CHAPTER ONE

1.0 INTRODUCTION

This technical report was written in fulfillment of the Student Industrial Work Experience
Scheme (SIWES) as part of the approved minimum academic standards in Nigerian tertiary
institutions in order to provide students with an opportunity to apply their knowledge in real
work situation and also acquire industrial skills and experience before leaving school.

1.1 BRIEF HISTORY OF SIWES

Student Industrial Work Experience Scheme (SIWES) was introduced by Federal Government of
Nigeria to provide adequate practical background studies and bridge the gap between theory and
practice among students of tertiary Institution. The scheme is a skill training program designed to
expose and prepare students of universities, polytechnics, colleges of Technology, colleges of
Agriculture and colleges of Education of the industrial work situation they are likely to meet
after graduation. The scheme also affords students, the opportunity of familiarizing and exposing
themselves to the needed experience in handling equipment and machinery that are usually not
available in their institutions.

SIWES was introduced in 1973/74. The scheme was first initiated and funded by the Industrial
Training Fund (ITF) during its formative years to acquaint students with the skills of handling
employers’ equipment and machinery, but as the financial involvement became unbearable to be
fund, it withdrew from the scheme in 1978. The Federal Government handed over the scheme in
1979 to both the National Universities Commission (NUC) and the National Board for Technical
Education (NBTE).

Later, the Federal Government, in November 1984, reverted the management and
implementation of the SIWES program to ITF and it was effectively taken over by the Industrial
Training Fund in July 1985 with the funding being solely borne by the Federal Government.

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1.2 GOAL OF THE SCHEME

SIWES is strategized as an avenue to prepare and expose students of higher institutions to the
real life work situation they are likely to encounter after graduation. It is key factor needed to
induce scientific and technological skills on students required to inject and engender
industrialization and economic development in our nation.

1.3 OBJECTIVES OF SIWES

The objectives of Student Industrial Work Experience Scheme are specifically to;

 To provide an avenue for students in tertiary institutions acquire industrial skills and
experience during their course of study.
 To provide students with the opportunities to apply their educational knowledge in real
work situations, thereby bridging the gap between theory and practice.
 To expose students to work methods and techniques in handling equipments and
machineries that may not be available in their institutions.
 To prepare students for industrial work situations that they are likely to meet after
graduation.
 To gain experience in writing reports on industrial works /projects
 To strengthen employer involvement in the entire educational process and prepare
students for employment in the industry and commerce.
 To expose students to industrial responsibilities and ethics.

1.4 BRIEF HISTORY OF SUPERCHEFS LIMITED

Superchefs Limited is a bakery company which deals on bread and pastries production, is a home
grown bakery into multi owned company. Superchefs Limited is a multi-owned company having
three managing Directors with the largest shareholder Mr. Femi Oladipupo being the executive
managing Director takes the complete charge of the company while the remaining two; Mr.
Stephen and Mr. Biodun only share in the profit. The firm is basically aimed at producing
tastefully fresh breads and pastries at easy-to-assess locations especially in Lagos. The company
is well known for her Delight Justrite Bread and Sardine Bread which are readily available in
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most of her branches including other bread varieties like: Butter Bread, Tea Cake Bread, Wheat
Bread and Pastries such as Jam and Plain Doughnut, Sausage Roll, Delite Roll, Sardine Roll,
Pizza Roll, Meat Pies, Chicken Pie, Fish Pie, Super Roll, Tata Roll etc.

The company came to being in May 1st, 2012 at Awoyaya, Island Lagos in a small shop which
has grown greatly and is currently the headquarters, with the aim of meeting the ever demanding
needs of people for quality bread varieties and tastefully fresh pastries. Superchefs Ltd is a
bakery industry, an arm of Justrite super stores, having twelve (12) branches in Lagos State. I
had my SIWES at the Isolo branch and the specific location is Oke-Afa, opposite Jakande Gate,
Isolo way, Lagos State.

Over the years, Superchefs Bakery Ltd built its reputation on the foundation of hard work,
commitment, team work, integrity, providing great value to customers and delivering quality
baked products. The company has also acquired fourteen (14) branches in Abuja, Osun state,
Ogun state and twelve branches in Lagos state. All the branches except the Abuja branch are in
partnership with the Justrite Super Stores, a firm basically concerned with the sales virtually all
products at affordable prices. Super Chefs Bakery Ltd partners with super stores such as Blenco
super stores, Ebano super stores and Justrite superstores to extend the business and a form of
marketing Super Chefs Bakery Ltd. The company production process embraces several activities
and actions that result in specific end products. These processes require resources and inputs for
it to be functional. The resources can be grouped into raw materials (Raw materials can be
divided into process materials, ingredients and packaging materials), money, machines,
procedures and manpower.

Baked products are produced with great care using high quality ingredients and processes. The
company ensures that her customers gets a nutritious, delicious, healthy and fresh baked bread
and pastries which is safe and of a high quality product. The company prides herself with the
motto “Tastefully Fresh…” and has the NAFDAC number LA/0286B/KTU. The organization is
well registered with the National Agency for Food and Drugs Administration Control
(NAFDAC) and the Standard Organization of Nigeria (SON) as well as other environmental
regulatory agencies. The company also adheres with principles of Good Manufacturing
Practices, Quality Assurance Management System, and Food Safety Management System to
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ensure that our products are safe and healthy. NAFDAC and SON often visits with periodic
inspection and analysis confirming that the company meet regulatory requirements for
manufacturing, handling, distribution, storage and sale of safe food products to consumers.

1.5 OBJECTIVES OF THE ORGANIZATION

Superchefs Limited is an industry basically into bakery products such as; Delight Bread, Sardine
Bread, Tea cake Bread, Buttered Bread and Wheat Bread, including pastries such as Pizza roll,
Doughnut, Sausage roll, Sardine roll, Egg roll, Super roll, Meat pie, Chicken pie, Delite roll,
Super buns, Fish pie, Tata roll, etc. The company was put in place for reasons listed below:

 To produce uniform quality bakery products that would have high quality as well as unique
and fresh taste.
 To meet the ever demanding need of people for bakery products.
 To make available bread and pastries at locations easily assessable to customers
 To produce an atmosphere for customer to lodge their commendation, complaints and
corrections.
 To make profit to be shared among shareholders
 To provide job opportunities for people with experience and knowledge in bakery as bakers
as well as cleaning, accountancy, business administrative as Managers and Food scientists or
Micro biologist as quality control staff, including Home Economist to formulate new recipe
or bring about improvement on the existing recipes.

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 1.6 ORGANOGRAM OF SUPERCHEFS LTD

MANAGING DIRECTOR

BOARD OF DIRECTORS

FINANCE QUALITY ASSURANCE PRODUCTION MANAGER

MANAGER MANAGER

ACCOUNTANT QUALITY CONTROL OFFICER ADMIN OFFICER

SALES MANAGER MAINTENANCE OFFICER PRODUCTION SUPERVISOR

HEAD BAKER

SALES
ASS. HEAD BAKER/STORE
REPRESENTATIVE
SUPERVISOR

SECURITY BAKERS

CLEANERS

Fig. I: Organizational structure of Super Chefs Bakery

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1.7 FUNCTIONS AND DUTIES OF THE ORGANIZATIONAL HEADS

Below are the functions of various heads in the organization:

 MANAGING DIRECTOR: He is the founder and owner of the company. He delegates

duties to the general manager, quality assurance manager and production manager on
how the affairs should be ran while the mangers report to him the state of the company.

 BOARD OF DIRECTORS: They are group of shareholders; they jointly make policy
decisions and setting of goals to ensure that the company has adequate resources at its
disposal.

 GENERAL MANAGER: He controls, directs and organizes the affairs of the company.
He plays a major role in decision making and polices of the company for the smooth
operations of the company and all the departmental heads and managers’ report to him.
He is in charge of employing people.

 QUALITY CONTROL MANAGER: He monitors the overall production process in the

production floor to ensure the production process conforms to the set standard.
Furthermore quality control manager ensures that the GMPs and SOPs of the company
are kept to prevent production of substandard product and as well oversees the general
cleanliness of the employees and facilities in the company.

 QUALITY ASSURANCE OFFICER: He ensures that the standard adopted during

processing a product is maintained and that the final product is of high quality. He also
makes sure that the raw material or any recipe used in production meets the required
standard.

 MAINTENANCE OFFICERS: The maintenance officer ensures safety in handling the

facilities in the company and ensures the regular maintenance and servicing of all the
machines and equipment in the company as well as utilities used in the firm are in good
condition and also repair any faulty machines.

 PRODUCTION MANAGER: The production manager controls all the affairs that relate
to production of various breads and pastries, from the raw materials, the mixing process,
baking process, the packaging of the various breads as well as the dispatching of baked

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 food products. Its main responsibilities are; Production control and supervision of the
production workforce.

 PRODUCTION SUPERVISOR: He supervises the production activities.

 STORE SUPERVISOR: Keeps every record of what is in the store and ensures that the
appropriate recipes and quantity are being carried for production.

 HEAD BAKER: They see that the targeted number of product is produced and at
appropriate time.

 ASSISTANT HEAD BAKER: He helps the head baker so that all the works are
accomplished.

1.8 DEPARTMENTS OF SUPERCHEFS AND THEIR FUNCTIONS

The departmental division of Superchefs is basically into;

 The Production Department is concerned with the transformation of raw materials into
finished product, that is, bread and pastries. This department however has different arms
including the:

Production unit: this department is concerned basically with the ingredients that are mixed in a
given proportion according to the recipe to produce the finish product. The unit is of great
importance to the survival of the company, its task includes;

1. The weighing of various bread and pastries ingredients on the scale for accuracy in line
with the recipe
2. The weighed ingredients are transferred into the mixer for mixing (whose capacity is a
bag of flour and other ingredients for a batch), it mixes the ingredients into the desired
and uniform dough texture
3. The mixed dough is transferred to the cutting or dividing table where it is cut and
weighed to regular sizes (within a particular range)
4. Moulding is done after cutting the dough into the required sizes. This is done for the sake
of shaping the dough and in order to prevent irregular shape after rising.

