How to Design an Optimal BSG Manufacturing Process Based on

Circular Economy Principles?

T. den Hoedta, M. Olijveb, S. van der Donkc, C. Groiand, C. Sune, Z. Dengf
a,b,c,d,e,f
Department of Process and Food Technology, Faculty of Technology, Innovation, and Society, The Hague University of
Applied Sciences, The Netherlands

Abstract
Increasing attention is paid on the reuse of agro-industrial by-products, from both economic and environmental
perspectives. BSG is an abundant byproduct which can be obtained from beer brewing industry and
incorporated into the bread production, by partially replacing wheat flour with BSG. BSG addition improves the
nutritional value of bread, particularly the protein and fiber content compared with traditional bread -without
BSG. Except for BSG, another main waste collected from the beer brewing waste stream, yeast can also be used
in bread making. After going through some pretreatments, the yeast is ready to ferment the bread with a
function to give a special flavor to the BSG bread.
However, BSG cannot be added more than one-third of the total bread mass due to the lack of gluten.
Otherwise, as a result, an unstructured bread will be gained, which is not good. Moreover, the addition of
bread changes the properties of bread such as texture, only the 5-15% of flour can be altered by BSG within the
desirable level. Therefore, in practice, we made our own bread with the 15% BSG replacement which was finely
milled in 3 different processes and heat treated at 190 °C. Based on our survey, it’s found that bread 2, by using
mortar and pestle milling is the most popular one. Bread 2 owns the most stable score towards each item in
terms of odor, flavor, mouthfeel, texture and so on. The size of milled BSG in bread 2 is mostly distributed
between 0.25-1 mm range.
To scale up the trial in industrial scale, it goes through from milling, sieving, mixing, kneading, fermentation,
dough make up, baking to get the final bread. During these processes, GMP and other instruction should be
implemented to reach acceptable sanitation condition. Certain cleaning and disinfection techniques are
applied.
© 2017 Process and Food Technology. All rights reserved.
Keywords: BSG, Circular Economy, bread, Bakery

