Project Bread Final

EXECUTIVE SUMMARY
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EXECUTIVE SUMMARY
OBJECTIVE:-
To make a study of Bread Manufacturing & Processing of STAR FOOD PRODUCTS
UDAIPUR.
So, the objective of the study is to know about the manufacturing and processing of a
bread company and the process of supplying goods and products to retail stores then the
end users. The channel through which the whole process is completed and the various
intermediaries who plays important role to maintain the proper supply of goods and
products.
RESEARCH METHODOLOGY:-
The method of data collection used was survey method and the tool used for
survey was questionnaire. The sample population consists of the executives, purchase
manager, employees, salesmen, workers and outlets who keeps all the documents and
general information about manufacturing, processing, supply, distribution and warehousing.
Sampling Element : STAR FOOD PRODUCTS UDAIPUR.
Sampling Units : Executives, Purchase Manager, Employees,
Salesmen, Workers, Retail Outlets.
Extent : UDAIPUR(RAJ.) and the local area of it.
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INTRODUCTION
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"INTRODUCTION"
INTRODUCTION TO THE SUBJECT:

Bread Manufacturing & Processing is the combination of art and science that
goes into improving the way your company finds the raw components it needs to make a
product or service and deliver it to customers. The following are the five basic components
of Manufacturing & Processing:
PLAN
SOURCE
MAKE
DELIVER
RETURN
CLASSIFICATION OF LOGISTIC APPLICATION:
There are basically 6 applications of logistic management:
• DECISION-WISE,
• INBOUND & OUTBOUND LOGISTICS,
• PRIVATE & PUBLIC SECTOR,
• SINGLE & MULTIPLE PLANTS,
• NATURE OF THE PRODUCT,
• MADE TO STOCK & MADE TO ORDER.
• TOTAL LOGISTIC COST:
The important elements of logistic cost are:

• PRODUCT INVENTORY AT SOURCE,
• PRODUCT INVENTORY AT WAREHOUSE & DEALERS,
• TRANSIT LOSSES/INSURANCE,
• STORAGE LOSSES/INSURANCE,
• HANDLING & WAREHOUSE OPERATION,
• PACKAGING,
• TRANSPORTATION,
• CUSTOMERS SHOPPING.
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RESEARCH OBJECTIVES
OBJECTIVES OF THE RESEARCH:

There are various objectives of the research, which are as follows:
• CONDUCTING A STUDY OF MANUFACTURING & PROCESSING OF A BREAD

COMPANY.
• IDENTIFYING KEYS FOR SUCCESS IN FOOD BUSINESS.
• KNOWING THE PROBLEMS, CHALLENGES IN MANUFACTURING &

PROCESSING.
• KNOWING THE PROBLEMS, CHALLENGES IN TRANSPORTATION.
• EXPECTATIONS OF TRANSPORTERS (SALESMEN) FROM THE COMPANY.
• EXPECTATIONS OF EMPLOYEES FROM THE COMPANY.
• EXPECTATIONS OF CUSTOMERS FROM THE COMPANY.
• TO FIND OUT THE COMPANY'S EFFORTS FOR A PROPER & SYSTEMATIC

DISTRIBUTION OF GOODS.
• TO CREATE A VALUE BASED FLOW OF GOODS & INFORMATION.
• TO INCREASE MARKET COVERAGE THROUGH BETTER SERVICES.
• IDENTIFY SIGNIFICANCE OF BRAND BUILDING EFFORTS USED BY STAR

FOOD PRODUCTS UDAIPUR.
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COMPANY PROFILE OF
STAR FOOD PRODUCTS,
UDAIPUR
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BEGINNING
Seventy years ago, in the year 1940, Late Mr.Akbar Ali, started the production of Baked
goods. With his decent efforts and hardships, the demand for the product made a rapid
growth.
In the year 1980, in order to elevate the business started by Late Mr. Akbar Ali,
Mr.Ismail Ali (S/O Late Mr.Akbar Ali)started the company STAR FOOD PRODUCTS
UDAIPUR and began the production of Star Milk Bread. With God's grace and
active participation of the people of Udaipur, the product made its signified place in the
market.
Its been 30 years since then. The firm has achieved a milestone. In all these years,
Mr.Ismail Ali, at STAR FOOD PRODUCTS UDAIPUR, have always tried to be perfect in
quality matters of their food products. But in case, if the people are not fully satisfied with
the products, the company will always be ready to welcome all their grievances. The
company promises to the people of Udaipur that they will try their level best to enhance and
maintain the quality of food products.
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COMPETITIVE STRENGHTS:-
It is believed that its primary competitive strenghts are:
* Understanding of the 'Manufacturing & Processing' segment,
* Supply Chain Management,
* Logistics & Distribution network,
* Geographical spread,
* Identifying new locations,
* Private labels,
* Information Technology Systems, and
* Experienced & Skilled management team.
ITS STRATEGY:-
It intends to pursue the following strategies in order to consolidate its position as
an operator in the 'Manufacturing & Processing segment in Udaipur (Raj.):
* Increasing its penetration in the city by leveraging its supply chain,
* Distribution & Logistic network,
* Emphasis on backward integration,
* Expansion of quality food products,
* Procurement from low-cost production centres,
* Increasing customer satisfaction, and
* Its base of loyal customers.
SALES PROMOTION & CUSTOMER SERVICE:-

Its category management system is used to plan promotional schemes. It launches
promotional schemes weekly. Apart from general sales promotion, the category manager
formulates promotional plans for 'Slow Movers'. In addition, to promote sales, it focuses on
layout of the stores & positioning, presentation & display of merchandise, in order to
appeal to the customers.
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HUMAN RESOURCE:-
Its Human Resource policies are aimed towards creating a skilled & motivated
workforce. It has 50 employees both employed in its corporate office as well as in its
manufacturing unit & other facilities. Description is as below:
*According to age –
AGE NO. OF EMPLOYEES

18-24 10
25-35 25
35 & above 15
TOTAL 50
QUALITY CONTROL:-
Its dedicated professional quality control team ensures the quality of its products.
Its quality checks start the basic raw materials and end with its doing a full inspection on
the finished goods & products. It believes that Quality Control is the key to success. Basic
goal is to give the customer with the best quality and value for his money.
INFORMATION TECHNOLOGY SYSTEM:-

It focused on acquisition & implementation of advanced information technology
systems, processes and business applications in order to handle all stores operations
including inventory management & billing. Its office processes are also computerized which
support procurement, supply chain logistics, distribution centres management & inventory
control.
Based on its existing I.T. system, they are able to generate daily reports covering the
various aspects of its business such as Division & Area wise sales per store, inventory
movement & position at stores & distribution centres & generation of purchase and delivery
orders.
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COMPETITION:-
They face competition from other manufacturers of similar products & services.
These include manufacturers & processors in the organized and
unorganized sectors. They focus on offering their customers a vast variety of products
and services catering to their diverse requirements & needs.
INCENTIVE SCHEMES:-
Latest incentive scheme of STAR FOOD PRODUCTS UDAIPUR, is as follows:
90% to 99.99% Target achieved : 5% of Salary.
150% and Above : 35% - 50% of Salary.
Products Range
Sr. No. Products

01 Star Bread
02 Star Milk Bread
03 Star Atta Bread
04 Star Toast and Biscuits
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BOARD OF DIRECTORS OF STAR FOOD PRODUCTS
UDAIPUR
Mr. Ismail Ali

Founder Chairman & Managing Director
Star Food Products
Udaipur (Raj.)
Mr. Yahya Ali

Executive Director
Star Food Products
Udaipur (Raj.)
Mr. Sabir Ali

Executive Director
Star Food Products
Udaipur (Raj.)
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RESEARCH
METHODOLOGY
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RESEARCH METHODOLOGY
A Systematic approach is essential in any project work each and every step must be
so planned that it leads to the next step. It is usually difficult to go back and correct the
mistakes of the previous steps. Sometimes it is impossible and if possible, it involves loss of
time and energy.
The project has been divided into number of steps. Planning and organization are
part of this systematic approach with a lot of emphasis given to their inter dependence of
the various steps. The plan of this project report is as under:
[1] TITLE OF THE PROJECT.
[2] DURATION OF THE PROJECT.
[3] METHODOLOGY.
[4] OBJECTIVES.
[5] TYPE OF RESEARCH (HYPOTHESES.)
[6] RESEARCH PLAN.
[7] SAMPLE DESIGN (SAMPLE SIZE AND METHOD OF SELECTING SAMPLE.)
[8] SCOPE OF THE STUDY.
[9] LIMITATIONS OF THE STUDY.
[1] TITLE OF THE PROJECT

Title : Bread Manufacturing and processing
[2] DURATION OF THE PROJECT

Date: 2nd August 2010 to 23th August 2010
Duration: 22 days
[3]. METHODOLOGY:-
In order to achieve the objectives different methods were adopted
regarding Bread Manufacturing & Processing by discussion with Companies Management
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and deliberations with Professionals Academicians etc. these exercises helped a lot in
collecting relevant information in time for the purpose of the present study and also to
interpret and analyze the result as also getting important clarifications
about various aspects of the study.
[4]. OBJECTIVES:-
To understand the Manufacturing & Processing of a food product i.e.