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 5. The moulded dough are then panned in a clean already greased (with melted butter)
baking pan/sheet to prevent dough from sticking to the pan during and after baking
6. The panned dough are allowed to go through the proofing process where yeast is allowed
to carry out its effect, the duration time of the dough determines the temperature for
baking
7. The proofed dough is wheeled on trolley into the oven for baking.

Baking unit: this unit deals with temperature regulation for a particular batch, each batch is
made up of hundred (100) loaves. The following are their activities;

1. The oven is first pre-heated before the breads or pastries are wheeled into it to allow for
regulation of heat in the oven so as not to increase the rising of the dough as it is
required.
2. The proofed batch is wheeled into a pre-heated oven. The temperature is increased to
particular temperature depending on the level of rising. The breads become cooked after
a stipulated time which is also dependent on the temperature of baking.
3. The trolley is wheeled out to the work space (table) where offloading of loaves from the
pan to the table when done.
4. The loaves are then arranged on the bread shelve made of cooling rack where it is cooled
prior to packaging.

Packaging unit: packaging is an important part of a consumer’s appeal for a product, especially
with first time purchases. It is important to consider how consumers will view the packaging
such that it would appear as being of high quality product. Thus the packaging unit does;

1. Justrite bags and variety nylons are provided for this unit to package the cooled but
not cold breads
2. The SLICING of bread is also done by the unit; they make use of the slicing
machine to slice them (though only Delight bread and wheat bread are sliced). After
which they are packaged in Justrite customized bags and then sealed using the
sealing machine.

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 3. The packaged breads are arranged on the shelves while some are taken to the sales
shelves in order to display them for sales.
 Quality Control Department: the department is basically concerned with Good
Manufacturing Practices (GMP) aimed at manufacturing safe and quality products and
ensuring that the bakery products are consistently produced to meet specification and
consumer expectation. The GMP has guidelines that cut across all the production units so
as to produce awesome and safe product under sanitary condition.
 Maintenance Department: The maintenance department ensures safety in handling the
facilities in the company and ensures the regular maintenance and servicing of all the
machines in the company as well as utilities used in the firm. They include the engineers,
mechanical and electrical technicians.
 Finance Department: They are involved in the sales, calculation and recordings. The
department also involves in financial reports and activities in the company.

1.9 RELEVANCE OF TRAINING/EXPERIENCE TO FOOD SCIENCE AND

TECHNOLOGY

 Super Chefs gave practical knowledge on work learnt theoretically in the lecture room
 Super Chefs provided opportunity to experience professional work methods in relation to
the course of study
 The company also improved technical knowledge on equipment and machinery.
 Super Chefs gives a light on the labour market environment after graduation.
 Association with professionals of the course of study and other staff.

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 CHAPTER TWO

2.0 SCIENTIFIC BASIS AND PRODUCTION ACTIVITIES

The process of production of baked food products involves some scientific basis that happens
starting from the mixing process of the dough, the reaction of gliadin and glutenin to form
gluten, the leavening reaction of azodicarbonamide and calcium propaionate, the maillard
reaction which gives baked food products its distinctive colour and flavour, are all discussed
below.

2.1 SCIENTIFIC BASIS

2.1.1 Gluten Formation (Protein Bonding)

Flour contains two important proteins -- glutenin and gliadin. When water is added to flour to
make dough, it allows these proteins to bond together and from a new protein called gluten.
During mixing, there is gluten formation when the two gluten forming proteins; glaiden and
glutenine interact with each other when hydrated as they are inactive outside water. Gliadin is
sticky when wet and imparts extensibility while Glutenin gives dough strength and elasticity, and
this helps in rising of the dough and gives it a chewy texture. Glutenin is a large and complex
protein which gives dough strength and elasticity. Kneading the dough intensifies these gluten
bonds. After the dough is place into a heated oven, it begins to rise and grow the gluten network.
This network eventually hardens during the baking process, giving the inside of a loaf of bread
or similar baked foods its signature structure.

Plate I: Gluten structure

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2.1.2 Fermentation

Fermentation occurs when yeast inside the dough converts carbohydrate to carbondioxide
causing gas bubbles to form, which has a leavening effect on dough. This process is very similar
to wine, beer and sour kraut and causes a strong aromatic sensation that is usually pleasing. The
gas bubbles expand inside the dough making the dough appear larger, this is called leavening.
Fermentation is the process by which yeast acts on sugars and changes them into carbondioxide
gas and alcohol. This release of gas produces the leavening action in yeast products. The alcohol
evaporates completely during and immediately after baking (Ali et al., 2012). The following
formula describes this reaction in chemical terms:

C6H12O6 yeast 2C2H5OH + 2CO2

(Sugar) (Alcohol) (Carbondioxide)
Because yeast is a living organism, it is sensitive to temperatures;

34oF (1oC) Inactive (storage temperature)

60oF – 70oF (15- 20oC) Slow action

70oF – 90oF (20 – 32oC) Growth (best temperature for fermentation and proofing of bread
dough)

Above 100oF (38oC) Reaction slows

140oF (60oC) Yeast is killed (Gisslen, 2005)

2.1.3 Maillard Reactions

Maillard reaction is the chemical reaction which occurs between amino acids and reducing
sugars in the presence of heat that results the browning of food while forming new aroma and
flavours to give baked products its distinctive flavour and colour.

Simple sugars (reducing sugars) are sugars which can act as reducing agents in biochemical
processes. Amino acids and reducing sugars found in food are rearranged in rings and groups of
rings so that they produce more complex aromas and flavours. Temperature, moisture and time
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are the key factors in Maillard reaction. High temperature speeds up the Maillard reaction as it
increases the rate of the chemical reaction and speeds up evaporation of water in the food. As
evaporation of water takes place, the sugars and proteins become more concentrated, resulting in
the speed up of the reaction. All these browning, aromas and flavour bursts are a result of simple
sugars reacting together with proteins.

2.2 MAJOR RAW MATERIALS USED IN PRODUCTION

There are various ingredients used in varying proportions for the production of bread and pastries
in Superchefs Bakery, which are as follows:

FLOUR: is a basic ingredient in baking that holds other ingredients together. It provides most of
the bulk of the baked item and the structure in baked foods. Superchef uses the Honeywell
refined wheat flour for white bread and Honeywell whole wheat flour for wheat bread.

Flour has a lot of (CHO) carbohydrate in form of starch and contains gluten forming proteins
which is responsible for the volume of baked products. The quantity of gluten yielded determines
the bread volume. For bread baking, the flour should be wheat flour which is high in gluten
(protein), as this is the substance that gives bread its fine texture and supports the ingredients
during rising. Wheat flour contains proteins that interact with each other when mixed with water,
forming gluten. The gluten develops into a thick, cohesive, elastic mass. It is this elastic gluten
framework which stretches to contain the expanding leavening gases during rising, when placed
in an oven, it puffs up to many times it original volume and sets with a light, airy texture. This
characteristic enables gluten to provide the structure in baked products. The protein content of
the flour affects the strength of dough. The different wheat flour types contain varying amounts
of the gluten forming proteins.

Wheat flour is the most common type of flour used when baking with yeast. Wheat flour is a
powder made from the grinding of wheat used for human consumption. It is made from the
endosperm which contains majority of the protein content. Wheat varieties are called "soft" or
"weak" if gluten content is low, and are called "hard" or "strong" if they have high gluten
content. Hard flour or bread flour, is high in gluten, with 12% to 14% gluten content, and its
dough has elastic toughness that holds its shape well once baked. Soft flour is comparatively low
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in gluten with about 7% to 9% and will give products a finer texture than baked goods made with
hard flour. The wheat flour is composed of carbohydrate (as starch), protein and fat, together
with some fiber, ash and trace minerals and vitamins (Walker and Eustace, 2016).

Unlike refined wheat flour, Whole wheat flour includes the bran, endosperm, and germ of the
wheat grain which gives it a slightly darker brown colour and makes it more nutritious. It has
fiber and higher protein content than all- purpose flour (wheat flour). The bran and germ get in
the way of gluten formation which makes whole wheat flour have a bad rap for making baked
goods dense.

SUGAR: Common sugar (sucrose) is a carbohydrate derived from sugar cane or sugar beet. It is
a disaccharide composed of two monosaccharides, a molecule of glucose joined to a molecule of
fructose (Figoni, 2011). Sugar used in baking was in a granulated or powder form. Sugar is a
major ingredient used in baking, apart from imparting a sweet taste it also serves various
functional properties in the processing of the dough as well as in the structural and organoleptic
properties of the baked product. Sugar has many functions in food other than providing
sweetness. It provides a direct food source for the yeast which converts it to carbon dioxide and
alcohol, improving its action. Sugar is a sweetener that adds sweetness and contributes to the
bread's browning. Sugar enhances the flavour of baked products, gives the crust a golden colour,
improves the crumb texture, and helps retain moisture in bread.

SALT (NaCl): Salt does a couple different things in baking; it helps to preserve the colour and
flavour of flour. Sodium chloride (NaCl) is used as a flavour enhancer and also to control the rate
and extent of fermentation. Salt is an important ingredient in bread baking because it
regulates/controls the rate of yeast activity (fermentation), providing a slow and steady rise. Salt
strengthens the gluten structure of the dough, not allowing the trapped carbondioxide bubbles to
expand too quickly. Salt adds flavour, helps produce bread with fine texture and grain
strengthens soft fat and sugar mixtures.

YEAST: (Saccharomyces cerevisiae) – yeast is a living microorganism until it is destroyed by

heat, convert sugar into alcohol and carbondioxide. As yeast grows and multiplies it gives off
carbondioxide which causes the dough to rise during fermentation (Madigan et al., 2003). Its

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action is affected by the addition or deletion of other ingredients such as salt and sugar. Using
less yeast than specified in a recipe causes the dough to take longer to reach the desired volume
in the rising stages. It lightens the dough and impart to it a characteristic aroma and flavor. Its
primary function is to provide leavening. It contributes to flavour and aroma during
fermentation. The CO2 bubbles give the dough a light, airy texture. Several forms of yeast are
used, such as;

Compressed yeast: is a fresh yeast that must be kept refrigerated to retain its moisture and
freshness. It is considered active.

