Maqsood Ahmad

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BSFS-FA12-004

Internship Report

Merit Bread
By
Maqsood Ahmad
(BSFS-FA12-004)
School of Food Science & Technology
THE UNIVERSITY OF FAISALABAD,
FAISALABAD

Research Project Report Approval Sheet

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The undersigned certify that they have read following report, examine the presentation, are
satisfied with overall performance, and recommended the report to Department of Food
science and Technology studies for acceptance.

Report Title: Research & project report

Registration No: BSFS-FA12-004
Bachelor of Food science &Technology

Dr. A.D Chouhdary

Signature

Head of Department

Maqsood Ahmad

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In the Name of ALLAH Most Benevolent ever Most Merciful

Maqsood Ahmad

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Maqsood Ahmad

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TABLE OF CONTENTS
Ch No.
1

Title

Page No.
7

Introduction
2
3
4

Merit s products
Equipments used in industry

8
9 - 10
11 - 13

Purchasing and receiving

14 20

5
Characteristics & function of ingredients

21

6
General recipes for important products
7

Flow sheet diagram of bread and processing

22 24
25 37

8
Processing steps

9
10

38 42
43 44

Bread faults
General recipes for important products

45 52

11
Types of ingredients and role

53

12
General flow sheet diagram for bakery products

54 55

13
Processing steps

56

14
Sanitation and cleaning
15

Results

57

16

Discussion

58

17

Conclusion

59

18

Reference

60 62

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Acknowledgement

First I would like to thanks Allah Almighty who gave me goodness and horseshoe to
complete my internship work with honestly and labor. It could never be completed without
bounties and affection of my ALLAH. Im again very thankful to ALLAH who gave me this
glorious chance to work in my dream and famous organization the Team Enterprises.
I also offer my humblest thanks to the Holy Prophet Hazrat Muhammad (S.A.W) who has
always been a source of inspiration and encouragement. His life is a role modal in this world
and the world there after.
Without prayers of my Loving Parents, Siblings, Teachers and Friends it could never be
happen. They gave me courage and supported me much as they can, so Im really thankful to
all above mentioned.
After that Im really thankful to my head of department Mr. A.D. Chouhdary and the most
cooperative teachers Mr. Nadeem Akhtar, Mr. M Nadeem, Mr. Nadeem Amin, Mr.
Khalil Ahmad, Mr. Abdul Haris, Mr. Afzaal and other faculty teachers.
With deepest sense of honor and gratitude, I acknowledge the cordial thanks to Mr. M Sajid
Hafeez production manager Merit Bread Faisalabad for his kind behavior and keen interest
during my internship program under his supervision. A special thanks to all workers, shift in
charges, (Mr. Youasf Mr. Shahbaz, and Mr. Altaf ), quality assurance staff ( Mr. Fraz Ali
and Mr. M Bilal) .

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CHAPTER # 1
INTRODUCTION:
Merit Bread is one of the most famous bread industry of Pakistan. It makes bread bun, Rusk,
cake, burger bun, a bakar khwani etc. It started work in Lahore its head office is also in
Lahore Kala Shah Kaku. Faisalabad plant is located at Plot No. 945, street No. 2, All
Masoom Road, Faisalabad. Area of the Faisalabad plant is three acre. Daily production of this
plant is about 11 lakhs.
HISTORY:
First name of this industry was Merry Gold and it is started production in 2005. There were
two founders of this industry Tariq Mauli and Dr Shafique both were the owner of the
industry. After that they got separated and now Tariq Mauli is the owner of Merit Bread and
Dr Shafique is the owner of Merry Gold. Hammad Teriq s/o Tariq Mauli is the managing
director of the industry. Faisalabad plant started production in 2008 as, before it was a ware
house up till 2005.
MISSION STATEMENT:
1. To bring a change in the eating habits of a common man with the provision of healthy and
nutritious bakery products for the health and happiness of the nation
2. Customer satisfaction through high standards
3. Security for vendors, agents, employees and stack holders.
4. Provide the nutritional satisfaction of consumers

GROUPS OF MERIT BREAD:

a) Head office Kala Shah Kaku
b) Kot lakh pat Lahore
c) Team Enterprises Faisalabad unit

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CHAPTER # 2
MERIT S PRODUCTS
A.

BREAD

1.

Milky Open Top Bread (standard)

2.

Large Bread (white)

3.

Standard Bread (White)

4.

Milky Mini Bread

5.

Sandwich Bread (white)

6.

Milky Plain Standard Bread

7.

Bran Bread

B.

BUNS

1.

Fruit Bun

2.

Burger Bun (Round)

3.

Burger Rolls (Long)

C. RUSK
1.

Pillow Pack Rusks

2.

Simple Ruks (Open Top & Plane)

3.

Goal Rusk

D. CAKES
1.

Fruit Cake

2.

Mini Cak

3.

Muffins (Mango & Strawabery + Vanilla)

E. Baqar Khani (Large & Small)

1. Bakerkhani 25 Pc
F. Shawarma

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CHAPTER # 3
EQUIPMENTS USED IN INDUSTRY
Various types of equipment are installed in MERIT BREAD for performing different
functions.
1) Weighing Balances
Weighing balances is used to weigh different bread ingredients. There are two types of
weighing balances at plant.
a) Mechanical Balances:
Used to weigh flour, sugar and others suitable ingredients.
b) Electronic scales:
Used to weigh different ingredients in small fractions (Yeast, improver, salt etc)
2) Sifter
Sifter is used to remove the undesirable foreign particles and dust if any present.
3) Mixer
Spiral Mixer is used in industry for bread, bun and rusk mixing. It consists of a rotating steel
bowl. The spiral mixer is industrial equipment conceived to prepare food, ceramic dough or
other sort of product, replacing manual labour through a mechanical system that allows
producing, continuously, large quantities of dough. They are composed by:

Bowl for ingredients placement

Mixing element (spiral hook, fork, arm or other system)

Two independent motors that start/trigger the bowl and spiral hook movements

Interconnection of technological procedures that allows to the operator the control of the
mixing process and other labour (measuring ingredients, programming times and
speeds)

Although being prepared to produce a wide range of doughs. The spiral mixers are mainly
projected to produce bakery and pastry doughs, such as, bread dough and others, providing a
correct food treatment, ensuring high productive performances.

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Z - MIXER is used for mixing. The mixer is usually a wheel-mounted, heavy tub with
vertical sides, round ends, and a flat bottom. The mixer is designed so that it may be wheeled
into the position below the mixer head and locked into place. The spindles are lowered into
the mixer and move in either a planetary or a stationary, circular motion when activated. The
mixer blades are designed to provide a cutting action rather than kneading or stretching the
dough
4) Steam Boiler
A boiler is a device used to create steam by applying heat energy to water. Water is boiled
under pressure inside it to produce the steam for proofing. It has water inlet & a steam out-let.
Steam boiler has pressure gauge for the regulation of pressure.
5) Ovens
An oven is a thermally insulated chamber used for the baking of a substance. Swing type
oven is used. It has 8 wings which have trays suspended between the iron-wheels. Below
these trays, there are gas burners for baking. Temperature control meter are set on the front
wall of the oven to control the temperature.
6) Rusk oven:
Tunnel type oven is used for rusk drying. Its length is 55ft and divides in to two zones with
50 burners inside it. A piece of rusk takes approx. 5-7 minutes for complete drying. In first
zone low heat are apply as compare to the second zone. It is used for the baking of rusk.
7) Slicer
It consists of varying number of knives, which have distance according to the thickness of the
slice required. Two loaves are fed in the inclined plane of slicer & the knives cut the loaves
without tearing the crust.
8) Packaging machines
These are automatic machines which rap product in required packet. Paper is used for the
raping of the product.
10) Sealing machine
It has electric heating rod which seal the packaging material & the temperature of the rod is
120 C.

