Internationally Approved Food Technology Program by IFT and IUFoST

ITP231

Principles of Food Processing

Sugiyono & Nugraha E Suyatma

Food Technology Study Program

Department of Food Science and Technology
Bogor Agricultural University
Topic 8. Baking Technology
Definition
Bread Classification
Ingredients
Processing Equipment
Processing Technology
Product Quality

Internationally Approved Food Technology Program by IFT and IUFoST

Course Objectives

After completing this topic, students will be able to

explain definition, scope of baking technology
(ingredients, processing equipment, processing
steps, and quality criteria)

Internationally Approved Food Technology Program by IFT and IUFoST

Baking

Objectives:
▪ Improve eating qualities
▪ Improve shelf life (preservation through thermal
degradation of enzymes, microbes, reduced
water activity)

Internationally Approved Food Technology Program by IFT and IUFoST

Baking

Includes all processing steps to produce bakery

products
Bakery Product Classification

▪ Yeast-raised goods, ex. Bread and sweet bread.

▪ Chemically-leavened goods, ex. Layer cakes and
biscuits made with baking powder.
▪ Air-leavened goods, ex. Angle cakes and sponge
cakes made without baking powder.
▪ Partially-leavened goods, ex. Pie crusts leavened by
expanding steam and other gases during baking
 Basic Ingredients

Wheat Flour
▪ Proteins :
▪ alcohol – soluble prolamin : gliadin
▪ acid or alkali soluble : glutelin Gluten
glutenin (elastic dough)

▪ Amylolitic enzymes producing fermentable sugars

▪ Existing fermentable sugars
Basic Ingredients
Wheat flour
▪ Hard wheat, bakers flour (11 - 12% protein) : for bread,
noodle, fermented biscuits
▪ Soft wheat, cake flour (8 - 9% protein) : for cake, non-
fermented biscuits
▪ Medium strength, all purpose (10 - 11% protein) :
multipurposes
▪ Many researches have been conducted to explore local
resources-based flour for bakery product manufacturing
Basic Ingredients
Shortening
▪ To produce shortness & tenderness
▪ To aid aeration
▪ To improve eating quality
▪ To improve keeping quality
▪ Melting point of shortenings 46-51oC

Internationally Approved Food Technology Program by IFT and IUFoST

 Basic Ingredients
Baking powder
- To increase volume
- Sodium bicarbonate or ammonium bicarbonate and acid to
generate carbon dioxide when water and heat are supplied
3CaH4(PO4)2 + 8NaHCO3 Ca3(PO4)2 + 4Na2HPO4 +
8CO2 + 8H2O
Salt
- Flavor
- Strengthen gluten
- Keep moisture
Basic Ingredients
Water
▪ Dissolve ingredients
▪ Form dough consistency
▪ Starch gelatinization
▪ Control dough temperature

Yeast
▪ S. cerevisiae
▪ Dough fermentation (volume, flavor, aroma)
▪ Cream yeast, compressed yeast, active dried yeast (instant)
Other Ingredients
Sugar
▪ Fermentable sugars
▪ Improve flavor
▪ Color (brown) development
▪ Keep moisture

Skim) Milk Powder

▪ Improve nutrition value
▪ Improve flavor, color and crumb

Egg
▪ Improve flavor, color and nutrition value
▪ Improve volume
Other Ingredients

Mineral Yeast Foods:

▪ Ammonium salts
▪ Phosphates & sulphates
Dough improver: Potassium bromate & ascorbic acid
Crumb softener: Mono / di – glycerides of fatty acids or other
emulsifiers
Enzymes
▪ Amylase : fermentable carbohydrate/sugars
▪ Protease : act on gluten
Complex Dough Improver
Function Component
Gluten strengthening Potassium bromate, ascorbic acid,
chlorine dioxide
Gluten softening L-cysteine, sodium metabisulphite
Yeast foods Ammonium salts, phosphates &
sulphates
Enzyme supplements Amylase, protease
Crumb softener Mono / di – glycerides of fatty acids
or other emulsifiers
Equipment
▪ Dough mixing equipment (dough mixer)
▪ Dough divider
▪ Dough rounder
▪ Dough moulder
▪ Proofer
▪ Baking pans and trays
▪ Baking oven
▪ Bread slicer
▪ Bread wrapping machine
 Equipment
Mixing and Forming