Active dry yeast: differs from compressed yeast due to the moisture completely removed. This
renders the yeast dormant and must be rehydrated and activated using warm water before use.

Instant dry yeast: is popular due to its ease of use and is added directly to the dry ingredients
without rehydrating. This is the type of yeast used in bread production in Superchefs Limited.
Instant yeast requires no blooming and activates more quickly than active dry It becomes active
instantly when it is rehydrated with liquid. This type of yeast is very convenient, but the rise is so
fast that it doesn't allow much flavour to develop during fermentation. STK royal dry yeast is the
yeast used in production at Superchefs Bakery.

BUTTER: is a solid fat used for baking. It adds flavour, helps in leavening and adds moisture.
Butter gives a softer texture, more tender mouth feel, slows moisture loss, and improves
freshness and shelf life. It adds flavour, richness, moisture, helps prevent the CO 2 bubbles from
escaping from the mixture too soon and make the bread tender. Butter helps the elasticity of the
bread, but if added in larger amounts, just like sugar, it will slow down the action of the yeast,
increasing the rising time.

WATER: Water is the most commonly used liquid ingredient in baking for hydration. It is one
of the ingredients that it is indispensable, just like flour. Water is necessary in baked goods for
hydrating protein, starch and leavening agents. Water, when in contact with flour, causes the
gluten to form and starch to gelatinize. It also helps dissolving other ingredients like sugar, salt
and it pays a very important role in yeast fermentation. Yeast needs water in order to develop,
reproduce, multiply, and form by-products which make the bread rise. Water is also used to
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control dough temperature and act as steam during baking, contributing to the tenderness of the
product. When hydration occurs, water is absorbed and the chemical changes necessary for
structure and texture development can take place. When water vaporizes in a batter or dough, the
steam expands the air cells, increasing the final volume of the product. Main function is
hydration of dry materials.

MILK: adds structure to dough so it doesn’t collapse in the oven. It also gives baked foods their
crisp crust. The protein in milk creates a strong batter or dough, capable of rising and
withstanding the rigors of baking. The sugar and fat in milk help soften, tenderize and moisten
the baked product, while adding flavour and colour. Milk enriches the dough and gives
the dough a creamy colour, soft crumb and creates a soft crumb and golden crust on baked
products. Superchefs use powdered milk because it is more stabled and easier to bulk transport.

EGGS: are leavening agent and enhance the rising of the dough. Eggs also contain the emulsifier
lecithin. Lecithin can add to the overall consistency of the loaf. Eggs add food value, colour and
flavour to breads. They also help make the crumb fine and the crust tender. Eggs acts as a binder,
emulsifiers, moistener and nutritionally, as a source of fat and all the essential amino acids.
When egg is used as a glaze, it also acts as a source of protein for the Maillard reaction.

Functions of Eggs in Baking

(a) Eggs work to bind baked goods together because of the protein content and how it gels as the
egg heats up. This adds structure and strength to baked goods.

(b) Eggs contain so much water content they also help with the leavening. It also adds flavor,
color, tenderness, moisture and richness to our baked goods.

(c)Eggs can be used as an egg wash to enhance its visual appearance and finished texture.

(d)Eggs can be employed as “glue" to make items stick together.

(e) Eggs make yeast breads richer, help provide colour and volume and also bind the ingredients
together.

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CALCIUM PROPIONATE: Calcium propionate (also known as E282) is the calcium salt of
propanoic acid commonly used in commercial bread preservative globally (EFSA, 2014). It is an
effective growth inhibitor of most molds and some bacteria. It is widely employed in bread and
other yeast-based bakery goods to keep them fresh by preventing mold, bacterial growth rope
formation and to extend their normal shelf life. In addition, calcium propionate is preferred in
rolls and bread because it contributes to the nutritional enrichment by supplying calcium.

Besides preserving baked bread for longer periods of time, calcium propionate also contributes to
the nutritional value of the food because it is a source of calcium. Calcium is, of course, a very
important mineral for the human body. Calcium contributes to bone and tooth health, blood
clotting, nerve function, hormone and chemical regulation, and even helps keep a regular
heartbeat in the human body. Calcium propionate is the ideal preservative for bread and rolls
because it has little effect on yeast and does not interfere with its fermentation.

AZODICARBONAMIDE (ADA): is a flour improver and texturize at 10-20g per 100kg of

flour. ADA texturize bread even when external bread improver is used at 50g per 100kg. It is a
maturing agent and flour improver also called improving agent, dough conditioner and maturing
because it matures flour through oxidation, leavening agent and dough improvers used in flour
premixes, providing immediate oxidation when water is added. Azodicarbonamide is also known
as Azobisformamide (AZA) are food additives approved by U.S. Food and Drug Administration
combined with flour to improve baking functionality. It is a chemical compound with the
molecular formula C2H4O2N4. Bread made from ADA-treated flour is characterized by increased
loaf volume and improved grain texture and outside appearance. Natural or enrichment vitamins
are unaffected by azodicarbonamide.

BAKING POWDER: is baking soda with acid added, made from cream of tartar and starch, it is
a leavening agent, which causes batter to rise. Baking powder is essentially a mixture of
NaHCO3 and a weak solid acid or acid salt. This neutralizes the base and produces more CO 2.
When the mixture dissolves in water and the temperature is raised, CO 2 is released according to
the equation:

NaHCO3 + H+ → Na+ + H2O + CO2

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When baking powder is used rather than baking soda alone, the by-products are less alkaline than
Na2CO3 and thus they have no undesirable effects on the taste of the product. The type of acid
used in the baking powder affects the rate of CO 2 production, which in turn affects the product,
e.g. a fast rate of CO2 production is required for doughnuts so that the batter is aerated quickly
and will float in the hot oil, ensuring a crisp product. In baking, the rate at which CO 2 is
produced and the continuity of CO2 production are both important.

2.3 UNIT OPERATIONS AND EQUIPMENT USED FOR PRODUCTION

The unit operations and equipment used for production and their uses are:

WEIGHING/SCALING OF INGREDIENTS: Accuracy is crucial in baking because most

baked products are made from the same basic ingredients. All dry and wet ingredients are
measured by weight. The difference between two baked products is often the proportion of each
ingredient in the formula. Accurate, measurement, or scaling, of all ingredients is therefore
critical in the preparation of quick dough for production. Too much or too little of an ingredient
will affect product quality. A baker’s scale is used to weigh all ingredients and these include
flour, yeast, shortening, salt and sugar for accuracy, to ensure consistency and quality of the
product. They are weighed using the weighing scale and measuring tools such as measuring
bowls, cups and spoons, in their right proportion and quantities before mixing.

Plate II: Weighing scale

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MIXING: Mixing is essential for combining ingredients and forming the dough. Flour, yeast,
water, fat, sugar, and salt are mixed together to make dough. The major objectives of dough
mixing process are;

(a) To distribute the yeast cells throughout the dough and initiate fermentation

(b) Thorough and uniform dispersion of the ingredients to form a homogeneous mixture and

(c) To develop the gluten and bring about the physical development of gluten in the dough into a
uniform structure having optimum desired dough characteristics with respect to plasticity,
elasticity and viscosity.

The ingredients are mixed in a large spiral dough mixer. Ingredients are combined into smooth,
uniform dough; the yeast and other ingredients are evenly distributed through the dough, the
gluten is developed, and fermentation is initiated. During the mixing process, bakers pay special
attention to mixing times and speeds. Focus and precision is key during mixing (Sievert and
Delcour, 2017).

Plate III: Spiral dough mixer

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CUTTING/ SCALING: Cutting/scaling is the next step after the dough has been mixed; the
dough was cut/divided into sizes and scaled by weighing the weight of the dough into the desired
individual portions. The dough is cut manually using the dough scrapper and scaled using the
weighing scale. This is done so as to obtain a uniform weight.

Plate IV: Dough/pastry cutter and scrapper

KNEADING: Kneading is a process in baking that helps to evenly distribute the ingredients and
incorporate air, which assists in making the dough light and contributes to the overall texture and
add strength to the final product both inside and out. Most importantly, the act of kneading
develops gluten, which is necessary for the bread to expand without bursting. Wheat flour
contains two proteins (gliadin and glutenin) that come together to form gluten, which is
responsible for creating the elastic texture in the dough. Simple mixing, leaves these proteins in a
random order, but when the dough is kneaded, the proteins begin to organize and line up together
creating gluten, a giant chains of amino acids, creating a matrix within the dough itself in such a
way that strands of gluten develop and create a structure that allows for the trapping of gases
released by the yeast and resulting in the rise of dough (Cauvain, 2016). This allows the bread to
form a stable structure with a tender interior and crusty exterior. It also creates structure and
strength in the dough.

Kneading is done for four reasons:

(a) To release some of the carbondioxide trapped in the gluten (the primary protein in wheat)

19
(b) To allow the gluten to relax

(c) To help equalize the interior and exterior temperature of the dough

(d) To redistribute the nutrients.

MOULDING: Moulding is a process in which the dough is formed into its final shape and
placed in the baking pan or baking sheet/tray. The object of moulding is to shape the dough into
rolls or loaves properly before baking, to give the baked product its shape and attractive
appearance.

PANNING: The moulded dough is placed into the greased baking pans and the pastries placed
on the greased baking sheet/tray. The baking pans and baking sheets/trays are greased so as to
enable easy depanning and to prevent damaging of the bread and pastries.

Plate V: Panned dough

EGG WASHING: is a process of finishing touch of breads, rolls, pastries, pies and other
desserts. Egg wash is whole egg beaten, sometimes with water or milk is added. Egg whites only
will give a shine, while baked foods brushed with whole egg wash will give more golden shine.
Egg wash can applied to seal edges together, add shine, or enhance the golden color of baked
goods. Not only does it give the creations colour and shine that enhance their visual impact, it
20
can also act as glue when sticking two pieces of dough together or when getting sprinkles or
other sugar decorations to adhere to your baked goods. An egg wash can be applied to shaped
bread or rolls after proofing before baking. After proofing, use a very light touch with the brush
to avoid deflating the bread.

