replaced by CO 2 , is less suitable for bake-off bread. The quality of back-off bread is good, but slightly less than that of freshly baked bread. Because of the disrupted baking process and freezing, the bread suffers a slight quality decrease.
When freezing it is very important that the bread is frozen rapidly. In this way the formed ice crystals remain small. When the bread is frozen slowly, the large ice crystals which are formed are damaging to the structure of the bread. This will result in soggy bread. Baking a frozen bread will minimize this effect, because most moisture will evaporate during the baking process.
The fermentation process provides, in terms of temperature and relative humidity, the ideal conditions for the growth of undesired micro-organisms. If the yeast develops quicker it slows down the development of unwanted microorganisms. Whenever water is used during the fermentation process, the equipment and machines must be designed hygienically, so that they are cleanable to a microbial level. Other parts of the production process are allowed to be of a GMP-class, meaning that the machinery and equipment must be visibly clean before use.
In case that the machinery cannot be drained fully and set aside clean and dry , the machinery has to be thoroughly cleaned and disinfected before the production process can start.
A light microbial contamination should not be a problem if the dough is directly fully baked. During the baking process the air in the bakeries can become really humid. It is important that this moisture is removed as quickly as possible, to make sure that the moisture does not condense anywhere — especially not inside the air ventilation system. Condensation is often the cause of fungal growth.
The 5 micrometers small mold spores can easily float freely through the air and infect the bake-off bread. This contamination will become visible after some time as circular gray or colored spots on the bread.
Baking the bake-off bread for consumption will kill the fungus, but the consumer will still ingest the toxins that are left behind. Aviateur Banketbakkerijen B. More than half a million Dutch short biscuits, almond boats, treacle waffles and almond rounds roll off the production line every hour at the five factories owned by Dutch pastry specialist Aviateur Banketbakkerijen.
What started as a small-scale family enterprise in Wogmeer has grown to its current position supplying a long list A-brands in the inter national food industry, and as a purveyor to the Royal Household. Aviateur's head office stands right between two large production units in Broek op Langedijk in the Province of Noord-Holland, looking out onto the Wijde Vaart polder waterway at a particularly pleasant spot on the Spanjaardsdam.
Here administration, transport and sales staff work literally side by side with production staff in the factory. The logistics heart of the business is housed in the adjoining distribution centre, where Aviateur trucks are loaded up with the daily production yield from the m 2 workfloor of the industrial bakery.
The twelve ten-tonners operated by Aviateur distribute the produce and come back fully laden with packaging materials and basic ingredients so that production can keep going. The production lines only go quiet during the daily cleaning cycle. Dutch people enjoy a cake with their coffee, but even beyond our borders Dutch pastries enjoy great popularity. Aviateur currently exports nearly forty percent of all its products. The producer is aiming to grow its exports further in Aviateur believes this is achievable since demand for Dutch treacle waffles is growing exponentially in the US and China.
As part of its strategy, Aviateur is constructing a completely new line for the production of 40, treacle waffles per hour in Broek op Langedijk. This is enough capacity to bring the waffles to the inter national market at a competitive price. The new line is a model of modern industrial design, based on the latest developments in food-safe production facilities. Aviateur has considered every angle in its efforts to eliminate all risks of bacterial contamination and foreign objects entering the food chain - from the stainless steel cooling towers and hygienically designed junction boxes to the easy clean cable conduits for the motor drive of the transport and handling systems.
The company is willing to innovate and is not afraid to play an active role by investing in new solutions. Aviateur uses the freedom of choice it has as a family-owned enterprise to focus in on sustainability, user friendliness and food hygiene without compromise.
As Technical Facilities Manager, Jaap Jonk has had charge of the technical facilities at the Aviateur production locations for many years now, including in Broek op Langedijk. He brings a down-to-earth Noord-Holland outlook to his role.
According to Jonk , "The best way to ensure maximum food safety is by eliminating all risks of bacterial infection in your production environment. To be able to do this, you first need to identify the risks. Two years ago, I attended a seminar run by SafeFoodFactory on the subject of hygienic cabling which made me look at open cable conduit systems in a new light.
The objective is yeast growth, production of CO 2 , ethanol and organic acids, development of flavors and aromas, and modification of dough handling properties. Variables to monitor and control include fermentation time, temperature, titratable acidity TTA , pH, microbial count:. The divider cuts bulk dough into single pieces of proper weight with as little stress exerted on dough as possible so that these can be rounded and rested prior to taking their final shape.
The divider must process the entire dough load quickly to prevent excessive gassing that creates scaling errors. The sheeter and moulder encompass the sheeting stage, curling chain, pressure board, and guide bars.
These influence the gas bubble structure, shape and length of the dough piece to place in the pan. The moulder should be adjusted to achieve the desired shape with a minimum amount of pressure and stress on the dough to avoid damaging cell structure obtained during mixing and fermentation.
The objective is to convert raw dough into bread, set structure of product, crust and crumb formation, kill-step and shelf-life extension. Variables to monitor and control include temperature, time governed in continuous ovens by conveying speed. Other relevant variables include heat flux burners , humidity dampers and air velocity or flow.
Is it possible to calculate material efficiency from total input of raw material in kg and total output bread in kg given all the processes involved in production of bread? Hi Segun, we are addressing questions in our forum, so others can participate and contribute. Download our latest paper. How does it work? Application The style and type of bread dictates the dough system to use as well as the processing conditions during mixing, makeup and baking.
Mixing The objective is the blending and hydration of dry ingredients, air incorporation and gluten development for optimum dough handling properties. Variables to monitor and control include mixing time, energy input, dough temperature: Mixing time: a function of flour strength, its protein, damaged starch and non-starch polysaccharides and bran particles content.
Mixing equipment: vertical planetary , spiral open and closed for vacuum mixing , horizontal, continuous open and closed. Process specifications: 9—15 minutes at high speed in horizontal mixers.
Variables to monitor and control include fermentation time, temperature, titratable acidity TTA , pH, microbial count: Fermentation time: controlled by the temperature of dough, sponge , starter or pre-ferment, hydration level free water , pH, osmotic pressure, yeast food amino acids, minerals, fermentable sugars and yeast level or lactic acid bacteria count.
Second proving The tins pass along the conveyor belt into a warm area. Here the second proving stage takes place, lasting around 50 minutes.
Baking The tins move slowly on a conveyor belt through a huge oven for about 20 minutes. Depanning and cooling The baked loaves come out of the oven into the cooling area. Once cooled, it passes down the conveyor belt to be sliced if needed and bagged. Facts about flour How to store flour The role of flour in the diet Traditions, quotes and proverbs fab bread fab bread home Types of bread Misconceptions about bread Top ten benefits of bread Facts about bread Bread and obesity Bread does NOT cause bloating Chorleywood Bread Process Does bread make you fat?
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