Bread followed by STAR FOOD PRODUCTS UDAIPUR, and to analyze them is the main
objective. Other objective is to find out satisfaction and dissatisfaction of employee.
[5]. HYPOTHESES:-
It could be assumed that Manufacturing & Processing of a food

product i.e. Bread followed in STAR FOOD PRODUCTS UDAIPUR, is based on the theory
given by the various Chefs & Culinary Institutes around the world. The objective is to be
tested and verified to prove any hypotheses.
[6]. RESEARCH PLAN:-
It is based on following tools such as:
[i]. SOURCES OF DATA COLLECTION:- It is of two types:
(A). PRIMARY SOURCE.
(B). SECONDARY SOURCE.
(A). PRIMARY SOURCE:- It is based on two types:
[1]. QUESTIONNAIRE:-
It is used to collect information about selected employees. There are two types of
questionnaire, Open ended (i.e. inviting free response) and Close ended (Le. Yes/No). The
questions, which are prepared, is to be easy and clear wording for the understanding of the
executives.
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[2]. OBSERVATION METHOD:-
It is another tool that has been used in soliciting primary data about the subject of
study.
(B). SECONDARY SOURCE:- It includes:
[i]. Annual report of STAR FOOD PRODUCTS UDAIPUR.
[ii]. Quarterly reports and financial statements of the organization.
[iii]. A co-operate profile of STAR FOOD PRODUCTS UDAIPUR- The Past, the
Present and the Future.
[iv]. Text Books.
[v]. Study materials- in form of pamphlets and manuals.
[7]. SAMPLE DESIGN (Sample size & methods of selecting sample):-
The Plant & Corporate Office of STAR FOOD PRODUCTS UDAIPUR, have been
considered for this study.
(A). SAMPLING UNIT:- Executives working at corporate office are surveyed.
(B). SAMPLING SIZE:- A sample of 10 salesmen 40 employees was selected.
(C). SAMPLING PROCEDURE:- Non-probability sampling and that too
convenience samplings have been considered for the study.
[8]. SCOPE OF THE STUDY:-
The scope of the study is confined to the STAR FOOD

PRODUCTS UDAIPUR. Its Plant & corporate office is situated at Udaipur City. It is dealing
in manufacturing and processing of various types of food products like Milk Bread, Atta
Bread and different varieties of Toasts & Biscuits.
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[9]. LIMITATIONS OF THE STUDY:-
In the study both primary and secondary source of

information have been used. The researcher being a new person in the field, of research
has encountered a number of limitations in the completion of this report.
[1]. TIME PRESSURE:-
Not only the researcher had to attend to the dissertation work,

but also he had to give equal consideration to other papers of the course. So, the time
factor was a very big constraints as the exercise was the time consuming and tiresome.
[2]. INSUFFICIENT INTERACTION AND COOPERATION FROM THE RESPONDENTS:-
From the viewpoint of the respondents, research work was out

of their concern. On many occasion the researcher had to interrupt their routine work.
Under such circumstances he had to comply incase he was requested to come another
time or to wait until he was attend to. In this regard patience was his big asset.
[3]. MISUNDERSTANDING AND MISINTERPRETATION OF QUESTIONNAIRES:-
Some respondents could not provide the required information

in the questionnaires as they left some questions unattended or gave information that was
not at all relevant to particular question.
This can be attributed to misunderstanding of the questions or

due to the sensitivity they attached to some of the questions.
[4]. LACK OF SCIENTIFIC TRAINING IN THE METHODOLOGY OF RESEARCH
The researcher jacked scientific training in the methodology of

research but with proper guidance and supervision from the esteemed supervisor be as in
position to overcome this problem. Despite this constraints, the findings presented here are
well polished and could be said up-to-date and suffice for application.
After having described the methodology employed in this study,

an attempt is made to discuss the profile of the sample unit.
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FACTS AND FINDINGS &
LITERATURE REVIEW
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BREAD
Bread is a staple food prepared by cooking a dough of flour and water and frequently
additional ingredients. Doughs are usually baked, but in some cuisines breads are
steamed, fried, or baked on an unoiled skillet. It may be leavened or unleavened. Salt, fat
and leavening agents such as yeast and baking soda are common ingredients, though
bread may contain other ingredients, such as milk, egg, sugar, spice, fruit (such as raisins),
vegetables (such as onion), nuts (such as walnuts) or seeds (such as poppy seeds). Bread
is one of the oldest prepared foods, dating back to the Neolithic era, and is referred to
colloquially as the "Staff of life". The development of leavened bread can probably also be
traced to prehistoric times.
Fresh bread is prized for its taste, aroma, quality, appearance and texture. Retaining its
freshness is important to keep it appetizing. Bread that has stiffened or dried past its prime
is said to be stale. Modern bread is sometimes wrapped in paper or plastic film, or stored in
a container such as a breadbox to reduce drying. Bread that is kept in warm, moist
environments is prone to the growth of mold. Bread kept at low temperatures, in a
refrigerator for example, will develop mold growth more slowly than bread kept at room
temperature, but will turn stale quickly due to retrogradation.
The soft, inner part of bread is known to bakers and other culinary professionals as the
crumb, which is not to be confused with small bits of bread that often fall off, called crumbs.
The outer hard portion of bread is called the crust.
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ETYMOLOGY
The word itself, Old English bread, is common in various forms to many Germanic
languages; such as Frisian brea, Dutch brood, German Brot, Swedish bröd, Norwegian and
Danish brød; it has been claimed to be derived from the root of brew. However, it may be
connected with the root of break, for its early uses are confined to broken pieces, or bits of
bread, the Latin crustum, and it was not until the 12th century that it took the place—as the
generic name for bread—of hlaf ([hlaifs] in Gothic: modern English loaf), which appears to
be the oldest Teutonic name; Old High German hleib and modern German Laib, or Finnish
leipä, Estonian leib, and Russian(khleb) are similar (all are derived from the Indo-European
word for "loaf").
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HISTORY
History of Bread
Grown in Mesopotamia and Egypt, wheat was likely first merely chewed. Later it was
discovered that it could be pulverized and made into a paste. Set over a fire, the paste
hardened into a flat bread that kept for several days. It did not take much of a leap to
discover leavened (raised) bread when yeast was accidentally introduced to the paste.
Instead of waiting for fortuitous circumstances to leaven their bread, people found that they
could save a piece of dough from a batch of bread to put into the next day's dough. This
was the origin of sour-dough, a process still used today.
In Egypt, around 1000 BC, inquiring minds isolated yeast and were able to introduce the
culture directly to their breads. Also a new strain of wheat was developed that allowed for
refined white bread. This was the first truly modern bread. Up to thirty varieties of bread
may have been popular in ancient Egypt.
It was also during this time that bread beer was developed. The bread was soaked in water
and sweetened and the foamy liquor run off. Beer was as popular in ancient Egypt as it is in
America today.
The Greeks picked up the technology for making bread from the Egyptians; from Greece
the practice spread over the rest of Europe. Bread and wheat were especially important in
Rome where it was thought more vital than meat. Soldiers felt slighted if they were not
given their allotment. The Roman welfare state was based on the distribution of grain to
people living in Rome. Later the government even baked the bread.
Through much of history, a person's social station could be discerned by the color of bread
they consumed. The darker the bread, the lower the social station. This was because whiter
flours were more expensive and harder for millers to adulterate with other products. Today,
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we have seen a reversal of this trend when darker breads are more expensive and highly
prized for their taste as well as their nutritional value.
In the middle ages bread was commonly baked in the ovens of the lord of the manor for a
price. It was one of the few foods that sustained the poor through the dark age.
Bread continued to be important through history as bread riots during the French Revolution
attest. The famous quotation attributed to Marie Antoinette that if the poor could not get
bread for their table then "let them eat cake," became a famous illustration of how royalty
had become ignorant of the plight of the lower classes. Actually, Marie Antoinette never
said this and was merely being slandered by her detractors.
Still thought of as the "staff of life", for centuries bread has been used in religious
ceremonies. Even the lord's prayer requests of God to "Give us this day our daily bread" -
meaning not merely loaves, but moral sustenance.
Today, even with the competition of a growing variety of foods, bread remains important to
our diet and our psyche. It has a prominent place in at the local market, in our cupboards,
and even in our language. The word "bread" is commonly used as a slang term for money.
It connotes importance as when we say that some aspect of our work is "our bread and
butter". In many households bread is still served with every meal.
Bread has a long history for a reason. It is a healthy and nutritious food that fills the
stomach as well as the soul.
Bread is one of the oldest prepared foods, dating back to the Neolithic era. The first bread
produced was probably a cooked version of a grain-paste, made from ground cereal grains
and water, and may have been developed by accidental cooking or deliberate
experimentation with water and grain flour. Yeast spores are ubiquitous, including the
surface of cereal grains, so any dough left to rest will become naturally leavened.There
were multiple sources of leavening available for early bread. Airborne yeasts could be
harnessed by leaving uncooked dough exposed to air for some time before cooking. Pliny
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the Elder reported that the Gauls and Iberians used the foam skimmed from beer to
produce "a lighter kind of bread than other peoples." Parts of the ancient world that drank
wine instead of beer used a paste composed of grape juice and flour that was allowed to
begin fermenting, or wheat bran steeped in wine, as a source for yeast. The most common
source of leavening, however, was to retain a piece of dough from the previous day to use
as a form of sourdough starter.
A major advance happened in 1961 with the development of the Chorleywood Bread
Process, which used the intense mechanical working of dough to dramatically reduce the
fermentation period and the time taken to produce a loaf. The process, whose high-energy
mixing allows for the use of inferior grain, is now widely used around the world in large
factories.
Recently, domestic breadmakers that automate the process of making bread have become
popular in the home.
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CULTURAL AND POLITICAL IMPORTANCE OF BREAD
As a foodstuff of great historical and contemporary importance, in many cultures in the
West and Near and Middle East bread has a significance beyond mere nutrition. The Lord's
Prayer, for example, contains the line "Give us this day our daily bread"; here, "bread" is
commonly understood to mean necessities in general. Bread is also significant in
Christianity as one of the elements (alongside wine) of the Eucharist; see sacramental
bread. The word companion comes from Latin com- "with" panis "bread". The Roman poet
Juvenal satirised superficial politicians and the public as caring only for "panem et
circenses" (bread and circuses). In Israel the most usual phrase in work related
demonstrations is "lekhem, avoda" [bread, work], and during the 1950s, the beatnik
community used the term bread as a euphemism for money. In Cockney Rhyming Slang,
bread means money and is derived from the phrase bread and honey. The word bread is
now commonly used around the world in English speaking countries as a synonym for
money (as also is the case with the word dough.)
The cultural importance of "bread" goes beyond slang, however, to serve as a metaphor for
basic necessities and living conditions in general. A "bread-winner" is a household's main
economic contributor and has little to do with actual bread-provision, for example. This also
goes along with the phrase "putting bread on the table". A remarkable or revolutionary
innovation is often referred to as "the greatest thing since sliced bread". In the USSR in
1917, Lenin and his fellow Bolsheviks promised "Peace, Land, and Bread." The term
"breadbasket" is often used to denote an agriculturally productive region. In Slavic cultures
bread and salt is offered as a welcome to all guests. In Egyptian Arabic, the word for life,
'ayish, is also the colloquial word for bread (the formal is 'khoubz'). In India, life's basic
necessities are often referred to as "roti, kapra aur makan" [bread, cloth and house.
The political significance of bread is considerable. In Britain in the nineteenth century the
inflated price of bread due to the Corn Laws caused major political and social divisions, and
was central to debates over free trade and protectionism. The Assize of Bread and Ale in
the thirteenth century demonstrated the importance of bread in medieval times by setting
heavy punishments for short-changing bakers, and bread appeared in the Magna Carta a
half-century earlier.
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Types
Bread is the staple food in Europe, European-derived cultures such as the Americas, and
the Middle East/North Africa, as opposed to East Asia whose staple is rice. Bread is usually
made from a wheat-flour dough that is cultured with yeast, allowed to rise, and finally baked
in an oven. Owing to its high levels of gluten (which give the dough sponginess and
elasticity), common wheat (also known as bread wheat) is the most common grain used for
the preparation of bread, but bread is also made from the flour of other wheat species
(including durum, spelt and emmer), rye, barley, maize (or corn), and oats, usually, but not
always, in combination with wheat flour. Although common wheat is best suited for making
highly risen white bread, other wheat species are capable of giving good black bread. Spelt
bread (Dinkelbrot) continues to be widely consumed in Germany, and emmer bread was a
staple food in ancient Egypt. Canadian bread is known for its heartier consistency due to
high protein levels in Canadian flour.
White bread is made from flour containing only the central core of the grain (endosperm).
Brown bread is made with endosperm and 10% bran. It can also refer to white bread with
added colouring (often caramel colouring) to make it 'brown'; commonly labeled in America
as "Wheat" bread (as opposed to "Whole Wheat" bread.)
Wholemeal bread contains the whole of the wheat grain (endosperm and bran). It is also
referred to as 'whole grain' or 'whole wheat' bread, especially in North America.
Wheat germ bread has added wheat germ for flavoring.
Whole grain bread can refer to the same as 'wholemeal bread', or to white bread with
added whole grains to increase its fibre content (i.e. as in "60% whole grain bread").
Roti is a whole wheat based bread eaten in South Asia. Chapatti is a larger variant of Roti.
Naan is a leavened equivalent to these.
Granary bread is bread made using flaked malted wheat grains malt. Trademarked to
Hovis, it is made from white or brown flour and flaked malted wheat grains. The standard
malting process is modified to maximise maltose / sugar content but minimise residual
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alpha amylase content. Other flavour components are imparted from partial fermentation
due to the particular malting process used and to Maillard reactions on flaking / toasting.
Rye bread is made with flour from rye grain of variable levels. It is higher in fiber than many
common types of bread and is often darker in color and stronger in flavor. In Scandinavia,
Germany, Finland, the Baltic States, and Russia, rye is a popular type of bread.
Unleavened Bread or Matzah used for the Jewish feast of Passover, does not include
yeast, thus it does not rise.
Sourdough bread is made with a starter.
Researchers at the Agricultural Research Service are inventing new whole-grain oat and
barley breads that offer more antioxidants and fibers than traditional whole-grain breads.
Quick breads
Quick breads usually refer to breads chemically leavened, usually with both baking powder
and baking soda, and a balance of acidic ingredients, and alkaline ingredients. Examples
include: pancakes and waffles, muffins and carrot cake, Boston brown bread, and zucchini
and banana bread.
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Composition and chemistry
Formulation
The amount of flour is the most significant measurement in a bread recipe, as it affects
texture and crumb the most. Professional bakers use a system of percentages known as
Bakers' Percentage in their recipe formulations, and measure ingredients by weight instead
of by volume. Measurement by weight is much more accurate and consistent than
measurement by volume, especially for the dry ingredients.
Flour is always stated as 100%, and the rest of the ingredients are a percent of that amount
by weight. Common table bread in the U.S. uses approximately 50% water, resulting in a
finely textured, light, bread. Most artisan bread formulas contain anywhere from 60 to 75%
water. In yeast breads, the higher water percentages result in more CO2 bubbles, and a
coarser bread crumb. One pound (~ 450 g) of flour will yield a standard loaf of bread, or two
French loaves.
Calcium propionate is commonly added by commercial bakeries to retard the growth of

