BREAD

MAKING
 INTRODUCTION
Bread is a popular staple food throughout the world

There are many varieties of bread that differ according to the

ingredients and preparation methods used

The basic ingredients for bread making are flour, yeast, salt, and water

 Due to the increased awareness of the importance of healthy eating,

along with environmental issues nowadays,

breads containing whole grain, or other functional ingredients

are becoming increasingly available in the market
 BREAD-MAKING PROCESSES
The qualities of bakery products rely on both formula and processing
conditions

Bread is produced mainly according to two methods:

the sponge and dough method and
the straight dough method

With technological innovations and design of improvers, several

modifications of these methods have arisen
Sponge and dough process
One third or a half of the total amount of flour is mixed with part of
water and total amount of yeast

allowed to ferment for 3 to 20 h at 21°C to 27°C, depending on the

amount of yeast, consistency of the dough, temperature, and bread
type

After the first fermentation is ended, the remaining ingredients are

added and mixed to form the dough

The disadvantage of this process is that more bowls for the sponge and
more space are needed
 BREAD-MAKING PROCESSES
Straight dough process
All ingredients are mixed together at the same time

The bulk fermentation lasts from 0.5 to 3 h, depending on the

quality of the flour,
yeast level, dough temperature, and variety of bread produced

The resulting breads have fine and uniform crumb structures, but
 lower volume and harder crumb than breads produced by
indirect methods
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Straight dough process
Modification of this methods

 the no-time method

refers to having no resting time or a short resting time of

 up to 30 min before dividing the bulk of the dough

requires high-intensity mixers and a larger quantity of yeast

 Eg. Chorleywood bread-making process

dough is prepared by high-speed mixing of all ingredients for 3
to 5 min
 BREAD-MAKING PROCESSES
Chorleywood bread-making process

After a short resting time, the dough is conventionally shaped,

proofed, and baked

 Process is suitable for

 weak flours and produces bread of high quality with respect to
volume, color, and shelf life

 Large bakeries commonly use this method because

 it considerably reduces the cost and time of production
(1 to 2 h for completion)
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Sourdough bread-Making process

Traditionally, a mixture of flour and water was fermented in several

refreshing stages with microbes originating from the flour

It is fermented for up to 24 or even 48 h at 22°C to 30°C until reaching

pH ≤ 4

Nowadays, the interest in sourdough has been renewed because of its

positive effects on
nutritive value, texture,
flavor, and the shelf life of bread
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Continuous System
 The most common are the Do-Maker and Amflow systems

 A liquid preferment or liquid sponge is prepared and fermented in

stainless steel tanks under controlled conditions for several hours

 Optionally, the fermented mixture is cooled by refrigerated coils

between the walls of the tanks until needed

 Preferment is mixed with other ingredients and then

pumped to a developer that kneads the dough at high speed
under pressure for 1 to 5 min
 BREAD-MAKING PROCESSES
Continuous System
 Air can be injected into the developer

 There is no bulk fermentation, or if there is, it is achieved in the

machine

 The dough is pumped from the developer into an integrated divider,

and then proofed and baked

 The bread produced by this method has a finer, more uniform

structure and more consistent quality compared with other systems
 Raw materials
Flour

 It is the contributor of the proteins necessary for gluten formation

 The higher the protein content of a flour, the better is its ability to
 trap and retain carbon dioxide gas and the larger can be the
bread volume
 Protein quality also influences final product quality

 The higher the grade colour figure (GCF), ash or Branscan value, the
lower will be bread volume,
 because of the dilution effect on the functional protein content
 Raw materials
Yeast
 Saccharomyces cerevisiae
form

 Wet Yeast –known as Cake Yeast, Fresh Yeast, or Compressed Yeast

 Dry Yeast – Sold as Active Dry and Instant Yeast

Yeast + carbohydrates = alcohol + CO2

 The yeast produces carbon dioxide gas to expand the dough

Salt

 A basic function is to contribute flavour but it also has an inhibiting

effect on the formation of gluten during mixing and on yeast activity
Sugar (sucrose)
Raw materials
 High levels of sugar inhibit yeast activity even though it is fermentable

 It also contribute to product sweetness and crust colour

Fat

 are used to improve the gas retention of dough and thereby increase
volume and softness

 level used will vary according to the type of flour

 Raw materials
Water

 Too little and the dough will be firm and difficult to mould
 producing breads that have small volume and poor external
appearance

 Too much and the dough will be soft and also difficult to mould;
 it will flow in the prover and give poor-quality bread

Improvers

 any ingredient added to ‘improve’ the breadmaking potential of a

given flour
 Improvers
ingredients used in improvers

 Oxidising agents to improve the gas retention abilities of the dough

 Reducing agents such as L-cysteine may be added to ‘weaken’ the

dough structure

 reducing dough resistance to deformation it helps in

moulding and shape forming without structural damage
 Emulsifiers may be added to bread to improve its quality

 DATA (diacetyl tartaric acid esters of mono and di-

glycerides) esters,
 sodium stearoyl lactylate,
 Bread-making steps
Dough Mixing

Objectives

 To uniformly incorporate all ingredients,

 To hydrate the flour and the other dry ingredients, and

 Air inclusion

 To develop the gluten via mechanical energy input

 In mixing water is absorbed by flour’s components

 Bread-making steps
Dough Mixing

 The mixing speed and work input must be above a certain value to
 develop the gluten network and
 produce bread of satisfactory quality