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CHAPTER # 4
PURCHASING AND RECEIVING
Raw material is sampled. Samples are checked according to the given specifications of
quality. If samples give positive results then order is given to concerned firm according to the
demand of industry. When raw material is arrived samples are taken and again these samples
are checked following the same procedure as done before if these samples give same results
then raw material is unloaded and then store according to the given specific conditions.
Quantity of raw material is purchased which can be utilized within 15 days.
List of raw material:
Flour
Yeast
Sugar
Salt
Eggs
Butter
Margarine
Banaspati ghee
Vegetable oil
Bread improver
Chemicals
Muraba
Cremo
Misllinous ingredients
Packaging material

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Raw Material Tests

1) Flour

Dry gluten percentage

Wet gluten percentage

Peaker color test

2) Yeast

Color

Taste

Temperature

Smell

3) Butter

Taste

Color

Smell

Temperature

4) Eggs

Physical appearance

5) Salt

Impurities present

Color

Taste

6) Oil

Color

Smell

Impurities

7) Muraba

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Taste

Smell

Color

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CHAPTER #4
CHARACTERISTICS & FUNCTION OF INGREDIENTS
1) Flour
It is the main constituents of bread used for nourishment.
It provides proteins (gluten) that provide strengthening to the bread.
It provides the final volume to the bread.
It acts as media.
It contains nearly1-3%ash contents.
It also provides fiber content nearly 2-5% which is helpful in the diet and digestion of food
properly.

Conditioning of gluten refers to its mechanical development in mixing and change, which
occurs during the fermentation.
Moisture contents in flour should always less than 12%. Moisture.
Wheat flour contains varying amounts of proteins, fats, carbohydrates, constituents ash,
fiber, vitamins, and enzymes.
Baking quality is affected by
o Protein contents
o Protein quality

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2) Water
It is used to dissolve the ingredients forming homogenous mixture.
It binds the protein contents as the protein contents are water absorbent.
It is also important for the yeast activity.
It helps to maintain the dough temperature.
It helps in swelling of starch granules.
It gives the volume to the bread.
It acts as a medium for many chemical reactions occurring in bread making.
To a certain extent it regulates the yield and profit.
It helps in transforming the protein of the flour into gluten.

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3) Yeast
It cause fermentation.
It is a small plant. Microscopic in size.
It acts as a leavening agent leaving CO2 used to increase the volume of product.
During fermentation yeast, provide alcohol, CO2 and other bi product as alcohol.
provides aroma and flavor to bread.
It gives the loaf good texture.
YEAST TYPES
Commercially yeast is of two kinds
Fresh Yeast (Compressed Yeast)
Yeast is made of a single-celled organism called saccharomyces cerevisiae. This
organism multiplies rapidly when fed sugar in a moist environment. It is mostly sold
as dried dormant granules, known as active, instant, or rapid-rise yeast. Dried yeast
has a long shelf life and can be stored at room temperature. Fresh yeast, sometimes
called cake yeast or compressed yeast, is a block of fresh yeast cells that contains
about 70% moisture and is commonly used by baking professionals. It's pale beige in
color, soft and crumbly with a texture similar to a soft pencil eraser, and has a
stronger yeast smell than dry yeast.

Dried Yeast
It's a type of dry yeast that's granular, with a consistency similar to cornmeal. It's a
living organism that's dormant until proofed or dissolved in a small amount of
lukewarm warm water (about 110F). It's then added to the rest of the ingredients,
where it will cause dough to rise. Active dry yeast is typically sold in individual
packets or small jars.

o In both form yeast organism is alive and can be killed by too much heat. Fresh yeast is
collective of yeast organisms packed in moist yeast food material .The activity of yeast can
be slowed by temperature.

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4) Sugars
It provides sweetness.
It acts as a food for yeast activity.
It helps in retention of moisture and prolongs the freshness of bread.
It delays the gelatinization of starch and denaturation of protein.
It gives to bread a very appetizing color due to Caramelization of residual sugar.
It gives nutritive value to the bread.
It improves the texture of bread.
Sugar makes the bread tender because of its property to retain moisture. This property
termed as hygroscopic.
It also affects the volume of loaf.

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5) Antimicrobial Agents
Antimicrobials are most often used with other preservation techniques, such as refrigeration,
in order to inhibit the growth of spoilage and pathogenic microorganisms. Sodium chloride
(NaCl), or common salt, is probably the oldest known antimicrobial agent. Organic acids,
including acetic, benzoic, propionic, and sorbic acids Calcium propionate and Acetic acid, are
used against microorganisms in products with a low pH. Sulfur dioxide and sulfites are used
to control the growth of spoilage microorganisms in bread industry. Nisin and natamycin are
preservatives produced by microorganisms. Nisin inhibits the growth of some bacteria while
natamycin is active against molds and yeasts.
In MERIT BREAD, Calcium propionate and Acetic acid is used. Objectives of antimicrobial
agents are to kill the microbes and to increase the shelf life.
Calcium Propionate
As a food additive, it is listed as E number 282 in the Codex Alimentarius. Calcium
propanoate is used as a preservative in a wide variety of products, including but not limited
to: bread, other baked goods, processed meat, whey, and other dairy products. In agriculture,
it is used, amongst other things, to prevent milk fever in cows and as a feed supplement.
Propanoates prevent microbes from producing the energy they need, like benzoates do.
However, unlike benzoates, propanoates do not require an acidic environment. Calcium
propanoate is used in bakery products as a mold inhibitor, typically at 0.1-0.4% (though
animal feed may contain up to 1%). Mold contamination is considered a serious problem
amongst bakers, and conditions commonly found in baking present near-optimal conditions
for mold growth. A few decades ago, Bacillus mesentericus (rope), was a serious problem,
but today's improved sanitary practices in the bakery, combined with rapid turnover of the
finished product, have virtually eliminated this form of spoilage.[citation needed] Calcium
propanoate and sodium propanoate are effective against both B. mesentericus rope and mold.
It checks the growth of bacteria as Bacillus subtilis and B. mesentricus by decreasing the pH
which otherwise if goes unchecked cause Ropiness in bread.
Acetic Acid
It checks the growth of micro organisms in bread by reducing the pH. It inhibits the growth of
microorganism and preserves the bread and increase the shelf life.