The protein and fat in an egg cause different effects. Protein promotes browning, while the fat in
the yolk gives crusts a nice shine. Since there is protein in egg, it will make the crust both shiny
and brown. Egg wash is applied using the pastry brush.

Plate VI: Egg Washing Process

PROOFING: After moulding and panning, the baked foods are set aside and left for proofing.
Proofing is a process by which dough is fermented, during this stage, more flavours are
developed in the dough and the dough is allowed to ferment and rise to the correct size for
baking, the action of the yeast is speeded up by the higher temperature and the gluten becomes
more mellow and elastic.

Fermentation is the process by which the yeast acts on the sugar and starches and produces
carbon dioxide and alcohol. During the fermentation process, the yeast feeds on the naturally
present sugars in the flour and converts the sugar into carbondioxide and ethanol. The ethanol

21
evaporates during baking while the carbon dioxide leavens or raises the dough. The length of
fermentation varies from dough to dough and helps determine both the flavour and structure of
the finished product (Figoni, 2011).

Rising is the most dramatic physical change dough undergoes on account of yeast activity.
Rising is a product of a process called respiration, which happens because of the fermentation.
As the yeast eats sugars, it releases carbondioxide in the form of tiny air bubbles in the dough.
As the yeast "breathes" or respires, it causes the bread to grow and rise. The alcohol produced by
the yeast during fermentation, along with a multitude of other reactions gives great breads its
characteristic flavours and aroma. The more fermentation takes place, the tastier the baked foods.

Plate VII: Proofing of bread dough and doughnut

BAKING: The final stage in bread production is to place the pans of dough and trays of pastries
in an oven that is heated to at temperature sufficient to heat the dough quickly (165-180 oC)
for 45minutes and to cause the carbon dioxide of the dough to expand, there by greatly
increasing the size of the dough. After the dough has proofed, it is ready to go into the oven.
At the end of the pan proofing period, the loaves are loaded quickly, but carefully into the oven
for baking. The panned loaves are loaded to the trolley and loaded into the oven.

During the first minutes of the baking process the carbon dioxide gas within the dough expands.
This expansion causes a very rapid rise of the dough known as oven spring. Fermentation is
22
more vigorous and more rapid at this stage than at any previous stage. When the inside
temperature of the loaf reaches 1400F. the yeast is killed and fermentation ceases. Alcohol
produced during fermentation evaporates in the form of vapour. After the oven spring, the
pliability of the dough gradually lessons and the dough becomes set and slowly changes to bread.
Some of the moisture evaporates, the starch becomes gelatinized and more digestible gluten and
other proteins become coagulated (Gisslen, 2017).

After the loaf sets, the intense heat dries out the part exposed to the air and causes a crust to
form. The golden brown colour of the crust is the result of chemical changes in the starch, sugar
and milk known as a browning reaction also known as Mailard reaction.

Within the loaf, the crumb near the crust is subjected to a temperature as high as 300 0F. The
temperature gradually decreases towards the centre of the loaf at which point it reaches about
2120F. the same temperature at which water boils at sea level. At this temperature the gluten
becomes stiff enough to give the loaf permanent form and retain its structure. When the baking
process is complete, the loaves are unloaded manually or automatically and either dumped on
cooling racks or travel on enclosed air conditioned conveyor belts to the cooling area. The loaves
are allowed to cool for about 1 hour at which point the internal temperature of the loaf drops to
about 100 degrees F. and is ready to be sliced and wrapped or bagged.

Baking requires a thermal process that uses an oven, which transfers heat to the dough pieces
via:

- Conduction through heated surfaces

- Convection through hot air
- Radiation from heat sources

The heat in turn activates a series of physicochemical changes, responsible for transforming the
raw dough into a baked good with a firm, dry crust and a soft crumb. Baking sets the final
structure to baked goods. It involves simultaneous heat and mass transfer phenomena. The heat
travels from the surrounding air into the interior of the dough or batter while moisture and other
liquid compounds travel/escape from the core towards the exterior or surrounding air due to
evaporation. While both yeast and chemical leaveners can result in gas development and volume
23
build-up, yeast is essential for the development of unique flavours in breads and some baked
goods.

The changes that take place during the baking process include:

 Formation and expansion of gases

 Trapping of the gases in air cells
 Gelatinization of starches ( 60 °C)
 Coagulation of proteins ( 74 °C)
 Evaporation of some of the water
 Melting of shortenings
 Crust formation and browning

Source: (Gisslen, 2005).

1. Formation and Expansion of Gases: the gases primarily responsible for leavening, which is
released and incorporated into dough and batters during mixing; and steam, which is formed
during baking. Some gases such as carbondioxide and air are already present in the dough. As
they are heated, the gases expand and leaven the product. Some gases are not formed until heat is
applied.

2. Trapping of the gases in air cells: as the gases are formed and expand, they are trapped in a
stretchable network formed by the proteins in the dough. These proteins are primarily gluten and
sometimes egg protein. Without gluten or egg protein, most of the gases would escape, and the
product would be poorly leavened. Breads without enough gluten are heavy. Quick breads
usually do not have too much gluten (which is desirable) and they tend to be heavier than yeast
breads.

3. Gelatinization of starches: the starches absorb moisture, expand, and become firmer. This
contributes to structure. Gelatinization of starches begins at about 60°C.

4. Coagulation/denaturation of proteins: Like all proteins, gluten and egg proteins coagulate
or solidify when they reach high enough temperatures. This process gives most of the structure to
24
the bread. Coagulation begins when the temperature of the dough reaches about 74 °C, the
proteins begin to denature. . As a consequence, gluten becomes increasingly tough and stiff as it
irreversibly forms a gel. Moisture loss also imparts rigidity to the product being baked. Correct
baking temperature is important. If the temperature is too high, coagulation starts too soon,
before the expansion of gases reaches its peak. The resulting product has poor volume or a split
crust. If the temperature is too low, the proteins do not coagulate soon enough, and the product
may collapse.

5. Evaporation of some of the water: This takes place throughout the baking process. If a
baked product of a specific weight is required, allowance must be made for moisture loss when
scaling the dough. The percentage of weight loss varies greatly, depending on such factors as
proportion of surface area to volume, baking time, and whether the item is baked in a pan or
directly on the oven hearth.

6. Melting of shortenings: Different shortenings melt and release trapped gases at different
temperatures, so the proper shortening should be selected for each product.

7. Crust formation and browning: which are non-enzymatic reactions and caramelization.
Towards the end of the baking process, a crust is formed as water evaporates from the surface
and leaves it dry. Browning occurs when sugars caramelize and starches and sugars undergo
certain chemical changes caused by heat. This contributes to flavour. Milk, sugar, and egg
increase browning. Maillard browning takes place above 105°C (220°F) and requires the
presence of a reducing sugar together with an amino acid. Sugars caramelize at 160°C (320°F).

8. Killing of yeast and other microorganisms: This usually occurs at an internal temperature
where the cells can no longer contribute to the gas production or volume increase.

9. Inactivation of enzymes: Inactivation of enzymes in the dough (naturally-occurring or added)

at 80–95°C (176–203°F). The main parameters involved in the baking process include: time,
temperature, humidity, air flow (convection systems) and heat flux. These process variables are a
function of the size, unit weight, formulation, water absorption, type and target characteristics of
the finished product. Baking times may range from 2–60 minutes, depending on the type of oven

25
and heating pattern. The baking process is now complete and the bread is ready to be cooled and
stored. After the dough has proofed, it is ready to go into the oven.

Plate VIII: Oven and trolley in the oven

DEPANNING: The baked breads are offloaded and de-panned on the working table
immediately with padded gloves, so as to avoid moisture soaking and falling of the bread. After
de-panning, the bread is arranged on the cooling rack.

COOLING: The loaves are cooled on racks that allow the air to circulate around them and
prevent the crusts from becoming soggy. The cooling racks allow the bread to cool evenly and
prevent condensation from forming on the loaves. The bread should be cooled at least 1-2 hours
to allow the crumb structure to stabilize and intensify in flavour. During the cooling process, the
baked bread and pastries loses moisture, dries out and intensifies in flavour. The starches in the
loaf start retrogradating, helping to set the crumb texture. The temperature gradient between the
crust and the crumb becomes zero with progressive cooling. Cooling is carried out at room
temperature. It is important to allow baked bread to cool before packaging, because during the
cool process, the moist heat tend to pass out into the atmosphere; so if packaged and then allow

26
to cool those heat will accumulate in the packaging material and thereby increase favourable
environment for microbe activity.

Plate IX: Cooling of baked breads

SLICING AND PACKAGING: The Delite bread is packaged using company-branded

polyethylene bags, the Sardine, Butter, Teacake and Wheat bread are packaged using the variety
bags which are non-toxic. Some of the Delite breads are sliced using the slicing machine,
packaged and sealed, afterwards, dispatched to the sales point and displayed on the bread
shelves. Packaging protects the product by providing covering, conserves moisture and helps in
selling of the product.

Plate X: Slicing machine and sealing machine

27
Plate XI: Packaged Delite bread before sealing

2.4 OVERVIEW OF BAKING AND PRODUCTION OF BAKED FOODS

Baking is a method of cooking food that uses prolonged dry heat, usually in an oven. The most
common baked item is bread but many other types of foods are baked. As heat travels through, it
transforms batter, pastry and dough into baked goods with a firm dry crust and a softer centre
(Hsi-Mei and Tze-Ching, 2006). The dry heat of baking changes the form of starches in the food
and causes its outer surfaces to brown, giving it an attractive appearance and taste. The browning
is caused by Maillard reaction. Because foods contain many different types of sugars and
proteins, Maillard browning contributes to the flavour of a wide range of baked foods, such as
rolls, nuts, pie, bread, etc.