molds.
Flour
Flour is a product made from grain that has been ground into a powdery consistency. It is
flour that provides the primary structure to the final baked bread. Commonly available flours
are made from rye, barley, maize, and other grains, but it is wheat flour that is most
commonly used for breads. Each of these grains provides the starch and protein necessary
for the production of bread.
The quantity of the proteins contained in the flour serve as the best indicator of the quality
of the bread dough and the finished bread. While bread can be made from all-purpose
wheat flour, for quality bread a specialty bread flour, containing more protein, is
recommended. If one uses a flour with a lower (9-11%) protein content to produce bread, a
longer mixing time will be required to develop gluten strength properly. This extended
mixing time leads to oxidization of the dough,[citation needed] which gives the finished
product a whiter crumb, instead of the cream color preferred by most artisan bakers.
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Wheat flour in addition to its starch contains three water-soluble protein groups, albumin,
globulin, proteoses, and two non-water soluble protein groups, glutenin and gliadin. When
flour is mixed with water the water-soluble proteins dissolve, leaving the glutenin and gliadin
to form the structure of the resulting dough. When worked by kneading, the glutenin forms
strands of long thin chainlike molecules while the shorter gliadin forms bridges between the
strands of glutenin. The resulting networks of strands produced by these two proteins are
known as gluten. Gluten development improves if the dough is allowed to autolyse.
Liquids
Water, or some other liquid, is used to form the flour into a paste or dough. The volume of
liquid required varies between recipes, but a ratio of 1 part liquid to 3 parts flour is common
for yeast breads, while recipes that use steam as the primary leavening method may have a
liquid content in excess of one part liquid to one part flour by volume. In addition to water,
other types of liquids that may be used include dairy products, fruit juices, or beer. In
addition to the water in each of these, they also contribute additional sweeteners, fats,
and/or leavening components.
Leavening
Leavening is the process of adding gas to a dough before or during baking to produce a
lighter, more easily chewed bread. Most bread consumed in the West is leavened.
However, unleavened breads have symbolic importance in Judaism and Christianity. Jews
consume unleavened bread called matzo during Passover. They are also used in the
Roman Catholic Christian liturgy when they celebrate the Eucharist, a rite derived from the
narrative of the Last Supper when Jesus broke bread with his disciples, perhaps during a
Passover Seder. On the other hand, the Orthodox Church always uses leavened bread.
Chemical leavening
A simple technique for leavening bread is the use of gas-producing chemicals. There are
two common methods. The first is to use baking powder or a self-rising flour that includes
baking powder. The second is to have an acidic ingredient such as buttermilk and add
baking soda. The reaction of the acid with the soda produces gas.
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Chemically leavened breads are called quick breads and soda breads. This technique is
commonly used to make muffins, pancakes, American-style biscuits, and sweet breads
such as banana bread.
Yeast leavening
Yeast
Many breads are leavened by yeast. The yeast used for leavening bread is Saccharomyces
cerevisiae, the same species used for brewing alcoholic beverages. This yeast ferments
carbohydrates in the flour, including any sugar, producing carbon dioxide. Most bakers in
the U.S. leaven their dough with commercially produced baker's yeast. Baker's yeast has
the advantage of producing uniform, quick, and reliable results, because it is obtained from
a pure culture. Many artisan bakers produce their own yeast by preparing a 'growth culture'
which they then use in the making of bread. This culture kept in the right conditions will
continue to grow and provide leavening for many years.
Both the baker's yeast and the sourdough method of baking bread follow the same pattern.
Water is mixed with flour, salt and the leavening agent (baker's yeast or sourdough starter).
Other additions (spices, herbs, fats, seeds, fruit, etc.) are not necessary to bake bread, but
are often used. The mixed dough is then allowed to rise one or more times (a longer rising
time results in more flavor, so bakers often punch down the dough and let it rise again),
then loaves are formed, and (after an optional final rising time) the bread is baked in an
oven.
Many breads are made from a straight dough, which means that all of the ingredients are
combined in one step, and the dough is baked after the rising time. Alternatively, dough can
be made using a pre-ferment, when some of the flour, water, and the leavening are
combined a day or so ahead of baking, and allowed to ferment overnight. On the day of the
baking, the rest of the ingredients are added, and the rest of the process is the same as
that for straight dough. This produces a more flavorful bread with better texture. Many
bakers see the starter method as a compromise between the highly reliable results of
baker's yeast, and the flavor/complexity of a longer fermentation. It also allows the baker to
use only a minimal amount of baker's yeast, which was scarce and expensive when it first
became available. Most yeasted pre-ferments fall into one of three categories: poolish or
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pouliche, a loose-textured mixture composed of roughly equal amounts of flour and water
(by weight); biga, a stiff mixture with a higher proportion of flour; and pâte fermentée, which
is simply a portion of dough reserved from a previous batch. Sourdough (also known as
levain or "natural leaven") takes it a step further, creating a pre-ferment with flour and water
that propagates naturally occurring yeast and bacteria (usually Saccharomyces exiguus,
which is more acid-tolerant than S. cerevisiae, and various species of Lactobacillus.)
Sourdough
The sour taste of sourdoughs actually comes not from the yeast, but from a lactobacillus,
with which the yeast lives in symbiosis. The lactobacillus feeds on the byproducts of the
yeast fermentation, and in turn makes the culture go sour by excreting lactic acid, which
protects it from spoiling (since most microbes are unable to survive in an acid environment).
All yeast-leavened breads used to be sourdoughs, and the leavening process was not
understood until the 19th century, when with the advance of microscopes, scientists were
able to discover the microbes that make the dough rise. Since then, strains of yeast have
been selected and cultured mainly for reliability and quickness of fermentation. Billions of
cells of these strains are then packaged and marketed as "Baker's Yeast". Bread made with
baker's yeast is not sour because of the absence of the lactobacillus. Bakers around the
world quickly embraced baker's yeast for it made baking simple and so allowed for more
flexibility in the bakery's operations. It made baking quick as well, allowing bakeries to make
fresh bread from scratch as often as three times a day. While European bakeries kept
producing sourdough breads, in the U.S., sourdough baking was widely replaced by baker's
yeast, and only recently has that country (or parts of it, at least) seen the rebirth of
sourdough in artisan bakeries. According to Alton Brown, host of Food Network's Good
Eats television show, each region of the world has different strains of lactobacillus, hence
the flavor of the bread made from home starters is unique. The San Francisco Bay Area is
especially famous for its sourdough breads.
Sourdough breads are most often made with a sourdough starter (not to be confused with
the starter method discussed above). A sourdough starter is a culture of yeast and
lactobacillus. It is essentially a dough-like or pancake-like flour/water mixture in which the
yeast and lactobacilli live. A starter can be maintained indefinitely by periodically discarding
a part of it and refreshing it by adding fresh flour and water. (When refrigerated, a starter
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can go weeks without needing to be fed.) There are starters owned by bakeries and
families that are several human generations old, much revered for creating a special taste
or texture. Starters can be obtained by taking a piece of another starter and growing it, or
they can be made from scratch. There are hobbyist groups on the web who will send their
starter for a stamped, self-addressed envelope, and there are even mailorder companies
that sell different starters from all over the world. An acquired starter has the advantage of
being more proven and established (stable and reliable, resisting spoiling and behaving
predictably) than from-scratch starters.
There are other ways of sourdough baking and culture maintenance. A more traditional one
is the process that was followed by peasant families throughout Europe in past centuries.
The family (usually the woman was in charge of breadmaking) would bake on a fixed
schedule, perhaps once a week. The starter was saved from the previous week's dough.
The starter was mixed with the new ingredients, the dough was left to rise, then a piece of it
was saved (to be the starter for next week's bread). The rest was formed into loaves which
were marked with the family sign (this is where today's decorative slashing of bread loaves
originates from), and taken to the communal oven to bake. These communal ovens over
time evolved into what are known today as bakeries, when certain people specialized in
bread baking, and with time enhanced the process so far as to be able to mass produce
cheap bread for everyone in the world.
Steam leavening
The rapid expansion of steam produced during baking leavens the bread, which is as
simple as it is unpredictable. The best known steam-leavened bread is the popover. Steam-
leavening is unpredictable since the steam is not produced until the bread is baked.
Steam leavening happens regardless of the rising agents (baking soda, yeast, baking
powder, sour dough, beaten egg whites, etc.)
The leavening agent either contains air bubbles or generates carbon dioxide.
The heat vapourizes the water from the inner surface of the bubbles within the dough.
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The steam expands and makes the bread rise.
It is actually the main factor in the rise of bread once it has been put in the oven. CO2
generation, on its own, is too small to account for the rise. Heat kills bacteria or yeast at an
early stage, so the CO2 generation is stopped.
Bacterial leavening
Salt rising bread employs a form of bacterial leavening that does not require yeast.
Although the leavening action is not always consistent, and requires close attention to the
incubating conditions, this bread is making a comeback due to its unique cheese-like flavor
and fine texture.
Aeration
Aerated bread is leavened by carbon dioxide being forced into dough under pressure. The
technique is no longer in common use, but from the mid 19th to 20th centuries bread made
this way was somewhat popular in the United Kingdom, made by the Aerated Bread
Company and sold in its high-street tearooms.
Fats or shortenings
Fats such as butter, vegetable oils, lard, or that contained in eggs affects the development
of gluten in breads by coating and lubricating the individual strands of protein and also
helping hold the structure together. If too much fat is included in a bread dough, the
lubrication effect will cause the protein structures to divide. A fat content of approximately
3% by weight is the concentration that will produce the greatest leavening action[citation
needed]. In addition to their effects on leavening, fats also serve to tenderize the breads
they are used in and also help to keep the bread fresh longer after baking.
Bread improvers
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Bread improvers are frequently used in the production of commercial breads to reduce the
time that the bread takes to rise, and to improve the texture and volume of bread. Chemical
substances commonly used as bread improvers include ascorbic acid, hydrochloride,
sodium metabisulfate, ammonium chloride, various phosphates, amylase, and protease.
Sodium/salt is one of the most common additives used in production. In addition to