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6) Dough Improver
Different bread improvers are being used in bread industry e.g. SOFT AND MIX 120 etc.
Advantages of bread improvers:
More tolerance
More shelf life
More oven spring
More uniform crumb structure
More volume

7) Shortening (Fat/Oil)
Shortening mean fat or oil used to tenderize baked products or to fry products. Fats are solid
at room temperature but oil is liquid .The best shortening in order of preference are
1. Butter
2. Hydrogenated veg.oil
3. Butter oil
4. Vegetable oil edible tallow
In MERIT BREAD the combination of vegetable oil and ghee is being used as shortening
agent
Objective of Shortening
It is used to soften or tenderize the bread
It increases the nutritive value of the bread
It increases the flavor of the bread
It confers the moisture on bread and hence retard staling
It assists in gas retention by making the gluten more airtight thus giving better volume
and crust

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8) Common Salt
Salt has an important role in bread making salt controls and to a certain extent regulate the
fermentation process
Functions of Salt
It toughens the gluten and thus permits greater volume
It allow the absorption of more water
Sugar caramelizes more rapidly in presence of salt
It also acts as a anti microbial agent (it retards the growth of undesirable bacterial in
dough)
It contribute the freshness of bread and its keeping qualities
It gives its specific taste
9) Milk
Milk is used in milky bread. In MERIT BREAD milk is used in powder form which contain
28%fat
It enhance the food value
It enhances the crust color and crumb color
It gives taste
It enhances the yield
It enhances the keeping quality of bread
It enhances the volume of bread

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CHAPTER #6
GENERAL RECIPES FOR IMPORTANT PRODUCTS
Ingredients

Bread

Fruit Bun

Rusk

Flour

100 Kg

60 Kg

80 Kg

Mori Yeast

2 Kg

2 Kg

--------

Sugar

2 Kg

8 Kg

24 Kg

OIL

1 Kg

2.200 Kg

---------

Salt

1.600 Kg

0.650 Kg

0.800 Kg

Ca. Propionate

0.350 Kg

0.180 Kg

-------

Soft Improver

0.300 Kg

0.120 kg

-------

Mix. (120) Improver

0.80 Kg

0.050 Kg

0.035 Kg

Acetic Acid

0.04 Kg

---------

--------

Ca. Acetate

0.050 Kg

---------

-------

Banaspati Ghee

-------

1 Kg

8 Kg

Safe yeast

-------

0.075 Kg

1.200 Kg

Vanila powder

-------

0.020 Kg

0.100 Kg

Muraba

--------

2 Kg

--------

Food Color

--------

0.007 Kg

Lemon Essence

--------

0.030 Kg

Orange Essence

--------

0.030 Kg

Crown Improver

--------

Milk Powder

--------

Maqsood Ahmad

---------

0.200 Kg
0.200 Kg

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CHAPTER # 7
FLOW SHEET DIAGRAM OF BREAD AND PROCESSING
Aging

Sifting

Weighing

Mixing

Fermentation

Dough Dividing

Moulding

Baking

Damping

Proofing

Depaning

Panning

Cooling

Slicing

Dispatch

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Packing

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Flow Sheet Diagram of Rusk Production

Aging

Sifting

Weighing

Mixing

Dough Dividing

Moulding

Baking

Damping

Cooling

Packing

Maqsood Ahmad

Proofing

Depaning

Panning

Cooling

Rusk Drying

Slicing

Dispatch

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Flow Sheet Diagram of Fruit Bun Production

Aging

Sifting

Weighing

Baking

Cooling

Mixing

Proofing

Moulding

Damping

Dough Dividing

Polishing

Dispatch

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Fermentation

Packing

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CHAPTER # 8
PROCESSING STEPS
Demand sheet is made according to the demand in market. In this demand sheet production
department set the amount of ingredients for the production of each product and then this
demand sheet is given to the store and store incharge issues all the ingredients according to
this demand sheet.
1) Aging:
Aging is done for almost one week. This process is necessary for oxidation. When the flour is
exposed to air .The natural bleaching is done (oxidation of pigment is done).
2) Sifting:
Sifting is done by sifter. It is estimated that 85 kg bag takes 2 minutes for sifting. Purpose of
this process is that no other foreign materials remain in the flour.
3) Weighing:
First of all, the ingredients are weighed according to recipe.
4) Mixing:
Mixing is done by two ways:
1) Straight method
2) Sponge method
Straight method:
In this method, all the ingredients (mainly flour, yeast, sugar, and water) are put at one time
in mixing bowl and mixing is carried out.
Sponge method:
The sponge method of mixing is complete in two steps. In first step, sponge is prepared by
mixing full flour +1/3 water + half yeast + half sugar and allow this sponge to ferment for 45
mints. In second step remaining sugar, yeast and water is add and mixing is complete as in
straight method.
In MERIT BREAD, mixing of Burger buns, Tiki Rusk is done by sponge method and mixing
of Bread, Fruit bun etc. is done by straight method

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Process of mixing:
Different size of bread is made and the procedure of mixing in all bread is same which is
given below
First Step (Sponge Prepare):
Half flour + half sugar + half yeast+ water
(2 mints slow mixing)
(5-6 min fast mixing)
Standing for 45 mints
Second step:
Add remaining flour, sugar, yeast and water + Improvers + C. propionate + + acetic acid
(Fast mixing for 5-6 min)
Salt solution (mixing for 2 mints)
Oil (mixing for 5-6 mints)
Mixing of bun and Rusk:
In bun mixing, it is required that dough should remain little harder than that of the bread
dough. To make harden dough less amount of water is added. But it is difficult to maintain
the dough temperature up to 28 29 0C by adding less amount of water, so we use ice in bun
mixing to maintain the temperature.
Procedure:
Add flour + yeast + Sugar +Water +Color + improvers +calcium propionate
+ Vanilla powder
(1-2 min slow mixing)
Add flour + yeast + more water if required
(4 5 min fast mixing)
Add oil + flavor +oil + salt + Muraba + Essences
(3-4 min fast mixing)
Finally added oil for shortening (Slow mixing for few seconds)

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Mixing Test:
At the beginning of the kneading time takes off the walnut- size ball of dough. Using both
hands, hold the ball between the thumb and fore finger and stretch it, much like stretching a
balloon before blowing it up. At this time dough will probably tear easily. Work the dough
piece back in to the dough and repeat this process after every couple of minutes. When the
dough has been kneading enough, it will not tear easily, but rather will stretch, and
translucent membranes will be visible. This is known as Gluten Window. At this stage stop
the mixer, mixing is complete, no addition kneading is required.

Water Tempering:
Temperature of the flour is about 34-36oC and finally required temperature of dough is 28290C, so temperature of adding water adjusts such that temperature of dough becomes 28290C. This process is known as water tempering.
Water to be used for mixing is 10-110C (in summer) and 24-250C (in winter) temperature.

Mixing Time:
Mixing time depend upon quantity of flour, greater the quantity of flour greater will be
mixing time. The protein content of flour also can effect mixing time. It has been shown that
low protein flours (<12%protein) require less mixing time. Certain chemical agent, particular
reducing agent such as cystein, sodium bisulfite, and related compound, are quite effective in
shortening mixing time. These reagents apparently work by breaking disulfide bond in the
glutenin protein, thus making the protein smaller. These smaller proteins hydrated more
easily and lead to smaller mixing time.