Production of baked food products involves different unit operations such as weighing, mixing,
cutting, scaling, kneading, flattening, baking, etc. The quality of baked foods depends on the
formulation, quantity and quality of ingredients. Equally important are the controls in processing
steps to achieve desired quality end product. The essential ingredients of baked food products are
flour, yeast, salt and water. Many other ingredients are used to improve the quality of baked food
products. These are milk, shortening, sweeteners, yeast foods, oxidizing and reducing agents,
preservatives, etc.

28
2.5 PRODUCTION PROCESS FLOW CHARTS

[RAW MATERIALS]

Weighing of ingredients

Mixing

Cutting

Scaling

Kneading

Moulding

Panning

Proofing (200C -320C for 30-60 minutes)

Baking (1650C-1700C for 25-30 minutes)

De-panning

Cooling

Packaging

[BREADS]

Fig. 2: Flow chart for the production of Delite bread, Sardine bread, Butter bread, Teacake
bread and Wheat bread

29
 [RAW MATERIALS]

Weighing of ingredients

Mixing

Cutting (100g each)

Kneading

Flattening

Add filling

Coupling

Remove excess dough

Place on greased baking sheet

Egg wash

Bake at 1850C for 25-30 minutes

[MEAT PIE, FISH PIE AND CHICKEN PIE]

Fig. 3: Flow Chart for the production of Meat pie, Fish pie and Chicken pie

30
 [RAW MATERIALS]

Mixing

Kneading

Flattening

Add filling

Roll to cover

Cut into sizes

Apply egg to seal

Place on greased baking sheet

Allow to rest for 20 minutes

Egg wash

Bake at 1650C for 15-30 minutes

[ROLLS]

Fig. 4: Flow chart for the production of Sausage roll, Delite roll, Pizza roll, Tata roll, Super
roll and Sardine roll

31
 [RAW MATERIALS]

Weighing

Mixing

Cutting

Mould

Allow to rest/rise

Deep fry at medium/low temp for 15-20 minutes

[DOUGHNUT, SUPER BUNS AND EGG ROLL]

Fig. 5: Flow chart for the production of Doughnut, Super buns and Egg roll

[RAW MATERIALS]

Weighing

Pour into greased pan

Design with chicken franks

Bake at 1650C for 20-25 minutes

[FIESTA]

Fig. 6: Flow chart for the production of Fiesta

32
2.6 PRODUCTION PROCESSES

2.6.1 BREAD

Bread is a staple food product prepared from baking a mixture of flour, water, salt, yeast and
other ingredients. Commercial bread commonly contains additives, to improve flavour, texture,
colour, shelf life, and ease of manufacturing. The basic process involves mixing of ingredients
until the flour is converted into dough, followed by baking the dough into a loaf. To make good
bread, dough made by any process must be extensible enough for it to relax and to expand while
it is rising. Good dough is extensible if it will stretch out when pulled. It also must be elastic, that
is, have the strength to hold the gases produced while rising, and stable enough to hold its shape
and cell structure.

Chorleywood baking process is no-time dough system combined with a high speed mixer that is
used in large scale production of yeast-leavened bakery products (Cauvain and Young, 2016).
The Chorleywood Bread Production Process is the bread production process used in making
bread in Superchefs Ltd. Bakery. Chorleywood bread production process uses mechanical energy
in the form of high speed mixing to develop the dough for proving and baking. It is essentially a
rapid form of kneading helping to develop the gluten (protein) structure within the dough (this
means that the lengthy bulk fermentation of traditional processes is not needed). Other than
mixing and bulk fermentation, all other parts of the bread making process – dough
dividing/cutting, proving, baking, cooling and slicing are the same as any other way of making
bread.

DELITE BREAD INGREDIENTS

 Flour
 Butter
 Salt
 Sugar
 Milk
 Instant yeast
 Preservative (Calcium propionate)
33
  Improver (Azodicarbonamide (ADA)
 Water
 Flavour

VARIOUS KINDS OF BREAD PRODUCED IN SUPER CHEFS BAKERY

The various kinds of bread produced in Superchefs bakery varies with the quantities or
proportion of ingredients used, the weight and shapes in which they are moulded. The unit of
operation remains the same which are explained and shown above.

(a) DELITE BREAD: is the main bread produced by Superchefs bakery and packaged with
the company’s customised polyethylene bag. The ingredients listed above are used in the
production of Delite bread. The production processes/flowcharts are shown in fig. 2 above. After
the mixing of Delite bread ingredients, the dough was cut into sizes and at the weight of 900g
each. Delite bread is the only bread which dough was rubbed with butter before panning and the
pan covered after panning to give the dough a flat surface and rectangular shape after proofing
and baking at 1650C for 28-300C. Delite bread is the only bread that can be sliced after cooling
using the slicing machine.

Plate XII: Packaged Delite bread

(b) BUTTER BREAD: is a sweet, soft and smooth textured bread which was produced with
same ingredients used for making Delite bread but contains extra butter which gives the bread a

34
light yellowish butter colour, sweet taste and a very smooth texture to the bread. The ingredients
vary in quantity and proportion. After mixing, the dough was cut into sizes and at the weight of
700g, kneaded, moulded into shape and panned, the pan was not covered to give a loaf shape to
the bread, allowed to proof for 30 minutes and baked at 165 0C for 28-300C.

Plate XIII: Freshly baked Butter bread

(c) SARDINE BREAD: was produced with the same ingredients used for making Delite
bread but contains sardine inside it. After mixing, the dough was cut at the weight of 700g,
kneaded, moulded with sardine inside, panned and the baking pan was not covered, the sardine
oil was applied on the dough instead of egg wash before proofing and baked at 165 0C for 28-
300C.

Plate XIV: Packaged Sardine bread

(d) TEACAKE BREAD: is the sweet bread which was produced using same ingredients
listed above in varying quantity and proportion, with more amount of sugar and contains dried
35
mixed fruits. After mixing, the dough was cut into sizes at 100g each into eight (8) pieces to give
a total of 800g, kneaded, moulded into round shapes and assembled into greased circular pan to
give a circular bread loaf after baking. The dough was egg washed after proofing and baked at
160-1650C for 28-30 minutes.

Plate XV: Before and after baking of Teacake bread

(e) WHEAT BREAD: is a non-sugar brown bread made using 80% whole wheat flour, 20%
wheat flour and the ingredients listed above, excluding sugar, milk and flavour. After mixing, the
dough was cut at the weight of 700g, kneaded, moulded into shape, panned, allowed to proof for
30 minutes and baked at higher temperature, 1900-2000C for 28-30 minutes. The bread is
specifically produced for the elderly because of its health value and does not contain sugar, its
nutritional value.

Plate XVI: Packaged Wheat bread

36
2.6.2 PASTRY

Pastry products are products made from dough of flour, butter and water. The primary difference
between pastries and bread is the absence of yeast in pastries. Pastry is differentiated from bread
by having a higher fat content, which contributes to a flaky or crumbly texture. A good pastry s
light, airy and fatty, but firm enough to support the weight of the filling.

(a) MEAT PIE AND CHICKEN PIE

Meat pie is a popular snack because it is tasty, moist and does not produce crumbs if it is well-
prepared. Meat pie is a delicious snack filled with vegetables (usually potatoes and carrots) and
minced meat while chicken pie is filled with sliced chicken breast and vegetables. Chicken pie is
very similar to the meat pie. The major difference between these two snacks is the meat used in
the filling.

MEAT PIE AND CHICKEN PIE FILLING INGREDIENTS

 Irish potatoes
 Carrots
 Minced meat(for meat pie)
 Sliced chicken breast(for chicken pie)
 Large onion
 Vegetable oil for frying
 Knorr cubes
 Thyme
 Curry
 Garlic powder
 Ginger powder
 Grinded pepper
 Corn flour (to make a binder)
 Water
 Salt to taste
37
PREPARING THE MEAT PIE FILLING AND CHICKEN PIE FILLING

 Peel the Irish potatoes and scrape the carrots, wash and cut into cubes. Wash and chop the
onions.
 Boil the diced carrots and Irish potatoes.
 Heat the vegetable oil on medium heat, add the chopped onions and stir fry a bit, add the
minced meat/sliced chicken breast to the pot and stir vigorously till the minced meat loses
its pink color.
 Add knorr cubes, thyme, ginger, curry, cooked diced carrots and potatoes and water to
the pot.
 Add salt to taste; cover the pot and leave to boil for about 10 minutes.
 Add corn flour to the meat pie sauce in the pot. The corn flour helps to bind the filling
together and retain the moisture of the meat pie sauce when baking.
 Stir thoroughly until well incorporated, turn off the heat and set aside meat pie sauce and
allowed to cool.

(c) FISH PIE

Fish pie is similar to that of the Chicken pie and Meat pie. Unlike the Meat pie and Chicken pie,
which are filled with minced meat and baked, the Fish pie has a fish filling, no irish potato and
baked.

FISH PIE FILLING INGREDIENTS

 Titus Fish
 Vegetable oil for frying
 Carrots
 Chopped onions
 Green pepper
 Knorr cubes
 Curry
 Garlic powder

38
  Ginger powder
 Grinded pepper
 Salt to taste
 Water
 Corn flour

DIRECTIONS FOR MAKING FISH PIE FILLING

 Wash and boil the fish.

 Cut and tear the fish and take out the bones.
 Scrape, wash and grate the carrots. Wash and chop the onions and green pepper.
 Heat up the oil on medium heat, add the chopped onions and carrot, stir fry a bit; add the
boiled deboned fish and green pepper to the pot and stir vigorously.
 Add the knorr cubes, garlic powder, ginger powder, curry, grinded pepper and little water
to the pot.
 Add salt to taste, cover the pot and leave to boil for about 10 minutes.
 Add corn flour to the fish pie sauce in the pot to bind the filling together and retain the
moisture of the fish pie filling when baking. Stir thoroughly until well incorporated, turn
off the heat, set aside and leave to cool.