enhancing flavor and restricting yeast activity, salt affects the crumb and the overall texture
by stabilizing and strengthening the gluten. Some artisan bakers are foregoing early
addition of salt to the dough, and are waiting until after a 20 minute "rest." This is known as
an autolyse,and is done with both refined and with whole grain flours.
The principles of bread making

The basic ingredients of leavened bread are flour (usually wheat flour), salt, yeast and
water. Other ingredients can be added to alter the flavour, appearance and keeping
qualities of the bread.
Fat or oil can be added to improve the flavour and help to keep the bread fresh for longer.
Milk can be used instead of or in combination with water to make a bread with a softer
texture. Savoury ingredients such as onion, tomato, cheese or herbs and sweet ingredients
such as sugar, cinnamon and dried fruits can all be added to the basic dough to make a
range of products.
A combination of different flours, such as rye, cassava, sorghum, millet or maize can be
mixed with the wheat flour in different proportions to produce a range of different breads.
At least 70% wheat flour must be used in leavened breads to allow the bread to rise.
Unleavened breads are made from many different types of flour, depending upon what is
locally available. Salt and water are added to the flour, but no yeast is used. The flour and
water are mixed and kneaded to give a smooth dough that is baked into a crisp flat bread.
Examples of unleavened bread include chapattis, rotis, matzos and tortillas.
The serving of bread
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Bread can be served at any temperature. Once baked, it can subsequently be toasted. It is
most commonly eaten with the hands, or sometimes with a knife and fork. It can be eaten
by itself or as a carrier for another, usually less compact food. Bread may be dipped into a
liquid (such as gravy, olive oil, or sardine pâté), topped with various spreads, both sweet
and savory, or serve as the enclosure for the ubiquitous sandwich with any number of
varieties of meat, cheese, vegetables or condiments inside.
Bread crust
The bread crust is formed from exposed dough during the cooking process. It is hardened
and browned through the Maillard reaction using the sugars and amino acids and the
intense heat at the bread surface. The nature of a bread's crust differs depending on the
type of bread and the way it is baked. Commercial bread is baked using jets that direct
steam towards the bread to help produce a desirable crust. Bread crusts are sometimes
considered unpalatable, especially and notoriously by young children, who commonly
remove and throw away the crusts. Some manufacturers, such as Sara Lee, have begun to
market special crust-less breads. But for many, crusts are part of the allure of a delicious
loaf of bread.
Breads across different cultures