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5) FERMENTATION:
After the dough has been developed by mixing and kneading, it is placed in warm
environment (Usually 25 30 0C) for 10-15 minutes as fermentation proceeds. Dough
development occurs during fermentation as well as during mixing. Fermentation has a
pronounced effect on the nature of gluten complex. During this period balance is produced
between glutens ability to form thin, extensible films and the properties of dough that allows
for maximum gas retention by these films. The decrease in pH that occurs during
fermentation results chiefly from production of CO2 and lactic acid and from the assimilation
of ammonia.
The amount of yeast may be varied in accordance with desired of fermentation of alcohols
acids, eaters and the flavor precursors.
To participate in dough development.
Results of total fermentation process.
The fermentation time. Yeast ferments sugar to produce ethanol, CO2 and various byproducts. The basic function of yeast in the making of bread is fermentation.
Fermentation of sugars by yeast in generally an anaerobe process and involves a large
number of biochemical reaction.
To leave the dough by the CO2 that is produce.
To contribute to bread flavor as a consequence.
The overall reaction
C16H12O6 = = = = = = = = = = = >>>>> 2C6H12OH + 2CO2
Glucose

Ethanol + Carbon dioxide

The sugar substitute for yeast fermentation in dough may come from several sources
First: Flour contains small amount of sugar
Second: Beta-amylase activity in flour may produce some maltose from the hydrolysis of
starch in damaged granules.
Third: Small quantity of sugar, usually added in making bread dough.
The process of fermentation is very important in bread industry.
In industry the fermentation of products such as all size of bread, bun and Rusk is done
usually 10-15 minutes per batch.

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Fermentation time depends on the amount of yeast i.e. if the amount of yeast is less,
fermentation time is more and if the amount of yeast is become double then the fermentation
time will be minimum.
Fermentation time also depends upon the final temperature of bowl, if temperature is between
30-350C fermentation time is low i.e. 3-5 minutes if temperature is between 27-29;
fermentation is increase 10-15 minutes per batch.

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6) Dough Dividing:
Dough dividing is a process that divides the bulk dough into consistent smaller dough
weights. In dividing the dough is divided in pieces. This is done through mechanical dough
divider or scaling on the bench. One divider cut 16 pieces at one time for large bread and
second divider divides into 30 pieces. The divider rounders will divide blocks of dough to
round them in order to produce small breads.
The weight range will go from 20grs to 150grs per dough ball, depending on the model
selected.
After mixing, the operator will weigh blocks of dough (like with a hydraulic divider),
depending on the number of divisions of his machine (from 12 to 50 divisions most of
the time) and the weight of the dough ball required. For example, if the baker has a 30
division divider and he wants dough ball weighing 60grs, he will weigh blocks of dough
weighing 1800grs.
Then, the block of dough is placed on a tray and introduced in a divider rounder. The
process that presses the dough for spreading it, then divides and rounds is done by the
divider rounder machine. The automation of this process depends on the model of the
machine purchased.
These small balls can then go directly in fermentation before baking or can be moulded
in a moulder.
There are some fully automated lines for dividing-rounding continuously with loading
of the dough balls in a proofer, then automatic feeding in a moulder to mould the dough
balls into elongated breads. They can also include systems for automatic deposit on
trays.

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7) Moulding:
After bulk fermentation, dough is ready for moulding. The dough is dividing into individual
loaf-size pieces by the help of dough divider, which divide large dough in to equal sixteen
parts. The molding operation is essentially sheeting followed by curling, rolling, and
application of pressure. The dough dividing and moulding machine produces dough balls
with extremely high quality and weight accuracy. Due to the architecture of the dividing unit,
very soft doughs can be processed.
Saving of resources due to very high weight accuracy.
Gentle to the dough through unique processing of dough.
Great operational reliability due to the use of high-quality machine materials and drive
technology.
Second weight range producible through the use of a Multi-Measuring Drum Lifter.
Uniform round dough balls.

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8) Panning:
After being moulded, the dough piece is paned in the bottom of the pan. The pan should be
clean and is oiled by some greasing agent so that the bread, after proofing and baking, does
not stick to the pan and could be easily depanned. Otherwise the bread remains stuck to the
pan and during depanning of bread is deshaped or break due to some mass of it remaining
attached to the pan.
Pan or Loaf Breads the taller breads that are baked in pans because they need the
support of the sides to maintain their shape.
Make sure you use the pan size or shape specified in the recipe; if too small the bread
will rise over the sides; if too large the bread won't seem to have risen very much.
Bread pans vary as to volume.
To check for the right size, grease the pan lightly and place the unshaped dough in it; it
should reach -inch from the rim of the pan.
The baked breads center should rise.

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8) Proofing:
After panning, the proofing is done. Proofing is generally done to raise the volume .The
specific temperature and relative humidity is very necessary. For proofing temperature of
proofer should be, 35C-40C and the relative humidity should be 82-85%. Humidity is
important as this keeps the crust moist. Moist dough will proof quickly. Due to the moisture,
the crust will be thin and crisp .As rule bread with thin crust will loss less volume weight
during baking. Proofing time is different for bakery products, it ranges is 45 to 75 mints.
Proofing (also called proving or more rarely blooming), as the term is used by bakers, is the
final rise of shaped bread dough before baking. It refers to a specific rest period within the
more generalized process known as fermentation. In bread baking, the word proofing most
commonly refers to the final rise dough undergoes, which takes place after being shaped into
a loaf, and before it is baked. In practice, however, the words proof and fermentation are
sometimes used interchangeably. What's important to realize here is that shaping dough
affects its physical form, but doesn't impact its internal chemistrythe processes and
chemical reactions at work during our bulk and final rises are the same. With that vocabulary
in mind, let's take a look at the dough we all just birthed, and, armed with patience, get back
to work.
Fermentation is a step in creating yeast breads and baked goods where the yeast is allowed to
leaven the dough. Fermentation rest periods are not always explicitly named, and can appear
in recipes as "Allow dough to rise." When they are named, terms include "bulk fermentation,"
"first rise," "second rise," "final proof" and "shaped proof". Proofing yeast (as opposed to
proofing the shaped bread dough) refers to the process of first dissolving yeast in warm
water, a needed hydration step when using active dry yeast. Proofing can also refer to testing
the viability of yeast by dissolving it in water and feeding it sugar or carbohydrate. If the
yeast is viable, it will feed on the sugar and produce a visible layer of bubbles on the surface
of the water mixture.

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10) Baking:
Baking is done after proofing. In oven, direct heat is given Keep always in consideration that
the excess heat will set crust of bread in shorter time but crumb will remain under baked.
Good quality baking depends upon baking time and temperature of oven. Temperature and
time required for baking depend upon: -

The size of bread.

The sugar in dough at baking time.

Baking temperature and time of products are following

NAME OF PRODUCT

TEMPERATURE

TIME

Large bread

200 c

35 mints

Sand-witch bread

200 c

50 mints

Standard (p) bread

200 c

30 mints

Milky(P) bread

200 c

30 mints

Standard(OT)

200 c

30 mints

Milky mini

200 c

20 mints

Fruit bun

190 c

20 mints

Sheer mall

200 c

20 mints

Burger bun

230

12 mints

SPR(OT)

200 c

20 mints

Goal rusk(L)

180 c

20 mints

Burger roll

230 c

12 mints

Milky (OT)

200 c

30 mints

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Baking of Rusk:
Rusk is baked in two stages.
In first stage they are semi dry in an oven for 10 12 minute at a temperature of 2000C.
Then the loaves of Rusk are cool, sliced and then they are full dry on RUSK OVEN (Tunnel
dryer) where 1980C temperature is maintained.