MEAT PIE/CHICKEN PIE/FISH PIE PASTRY DOUGH INGREDIENTS:

 Flour
 Butter
 Knorr cubes
 Salt
 Vegetable oil for frying

39
PROCESSES FOR MAKING THE MEAT PIE/CHICKEN PIE/FISH PIE PASTRY
DOUGH

 Break some eggs, whisk and set aside for later use.
 Grease the baking tray by rubbing margarine on the inside and sides, and set aside for
later use. This is so that the undersides of the meat pies do not burn or stick to the tray
during baking.
 Measure all the raw materials using the weighing balance.
 Put the flour into a big bowl, add knorr cubes and salt. Mix well.
 Add the butter and mix thoroughly until the mixture looks more like bread crumbs.
 Gradually add little water and keep on mixing until you get stiff dough.
 Knead the dough until smooth and place on a lightly floured surface and leave to rest for
5 minutes. This makes the dough more elastic.
 Cut and mould into a circular shape and flatten the dough on the table using a rolling pin,
it should not be too flat or too thick.
 Place on a circular shaped coupler, and then scoop some of the meat pie/fish pie/chicken
pie filling and place in the center of the flattened dough, the quantity should be such that
you can comfortably close the dough without overflows.
 Now rub the whisked egg, on the edges of the dough. This is to ensure that your meat pie
is perfectly sealed and does not open up while it is being baked.
 Close the coupler and remove the excess dough
 Now transfer unto the greased tray and repeat this process for the remaining pastry
dough.
 Rub the whisked egg on the surface of the meat pies. The egg helps to give the meat pie a
golden brown sheen when done.
 Preheat the oven at 180oC, load the baking sheet of pies into the trolley and then push
into preheated oven and leave to bake for 28-30 minutes or until the meat pies are lightly
browned.

40
Plate XVII: Before and after baking of Chicken pie

Plate XVIII: Before and after baking of Meat pie

Plate XIX: Freshly baked Fish pie

(d) SAUSAGE ROLL

Sausage roll is a popular baked snack made with flour and filled with satice (minced sausage
meat).
41
SAUSAGE ROLL DOUGH INGREDIENTS

 Flour
 Knorr cubes
 Butter
 Salt
 Water
 Egg(for brushing the rolls)

SAUSAGE ROLL FILLING INGREDIENTS

 Satice (minced sausage meat)

 Grinded pepper
 Curry
 Thyme
 Vegetable oil
 Knur cubes
 Eggs

PROCESSES FOR MAKING SAUSAGE ROLL

For The Sausage Filling:

 Weigh all the raw materials using the weighing scale.

 Put the satice (sausage meat) into a large bowl. Add knorr cubes, grinded pepper, curry,
thyme, eggs and vegetable oil. Mix thoroughly to get all the spices in. Add water to get a
paste smooth texture, mix together and keep aside.

For The Sausage Pastry:

 Scale all the raw materials using the weighing balance.

 In a bowl, add the flour, knurr cubes and salt. Mix well and add the butter. Mix well by
rubbing the butter into the flour; Continue mixing until the mixture looks like bread
42
 crumbs.
 Now add a little water, bit by bit, until you get non-sticky smooth dough.
 Place the dough on a lightly floured table and knead for 5 minutes.
 Break an egg, whisk and keep aside.
 Grease the baking tray and keep aside.
 Using a rolling pin, roll the dough flat on the table in a rectangular form to cover the table
(but not too flat).
 Add the sausage filling on the dough end, in a straight line and fold/roll the dough.
 Rub the whisked egg, on the edges of the dough to seal the roll.
 Cut the folded/rolled dough into equal length size.
 Place the sausage roll on the greased baking tray and brush with whisked egg.
 Bake in the Oven at 180oC for25-30 minutes.

Plate XX: Freshly baked Sausage roll

(e) DELITE ROLLS

Fish Rolls is a baked snack made with flour and then filled with mashed spiced fish and chicken
franks.

DELITE ROLL DOUGH INGREDIENTS

 Flour
 Butter
 Egg
 Milk
43
  Instant dry yeast
 Salt
 Sugar
 Water

DELITE ROLL FILLING INGREDIENTS

 Titus fish
 Diced carrots
 Chopped onions
 Vegetable oil for frying
 Chopped cabbage
 Curry
 Powdered ginger and garlic
 Knorr cubes
 Chicken franks (used for moulding)

PROCESSES FOR MAKING THE DELITE ROLLS:

The Delite Sauce:

 Wash and boil the fish

 Cut the fish and remove the bones
 Scrape, wash and grate the carrot, also wash and chop onions and cabbage.
 Heat up the oil on medium heat, add the chopped onions, cabbage and grated carrot, stir
fry a bit; add the boiled fish to the pot and stir vigorously.
 Add the Knorr cubes, powdered ginger and garlic, curry and little water to the pot.
 Add salt to taste, cover the pot and stir constantly for about 10 minutes.
 Turn off the heat, set aside and leave to cool.

44
The Delite Roll Dough

 Measure all the raw materials using the weighing balance and water in liters.
 The weighed flour, sugar, powdered milk, yeast and salt are added into the mixer. Mix
well and add butter into the mixer, add water; continue mixing until the dough is smooth
and non-sticky smooth dough.
 Break egg, whisk it and set aside.
 Grease baking tray and set aside.
 Place the dough on a lightly floured table and knead for 5 minutes, leave to sit for 10
minutes.
 Using a rolling pin, roll the dough flat on the table in a rectangular form to cover the
table.
 Add the delite sauce on the dough end, in a straight line and fold the dough once.
 Place the chicken franks and fold again
 Rub the whisked egg, on the edges of the dough to seal the roll
 Cut the folded/rolled dough into equal length size according to the length of chicken
franks..
 Place the Delite roll on the greased baking tray and brush with egg.
 Bake in the Oven at 180oC for25-30 minutes.

Plate XXI: Freshly baked Sausage roll

(f) SUPER BUNS

Super Buns is a deep fried snack which is a bit crusty on the outside but fluffy inside.
45
SUPER BUNS INGREDIENTS

 Flour
 Butter
 Sugar
 Salt
 Milk
 Instant dry yeast
 Water (to form a thick batter)

PROCESSES FOR MAKING SUPER BUNS

 Measure the raw materials using the weighing balance.

 Put the measured flour, sugar, yeast, egg, salt, butter and milk into the high speed mixer
and mix together.
 Add water and mix thoroughly until the dough is smooth and non-sticky.
 Cut the dough at 90g each and mould into circular shape.
 Leave for 5 minutes.
 Heat up the oil until moderately hot using medium heat.
 Deep fry using medium heat for about 15-20 minutes, so that the inside of the buns will
be done at the same rate as the outside of the buns.
 When you drop the batter, it should sink to the bottom of the pot or pan. Just wait a few
seconds and stir it a bit with the frying spoon.
 To fry the next batch, reduce the heat to low. This is because the oil is going to be too hot
after the first batch.
 The buns are ready when they are golden brown.

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Plate XXII: Freshly fried Super buns

(g) JAM AND PLAIN DOUGHNUT

Doughnuts are popular snacks, made with flour, butter, milk, sugar and yeast and then cut,
moulded and deep fried. Sometimes filled with jam, marmalade, or coated with sugar.

DOUGHNUT INGREDIENTS

 Flour
 Instant dry yeast
 Water
 Butter
 Egg
 Milk
 Sugar
 Salt

PROCESSES FOR MAKING JAM DOUGHNUT AND PLAIN DOUGHNUT

 Measure all the raw materials or ingredients using the weighing balance.
 Put the flour, sugar, salt, milk, and yeast into the high speed mixer.
 Add the egg, butter and mix thoroughly. Add water into the mixer and mix thoroughly for
47
 about 10 minutes.
 Cut the dough at 100g per cut using the dough cutter, mould into circular shape, place on
the floured tray and leave for 20-30 minutes to rise.
 Heat up the vegetable oil and fry the doughnuts at low heat to ensure that the inside get
done, turn each side from time to time to get at even light brown colour.
 Bring out doughnuts from the frying vegetable oil using the frying spoon to sieve out
excess oil.
 For the jam doughnut, make a hole and pipe the jam inside the doughnuts.
 For the plain doughnut, coat the doughnut with sugar by rolling the doughnut in sugar.

Plate XXIII: Freshly fried Jam doughnut and Plain doughnut

(h) SARDINE ROLL

Sardine roll is a baked snack made with flour and filled with mashed sardine to enrich and
improve the taste as well as the nutritional quality.

SARDINE ROLL INGREDIENTS

 Sardine
 Flour
 Instant dry yeast
 Water
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  Butter
 Egg
 Milk
 Sugar
 Salt

PROCESSES FOR MAKING SARDINE ROLL

 Measure all the ingredients or raw materials using the weighing balance and water in
liters.
 The weighed flour, sugar, powdered milk, yeast and salt are added into the mixer. Mix
well and add the butter and egg into the mixer, add water; continue mixing until the
dough is smooth and non-sticky smooth dough.
 Break egg, whisk it and set aside.
 Grease baking tray and set aside.
 Mash the sardine.
 Knead the dough and leave to sit for 10 minutes. After 10 minutes, place the dough on
the flat stainless table and roll flat with a rolling pin.
 Now add the mashed sardine and fold one end of the dough to meet the other end. Cut
and roll each cut-dough to your desired length.
 Tie one by one to give it its shape.
 Place the sardine roll on the greased baking tray, leave for 20 minutes and brush with
egg.
 Bake in the Oven at 165oC for10-20 minutes.

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Plate XXIV: Freshly baked sardine roll

(i) TATA ROLL

Tata roll is a baked snack made with flour and rolled with chicken franks.

TATA ROLL INGREDIENTS

 Flour
 Instant dry yeast
 Water
 Butter
 Egg
 Milk
 Sugar
 Salt
 Chicken franks (used for the moulding)

PROCESSES FOR MAKING TATA ROLL

 Measure all the ingredients or raw materials using the weighing balance and water in
liters.

50
  The weighed flour, sugar, powdered milk, yeast and salt are added into the mixer. Mix
well and add the butter and egg into the mixer, add water; continue mixing until the
dough is smooth and non-sticky smooth dough.
 Break egg, whisk it and set aside.
 Grease baking tray and set aside.
 Cut the dough into sizes; roll each of them into shape using your hand.
 Roll each rolled dough around the chicken franks to mould into shape.
 Place the Tata roll on the greased baking tray, leave for 20 minutes and brush with egg.
 Bake in the Oven at 165oC for10-20 minutes.