Being the simplest, cheapest and most basic type of food, bread is often referred as a
synecdoche for "food" in general, in some languages and dialects, such as Greek and
Punjabi. There are many variations on the basic recipe of bread worldwide, including pizza,
chapatis, tortillas, baguettes, brioche, pitas, lavash, biscuits, pretzels, naan, bagels, puris,
and many others.
In Mexico bread is called pan (Spanish for bread). Although corn tortillas are the staple
bread in most of Mexico, breadrolls in many varieties are an important daily food for city
dwellers. Popular breads in Mexico include the bolillo roll and pan dulce. There are many
varieties, about 1,000. Pan dulce, which is Spanish for "sweet bread", is primarily eaten at
breakfast.
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In Peru, pan has many variations due to the diversity of Peruvian cuisine. People usually
eat Pan de piso, and Pan serrano. There are also some kind of bread made of potatoes,
currently popular in the Andes. Bizcochos are sweet bread usually eaten with some butter
and hot chocolate. A dough made with cooked pumpkin or squash, often shaped and fried
into doughnuts and served with a sweet fruity dipping sauce, is a traditional favorite.
In Spain bread is called pan. There is a region called Tierra del Pan (literally translated as
"Land of the Bread"), located in the province of Zamora, where economy was in the past
joined to this activity.
In South Asia ( India, Pakistan, Middle East, etc.), roti or chapati, types of unleavened flat
breads usually made from wholewheat flour and baked on a hot iron griddle called a tava,
form the mainstay of the peoples' diet. Rotis and naans are usually served with curry
throughout the region. A variant called makki di roti uses maize flour rather than white flour.
Another variant is puri, a thin flat bread which is fried rather than baked and puffs up while
cooked. Paratha is another variation on roti. Naan (leavened wholewheat bread), however,
is baked in a tandoor or clay oven and is rarely prepared at home. White and brown breads
are also very common, but not as much as roti.
In the Philippines, pandesal (or pan de sal; literally, bread of salt or salt bread) is a rounded
bread usually eaten by Filipinos during breakfast.
Germany prides itself on having the largest variety of breads worldwide. More than 300-500
basic kinds of bread come together with more than 1,000 types of small bread-rolls and
pastries. It has been estimated that the basic kinds of bread are so widely varied by more
than 16,000 local bakeries that more than 1,000 different breads have been presented at a
2005 Cologne bread show.Germans are worldwide the biggest consumers (per capita) of
bread followed by Chile.
In Scandinavian and Nordic countries, four grain types dominated in the prehistoric era
(prior to 1000 AD). Barley and rye are the oldest; wheat and oats are more recent. During
the Iron Age (500 AD–1050 AD), rye became the most commonly used grain, followed by
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barley and oats. Scandinavian soldiers apparently learned baking techniques while working
as mercenaries in the Roman army (200–400 AD). They subsequently took the technique
home with them as a way to show that they had been employed in high-status work on the
continent. Early Christian traditions promoted an interest in bread. Rye was also the most
commonly used grain for bread up until the beginning of the 20th century. Today, older
grain types such as emmer and spelt are once again being cultivated and new bread types
are being developed from these grains. Culturally, Germany has influenced most of the
bread types in the Nordic countries. However, in the eastern part of Finland, there is a
cultural link to Russia and Slavic bread traditions.
In the late 19th century, Danish bakers in the larger towns baked fresh bread in the
morning. This bread, called morgenbrød, primarily made from wheat and intended for the
rising bourgeoisie, was baked into various shapes and with a variety of seasonings. Since
then, this freshly-baked bread has been produced in every Danish baker's shop, along with
a variety of other breads. This decentralised form of baking bread alongside the more
modern industrialised production of bread seems to be characteristic of the Danish bread
sector. Consumption, to a great extent, has switched from rye bread to wheat bread.
Finland and Russia both have dark, sourdough breads made of rye. Traditional Finnish rye
bread is disc-shaped, with a hole in the center for easier storing. These breads have a
rougher composition and a stronger taste than wheat bread, and can thus be stored for
longer periods of time. Some families may still have leaven, handed down from one
generation to the next, that they use for baking these breads. . Bread is made from all four
of the cereals grown in Finland: wheat, rye, barley and oats; these are usually ground into
various grades. Rye bread can be either light or dark in colour, depending on the type of
flour mixture used. A few wheat breads are still made in Finland, although most are simple
buns or loaves of sliced or unsliced bread. Vesirinkeli (water rings), are small, almost
tasteless rings of yeast-leavened wheat bread, which resemble bagels. The potato,
although a late introduction to Finland in the early 19th Century, features heavily in food
culture and has found its way into many kinds of bread.
With the settlement Iceland circa 800–900 AD, grain, in the form of barley was brought,
cultivated and used for bread and porridge. Grain cultivation is thought to have been
35
abandoned before 1600 due to harsher climatic conditions, and subsequently most grains
such as barley and rye were imported. The scarcity of grain was overcome in different ways
in different parts of the country. In some areas, grain was made to go further using dulse
(Palmaria palmata; Icelandic söl), Iceland Moss (Cetraria islandica; Icelandic fjallagrös) or
Irish Moss (Chondrus crispus; Icelandic fjörugrös) in compotes and breads. It was not until
the 18th century that it became common practice to make leavened rye breads; sourdough
was mostly used. Rye breads baked in hot springs are a popular item today, and are served
for local consumption as well as for tourists. In general, stock fish (harðfiskur) was served
as a bread substitute, eaten with butter on the side with almost every meal. Today, it is a
popular snack which has found a new target group within the sports food market due to its
high protein and favourable amino acid content. Most types of breads available in other
Western countries are now also available in Iceland, either baked in Iceland or imported.
Everyday bread is mostly made by industrial bakeries or at the local bakery. Of the bread
types currently available, flatbrauð (flatbread) and laufabrauð (leaf bread) have the longest
history.
Many new types of bread have reached the markets in Norway in recent years. A high
percentage of people reported regularly eating bread types such as spelt, specialty,
gourmet, and fibre/bran bread, as well as ciabattas and baguettes, although very few
reported doing so on a daily basis. Norwegian bakers now have competition from abroad.
The wholegrain bread from local bakers must give way to huge lorry loads of baguettes and
frozen dough offering cheaper products. Flatbread is still a very popular bread type.
In Sweden, during the transion to a modern urban and industrialised society (19th century
AD), bread types changed when large industrial bakeries introduced new soft bread. From
from the early 1920s, these were often sweetened. From then on, bread was bought from
stores and bakeries, rather than baked at home, as had previously been the case. Regional
variation decreased due to the transportation and marketing of bread as a national product.
The consumption of bread products of various kinds has increased since the 1990s, and
wholegrain bread and wheat bread are the most popular. Many older bread types still exist
alongside the newer varieties.
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In Britain there is a wide variety of traditional breads, often baked in a rectangular tin. One
such type of traditional bread is known as a stottie cake. This is a thick, flat, round loaf that
is common in North East England.
In Scotland, another form of bread called plain bread is also consumed. Plain bread loaves
are noticeably taller and thinner, with burned crusts at only the top and bottom of the loaf.
Plain bread has a much firmer texture than English and American pan bread. Plain bread is
becoming less common as the bread consumed elsewhere in Britain is becoming more
popular with consumers.
In Ireland, it is traditionally held that the end of a loaf of bread (the 'heel' or 'hilt' of the loaf)
is the best part of the loaf. Other stories and myths surround this piece of the bread in Irish
Mythology. Irish soda bread, developed to make the most of the soft wheat grown in
Ireland, is unusual for a European bread in that it is a quick bread, using the reaction of
buttermilk and baking soda rather than yeast to rise.
In France, pan bread is known as pain de mie and is used only for toast or for making
stuffing; standard bread (in the form of baguettes or thicker breads) has a thick crust and
often has large bubbles of air inside. It is often baked three times daily and is sold totally
unwrapped for a crisp crust. Some fancy breads contain walnuts or are encrusted with
poppy seeds.
Due to its long history of regional political division, Italy specializes in many different kinds
of bread, reflecting its great regional variation and widely different breadmaking recipes and
traditions. As a rule of thumb, rolls are typical of the northern regions, while large loaves are
typical of the southern regions. Bread often has a small quantity of olive oil, butter, or
rendered lard mixed into the dough to make it softer and more palatable. Traditional rustic
breads include sfilatino imbottito (a stuffed bread roll) and pizza bianca (a flat white
bread).Focaccia is quite popular in Italy and southern France. In Provence, it is known as
fougasse or fouace, with the former becoming increasingly common. Fougasse can now be
bought all over France. It is usually seasoned with olive oil and herbs, and often either
topped with cheese or stuffed with meat or vegetables. Focaccia doughs are similar in style
and texture to pizza doughs.
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In the United States, traditional breads include cornbreads and various quick breads, such
as biscuits. Cornbread is made from cornmeal and can differ significantly in taste and
texture from region to region. The South generally prefers white cornmeal with little to no
wheat flour or sweeteners added. It is traditionally baked in a cast-iron skillet and ideally
has a crunchy outside and moist inside. The North, however, usually prefers yellow
cornmeal with sometimes as much as half wheat flour in its composition, as well as sugar,
honey, or maple syrup. This results in a bread that is softer and sweeter than its southern
counterpart. Homemade wheat breads are made in a rectangular tin similar to those in the
United Kingdom. Rolls, made from wheat flour and yeast, are another popular and
traditional bread, eaten with the dinner meal. Sourdough biscuits are traditional "cowboy
food" in the West. The San Francisco Bay Area is known for its crusty sourdough. Spoon
bread, also called batter bread or egg bread, is made of cornmeal with or without added
rice and hominy, and is mixed with milk, eggs, shortening and leavening to such a
consistency that it must be served from the baking dish with a spoon. This is chiefly popular
in the South. Up until the 20th century (and even later in certain regions), any flour other
than cornmeal was considered a luxury; this would explain the greater variety in cornbread
types compared to that of wheat breads. Commercially, the most popular bread has been a
soft-textured type with a thin crust that is usually made with milk and is slightly sweet; this is
the type that is generally sold ready-sliced in packages. It is usually eaten with the crust,
but some eaters or preparers may remove the crust due to a personal preference or style of
serving, as with finger sandwiches served with afternoon tea. Some of the softest bread,
including Wonder Bread, is referred to as "balloon bread". Though white "sandwich bread"
is the most popular, Americans are trending towards more artisanal breads. Different
regions of the country feature certain ethnic bread varieties including the French baguette,
the Ashkenazi Jewish bagel, scali (an Italian-style bread made in New England), Native
American frybread (a product of hardship, developed during the Indian resettlements of the
19th century), and Jewish rye, a bread commonly associated with delicatessen cuisine.
Christian traditional societies (usually in poor communities), used to respect bread since
Jesus symbolised his body with it. The sign of the cross was performed with the knife on
the bread's surface, before the loaf was cut. Sometimes it was considered a sin to
desecrate bread (e.g., throw it away).
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Jews have traditionally baked challah, a type of egg bread with a thin, hard crust and a soft,
well-leavened center. It is made by wrapping plaits of dough and then lightly baking them in
an oven. Challah is sometimes sweetened using honey and sometimes includes raisins.
During Passover, unleavened bread, in the form of various types of matzo, is required due
to the Biblical injunction to avoid any form of leaven during this time of year. There is some
debate within the Jewish community as to whether dairy products are allowed in kosher
bread; some authorities maintain that bread must be strictly pareve to avoid combining
meat and dairy in the same meal, while others feel it is acceptable as long as a sign of
some sort (usually a different loaf shape, but others are known) is baked into the loaf to
distinguish it from pareve bread.
In Morocco and West North Africa, a round bread which is roughly four inches tall is used to
eat most of the Mediterranean's watery cuisine. They also have a thick and chewy fried
bread which is smothered in oil beforehand. The rghifa bread is a staple in Morocco's food
and consists of several layers of lightly cooked bread.
In China, the traditional bread is Mantou. It is made by steaming or deep frying dough made
from either wheat flour or rice. In Northern China, Mantou is often eaten as an alternative
staple to rice. Steamed Mantou is similar to western white bread, but since it is not baked, it
does not have a brown outer crust. Mantou that have a filling such as meat or vegetables
(Char Siu Bao, for example) are called "baozi".
There are different types of traditional 'cheese breads' in many countries, including Brazil,
Colombia, Italy and Russia.
39
BREAD MANUFACTURING
AND PROCESSING
METHODS & MATERIALS
40
AUTOMATED BREAD PLANT LAYOUT
Bread plants layout consists of mixers , dough elevators , divider ,hander up ,
inter prover , moulding , final prover , oven , depanner and cooling tunnel .
Point s to keep in mind while planning for bread plant layout
• Mixer with dough elevators or gravity tipping
• Final prover loading manual or automatic
• Oven to be either tunnel type or swingtray as per requirement
• Oven Loading to be manual or automatic
• Cooling tunnel to have atleast 2- 3 hours cooling time hence check the
length .
• Ventilation of the baking hall
41
BREAD MANUFACTURING
Flow Diagram for bread manufacturing
42
BREAD RECIPE
Added ingredients:
- Yeast -
Bakers yeast is a living micro-organism that is used to make the dough rise. When yeast
has optimal conditions to grow (warmth, moist and food) it becomes active and starts to
ferment. Yeast fermentation is the conversion of sugars to carbon dioxide, water and
alcohol.
Bakers yeast can be obtained as compressed fresh yeast, but is mainly available as dried
yeast. Dried yeast is easy to transport and store and has a longer shelf life than
compressed yeast. It needs to be reconstituted in five times its own weight of warm water
before it is used in a bakery. The amount of yeast added depends on the time and
temperature of fermentation but is usually between 0.3 and 1.0% of the flour weight.
Salt
Salt is obtained from two sources - rock salt and seawater. Powdered rock salt is
recommended for baking as it is purer than seawater salt. The salt should be clean, free
from large lumps and easy to dissolve. Salt is used during fermentation for the following
reasons:
It emphasises flavour
It improves colouring
It reduces staling
It helps to strengthen the gluten of the dough
It helps to control the rate of fermentation.
Salt is hygroscopic therefore helps to retain moisture in the baked loaf.