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11) Damping:
After baking, bread pans are removed from oven manually, and these are placed in oven hall
for 15-20 minutes for cooling. This is known as damping.

12) Depanning and Cooling:

After damping, bread is removed from pans and is arranged on wire rack for cooling (cooling
for 10-20 min). The loaf should be cooled so that it will not dry excessively. Cooling allow
the structure of the bread to firm up. At this stage, the bread is removed from the baking pan
and carried towards the cooling stage. The pan itself is conveyed back for re-use.
Main challenges in this process include:
Damage to baked product from clumsy transfer.
Condensation retention at depanning stage.
Rubber-top belts losing friction due to oil from pans.
Damage to pans from metal-on-metal contact.
Solutions:
Small pitch belts allow for smaller nose bars and smoother transfers.
Open-grid belt design minimizes condensation.
Textured surface maintains friction properties despite oil.
Plastic belts do not damage metal pans.

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13) SLICING:
Slicing and wrapping are carried out side by side. After proper cooling of bread loafs, they
are manually transferred to slicing and wrapping room. Bread loaves are fed into the inclined
plane of slicer. Two loaves are fed at one time. The slicer cuts the loaves to 12mm thickness
of slices for bread 13mm thickness of slices for Rusk. For proper slicing the
1. Crumb structure should be even, soft, velvety and without sign of toughness.
2. Proper dough moldings done for strong crumb.
3. The crust should be short and not rubbery. So that it will not tear away from the crumb
during slicing nor exert undue wear and tear the blades of the Slicer.
14) Wrapping:
Immediately after slicing wrappings is done manually in printed polythene bags especially
made for this purpose and then sealed manually with an elastic rubber band. Wrapping of
Rusk is done by using plastic foil. One is small pack which contain the piece of Rusk are
wrapped by using machine. Rusks are wrapped in one or half Kg of plastic foil, which is done
manually. Buns are packed in plastic bag and sealed by sealing machine.
15) Finished Goods Store:
After packing, the bread is ready for finished goods store until dispatch. It is store in cool and
dry place which have not contain any insect and any other contaminated material.
16) Dispatch:
Dispatching is done in 24 hours but large of quantity is dispatched at night 3-5 P.M. The
reason is that bread is used as breakfast. Therefore, this time is very critical for dispatch.
During dispatch, the proper handling of packed material is very necessary. Because if damage
is done into the packed material then there is a chances of bread spoilages before its normal
shelf life.

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CHAPTER # 9
BREAD FAULTS:
Bread faults are of two types:
A. External faults:
Following are the external faults of bread:
1) Volume Too Small:
Reasons of this fault are:
Less dose of yeast
Dough weight is less
Insufficient pan proofing
Oven is too hot

2) Volume Too Large:

Reasons of this fault are:
High dose of yeast
Excessive pan proofing
Dough weight is high
Cold oven

3) Crust Color:
Crust color of faculty bread may be either pale or dark and it is mainly due to:
Less sugar contents
Cool oven
Fermentation temperature too high
Lack of salt

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4) Thick Crust:
Following are the major reasons:
Less humidity in pan proofing
Less oven temperature
Over baking

5) Wrinkle Side:
Following are the main reason:
Use of less strong flour
Less mixing time
High oven temperature
Less baking time

6) M-Form (in large bread): Reason is:

Lose mixing
Handling problem

7) Dent In Bread
Reasons are:
Handling problem
Less baking

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B. INTERNAL FAULTS:
Following are the internal faults of bread:
1) Holes in Crumb:
Main reasons of this fault are:
Dough temperature is high
Large oil use during moulding
Mould the dough pieces not tightly
Excessive greasing

2) Yellow-Gray Streak in Crumb:

Main reasons are
Use large oil during moulding
Use large oil during dividing
Dough temperature is high

3) Coarse Crumb Structure:

Main reasons are
Less mixing
Final proof temperature is high
Decrease dosage of bread improver

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BUN FAULTS:
Faults are following
1) Holes under the Top Crust:
Main reason is
Use of strong bread flour
Increase humidity in final proofer
Oven temperature is high

2) White Crust on the Top Crust:

Main reason is
Higher humidity in the proofer
Avoid dough skinning during final proofer
Bulk fermentation is high

3) Cracks at the Side:

Main reasons are
Use strong bread flour
High dosage of bread improver
Mixing time is decrease
Increase dough temperature
More proofing time

4) Flat Bun:
Main reasons are
Less dose of bread improver
Use more water

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 Dough temperature is less

Final proofing time is more

5) Coarse Crumb Structure:

Main reasons are
Extra knocks the dough
Proofing temperature is high
Less dose of bread improver
Mixing time is less

6) Large Irregular Holes:

Main reasons are
Dough temperature is high
More oil use during moulding
Dough pieces are moulded not tightly

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CHAPTER # 10
GENERAL RECIPES FOR IMPORTANT PRODUCTS
INGRIDIENTS

MUFFINS

CAKE Rusk

MINI
CAKE

Flour

10 Kg

21 Kg

16.500 Kg

Sugar

10 Kg

13 Kg

11.500 Kg

Oil

2.50 Kg

1 Kg

5 Kg

Vanilla powder

------

------

0.004 Kg

Salt

------

0.070 gm

0.040 Kg

Baking powder

0.150 Kg

0.700 Kg

1.100 Kg

Butter

2.50 Kg

0.015 ml

0.050 Kg

Eggs

120 IN NOs

Food colors

0.030 Kg

0.015 gm

------

Milk powder

0.400 Kg

0.100 gm

0.200 Kg

Condense milk

-----

0.015ML

Bisco

2.50 Kg

7 Kg

Potasium sorbate

0.050 Kg

------

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Sorbic acid

0.050 Kg

------

0.050 Kg

Essence

0.175 Kg

------

0.050 Kg

0.050 Kg

------

------

Corn flour

1.300 Kg
Muraba

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CHAPTER # 11
TYPES OF INGREDIENTS AND ROLE
Role of ingredients use in bakery section is following.
1) FLOUR:
Flour provides the structure in baked goods. Wheat flour contains proteins that interact with
each other when mixed with water, forming gluten. It is this elastic gluten framework which
stretches to contain the expanding leavening gases during rising. The protein content of flour
affects the strength of dough. The different wheat flour types contain varying amounts of the
gluten forming proteins. Hard wheat, mainly grown in mid western U.S. has high protein
content. Soft wheat, grown in southern U.S. has less protein. In yeast breads, a strong gluten
framework is desirable, but in cakes, quick breads and pastries, high protein flour makes a
tough product.
Flour is a major component. It provides the basic structure. Among all cereal flours, only
wheat flour has the ability to form strong, cohesive dough that retains gas and produces light
aerated baked products. Flour is made up of starch, protein, sugar and minerals. The protein
content decides what the end use of the flour will be. Flour is a powdery substance produced
by finely grinding grain through a process called milling. The classification of flour is based
on the amount of protein that each type contains.
Protein determines the gluten strength of the flour.
Gluten gives the dough its shape.
Types of Flour
Bread Flour
Has the highest amount of protein thus, has high gluten content, so it is used for breads.
Bread flour is creamy in color and is rather rough and granular. Bread flour is hard wheat
flour with about 12 percent protein. Bread flour is used for yeast raised bread because the
dough it produces has more gluten than dough made with other flours. Sufficient gluten
produces a light loaf with good volume. Slices hold together, rather than crumble.
Cake Flour
Sometime called soft flour as it is milled from soft white wheat. It is described as weak
because the products made from it are tender with delicate texture. Cake flour is soft wheat