Plate XXV: Before and after baking of Tata roll

(j) SUPER ROLL

Super roll is a baked snack made with flour and rolled with chicken franks, mayonnaise and
ketchup.

SUPER ROLL INGREDIENTS

 Flour
 Instant dry yeast
 Water
 Butter
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 Egg
 Milk
 Sugar
 Salt
 Chicken franks (used for the moulding)
 Mayonnaise
 Ketchup

PROCESSES FOR MAKING SUPER ROLL

 Measure all the ingredients or raw materials using the weighing balance and water in
liters.
 The weighed flour, sugar, powdered milk, yeast and salt are added into the mixer. Mix
well and add the butter and egg into the mixer, add water; continue mixing until the
dough is smooth and non-sticky smooth dough.
 Break egg, whisk it and set aside.
 Grease baking tray and set aside.
 Mix mayonnaise and ketchup together and set aside.
 Knead the dough and leave to sit for 10 minutes, place the dough on the flat stainless
table and roll flat with a rolling pin.
 Rub the mixed mayonnaise and ketchup on the flattened dough.
 Cut the flattened dough in a zigzag form.
 Roll each piece round the chicken franks to form its shape.
 Place the super roll on the greased baking tray, leave for 20 minutes and brush with egg.
 Bake at 1650C for 15 minutes

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Plate XXVI: Before and after baking of Super roll

(k) PIZZA ROLL

Pizza roll is a baked snack made with flour and rolled with sliced chicken breast, sliced chicken
franks, ketchup, green pepper, red chilli pepper, onions and pizza cheese.

PIZZA ROLL DOUGH INGREDIENTS

 Flour
 Instant dry yeast
 Water
 Butter
 Egg
 Milk
 Sugar
 Salt

PIZZA ROLL FILLING INGREDIENTS

 Chicken breast
 Chicken franks
 Ketchup
 Green pepper
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  Red chili pepper
 Onions
 Pizza cheese

PROCESSES FOR MAKING PIZZA ROLL

 Measure all the ingredients or raw materials using the weighing balance and water in
liters.
 The weighed flour, sugar, powdered milk, yeast and salt are added into the mixer. Mix
well and add the butter and egg into the mixer, add water; continue mixing until the
dough is smooth and non-sticky smooth dough.
 Break egg, whisk it and set aside.
 Grease the zigzag baking tray and set aside.
 Wash and dice red pepper, onions and green pepper. Slice the chicken franks, spiced and
baked chicken breast, grate the pizza cheese and set all aside.
 Knead the dough and leave to sit for 10 minutes, place the dough on the flat stainless
table and roll flat with a rolling pin to spread on the table.
 Rub the ketchup at one end of the flattened dough.
 Add the sliced chicken franks, diced red pepper, onions and green pepper and then the
sliced chicken breast and grated pizza cheese.
 Fold the dough gradually to cover and roll, apply the whisked egg, on the dough end to
close or seal the roll.
 Cut the folded/rolled dough into size or length.
 Place the pizza roll on the greased zigzag baking tray, leave for 20 minutes and brush
with egg.
 Bake at 1650C for 10-15 minutes.

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Plate XXVII: Before and after baking of Pizza roll

(l) EGG ROLL

Egg roll is a healthy snack which dough is used to wrap the boiled egg and gets its round shape
from the boiled egg used in making it and deep fried.

EGG ROLL INGREDIENTS

 Boiled eggs
 Flour
 Butter
 Sugar
 Salt
 Milk
 Baking powder
 Water
 Vegetable oil, for deep frying

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PROCESSES FOR MAKING EGG ROLL

 Boil eggs and remove the shells.

 Weigh all the raw materials using the weighing balance.
 In a large bowl, add the dry ingredients, flour, milk, sugar, salt and baking powder, mix
thoroughly.
 Add the butter and mix well until the mixture looks like bread crumbs. Add little water
and continue mixing until you get sticky dough.
 Sprinkle some flour on a flat table and place the dough on it. Knead the dough and add
more flour if the dough is too sticky to get a smooth non-sticky dough.
 Cut out a bit and roll out, place a boiled egg on the flat dough and wrap the egg with the
dough. Cut out any excess dough and roll the egg roll with your palm until smooth.
Repeat the process for the remaining eggs,then set aside for 5 minutes and leave to rest a
bit.
 Heat up the vegetable oil on medium heat and transfer the rolled eggs into the hot oil and
deep fry, stirring the egg roll constantly.
 Deep fry until lightly brown and done inside.
 Remove egg rolls from the frying oil using the frying spoon to drain off the oil.

Plate XXVIII: Freshly fried Egg roll

(m) FIESTA

Fiesta is a baked snack made with lots of eggs with little flour, usually serves as breakfast.

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FIESTA INGREDIENTS

 Eggs
 Flour
 Knorr cubes
 Red chili pepper
 Spring onions
 Irish potatoes
 Chicken franks

PROCESSES FOR MAKING FIESTA

 Grease frying pan using margarine and set aside.

 Peel, wash, dice Irish potatoes. Wash and chop spring onions and red chili pepper.
 Slice some chicken franks and dice some.
 Break and whisk eggs in a large bowl, add knorr cubes, diced Irish potatoes and chicken
franks, chopped onions and chili pepper.
 Add flour bit by bit till very creamy but not too thick
 Mix together by stirring well and pour into greased pan.
 Design using the sliced chicken franks.
 Bake in the oven at 1650C for 20-25 minutes.

Plate XXIX: Before and after baking Fiesta

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 CHAPTER THREE

3.0 QUALITY CONTROL

Quality control is an essential component of any food processing business. Quality control (QC)
is a procedure or set of procedures intended to ensure that a manufactured product or performed
service adheres to a defined set of quality criteria or meets the requirements of the client or
customer (Sachan et al., 2014). Quality control department evaluates output relative to a standard
and takes corrective measures when output doesn’t meet the predetermined standard or required
specification, monitors the overall production process in the production floor to ensure the
production process conforms to the set standard. Quality control is used to predict the quality of
the processed food and then control the process so that the expected quality is achieved for every
batch. Quality control personnel in the food company ensure that the food processing, handling
and packaging processes are of standards.

Furthermore, quality control ensures that the Good Manufacturing Practices (GMPs) and SOPs
of the company are kept to prevent production of substandard product, oversees the general
cleanliness of the employees and facilities in the company, protect the consumers from dangers
and ensure they get the weight and quality of food they paid for. Periodically, the quality control
personnel report the quality results to management. A high number of food quality problems
means something is wrong with the process and there may be many unhappy customers for the
company. Management reviews the number of quality problems and where they occur in the
process and take actions to address the issue.

3.1 QUALITY CONTROL MEASURES ADOPTED

In Superchefs Ltd, the company strives to maintain the highest standards in the production of
baked products. Baked products were produced with great care using high quality ingredients
and processes. The company ensures that her customers gets a nutritious, delicious, healthy and
fresh baked breads and pastries which is safe and of a high quality product. The company
adheres with principles of Good Manufacturing Practices, Quality Assurance Management
System, and Food Safety Management System to ensure that our products are safe and healthy.
NAFDAC and SON often visits with periodic inspection and analysis confirming that the
58
company meet regulatory requirements for manufacturing, handling, distribution, storage and
sale of safe food products to consumers.

Some of the quality control measures adopted in the company are outlined below:

I. Raw materials of the highest quality are used in production and these raw materials are
obtained from the production companies. For example, flour which is the main raw
material is obtained directly from the Nigerian Flour mills (golden penny/ honey well)
which we ensure that there’s consistency in the quality of the flour. The production
manager works directly with the procurement department in ensuring that raw materials
are of the highest standards possible and are suitable for the production process.

II. Serious attention is given to weighing of ingredients to ensure consistency in quality of

products.

III. Care is taken at all stages of production to ensure the quality of product especially during
mixing, baking and packaging. Experienced staffs are mandated to supervise these
operations and these operations cannot be carried out in the absence of the team leaders.
This step is critical to ensure appropriate mixing and proofing times and to ensure that the
products are baked properly.

IV. The appropriate equipment and machines are used at all stages of production. Most of the
equipment are made of stainless steel to prevent rusting, soiling and for easy cleaning.
Cleanliness is also an integral part of the quality control process.

V. The production area and all equipment used are cleaned and washed at regular intervals,
before and after production. This is to reduce the risk of contamination and to ensure that
production is carried out under hygienic conditions. All food waste and spillage are
removed daily.

VI. Regular monthly sanitation exercise is strictly observed. Mandatory general sanitations
are organized weekly on Thursdays and the entire bakery is cleaned. There is also regular
inspection of the bakery premises by the general manager and quality control officer to
ensure compliance with the company’s hygienic standards.

59
VII. There are defined personal hygiene rules for all production staff which includes keeping
nails short and unpainted, wear protective coverings (aprons, uniform, face mask, hair
nets and hand gloves).

VIII. Hand washing facilities water and automatic hand dryer close by is provided for
production staff and everyone.

IX. Baked bread and pastries must not be touched with bare hands.

X. Good Manufacturing Practices, Quality Assurance Management System, and Food Safety
Management System ensure that baked products are safe and of good quality. NAFDAC
and SON visits from time to time for periodic inspection and analysis confirming that the
company meet regulatory requirements for manufacturing, handling, distribution, storage
and sale of safe food products to consumers.

3.2 WASTE MANAGEMENT

Waste management is the process of handling waste products generated during production.

1. Non-biodegradable materials such as flour and sugar bags, butter buckets and used tins
are collected and washed, either reused or given/sold to the supplying companies.
2. Solid wastes generated in the bakery are usually disposed by the cleaner to the structured
waste point of the company; hence they can be permanently disposed.
3. Waste effluents are linked to a proper drainage system.