Z-blade mixer Drum moulder for bread doughs

 Equipment
Heating Oven
Direct heating ovens Indirect heating ovens
Equipment
Heating Oven Operations

▪ Batch
▪ Semi Continuous
▪ Continuous
Bread Processing
Ingredients Packaging

Weighing Cooling

Flour sieving Depanning

Mixing Baking

Fermentation proofing

Gas release Panning

Dough dividing Moulding

Rounding Resting
Bread Processing
Mixing
▪ Aims :
▪ to form homogeneous dough
▪ to develop gluten with optimum plasticity, elasticity &
viscous flow
▪ Mechanism : blend, combine, compress, fold, stretch, push
▪ Methods :
▪ Straight dough
▪ Sponge and dough
▪ Mechanical dough development (rapid process, batch or
continuous operation)
Bread Processing
Development of gluten matrix
(dough development)

Hydration of protein & starch

Uncoiling of protein molecules & their joining together by cross

linking to form network

S – S bonds involves
Bread Processing
Fermentation
- Complex biochemical changes
- Yeast ferments sugars producing ethanol, CO2,
organic acids, etc : Volume, flavor
- Development of acidity: Physical changes in dough
- Temperature increases
Bread Processing
Baking
▪ CO2 expands → raise volume
▪ Denaturation of proteins
▪ Swelling & gelatinization of starch
▪ Yeast & enzymes activity ceased
▪ Crust formed
▪ Develop color, texture, aroma and flavor
▪ Degradation of vitamins
Bread Processing
Baking
Process involved:
Heat transfer
Heat is transferred to
products

Mass transfer
Water is removed from
products

Diagram of material flow during baking

in an oven (P. Fellows, 2000)
Bread Processing
Baking
 Product Quality
• The quality of bakery products is commonly
assessed by sensory means.
• Characteristics of product which determine quality
are volume, color, crust, crumb, texture, aroma, and
flavor.
• Different of products may have specific
characteristics which largely determine the quality
of those products.
 Spoilage
Staling : Loss of aroma & flavour
Changes of texture (dry and crumbly)
Microbiology : molds, bacteria
Suggestions :
▪ Keep good sanitation
▪ Preservatives
▪ Crumb softener & anti – firming additives
▪ Appropriate packaging
▪ Good storage conditions
Bread Staling
▪ Physical & chemical changes which reduce the quality of
bread
▪ Increased crust moisture, crumbliness, firmness, starch
crystallinity, opacity
▪ Decreased soluble starch, hydration capacity of crumb & loss
of flavor
▪ The basic cause : slow change of starch from an amorphous to
a crystalline form, the latter binding considerably less water
than the former. This change leads to a rapid hardening & to
shrinkage of starch granules away from gluten skeleton →
crumbliness.
Bread Staling
▪ -amylase retards staling through a modification
of starch to dextrin & dextrins interfere with cross
– links between starch & protein
▪ -amylase reduces starch retrogadation. Starch
retrogradation causes bread staling.
References
▪ Fellows, 2000. Food Processing Technology,
Principles and Practice
▪ Potter and Hotchkiss. Food Science.

Internationally Approved Food Technology Program by IFT and IUFoST

Case Study
A food industry produces infant biscuits which have to
be fortified with vitamins and minerals. Some vitamins
are destroyed during baking. How do you produce
such biscuits while fulfilling the requirement of vitamin
contents ?

Internationally Approved Food Technology Program by IFT and IUFoST