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flour that is 7.5 percent protein. The lower gluten content causes products to have a tender,
more crumbly texture that is desirable in cake.
All Purpose Flour
Is made from a combination of bread and cake flour sources and has medium gluten strength.
It is suitable for almost any baking purposes. All purpose flour is blended during milling to
achieve a protein content of 10.5 percent. This medium protein flour can be used for all
baking purposes. If using all purpose flour in place of cake flour in a recipe, substitute 1 cup
minus 2 table spoons all purpose flour for 1 cup cake flour.
Self Rising Flour
Contain baking powder and salt.
Rye Flour
Has a distinctive flavor many people like and it contains no gluten. Rye flour is often used in
combination with wheat flour for bread. Light rye flour can be successfully substituted for 40
percent of wheat flour in a recipe without loss of volume. Medium and dark rye flours should
be limited to 30 percent and 20 percent, respectively, of the total flour amount.
Triticale Flour
It is a hybrid of wheat and rye. It has average protein content higher than that of wheat flour.
In yeast bread dough, triticale flour has better handling properties than rye flour because it
will form gluten, but does not handle as well as wheat dough. For good quality dough,
ferment yeast dough made with triticale flour for a shorter period than wheat flour dough.
Oat Flour
It has relatively high protein content, 17 percent, but does not form gluten. Oat flour can be
substituted for as much as 1/3 of wheat flour in bread.
Soy Flour
It contains 50 percent protein and is used primarily to boost the protein content of baked
goods. Soy flour cannot form gluten and does not contain starch. Its use in large amounts
affects the taste of baked goods and causes them to brown quickly. An acceptable substitution
is to take 2 tablespoons flour out of each cup of flour in a recipe and add 2 tablespoons soy
flour.

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2) SWEETENERS
Sucrose (Table Sugar)
It has many functions in food other than providing sweetness. In small amounts, added sugar
helps yeast begin producing gas for raising yeast dough. Sugar in large amounts slows yeast
fermentation; in very sweet dough the rising time is longer. Sugar tenderizes dough and batter
products and may help the baked product to brown. Moisture is retained better in sweetened
breads than in unsweetened breads. It is the sugar in cookie dough that causes spreading to
occur during baking. Reducing the amount of sugar by more than 1/3 can cause loss of
tenderness, moisture, browning, and sweetness. The volume may increase in a bread recipe
when sugar is reduced. Sugar is traditional and very important ingredient that increases the
nutritional value of product as well as enhances the flavor of the product. Normally sucrose is
used instead of any other sugar due to,
Its excellent solubility
Sweetness
Cheep cost
Availability
Fructose
In crystal form is nearly twice as sweet as sucrose and is more expensive. Fructose attracts
more water than sugar, therefore, fructose sweetened products tend to be moist. Baked
products made with fructose will be darker than if they were made with sucrose.
Honey
It is sweeter than sugar because it contains fructose. Honey has a distinctive flavor. When
using honey in place of sugar, use 3/4 cup plus 1 tablespoon honey in place of 1 cup sugar
and reduce the other liquid ingredients by 2 tablespoons. Even when liquid is reduced, a
product that contains honey will be moist because the fructose absorbs moisture from the
atmosphere. Too much honey may cause the product to become too brown.
Molasses
It is imparts a dark color and strong flavor to baked foods. It is not as sweet as sugar. When
using molasses in place of sugar, use 1-1/3 cups molasses for 1 cup sugar and reduce the
amount of liquid in the recipe by 5 tablespoons. Because molasses is more acidic than sugar,
it may be necessary to add 1/2 teaspoon baking soda for each cup of molasses used in

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substitution for sugar. Replace no more than 1/2 the sugar called for in the recipe with
molasses.
Artificial Sweeteners
The following artificial sweeteners are available for home use. They provide sweetness to
homemade foods but lack the browning, tenderizing, and moisture retaining properties
provided by table sugar. Specially formulated recipes are often needed to make a product
with acceptable texture and appearance when using artificial sweeteners. Because the
different low-calorie sweeteners vary in sweetness and bulk, package directions must be
followed for the amount to use in place of sugar.
Saccharin
It is a heat stable non caloric sweetener that, in its pure form is 200-300 times as sweet as
sucrose. Bulking agents are added to saccharin products to aid in measuring. Saccharin has a
bitter aftertaste.
Acesulfame K
Acesulfame K (Sweet One

SM

) is a very low calorie sweetener that is200 times as sweet as

sucrose. It is heat stable so it can be used in baked goods. For improved texture in baked
products, use acesulfame K in combination with granulated sugar. Acesulfame K reportedly
has no unpleasant aftertaste.
Aspartame
Aspartame commonly known as Nutrasweet

SM

, is not heat stable so it isnot an appropriate

sweetener for baked goods.

Role of sweetness
It provides sweetness.
It acts as stabilizer and plasticizer.
A balance mixture of sugar and starch improves better absorption of heat.
It also increase tenderness, crust color, volume, moisture retention while maintaining
proper balance between liquid and solids responsible for product contour.

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3) Fats & Oil:

Fats are the third major component used, but considerably more expensive than flour or
sugar. Besides being used in the dough, fats are used as surface sprays in cream filling and
coating and as release agent.
Fat, in the form of solid shortening, margarine, or butter; or in the liquid form of oil
contributes tenderness, moistness, and a smooth mouth feel to baked goods. Fats enhance the
flavors of other ingredients as well as contributing its own flavor, as in the case of butter. In
baked goods such as muffins, reducing the amount of fat in a recipe results in a tougher
product because gluten develops more freely. Another tenderizing agent such as sugar can be
added or increased to tenderize in place of the fat. A small amount of fat in yeast dough helps
the gluten to stretch, yielding a loaf with greater volume.
Oil is used in some muffin, bread and cake recipes. Oil pastry is mealy rather than flaky. To
substitute oil for butter or margarine, use 7/8 cup oil for 1 cup butter or margarine. If oil is
used in place of a solid fat for some cake recipes, the textures will behavior unless the sugar
and egg are increased.
Function of Shortening:
Shortening has the ability to stabilize air cells in emulsions and achieving desired
textural attributes in these products.
It improves the visual appearance of biscuits and other products and plays a part in
baked flavor.
They impart desirable eating qualities.
They interact with starch components to alter hydration and swelling properties.
The action of fat in dough to insulate the gluten forming proteins from the water and
consequently a less tough dough results.
3) EGGS:
Eggs serve many functions in baked goods. They add flavor and color, contribute to structure,
incorporate air when beaten, provide liquid, fat, and protein, and emulsify fat with liquid
ingredients. Reducing or omitting egg yolks can result in less tenderness. Reducing or
omitting egg whites can result in less volume. Cakes made without the emulsifying action
from the egg yolk may not have a uniform flavor and texture. If a low fat, low cholesterol

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baked product is desired, use 2 egg whites for 1 whole egg; the white has very little fat or
cholesterol. When a recipe calls for an egg, the best size to use is a 2 oz. Grade A large egg.
Whole egg, egg whites, or egg yolks may be used.
Eggs contribute color. Structure.
Add nutritional value and also flavor.
They also affect texture as a result of their emulsifying, tenderizing, leavening and
binding actions.