Salt should be added at around 2.5-3% of the total weight of water. Care must be taken not
to add too much salt as this can prevent the yeast from working properly. Salt should be
stored in a dry place away from stored liquids, high humidity or damp.
Salt and yeast should not be allowed to come into direct contact with each other in the raw
state as the salt will damage the yeast cell walls and reduce or prevent fermentation.
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Baking powder
Baking powder is a combination of two main ingredients - one alkaline (bicarbonate of
soda) and one acidic (cream of tartar). When the two ingredients are mixed together
thoroughly, then moistened and heated, they give off carbon dioxide gas. For the formula to
be successful, the ratio needs to be two parts of cream tartar to one part bicarbonate of
soda.
Sugar
Flour normally contains sufficient natural sugar (about 2.5-3%) for the fermentation, but
sometimes a little extra sugar is added to the yeast to help activate it.
In some countries sweetened bread is popular, but in general non-sweet breads are
preferred. Between 1 and 1.5% sugar is added to the flour.
Panela is unrefined dark sugar made from sugar cane juice. It can be used instead of
refined sugar.
Sugar for bread making should be fine and granulated. It gives breads their sweetness and
a good golden colour. Sugar also improves the eating and keeping quality of breads.
Fats
Fats used in baking include butter, margarine, bakers fats, vegetable oil.
When making bread, it is not necessary to add fat, although the inclusion of a small amount
of fat (up to 1% of the flour weight) can improve the keeping quality and softness of the loaf.
Some bakers like to add up to 3% fat as it improves the nutritional value of the bread.
Excessive use of fat is not recommended as it can inhibit the fermentation process.
Milk
Milk is used in several types of Breads. Fresh skimmed milk or reconstituted dried skimmed
milk are both suitable to use. Sour milk and buttermilk are also used in some products,
particularly for lactic fermented scones and buns.
Water
In breadmaking, water is mixed with the flour to make a strong, stretchy dough. The amount
of water added depends on the type of flour but is usually half the weight of flour used. The
water should be slightly warm (body temperature (36°C) is ideal) to encourage fermentation
by the yeast. It should not be hot as this reduces the yeast activity.
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The water should be clean and potable.
The pH of water varies from acid to alkaline. The length of time needed to mix the dough
depends partly on the pH of the dough. Alkaline doughs take longer to mix than acidic
doughs.
Fermenting dough has a pH between 5 and 6.
Raw materials: Flour
The quality of raw materials has an influence over the quality of the products. High quality
raw materials should be used.
Small-scale bakers do not normally have facilities for flour analysis and rely on information
supplied by the miller or wholesaler. There are a few simple tests that they can carry out
which give useful information about the flour quality.
Flour
Flour can be milled from a variety of cereals. The type available in each country or region
may depend upon the types of cereal grown, although wheat flour tends to be available in
most places.
Wheat flour
Wheat flour contains proteins known as glutens. These are capable of forming a strong
elastic network within the dough, which is very useful when making leavened bread.
The protein network traps the gas that is given off by the yeast during fermentation. This
causes the dough to increase in volume and produces a bread with a light texture.
If flours that are low in gluten are used to make leavened bread, the gas escapes and the
bread is flat and heavy.
Wheat flour is available in different grades according to the degree it is extracted from the
whole wheat grain. Flours of different extraction rates include the following:
- Wholemeal flour - 100% extraction
- Wheatmeal flour - 90-95% extraction
- Straight run flour - 70-72% extraction
- Patents - 20-40% extraction
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Non-wheat flours
There are a variety of non-wheat flours available that can be mixed with wheat flour to
make bread.
Cassava flour is a fine white powdery flour that has a shelf life of up to one year. It is widely
used as a staple food and for the production of a range of fried and baked goods including
bread, cakes and biscuits.
Cereal flours, especially from maize and sorghum, which are both staple crops, are used to
make breads and snackfoods.Sorghum is mainly used to make bread or porridge. Maize is
used to make tortillas, snacks and for the production of cornflour and thickeners.
Soy/composite flour is a fine creamy flour that is combined with maize flour or other cereal
flours to increase the protein content and balance the amino acid composition of the
composite flours. In this form it is used as a breakfast porridge and as a weaning food.
- Different types of wheat flour -
Different types of wheat flour are available in each country. Wholemeal flour is used for the
production of brown bread, rolls and other high fibre products.
Atta is a wheat flour that is suitable for making chappatis. It is also available as a
wheatmeal flour.
Special bakers flour (bread making flour) is a strong flour that is used for bread, rolls and
pastry. Bakers flour should contain a good quality gluten so that it can produce a light
bread.
Biscuit flour. This is a special blend of flour that is made for mechanical biscuit plants.
Self raising flour. This flour is a soft flour that is fortified with a chemical aerating additive
similar to baking powder. It is used for making chemically aerated breads such as soda
bread. Soft flour is used for cake making.
46
BREAD RECIPE NORMAL BREAD
INGREDIENTS PERCENTAGE ON WT. BASIS OF FLOUR

WATER 60%
SALT 1%
SUGAR 2%
SHORTENING 2%
YEAST 1.5-2%
BREAD RECIPE MILK BREAD

INGREDIENTS PERCENTAGE ON WT. BASIS OF FLOUR
YEAST 3.8%-4%
SUGAR 3%
MILK 18-20%
WATER 36%
Perservatives , flavours , essences , emulsifiers , dough conditioners

and other additives can be added as per requirement . Other varieties could be whole
meal wheat bread or multi grain bread .
47
CALCULATION OF BREAD YIELD
During the production of bread, there are several stages where weight is lost. During
fermentation there is about 1% weight loss of air through the knock-back procedure.
Moisture loss through evaporation during baking, depanning and cooling can account for
about 9-11% weight loss. The baker must allow for about 10% loss of weight.
To obtain a 500g baked loaf, a piece of dough of 560g must be used. For an 800g loaf, a
dough piece of 880g should be used.
48
PROCESS OF BREAD MAKING
49
The sponge and dough process
The sponge and dough process is suitable for small bakeries where there is no mechanical
dough mixer available. The whole process is completed by hand.
The advantages of this process are better flavoured bread, better keeping quality and,
often, better appearance.
The sponge and dough process can be broken down into two parts:
First, a 'sponge' is formed. This is a fairly stiff batter that is made from part of the flour, the
yeast, some sugar and part of the water. These ingredients are thoroughly mixed together,
covered and left to ferment at a set temperature for a certain time. The length of time is
determined by the quantity of yeast used and can be as long as 14-16 hours.
Second is the 'dough' stage. The remainder of the flour, sugar and water, the fat or
margarine, salt and, sometimes, a small amount of yeast, are added to the sponge and
thoroughly mixed together to make a smooth, fairly stiff dough.
The final dough mixing by hand is strenuous, but properly made bread using this process
has an excellent flavour and an enhanced keeping quality.
The lengthier fermentation times for the sponge are more suitable to the single-handed
baker who can set the sponge in the afternoon (eg between 4.00 and 6.00pm) and then
continue with the dough at 6.00am the following morning. This allows the baker adequate
time for rest. It also makes a substantial saving in yeast.
50
The straight dough process
The straight dough process is really only suitable for mechanical mixing, although it can be
used when very small quantities of dough are made by hand.
All the ingredients are mixed together at the same time. Before mixing starts, the yeast is
activated in a little of the dough water. The temperature of the dough water is adjusted to
produce a pre-determined dough temperature which, together with the quantity of yeast
used, determines the length of the bulk fermentation. This can either be 'no-time' dough,
which is processed into loaves as soon as the dough has been mixed. Or it can be a dough
that is mixed and allowed to ferment in bulk for 1 hour or up to 10-12 hours.
About three quarters of the way through the estimated bulk fermentation time (BFT), the
dough will have swollen to its fullest extension. At this stage it is necessary to expel all the
gas from the dough. This is known as knock-back and can be done by hand or using a
machine.
The temperature is even throughout the dough so the yeast starts to function again and
generates more gas.
With a sponge that has a lower viscosity than a dough, no knock-back is required ans the
sponge collapses by itself then rises up again.
51
BREAD MAKING PROCESS FLOW IN AUTOMATED
BREAD PLANT
Mixing
Mixing starts with sifting flour with help of vibratory sifter .Flour is then collected in
bowl and then weighed .All ingredient are then added in bowl .Ingerients are flour ,
sugar ,fat, salt, yeast, gms powder, sodium stearoyl lactilate, smp solution ,bio-bake ,
Improvers, ammonium cholride , ascorbic acid , cystiene, pot.bromate, calcium propianate
and acetic acid . These are added in std proportion as per requirement .
After addition of all ingredients bowl is moved to spiral mixer where is done .Water
is added in different quantities .Mixing time depends on quality of flour in general mixing
time can vary from 6- 12 min . under mixing and over mixing can have direct impact on
dough consistency . Dough quality can be checked with stretching the dough .dough
temperature is maintained between 80 deg f - 82 deg f .Role of Ingredients
FORMING
On completion of mixing dough bowl is lifted through tilting hoist and from the hoist
bowl is tilted so as dough goes into hopper of Divider Hopper.
DIVIDER
Dough is cut into two equal dough piece .Its a mechanical device which uses a
common crank to cut , push and drop dough piece through divider to conveyor .Volume of
the dough piece can be adjusted at divider . Divider is defined as no of dough piece per
min
HANDER UP
From divider the dough piece moves to hander up which is mechanical device
conical in shape on which dough piece takes curvelinear path .It has got blower attached
to it which continuously provides air on the path .Basic function of hander up is to give
dough piece spherical shape and remove moisture from surface from dough piece .
INTERPROOVER
52
Dough pieces are then transfered to buckets of interproover .Here dough piece are
allowed to travel for 5- 6 min .This helps in relaxation of dough as it would have stress due
to mechanical action on it at divider.
MOULDER
It has three set of roller . The dough piece is allowed to pass through these rollers .
Now dough piece are slighty flattened .
PRESSURE BOARD
Dough piece are turned and fed into pressure board where it takes cylindrical shape
.Air is passed through the board .
FINAL PROOVER
These dough pieces are then carried to platform where these lobes
are twisted and kept in moulds ,two lobes are twisted in one mould box as per wt required
like 400 gms or 800gms loaves . Mould box are greased prior to lobes being put into.
Final proover has arrangement for steam which spreads uniformly in entire
chamber.Temperatures at final proover is maintained between 36-38deg c.Humidity and
temperature are maintained so as to get maximum of yeast activity .Precautions are taken
to see if there is over or under development of dough . Speed can be varied at final
proover. Dough should rise 3/4 th of the mould .vol of mould is 1320cc for 400gm and
2700cc for 800 gm loaves . Travel of trays is longitudinal in swing tray type plant where as
in contray type it is vertical .Prooving time =75 min
Depending upon design we can define capacity of final proover as

cap/cycle : no of loaves .no of racks x no of moulds box per rack x no of mould in each box
.After dough has been developed these mould box are then transferred manually to baking
oven.
53
BREAD MANUFACTURING- BAKING
Mould with dough are placed in racks of oven . (They are developed from steam which
has been treated with at Final proover ) These are then allowed to travel in baking zones
with temperature inside between - 250 - 280 deg c . Baking time : 26- 28 min Basic ovens
are CONTRAY OVENS AND SWING TRAY TYPE.
CONTRAY OVEN : Compact and robust , lidding is done manualy and has fixed racks
where mould box are placed .
SWING TRAY : Large and spacious takes large area in comparison with contray oven . It
has hinged tray which swings either way .lidding and unlidding is done automatic .
Capacity of bread oven = no of racks x no of mould box x no of mould in each box
No of loaves /cycle . Baking consist of two process with regard to starch .
Gelatinasation, Dexterisation
Gelantinasation : This is a process where starch is heated in presence of water