3.3 WATER TREATMENT

Water used for production is sterilized using the UV (ultraviolet) water treatment system to
ensure production of wholesome baked food product. UV water treatment system offer the most
effective way of protecting water used for production against biological contaminants, water-
borne viruses, bacteria, moulds and pathogenic disease-causing microorganisms which are
known to be highly resistant to chlorine-treated water, can be relatively easily eliminated through
UV treatment. UV water purifier uses ultraviolet rays to sterilize water quickly and effectively, it
can eliminate 99% of germs present in water.

60
The UV light source is mounted in front of a tube chamber through which water passes. The
water is exposed to the UV light source as it passes through the chamber. Any harmful microbes
and bacteria that are present in the water are rendered sterile by the exposure to the germicidal
radiation. It gives instantly purified water which is used during mixing and production, it does
not use any chemicals which gives unaltered water taste and colour but requires constant
electricity supply and get purified water instantly.

Plate XXX: Ultraviolet water treatment system

3.4 HAZARD ANALYSIS AND CRITICAL CONTROL POINT (HACCP) SYSTEM

In order to enhance food safety, every stage of the food production (from purchasing, receiving,
transportation, Storage, preparation, handling, cooking to serving) must follow the HACCP
system.

The HACCP is a scientific and systematic system approach to identify, assess and control
hazards in the food production process. With the HACCP system, food safety control is
integrated into the design of the process rather than relied on the end product testing

The Seven Principles of a HACCP System are:

 Analyze Hazards;
 Determine critical point;

61
  Establish limits for critical control points;
 Establish monitoring; procedures for critical control points;
 Establish corrective action;
 Establish verification procedure;
 Establish a record system.

3.5 EMPLOYEE HYGIENE AND GOOD MANUFACTURING PRACTICE ETHICS

i. Employees should wear clean uniform, hair net, nose/face mask and safety shoes, should
always be kept clean.
ii. Never use make up, artificial eye lashes, artificial nails or painting of nails and strong
smelling deodorants or perfume to the production floor.
iii. All employees should wash hands with soap and water and sanitize their hands prior to
handling food, after using rest rooms, returning to their work station etc.
iv. All jewelries, including watches should be removed when entering production floor.
v. Males should shave beards clean before entering production floor.
vi. Taking alcohols and smoking in the production floor is highly prohibited.
vii. Personal clothing / belongings must not be kept in the production floor, but in the lockers
provided.
viii. Use of mobile phones while working in the production hall is strictly prohibited.

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 CHAPTER FOUR

4.0 MARKETING AND DISTRIBUTION

Marketing is the commercial process involved in promoting and selling and distributing a
product or service while distribution on the other hand is the commercial activity of transporting
and selling goods from a producer to a consumer.

Superchef bakery is a company which has been in existence since 2013. The company does not
usually utilize advertising jingles but focuses on maintaining the standards of quality for which it
is already known. The sales department sees to the sales of the freshly baked food product and
the dispatching of the baked foods. They ensure that freshly baked foods are displayed properly
and quality service rendered to the customers.

The company markets and advertises through good costumers’ service and their attachment and
partnership with various large super stores and shopping malls such as Blenco super stores,
Ebano super stores and Justrite super stores which are located in Osun state, Ogun State, Abuja
and about twelve locations in lagos states. These companies advertise through their online pages,
facebook pages and distributing freshly baked quality breads using a decorated van representing
the company.

Plate XXXI: Display of products

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 CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDATION

The industrial training experience gained at Superchefs Limited is invaluable and priceless; it
offered me a great opportunity to grow and develop as well as improved my professional and
ability to work in a multicultural environment. The training provided me the opportunity to see
and know machines in a standard bakery, their uses and how to operate them as well as acquire
practical knowledge on the science of breads and pastries production, understanding of the
relevance of various processing levels, quality, regulating the mixer during mixing to acquire
dough texture quality and other equipment exposed to, which are not available in the school
laboratories. It also provided the template for a better understanding, practical knowledge and
experience of food science and clear visualization of the benefits of food technology. It has also
installed in me some more integrity especially punctuality, being submissive to and taking views
of superiors, more tolerant, respectful and hardworking.

5.1 EXPERIENCE GAINED DURING THE PROGRAMME

During my stay at Superchefs Ltd, I was opportuned to gain a lot of experience which are as
follows:

 I was able to understand the uses of various bakery equipment and utensils and was
exposed to the practical world of baking and the various important steps in baking
 I was given the opportunity to apply the theoretical knowledge in real work situation in
the factory.
 I learnt interpersonal relationship as I developed communication among the workers in
the company which would surely play an important role for future purposes. .
 SIWES provided an avenue for me to acquire industrial skill and experience related to
food science.

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5.2 CHALLENGES ENCOUNTERED DURING THE PROGRAMME

There were different challenges encountered during the programme, which includes:

i. The major challenge faced was that of difficulty in securing placement. Many
organizations do not accept SIWES students and some due to reasons such as
unavailability of vacancy etc. Those available are not willing to give any allowance to
students even though students are made to work like the really employed staff.
Organizations should be enlightened on the importance of the SIWES program to
undergraduates
ii. Another challenge is that of payment and high cost of transportation to my place of
placement. Organizations don’t really have to pay the SIWES students much, but they
should at least pay to cover their transportation. This is because not everyone has
enough for transportation and most people do think of how to save for their school
fees and other things and that is why some students don’t resume on time.

iii. The company also hides their recipe from students which is a limitation to learning.

iv. Breakdown of machines due to mechanical and electrical equipment and machines
used during production, machine breaks down most times and takes a while to repair,
which leads to delay and affects the production process and delivery of products to
customers.

v. Due to damaged and wasted baked products, losses were recorded which affects the
profit and progress of the company.

5.3 RECOMMENDATION AND SUGGESTIONS FOR IMPROVEMENT

i. I recommend the industrial training fund should be able to work in union with the various
organization of attachment (employers) to help the students to secure job opportunities in
such organization upon graduation so as to reduce the high rate of students’
unemployment in Nigeria.
ii. Super chefs Ltd should recruit more professional bakers who have a good grasp of the
underlying science of baking and food processing.

65
 iii. Regular training programs should also be organized for already employed bakers to
augment their rudimentary knowledge.

iv. The company should make provisions for more stringent quality control program
especially with regard to the baked products.

v. Baking machines and equipment used, should be regularly monitored and serviced to
reduce breakdown, spare machines and equipment should be provided.

In conclusion, the student industrial work experience program really exposed me to working
environments and a whole lot of new things that can’t be taught in normal everyday classes
because of time constraint and other factors that are inevitable. Notwithstanding, SIWES in
general has being really helpful. It has also created a pathway for us to fly as eagles.

66
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roles in Fermentation during Bread making Process. Pakistan Journal of Food Sciences,
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Cauvain, S.P. (2016). “Bread: Bread-making Processes.” Encyclopedia of Food and Health,
Volume 1, Academic Press, Elsevier Ltd. pp. 478–483.

Cauvain, S.P., and Young, L.S (2006). The Chorleywood Bread Process, Woodhead Publishing
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European Food Safety Authority (2014). “Scientific Opinion on the re-evaluation of propionic
acid (E 280), sodium propionate (E 281), calcium propionate (E 282) and potassium
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Figoni, P. (2011) “Overview of the Baking Process” How Baking Works, 3rd edition, John
Wiley & Sons, Inc pp. 34–44.

Figoni, P. (2011). “Sugar and Other Sweeteners” How Baking Works: Exploring the
Fundamentals of Baking Science, 3rd edition, John Wiley & Sons, Inc., Hoboken, New
Jersey pp. 164–190.

Gisslen, W. (2005). Professional Baking, 4th Edition. John Wiley & Sons Inc, New Jersey. pp.
13 –51.

Gisslen, W. (2017). “Basic Baking Principles” Professional Baking, 7th edition, John Wiley and
Sons, Inc., Hoboken, New Jersey pp. 93–101.

Hsi-Mei, L. and Tze-Ching, L. (2006). “Bakery Products.” Handbook of Food Science,

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Madigan, M.T., Martinko, J. M. and Parker, J. (2003). Brock Biology of Microorganisms, 10 th
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Sachan, S., Utsav, N., Priyanda, G. and Rashit, S. (2014). An Overview of Pharmaceutical and
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Sievert, D., Hoseney, R.C., and Delcour, J.A. (2017). “Bread and Other Baked Products.”
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 APPENDICES

TABLE 1: WEEKLY ACTIVITIES

Dates Department/Unit Work done
Week 1 – week 2 Introduction/Production Orientation by industry based supervisor,
introduction to the manager and
familiarization of staffs.
Scooping and coupling of meat pies, fish
pies, chicken pies

Week 3 – week 4 Production Frying of doughnuts

Filling doughnuts with jam and coating the
plain doughnut with sugar
Panning of bread dough
Greasing of pans
Week 5 – week 6 Production Production of fiesta
Production of super buns
Production of egg roll
Production of jam doughnut and plain
doughnut
Week 7 – week 9 Production Production of sausage roll
Production of fish pies
Production of chicken pies
Production of meat pies
Week 10 – week 11 Production/cooking Preparation of sausage satice
Preparation of chicken pie sauce
Preparation of meat pies sauce
Preparation of fish pie sauce
Preparation of delite sauce
Week 12 – week 14 Production Production sardine roll
Production of tata roll
Production of super roll
Production of delite roll
Production of pizza roll
Week 15 – week 16 Production Weighing of ingredients.
Mixing using the mixing machine.
Cutting and scaling of dough.
Kneading and moulding of dough

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Week 17 – week 18 Production Coating of moulded delite bread with melted
butter.
Panning and loading of panned bread dough
into the trolley.
Baking using the industrial oven.
Offloading of various baked bread to the
cooling shelf
Week 19 – week 21 Production Production of delite bread
Production of butter bread
Production of sardine bread
Production of tea cake bread
Production of wheat bread
Week 22 – week 24 Packaging/sales Slicing of cool bread
Packaging of the different loaves after
cooling with non-toxic polyethylene bags
Dispatching of various bread to sales shelf
and pastries into the display case.
Sales of baked products

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