5) LEAVENING AGENTS:
Baking Soda
It produces gas for leavening when combined with an acidic ingredient such as vinegar,
lemon juice, or molasses. The volume of quick breads, cookies, cakes, and some candies
depends largely on the amount of baking soda added to the batter or dough. Reducing the
amount of baking soda without replacing it with another leavening agent will reduce the
volume and lightness of the finished product.
Baking powder
It contains baking soda and the right amount of acid to react with it. Batters made with double
acting baking powder rise twice; once when dry and moist ingredients are mixed together and
again when the product is baked.
Yeast
It is a living microorganism until it is destroyed by heat. As yeast grows and multiplies it
gives off carbon dioxide which causes the dough to rise. Its action is affected by the addition
or deletion of other ingredients such as salt and sugar. Using less yeast than specified in a
recipe causes the dough to take longer to reach the desired volume in the rising stages.
Carbon dioxide, water and/or ethanol vapor, ammonia and air are used as leavening agent in
biscuit manufacturing. The most common agents that produce carbon dioxide are Sodium and
Ammonium bicarbonates.

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Properties of Sodium bicarbonate

It has relatively low cost.
It is non-toxic.
It is easy to handle.
It gives a relatively tasteless and product.
The commercial product is of high purity.

6) GLUCOSE:
Different functions are:
It is used to prevent sugar crystals formation.
Give moderate sweetness and also participation in the formation of characteristics
brown color.

7) MILK POWDER:
It contributes water and valuable nutrients to baked goods. It helps browning to occur and
adds flavor. When making yeast dough, milk should be scalded and cooled before adding to
other ingredients. This is done to improve the quality of the dough and the volume of the
bread.
Milk powder combines with the gluten in wheat to produce soft and moist product after
baking.
Milk protein also combines with reducing sugar to give color and a browning effect.

8) SALT:
Sodium chloride is used in biscuits as flavor enhancer. It has a slight effect on the consistency
of hard dough due to ion shielding effect.
Salt also controls the fermentation and aids in suppressing undesirable bacteria by osmosis
process.

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9) CORN FLOUR:
It does not allow to gluten develop or less the gluten. Corn meal is coarsely ground dried
corn. Corn flour is more finely ground corn. Both corn flour and corn meal contain 7-8
percent protein on a dry basis. Neither corn meal nor corn flour will form gluten. A grainy
texture in cornbread can be avoided by mixing the cornmeal with the liquid from the recipe,
bringing to a boil, and cooling before mixing with the other ingredients.

10) FLAVORS:
Though used in relatively small amounts, but has quite important effects on the sensory and
physical qualities of bakery products.

11) WATER:
Water is often thought of as a processing aid or catalyst, rather than as an ingredient. It is
incorporated at the dough stage but driven off during baking.
Functions of Water:
Hydration of flour proteins and starch.
Dissolving sugars, salts and various leavening chemicals.
It also aids in ingredient distribution.
It also helps to control dough temperature

12) POTASSIUM SORBATE:

It acts as mould inhibiter in bakery products.

13) SORBIC ACID:

It is used as preservative. It lowers down the pH of products and inhibits the growth of microorganisms.

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CHAPTER # 12
GENERAL FLOW SHEET DIAGRAM FOR BAKERY PRODUCTS
Weighing

Grinding Of Sugar

Mixing

Moulding

Baking

Cooling

Packing

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CHAPTER # 13
PROCESSING STEPS
First of all, flour and all other raw materials of required grade are collected in the storeroom.
1) Weighing:
To make the balanced recipe, weighing of ingredients has much more importance.
2) Grinding of Sugar:
To reduce the granular structure of sugar and to get the icing sugar, the grinding of sugar is
done.
3) Mixing:
First, all the ingredients except the flour is mixed in the mixer (detachable mixer) to form the
emulsions for about 5-7 mints. Then flour is added and mixed it with the emulsion.
Mixing is done for the following reasons
To produce a uniform mixture
To incorporate air into it
Often requires creaming (mixing the sugar and shortening).
In that case, we dont want to develop the gluten.
4) Moulding:
The dough is then forced into molds. In MERIT BREAD moulding of bakery products is
manually done.
5) Baking:
The baking is done in direct-fired oven. As the products enters in oven, moisture starts to
remove from them without any apparent change. Here the bakery products may alter its
shape, size and structure. A careful balance must be maintained between heating the product
and allowing the correct structure to form. In this stage the heat transfer rate is high, the
upper surface begins to form a crust, sugar in the mix is caramelized and the final outer color
begins to develop. Additional heating at this stage will cause the rise in surface temperature.
During the final stage of baking; the outer and inner color of products is finally developed.

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6) Cooling:
Products, come from the oven, are too hot to be packed. So they are transferred to a cooling
band, which is mostly an open conveyor running between the end of the oven and the
wrapping machine.
There are several reasons behind this process,
The products may not be firm enough to withstand the packaging process while warm.
The packaging material may shrink around a warm product.
Sugar-rich biscuits (soft as they leave the oven) set rigid when cool.
There is also an appreciable loss of moisture.
7) Packaging:
It is highly desirable to pack all products in container/materials having low rates of moisture
vapor transfer if extended shelf lives are to be achieved.

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CHAPTER # 14
SANITATION AND CLEANING:
In MERIT Bread, a much consideration is given to proper sanitation and cleaning conditions
in order to ensure the good quality products.
First of all, consideration is given to control the contamination become of raw material. No
extraneous material should attach with raw material. All the containers and bags of
ingredients should be kept cover and clean the containers when they are empty and place
them out of the production area so that they will not become the houseflies and rodents.
Mixing bowls should be washed before and after mixing in order to avoid the bacterial
contamination.
Water on the floor of mixing room should be wiped regularly and clean tools should be used
for equipment. Lubricating oils should be kept away far from the equipment.
The Assistant Production Manager and Shift Incharge regularly inspect the workers for their
personnel hygienic conditions. They are said not to go in the production hall when they are ill
or when they are sneezing. Wash the hands thoroughly before mixing and molding.