.gelantinasation occurs inside of crumb which is soft and molten state during the baking
period .
Dextrisation : This is a process in which starch is heated in absence of water .It results
into a solid crust formation at the top .Temperature required for dexterisation is 225 deg c
-and above .
Baking temperature also stops yeast activity . Execessive Temperature results into
dark brown crust on loaves and to avoid such instances operator has to increase the
speed of oven . Hence by adjusting we can avoid under baking and over baking.
Baked loaves in mould box are then passed through Depanner where loaves are taken out
of mould box and placed on racks . Which are then stationed in cooling tunnel for loaves
to come to ambient temperature .
PACKING
Loaves are then passed on to bread slicer . These slicers has blades and no of blades
are as per no of slice required . normally 27 - 28 blades are used for normal bread .
Blades regularly regrinded .Slices are then packed in polybags with codes and price .
54
Automated bagging machines are also available where bagging is automated . Most
popular method is to pack manually .
BREAD PACKAGING
Bread packaging is evolving like any other bakery product packaging . Special
characteristic of bread which has to be considered while selecting packaging material are
Very short shelf life Softness Transportation Following materials are used by bakery
manufacturers for bread. Normal weights of bread packs available are 250g , 400g , 800g
, 1000g Paper bags :Preferred by local bakery manufacturers these are simple bags as per
size of the loaves. These are normally used for local population who prefers loaves rather
than slices of bread Wax paper : Still few of bakery manufacturers are using it . Automatic
sealing machines are used for sealing Hdpe bags : Breads are packed and sealing is
done at one side ,flow wrap machines are used in automated bread manufacturing.
Ldpe bags : These a re vertical bags used for packing bread .and bag closure of ties are
used to seal the bag Poly bags : For products like bun , pav these sorts of packing
material are used.
These are then placed in platic trays specifically made for handling of bread .These crates
are then transported to retail shop and returned back to the manufacturers
FEW OTHER ITEMS FOR BREAD PACKING Bag closure - Different type of bag closure
are available in market these re usable and bit trendy in use Twist n Tie or Wire tie : These
ties are used to tie knots in bread bags .Cost effective method to close bags Bread
Handling Plastic crates : These crates are used to handle bread bags during process,
packaging and transportation . Different types of plastic trays are available for this
purpose .Bread bags are placed into these trays and are loaded in vans to be unloaded at
reatil shops . Strength is important characteristics of these of trays.
55
NUTRITIONAL
INFORMATION
56
Nutritional Information
Nutritional value per 100 g (3.5 oz)
Energy 1,113 kJ (266 kcal)
Carbohydrates 51 g
Dietary fiber 2.4 g
Fat 3g
Protein 8g
Vitamin A 0 IU
Thiamine (Vit. B1) 0.5 mg (38%)
Riboflavin (Vit. B2) 0.3 mg (20%)
Niacin (Vit. B3) 4 mg (27%)
Folate (Vit. B9) 111 μg (28%)

Vitamin B12 0 μg (0%)
Vitamin K 3.1 μg (3%)
Calcium 151 mg (15%)
Iron 3.74 mg (30%)
Magnesium 23 mg (6%)
Sodium 681 mg (30%)
57
EQUIPMENTS FOR
TESTING & QUALITY
CONTROL
58
EQUIPMENTS FOR TESTING & QUALITY CONTROL
Name of
Equipment category Scale Technical Description
Equipment
Made of stainless steel (0-150 C), this thermometer comprises a

thermometer
mercury-filled, toughened bulb, with an anti-roll cap. Seven
Temperature control S-M general
versions are available, differing in temperature range and
purpose
graduation. Length: 30.5cm.
This measures the weight of foods. The add-and-weigh facility

add and weghallows the continuous weighing of ingredients to be carried out in
S-M
scale the same bowl. Measurements are carried out in 25g increments.
Capacity: 3kg.
These heavy duty, hanging scales have an adjustable tare.

S-M hanging scale
Capacity: 30kg x 100g.
Weight control These scales weigh bulky/large materials such as sacks of flour.
portable The equipment includes a cast iron box, steel knife edges, and a
M
platform scale platform-on-wheels. Weight of scales: 250kg. Dimensions: 40.6 x
63.7cm.
These scales weigh in 1g increments. Any type of bowl or solid

food can be placed onto the scales directly. There is also an add-
S-M electronic scale
and-weigh feature, and an automatic cut-off. Capacity: 4kg.
Dimensions: 15 x 16 x 3cm.
This jug can be used as either a measuring jug or a mixing bowl. It

is fabricated from heat-resistant polypropylene and can withstand
S-M mixer jugs boiling water. The jug is graduated in pints, fluid ounces and
millilitres with an overall capacity of 2 litres. Smaller jugs (0.57
and 1.1 litres (1 or 2 pints)) are also available.
Volume control
pyrex
S-M measuring This measuring cylinder has a capacity of 10-250ml.
cylinders
pH control
battery
This portable pH meter has a range of pH 2-12, with 0.1 pH
S-M operated pH
accuracy.
meter
S-M pH meterThis is a self-contained and portable instrument designed for

digital accurate pH reading. The meter has an LED display for easy
reading. Range: pH 0-14. Accuracy: pH +/- 0.01 unit, mV +/-
0.1% of full scale. Temperature compensation: 0-100°C. Power
supply: 230V.
59
This easy to use, hand held pH meter is completely water proof
and can be completely imersed in water. It has an easy-to read
LCD and a positive push-button ON/OFF switch. The display
Waterproof
indicates when a stable pH value has been reached, ensuring that
S-M pocket pH
only accurate readings are taken. Calibration is automatic and can
meter
be performed easily , even by non-technical operators. The meter
has an auto-switch-off feature (after 10 minutes) that prolongs the
life of the batteries and gives up to 300 hours of use.
This combination model measures pH, EC (conductivity) and TDS

(for measuring fertiliser application). It is an easy-to-use, hand
GroCheck
held meter that is battery operated (total battery life is about 150
S-M Meter pH, EC
hours). It is supplied complete with probe, pH 7 buffer, 1.41 EC
and TDS
and 1500ppm calibration solutions, a 9V battery and instruction
manual.
Combo
This battery-operated waterproof tester is designed for high
Waterproof
S-M accuracy pH, EC/TDS and temperature measurements. Calibration
pH/EC/TDS
and temperature compensation is automatic.
tester
Fisher AccumetA range of pH meters is available form Fisher Scientific. Easy to

S-M (AP71) pHuse, hand-held models come with a range of specifications and in
meters various prices.
This meter can be used to measure the percentage of salt in a

S-M Brine meter
solution.
Brine control Fisherbrand This hand held equipment is a two scale unit that measures specific
salt gravity and the concentration of salt in water (parts per thousand
S-M
water/brine (ppt)). It has automatic temperature compensation. The meter
unit measures salinity from 0-100ppt.
samplers forThese are ladles which are dipped into milk to obtain a sample for
Testing equipment M
milk testing.
These refractometers are handheld, easy to use and accurate, with

a focusing eye piece. Nine models are available, that cover a
range of applications and measurement scales. Some models have
Fisherbrand automatic temperature compensation (ATC) between 10 and 30C.
S-M
Refractometers The Brix scale is used to measure the sugar concentration in
solutions such as fruit juice, wine and soft drinks. Different sizes
are available as follows: 0-18 Brix; 0-32 Brix; 28-62 Brix; 45-82
Refractometers Brix; 58-90 Brix.
Pocket
S-M Comes with leather carrying case.
Refractometer
Sugar This measures sugar content. The following size ranges are
S-M
Refractometer available: 0-45% and 40-85%.
60
This high specification water filter removes the chlorine taste,
sodastream
organic particles and herbicides from water. Easy installation, no
filterstream on
S-M plumbing skills are needed. Continuous supply of purer water from
line water filter
an extra tap fitted on the sink. Up to 2000 litres from one
unit
cartridge, recommended replacement interval is 6 months.
Water treatment
This is used to treat water by destroying bacteria using ultra-violet

UV water
light. It uses a single phase, 220V 50Hz power supply, or
M disinfection
alternatively it can be battery-operated. Water flow is at 750 litres
unit
per hour.
61
BREAD TYPES
62
DIFFERENT TYPE OF BREADS
White bread
The most common variety of bread is white bread. It is made from wheat flour
(extraction rate of 77%) and is made into many different sizes, shapes and textures.
Ingredients such as other cereal or vegetable flours, seeds, herbs or a mixture of these can
be added.
Wholemeal or wholewheat bread Made from wholemeal flour (contains all the
components of the grain -close to 100% extraction rate), it has become more popular with
increasing knowledge of the health benefits of bran and wheat germ. Mixed grain bread
May be made from any combination of flours (e.g. wholemeal or white flour, rye meal or
flour), grains (e.g. kibbled grains, wheat germ, whole grains or wheat and other cereals)
and seeds (e.g. sesame seeds). Kibbled wheat and cracked wheat bread
Contains or is rolled in kibbled (cracked) wheat grains. Fibre-increased white breads
Made with the addition of bran or other fibre-containing material. Rye bread
Made from a combination of rye flour and wheat flour. Dark rye bread contains a higher
proportion of rye flour and rye meal than light rye and is consequently more dense, heavy
and has a stronger flavour. Pumpernickel is a heavy, dark bread made from rye flour, rye
meal and kibbled or cracked rye grains.
Sourdough bread Sourdough bread has a slightly sour flavour and a denser texture
than regular bread. Sourdough describes the raising agent used to make this type of bread.
A starter, made from a mixture of flour and water, serves as a medium for growing either
commercial yeast that is added to the mixture or the ever-present wild yeast that is
captured by the mixture from the air we breathe. (Yoghurt is also sometimes added to
provide yeast.) This mixture is allowed to sour through a fermentation process that
produces a gas and an acid. It is then used as a starter to leaven other breads; the gas
produced by the fermentation is trapped in the elastic gluten structure of the dough, causing
it to rise, while the acid imparts the final product with a tart flavour.
Damper
Traditionally baked in the Australian bush, damper is a chemically leavened white, round
bread.
63
Lavash bread
A thin, flat bread made from white wheat flour, yeast, salt and water which is oven-
baked on a heated metal plate.
Bagel
A Jewish bread where the dough (with yeast) is shaped into a ring and thrown into boiling
water before baking. This gives the crust a chewy texture. It may be coated with poppy or
sesame seeds and can be flavoured, e.g. raisin and cinnamon.
Middle Eastern flat, pocket or pita bread
Flat, oval or round wheat bread made from flour, water, yeast and salt. The "pocket"
in some breads is made by resting the flattened pieces of dough under dry conditions so
that both sides become slightly drier than the centre. During baking at high temperature, the
steam produced inside the dough is trapped by the baked, drier outside layers. The pocket
can also be stuffed with various fillings. The Turkish version of pita bread is pide.
Naan
Made in India, Pakistan and Afghanistan, naan is a wheat-flour bread leavened with
a starter of the sourdough kind and cooked in a clay Tandoor oven. The clay and the smoke
in the tandoor combine to produce a characteristic flavour. The bread is flattish and has a
crisp crust.
Chapatti (chappati)
Sometimes called roti, chapatti is served throughout India, Pakistan and also Iran.
They are made from finely milled wholewheat flour, called atta. The dough is rolled into thin
rounds which are cooked in an iron pan or on a griddle. They are made every day in North
India where they are used as a plate to hold other food, curved to scoop up food or used for
dipping in soups or sauces.
Paratha or parata
An Indian flaky bread prepared by smearing the unleavened dough with ghee or oil and
then folding the dough. This procedure is repeated three times. The dough is then rolled out
and fried in oil or dry cooked on a griddle.
64
Chinese steamed bread
Eaten in most countries of east Asia, Chinese steamed breads are shaped like a ball and
have either no filling, a sweet bean paste or a meat filling. Lao bing is a Chinese-style flat
bread which is baked in a pan until both sides are golden brown.
Chinese buns and dumplings
Buns and dumplings are common in north and South-East Asia. Manju, the generic term for
steamed Japanese buns, are either lightly baked or steamed buns prepared by steaming
fermented dough with a pork, curry or sweet bean paste filling. In northern China, mantou is
a steamed leavened bread without a filling, eaten as a staple in place of rice. Yit bien or
moon cake is a baked bun filled with nuts and seeds popular amongst Chinese populations.
Mantou or mantu describes the food category of dumplings in Asia. They resemble
ravioli and are stuffed with meat and/or vegetables and beans.
Gluten-free bread
Gluten-free bread is usually based on cornflour to which flour from gluten-free grains (such
as rice and maize), potato or pulses is added. Gluten-free bread has a denser, more
crumbly texture than traditional bread, since the presence of gluten is essential for the
typical structure and texture
65
Types of bread
[1] Anadama bread
[2] Beer bread
[3] Biscuit
[4] Bread roll
[5] brown bread
[6] Brioche
[7] Broa
[8] Bun
[9] Bush bread
[10] Canadian White
[11] Cardamom bread
[12] Challah
[13] Chapati
[14] Cornbread
[15] Cottage loaf
[16] Damper
[17] Flatbread
[18] Focaccia
[19] Indian bread
[20] Lavash
[21] Matzo
[22] Mantou
[23] Melonpan
[24] Monkey bread
[25] Naan
[26] Pandoro
[27] Paratha
66
[28] Pita
[29] Portuguese sweet bread
[30] Potato bread
[31] Pumpernickel
[32] Puri
[33] Roti
[34] Irish soda bread
[35] Rye bread
[36] Seed cakes
[37] Texas toast
[38] Tiger bread
[39] Tortilla
[40] White bread
[41] Whole wheat bread
[42] Zopf
67
SUMMARY &
CONCLUSIONS
68
FOOD MANUFACTURING
A total sequence of food operations, including the growth and selection of raw materials,
harvesting, processing, preservation, and distribution. In general, the aim of all food
manufacturing operations is to extend the availability of seasonal crops to year-round use.
Food manufacturing is not solely involved with the preservation of food but is also
concerned with the production of high-quality, appealing, wholesome food. To fulfill these
goals, five broad categories of food additives are often used: flavors, coloring agents,
preservatives, texturizing agents, and miscellaneous. The last category includes a variety of
substances that may retain moisture, control acidity, act as leavening agents, or provide
nutrients such as vitamins and minerals.
The final operation in the manufacturing process is that of packaging, which is governed by
the physicochemical attributes of the food, the preservation process involved, the gaseous
permeability desired, the conditions under which the product is to be stored, the desirability
of viewing the product through a clear film or glass, and the expense.
Food Manufacture:-
Packaged household food itemsPackaged foods are manufactured