 If the mixing energy is larger than the optimum,

 the dough becomes wetter;
 it starts to stick to trough walls and its gas-holding ability
drops

 An optimum work input or mixing time varies depending on

 the mixer type, flour composition, and ingredients
 Bread-making steps
Mixing time is influenced by

 Mixer design  Water absorption of the flour

 Dough size in relation to mixer  Amount of shortening

capacity  Amount and type of reducing

 Dough temperature and oxidizing agents

 Efficiency of cooling systems  Amount of milk solids and other

 Quality of the flour dry ingredients that compete for

the water
 Bread-making steps
 Dough mixing affects dough rheology

 Gas is occluded and concentrated in the liquid phase of dough only

during the mixing stage of bread making

 Oxygen and nitrogen gases present in the dough after mixing,

 but the oxygen is relatively quickly used up by the yeast cells
within the dough
 But nitrogen is remains entrapped, and it providing bubble nuclei into
which
 the CO2 produced later by yeast fermentation can diffuse and
 Dough Mixing

 The production of a defined cellular structure in the bread depends

entirely on

 the creation of gas bubbles in the dough during mixing and

 their retention during subsequent processing

spiral mixer Ribbon mixer
 Bread-making steps
Dough dividing

 To generate the shape and size,

 the bulk dough has to be first divided from the mixer into

individual pieces and then shaped

 At optimum dividing accuracy with minimal compression

damage

 The success of dividing depends on the homogeneity of the dough,

 which is largely determined by the distribution of gas bubbles
 Bread-making steps
 Dough is divided volumetrically with
 Piston dividing
 Extrusion dividing **

o Based on the ability to

 pump dough, usually by means of a helical screw
 density

o The dough is worked considerably and best suited to strong doughs

So use single-stage dividers

 directly from the hopper into the measuring chamber where
the dough volume is set and cut
 Rounding and first moulding

 Modification of the shape of the divided dough piece to deliver a

uniform dough piece to the final moulder

 Mimics an action that carried out by hand in the craft bakery

 Mechanical moulding subjects the dough to stresses and strains and

 may lead to damage to the existing gas bubble structure present

 During rounding the dough piece is rotated on its axis between the two
inner surfaces of a V- or U-shaped trough

 Factor affecting rounders were rotational speed, angle of cone, angle

and shape of track, inclination of track and surface finishes
Rounder and moulder
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Intermediate or first proving

 A period of rest between the work carried out by dividing and

rounding and before final shaping

 The length of time chosen for this process is related to the dough
rheology required for final moulding

 its elimination can lead to a reduction of loaf volume and an

increase in damage to the bubble structure in the dough

 The pocket-type prover is held in fixed frames round the proving

cabinet from charging to discharging stations
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Final moulding

 To shape the dough to fit the product concept and to re-orientate the
cell structure

 Passage of the round dough piece through sets of parallel rolls moving
at high speed to reduce its thickness

 The dough pieces should have low resistance to deformation and

minimal elasticity;
 otherwise the high pressures required to change the dough’s
shape can cause loss of product quality

Indicate WAC and optimizing added water levels during mixing

 Bread-making steps
Proving and retarding

 Proving is the practice of holding yeast based products under

controlled temperature and humidity conditions

 The temperature is designed to maximise yeast growth while

 the humidity is normally high to prevent the dough
forming a dry skin
 sometime referred to as fermentation

 During proof the starch from the flour is progressively converted into

dextrins and sugars by enzyme action

Proving
Proving
 Bread-making steps
Proving and retarding

 Yeast feeds on the sugars to produce carbon dioxide and alcohol

 The carbon dioxide diffuses into the gas bubbles in the dough, causing
them to grow and the dough to expand

 Progressively the size of the gas bubbles increases

 Retarding is holding a dough at a low temperature,

 around a refrigerator temperature,
 to hold up the fermentation process
retarding
 Bread-making steps
Proving and retarding

 Under retarding conditions

 the activity of the yeast is slowed but
 the activity of the flour amylase enzymes is reduced much
further

 Retarding can prevent a dough ‘‘going rotten’’

 as the action of the amylase breaks up so much starch that the
dough becomes sticky and unhandleable

 The ability of a dough to stand these conditions is referred to as its

tolerance  retarder is regarded as a life saver
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Scaling
 Is the process of weighing the dough out

 To ensure that under-weight loaves do not leave the bakery

BAKING OVENS

 Transform dough into a light, readily digestible and flavorful product

under the influence of heat
 Phenomena caused by oven heat includes
 expansion in volume, the formation of an enveloping crust,
 the inactivation of yeast and enzymatic activities,
 the coagulation of the flour protein, and
 partial gelatinization of flour starch, it absorb any free H2O
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 Types of oven include reel ovens, traveling tray ovens, tunnel ovens,
conveyorized ovens, rack ovens, etc.

 The selection of a particular type of oven is often based on the

following considerations:
 the bakery’s production volume,
 product varieties,
 plant space, and cost,

 Reel ovens are suited for low production volume at retail stores

 Larger production volumes, in industry or supermarkets,

traveling tray ovens
 Evaluation of Bread Quality
 Quality parameters include
 density
 specific volume
 pH, water activity, color, and
 Texture------Crust and crumb----for
brown & Glossy Interior
 Proximate analysis
 Flavor