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CHAPTER # 15
RESULTS
Baking Temperature and Time of Some Products Are Following
PRODUCT NAME

LOADING

BAKING

TIME

TEMPERATURE

TEMPERATURE

Fruit cake

250 C

200 C

35-40 MINTS

Queen cake

280 C

220 C

15 MINTS

Baker khani

250 C

180 C

45 MINTS

Muffins

200 C

200 C

25-30 MINTS

Mini cake

250 C

200 C

30 MINTS

Temperature and Time Chart Result

NAME OF PRODUCT

TEMPERATURE

TIME

Large bread

200 c

35 mints

Sand-witch bread

200 c

50 mints

Standard (p) bread

200 c

30 mints

Milky(P) bread

200 c

30 mints

Standard(OT)

200 c

30 mints

Milky mini

200 c

20 mints

Fruit bun

190 c

20 mints

Sheer mall

200 c

20 mints

Burger bun

230

12 mints

Goal rusk(L)

180 c

20 mints

Burger roll

230 c

12 mints

Milky (OT)

200 c

30 mints

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CHAPTER # 16
DISCUSSION
The survey showed that the microbiological status of 86.8% of bakery products sampled were
Satisfactory according to the Guidelines for the Microbiological Examination of Ready-to-eat
Foods. In addition, 9.6% of samples were within the marginal range giving a total of 96.4%
of samples with microbiologically acceptable limits. A total of 6 (2.4%) samples were of
unsatisfactory microbiological quality and 3 (1.2%) samples were potentially hazardous due
to high levels of the spore-forming organism Bacillus cereus, two were custard-filled
products and one was a cream-filled product.
The results of the microbiological quality of bakery products were comparable to those
reported in a similar survey which found 97.8% of samples had acceptable microbiological
limits. Only one sample, a sponge cake product, had a potentially hazardous level of Bacillus
cereus. In contrast, a survey reported 25% of custard samples and 21% of cream samples
were unsatisfactory based on their total bacteria count. E. coli was detected in 1.6% of cream
filled products at levels greater than 100cfu/g. These results are consistent which reported
that 1% of cream products had similar levels of E. coli (DoHSA, 2007).
The questionnaire conducted by Food Act Officers showed that, in general, most bakeries
throughout the country used good food safety practice. Almost all had appropriate personal
hygiene facilities (e.g. wash-hand basins with soap available). Over 80% of bakeries had
effective pest-control measures in place and the majority of bakeries had used appropriate
storage facilities for cream and custard-filled bakery products. Adequate cleaning facilities
and staff training programmes were observed in the majority of bakeries. Unacceptable levels
of bacteria are likely to occur if appropriate food handling and hygiene practices are not in
place. The questionnaire identified several areas of concern, including the following;
Average temperature of display cabinets was 8C.
4% of bakeries stored cream-filled products for the next day and 28% bakeries stored
custard filled products for the next day.
63% of bakeries didnt use disposable piping bags and only 70% of bakeries used
separate.
Piping bags for each product.

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CHAPTER # 17
CONCLUSION
The purpose of bread making process is to present cereal flours to the consumer in an
attractive palatable and digestibale form. Fermented baked products such as bread is leavened
by addition of baking yeast produced from saccharomyces cerevisiae. From the analysis
done, it was noticed that the crust colour, the texture, flavour taste and overall acceptability of
both solate and the control at 300C temperature of proofing are relatively the same. This
shows that a good source of bakers yeast and can be efficiently used in bread production. It
is therefore recommended that bread should be produced at the options proofing temperature
of 300c. Because the isolated yeast and the control (commercial bakers yeast) at temperature
of 300 C compared favourable in all the attributes tested.
The quality control Department of Merit bread seems to be catering to the needs and wants of
the customer & employees very effectively and efficiently. But issues like decentralizeddecision making is still lacking. The control is mostly in the upper levels. But the good aspect
is that they treat their lower levels in a nice manner. Also the quality control Department is
still going under its initial changes and need time to get settled in the organization. As the
technological advancement, is getting more intense with the passage of time, the quality
control of Merit bread is trying its best to settle the employees within the organization
according to this advancement. The practices they are performing in the organization and its
rapid growth shows its effectiveness and the accepting behavior of their employees shows
they want this new change in the environment and want to grow with the organization.
Overall quality control department of Merit bread is performing well; it is also providing its
employees opportunities for their career development and for their better future. The Merit
bread care the employs and safety meeting effect the employs, every week the safety meeting
to give the motivate the employs and control the many incidents.

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CHAPTER # 18
REFERENCES

American Home Economics Association. Handbook of Food Preparation.8th edition.

2010.

Aussenac, T., Carceller, J. L., & Kleiber, D. (2001). Changes in SDS solubility of
glutenin polymers during dough mixing and resting.Cereal Chemistry, 78,3945.

Biscuit Cookie and Cracker Manufacturing Manual 1 Ingredients, Woodhead

Publishing, Cambridge, 1998.

Biscuit Cookie and Cracker Manufacturing Manual 2 Biscuit Doughs, Woodhead

Publishing, Cambridge, 1998.

Biscuit Cookie and Cracker Manufacturing Manual 3 Biscuit Dough Piece Forming,
Woodhead Publishing, Cambridge, 1998.

Cauvain, S. (2003).Breadmaking: Improving Quality. Cambridge, UK: Woodhead.

Cereal Processing Technology, ed. G. Owens, Woodhead Publishing, Cambridge,

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Charley, H. Food Science.2nd edition. New York: Macmillan Publishing Company.

2005.

Manley, Technology of Biscuits, Crackers and Cookies, (3rd Edition) Woodhead

Publishing, Cambridge, 2000.

Dobler, M. Gluten Intolerance. Revised edition. Chicago: American Dietetic

Association. 2007.

Encyclopedia of Food Science and Technology, ed. F. J. Francis, volumes 14, John
Wiley & Son, 1999.

McGee, H. On Food And Cooking: The Science And Lore of the Kitchen. New
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P. C. Morris and J. H. Bryce, Cereal Biotechnology, Woodhead Publishing,

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Penfield, M., and Campbell, A. Experimental Food Science. 3rd edition. San Diego:
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Proteins in Food Processing, ed. R. Y. Yada, Woodhead Publishing, Cambridge,

2004.

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R. Guy, Extrusion Cooking Technologies and Applications, Woodhead Publishing,

Cambridge, 2001.

R. S. Igoe and Y. H. Hui, Dictionary of Food Ingredients (4th Edition), SpringerVerlag.

Rombauer, I., and Becker, M.R. Joy of Cooking.13th edition. New York: BobbsMerrill Company, Inc. 1997.

Rosell, C. M. (2007a). Cereals and health worldwide: Adapting cereals to the social
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S. Cauvain and L. Young, Baking Problems Solved, Woodhead Publishing,

Cambridge, 2001.

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University of Nebraska Cooperative Extension educational programs abide with the

non discrimination policies of the University of Nebraska-Lincoln and the
United States Department of Agriculture.

W.P. Edwards, (2007). The Science of Bakery Products, The Royal Society of
Chemistry.

Resource persons:

Mr. Sajid Hafeez (Production Manager)

Mr. M. Faraaz (Quality control officer)

Mr. M. Bilal (Quality control officer)

Mr. M. Yousaf (shift Incharge)

Mr. M. Altaf (shift Incharge)

Mr. M. Amanullah (shift Incharge)

Website:

http://meritbread.com.pk/
http://redstaryeast.com/yeast-baking-lessons/common-baking-ingredients/
http://www.recipetips.com/kitchen-tips/t--657/ingredient-functions.asp
http://www.culinate.com/articles/features/baking_chemistry
https://www.google.com.pk/urlsa=t&rct=j&q=&esrc=s&source=web&cd=4&ved
http://www.slideshare.net/ReinaLovesPinkForever0703/basic-bakingingredients
http://www.bakeinfo.co.nz/School-Zone/Baking-Basics/Ingredients-and-their-uses
https://www.google.com.pk/searchq=Role+of+ingredients+use+in+bakery&oq=Role

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http://digitalcommons.unl.edu/cgi/viewcontent.cgi?article=1412&context=extension

http://redstaryeast.com/yeast-baking-lessons/common-baking-ingredients/

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