outside the home for purchase. This can be as simple as a butcher preparing meat, or as
complex as a modern international food industry. Early food processing techniques were
limited by available food preservation, packaging and transportation. This mainly involved
salting, curing, curdling, drying, pickling, fermentation and smoking. Food manufacturing
arose during the industrial revolution in the 19th century. This development took advantage
of new mass markets and emerging new technology, such as milling, preservation,
packaging and labeling and transportation. It brought the advantages of pre-prepared time
saving food to the bulk of ordinary people who did not employ domestic servants.
At the start of the 21st century, a two-tier structure has arisen, with a few international food
processing giants controlling a wide range of well-known food brands. There also exists a
wide array of small local or national food processing companies. Advanced technologies
have also come to change food manufacture. Computer-based control systems,
sophisticated processing and packaging methods, and logistics and distribution advances,
can enhance product quality, improve food safety, and reduce costs.
69
FOOD PROCESSING
Food processing is the methods and techniques used to transform raw ingredients into food
for human consumption. Food processing takes clean, harvested or slaughtered and
butchered components and uses them to produce marketable food products. There are
several different ways in which food can be produced.
[A]. One Off Production
This method is used when customers make an order for something to be made to their own
specifications, for example a wedding cake. The making of One Off Products could take
days depending on how intricate the design is and also the ability of the chef making the
product.
[B]. Batch Production
This method is used when the size of the market for a product is not clear, and where there
is a range within a product line. A certain number of the same goods will be produced to
make up a batch or run, for example at XYZ Bakery they will bake a certain number of
Bread loaves. This method involves estimating the amount of customers that will want to
buy that product.
[C]. Mass production
This method is used when there is a mass market for a large number of identical products,
for example, chocolate bars, ready meals and canned food. The product passes from one
stage of production to another along a production line.
[D]. Just In Time
This method of production is mainly used in sandwich bars such as Subway. All the
components of the product are there and the customer chooses what they want in their
product and it is made for them fresh in front of them.
70
RECOMMENDATIONS
& SUGGESTIONS
71
RECOMMENDATIONS AND SUGGESTIONS
• The Performance Appraisal report must reveal the type of training input that any
executives needs and then only he/she should be nominated.
• The executives must make a presentation and must share experiences and
knowledge with colleagues.
• Strict action should be taken against those who remain absent during the factory
training programmes.
• There must be an increased number of factory training programmes to motivate the

executives and employees on a regular basis and a track record of the training
programme attended must be kept so as to see what effect does the training have on
an executives, which exists in STAR FOOD PRODUCTS UDAIPUR.
• More jobs related trainings should be arranged for the executives and the employees
of STAR FOOD PRODUCTS UDAIPUR.
• Equal opportunities must be given to all the executives, employees and workers of
STAR FOOD PRODUCTS UDAIPUR.
72
APPENDIX
73
BIBLIOGRAPHY
[1]. COMPANY PROFILE OF STAR FOOD PRODUCTS UDAIPUR.
[2]. GUIDANCE FROM FOUNDER CHAIRMAN OF STAR FOOD PRODUCTS

UDAIPUR.
[3]. GUIDANCE FROM DIRECTORS & EXECUTIVES OF STAR FOOD PRODUCTS

UDAIPUR.
[4]. WEBSITES:
[A]. www.bakerybazar.com
[B]. http://www.fao.org/inpho/content/fpt/CEREALS/prbread.htm.
[C]. www.wikipedia.org
74
QUESTIONNAIRE
[1]. Are you satisfied with the prevailing food manufacturing and processing of STAR
FOOD PRODUCTS UDAIPUR?
[A]. Yes. [B]. No.
[2]. Would you all like to make changes in prevailing food manufacturing and processing
of STAR FOOD PRODUCTS UDAIPUR?
[A]. Yes. [B]. No.
[3]. Are you providing quality products against the resources paid by the customer?
[A]. Yes. [B]. No.
[4]. Have you ever done a survey to know your feedback in the market?
[A]. Yes. [B]. No.
[5]. What type of feedback you have got?
[A]. Good. [B]. Fair. [C]. Average.
75
THANK YOU
76

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EXECUTIVE SUMMARY

Sampling Element : STAR FOOD PRODUCTS UDAIPUR.

Sampling Units : Executives, Purchase Manager, Employees,

Salesmen, Workers, Retail Outlets.

Extent : UDAIPUR(RAJ.) and the local area of it.

INTRODUCTION TO THE SUBJECT:

• INBOUND & OUTBOUND LOGISTICS,

• PRIVATE & PUBLIC SECTOR,

• SINGLE & MULTIPLE PLANTS,

• NATURE OF THE PRODUCT,

• MADE TO STOCK & MADE TO ORDER.

• TOTAL LOGISTIC COST:

The important elements of logistic cost are:

• PRODUCT INVENTORY AT WAREHOUSE & DEALERS,

• HANDLING & WAREHOUSE OPERATION,

OBJECTIVES OF THE RESEARCH:

• CONDUCTING A STUDY OF MANUFACTURING & PROCESSING OF A BREAD

• IDENTIFYING KEYS FOR SUCCESS IN FOOD BUSINESS.

• KNOWING THE PROBLEMS, CHALLENGES IN MANUFACTURING &

• KNOWING THE PROBLEMS, CHALLENGES IN TRANSPORTATION.

• EXPECTATIONS OF TRANSPORTERS (SALESMEN) FROM THE COMPANY.

• EXPECTATIONS OF EMPLOYEES FROM THE COMPANY.

• EXPECTATIONS OF CUSTOMERS FROM THE COMPANY.

• TO FIND OUT THE COMPANY'S EFFORTS FOR A PROPER & SYSTEMATIC

• TO CREATE A VALUE BASED FLOW OF GOODS & INFORMATION.

• TO INCREASE MARKET COVERAGE THROUGH BETTER SERVICES.

• IDENTIFY SIGNIFICANCE OF BRAND BUILDING EFFORTS USED BY STAR

* Understanding of the 'Manufacturing & Processing' segment,

* Supply Chain Management,

* Logistics & Distribution network,

* Identifying new locations,

* Information Technology Systems, and

* Experienced & Skilled management team.

* Increasing its penetration in the city by leveraging its supply chain,

* Distribution & Logistic network,

* Emphasis on backward integration,

* Expansion of quality food products,

* Procurement from low-cost production centres,

* Increasing customer satisfaction, and

* Its base of loyal customers.

SALES PROMOTION & CUSTOMER SERVICE:-

AGE NO. OF EMPLOYEES

INFORMATION TECHNOLOGY SYSTEM:-

90% to 99.99% Target achieved : 5% of Salary.

100% to 109.99% Target achieved : 10% of Salary.

110% to 119.99% Target achieved : 15% of Salary.

120% to 129.99% Target achieved : 20% of Salary.

130% to 139.99% Target achieved : 25% of Salary.

140% to 149.99% Target achieved : 30% of Salary.

150% and Above : 35% - 50% of Salary.

Sr. No. Products

Mr. Ismail Ali

Mr. Yahya Ali

Mr. Sabir Ali

[1] TITLE OF THE PROJECT.

[2] DURATION OF THE PROJECT.

[5] TYPE OF RESEARCH (HYPOTHESES.)

[6] RESEARCH PLAN.

[7] SAMPLE DESIGN (SAMPLE SIZE AND METHOD OF SELECTING SAMPLE.)

[8] SCOPE OF THE STUDY.

[9] LIMITATIONS OF THE STUDY.

[1] TITLE OF THE PROJECT

[2] DURATION OF THE PROJECT