DAWN BREAD

Introduction of Dawn Bread

• Dawn bread was established in October, 1981 in Karachi.
• The 2nd plant was commissioned in Islamabad in January 1985.
• The 3rd was opened in Hyderabad in January 1987.
• The next was also opened in Lahore in 1987.
• The 5th plant was established in Multan in 1889.
• The 6th plant commissioned in 1992 in Faisalabad.
• Dawn bread is one of the most famous bread industries of Pakistan.
• All the brands of industry are limited to go through a strict quality control
and regulation processes.
• The product that reaches the consumer is of pure quality with ideal taste and
nutritional value.
• Within a decades of their inception, they have grown to capture 35% of the
consolidated market share of all bread products of Pakistan.
 Quality Policy
• Dawn bread’s policy is “Quality is total consumer satisfaction.”
• Consumer satisfaction is achieved by making constantly superior products,
which are reasonably priced, promptly delivered and professionally serviced.
 Departments in Dawn bread
Dawn bread has following departments:
• Purchasing
• Marketing
• Production
• QC and QA control
• R&D
 Products
• Bread
• Cakes
• Buns
• Shawarma
• Dawn Rusk
 Ingredients
1.Flour 2. Salt 3. Sugar 4. Yeast 5.Water 6. Oil
7. Gluten 8. Preservatives(calcium propionate, calcium sorbate) 9. Improver
10. Food color
11. Vinegar 12. Soya flour 13. Ice 14. Baking powder 15. Milk powder
16. Gel 17. Eggs 18. Essence 19. Dry fruits 20. cream
 Water
• Water like another common ingredients of bakery products, must be
uniform in order to obtain uniform results in the products.
• Water plays critical role in bread making process and performs the following
roles:
dough consistency
maintain dough temperature
dispersing medium
hydrate the gluten proteins.
 Flour
• Flour is most important single ingredient, without which production of
bread would be impossible.
• In flour typically, moisture ranges from 11-14% and protein 10-14%.
• Flour act as absorption agent
affect the quality of taste
provide nutrition and structure
retain shape and volume after baking.
 Sugar
• Sugar act as food for Yeast.
• It increases crust browning.
• It increases flavor and aroma.
• White sugar produces a softer whiter internal texture or crumb.
• It increases a product’s shelf life increasing its moisture retention.
 Yeast
• Glucose,sucrose,fructose and maltose are readily fermented by Baker’s yeast
to produce CO2 and alcohol as principal end products.
• Three types of yeast are used in bread industry
1. Liquid yeast
2. Compressed yeast
3. Dry yeast
 Salt
• Salt is added to bring out the taste of other ingredients and help to improve
the flavor & characteristics of bread.
• Salt helps to control the yeast in raised dough and thereby the rate of
fermentation.
• It strengthen the gluten, making it tighter and more elastic.
 Equipment
• Equipments used in Dawn bread are following:
1.Weighing balance 2. Sifter
3. Water tank 4. Chiller
5. Bowls 6. Trays
7. Trolleys 8. Pans
9. Bag carriers 10. Divider
11.Shaper
 Quality Control
• Different tests are performed to check the quality of raw material
Moisture percentage Test
Pure flour Test
Gluten Test
Oil rancidity Test
Oil melting point Test
 Moisture Percentage Test

Equipment:
• Moisture detecting machine
Procedure:
• Take flour and fill it in detector.
• Now Close the cap.
• Note the value, it shows the percentage of moisture in flour.
 Pure Flour Test

Equipment:
• Beaker, Petri dish, weighing balance
Procedure:
• Take 20g flour in petri dish.
• Take 10ml water in beaker and make the dough ball.
• Take water in beaker and put dough ball in it for half an hour.
• After half hour, remove dough ball from water.
• Now get the gluten by wet and dry method.
• Now again weight it and determine gluten percentage by formula.

Gluten percentage=weight of dry gluten ball/weight of flour

sample x 100
 Oil Rancidity Test

Equipment:
Test tube, pipette

Chemical:
HCl,oil,ethanol
Procedure:
• Take 5ml oil in test tube by pipette.
• Take 5ml ethanol and 5ml HCl.
• Now put lid on its top.
• Shake well, leave for 10 mints.
• After 10 mints. Check changing in color.
• If color changes, its mean oil is rancid and if no change in color, there is no
rancidity.
 Melting point of oil

Equipment:
Micro tubes,beaker,burner,thermometer,rubber band
Procedure:
• Take oil in beaker, take micro test tube and fill it with oil.
• Place it in beaker full of ice, it will freeze.
• Turn on burner, put beaker fill with oil on it.
• Take thermometer and ties it with micro tube that is filled with oil.
• Put thermometer in beaker placed on burner.
• Note the temperature at which oil melt and bubbles come out.
• It is melting point of oil.
• If it melts at 35-40C, it is of good quality.
 Production of Bread
• Ingredients:
1. Flour 2. sugar 3. salt 4. oil 5. Yeast 6. water 7. improver
8. Calcium propionate 9. gluten 10. vinegar 11. soy flour
• Procedure:
 All ingredients are weighed.
 Mixing of all ingredients are done in a large bowl and dough is made having temp.
25C.
Moulding of dough is done and placed in oil greased pans.
After moulding ,pans are placed in proofing chamber at temp. 35C for 90
minutes having Rh 75%.
Bread is placed in oven at high temp. 240-250C for 20-25 minutes.
After baking, stay time is given to cool the bread and de-panning is done.
Slicing is done by slicer. There are 22 pieces in a pack. Packaging is done and
stored at cool place.
 Bread Faults
A. External Faults
1.Lack of Volume: Due to use of weak flour, too much salt, lack of
shortening, yeast dissolved in hot water.
2.Excessive Volume: Due to use of wrong type of flour, dough slightly over
aged, long proofing time.
3.Crust colour too Pale: Due to too lean formula, old dough, insufficient
humidity in proofing chamber and during baking.
B. Internal Faults:
1.Crumb is Gray: Due to use of too much malt, old dough, excessive
proofing, pans too large for amount of dough.
2.Coarse Grains: Due to weak flour, improper mixing, slack dough, young
dough, old dough.
 Bread Disease
• Staling of bread:
Staling of bread can be defined as the loss of palatability during storage
causes by changes other than those resulting from the action of spoilage
organisms.
The staling process involves the staling of crust as well as of crumb.