1. Introduction
The humankind is shown to consume the
equivalent of 1.6 planets in order to provide the
resources that are used and absorbed (Global Figure 1, Linear Economy
Footprint Network, 2017). There are a variety of The goal of the circular economy is to change the
consequences that derive from this over- term dispose into recycling or reusable. As can be
consumption such as climate change, air and water shown in the circular economy model in figure 2.
pollution, social and economic degradation. The
term of the circular economy is expanding as
means of lasting the human’s lifestyle, which is
dependable on resources while mitigating and
minimizing the unfavorable effects alongside.
The four terms existing in the nowadays life are:
take, make use and dispose of as can be shown in
Figure 2, Circular Economy
the linear economy model in figure 1.
A various number of industries are implementing
the circular economy, in order to reduce waste and
ultimately maximize the yield, which has a direct
impact on profit margins.
Some of the industries that are known to be
implementing the circular economy are the beer
brewing industry along with spent grains bread
making. The beer brewers ‘spent grains (BSG) is the
major by-product of the beer manufacturing,
constituting an 85% of the total amount of by-
products obtained. Therefore, the BSG is available
in large quantities throughout the year; however,
its main application was limited to animal feeding.
Nevertheless, due to its composition, which is a
high content of protein and fiber, it could serve as
human nutrition.
By applying the circular economy model, the
industry of making BSG bread was designed. Spent
grain consists of a higher fiber content compared
to regular bread. Some of the other benefits are
7% lower calories as well as higher protein content
and the amino acid content. All these factors play
an important role in making the spent grain bread
have an added value to nowadays baked bread.
The main purpose of this research is to investigate
all the aspects of the BSG bread manufacturing, in
order to design an optimal process that is based on
the circular economy principles.
2. Theory and Background
BSG bread differs from bread purely made from
wheat flour. The differences between BSG bread
and ‘normal’ bread are investigated and shown
below.
2.1 Characteristics of regular bread vs. BSG bread
At the moment there is a big issue with the
pollution arising from the industrial activities.
There is a political and social pressure to reduce
these environmentally unfriendly pollutants.
Almost all countries are aware of this problem and
try to adapt themselves to this problem by
optimizing their process where they use their
residual streams for recycling. Instead of seeing
your residue as a waste stream, it can be used as a
raw material for other processes.
The beer brewery industry has a large number of
residual streams. Their waste contains for 85% of
spent grain. This grain can be recycled and/ or
reused which makes the beer industry a relatively
environmental friendly industry. The grain that is
being reused/ recycled is called Brewers’ spent
grain (BSG).
Wheat characteristics
A wheat grain consists of 85% out of starchy
endosperm, 13% of the grain is in the outer layers
which make up the bran, and 2% of oily germ.
During the production of flour, the purpose of
milling the grains is to separate the endosperm
from the other kernel portions.  Nowadays, the
wheat kernels are cleaned or abided by the
addition or removal of moisture so the kernels split
open.
Furthermore, there are two types of wheat. Soft
wheat’s produce flours that are suitable for
minimal structured products such as cookies,
crackers, biscuits etc. They contain 8-12% proteins.
However, there also are hard wheat. They contain
12-15 % proteins. These wheat types are being
used to produce for example bread, because of
their suitable flour for products requiring stronger
structures.
Another difference in the types of wheat are the
spring and winter varieties. Spring-wheat grows
quickly. They are planted in early spring and
harvested in late summer or early autumn.
However, winter-wheat is planted in the autumn
and harvested in the late spring or early summer.
Winter-wheat can only grow in places where the
winters are mild. Places where winters are intense,
spring wheat’s are planted in addition that they are
harvesting before frost.   
For a table showing the Percent composition of
Whole-wheat flour compared to BSG flour, see
Appendix B.
Differences Whole-wheat flour bread compared to
BSG bread
BSG got a relatively brown color that affects the
color of the BSG baked bread. Bread made with
BSG is darker than bread made of whole-wheat
flour.
For a table comparing the differences between the
bread made from whole wheat with BSG, see
Appendix C.
Gluten
There are several types of proteins that make up
the total protein content in wheat grain, one of
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which is gluten. Gluten is an important factor in the
bread. It increases dough strength, gas retention
and elasticity, which gives products good structure
and uniform shape to bread. Also, it leads to better
water absorption and retention, improved yield,
product softness and extended shelf life of bread.
When more BSG is added, as bread contains more
amounts of ingredients that don’t contain gluten,
such as higher content of fibre and fat and so on,
See Appendix B, the overall amount of gluten in
the recipe is diluted then resulting in a reduced
volume in the final bread produced. This will
ultimately affect the structure of the end bread
product. Ingredients such as bran or germ can
weaken the dough structure physically, as these
larger particles can upset the gluten structure.
When water is mixed with flour the gluten is
formed as a rather homogenous mass, and it is
during the mixing process and rising of the dough
that the fibers and sheets of gluten which form the
supporting tissue of the loaf are developed. That’s
one of the reasons why we can’t use 100% BSG to
take place of wheat flour totally. The existence of
gluten in wheat flour at certain level ensures that
the gluten network is strong enough to hold up
these extra components like fat and liquid.
Besides, during mixing, the formed protein
network gives the strength and elasticity to the
dough. It is the elastic nature of gluten to make the
protein network rise during the fermentation as
gas is held inside the dough and expand in the
oven. Under this circumstance, the dough with
certain volume and shape is developed. Flours
without gluten do not provide the same elastic
matrix for the structure and textures we associate
with bread and baked goods. So BSG bread can be
described as denser and lacking in the open light
texture that we associate with wheat bread. In
addition to this BSG bread has a crumbly texture,
which stales quickly.
BSG characteristics
The chemical composition of BSG can vary due to
multiple reasons, for example; different kinds of
barley used, harvest time, milling conditions, the
quality and the type of adjuncts added to the
brewing process.
The composition of a BSG grain is coat layers that
cover the original barley grain. Depending on the
malting method, and if every grain has been
malted evenly, some more or less starchy
endosperm and walls of empty protein cells may
also be left. The starch content can be neglect;
however, there is a chance that some hops
residues can be present during mashing depending
on the process that is used in the brewing industry.
The ‘coat walls’ are rich in cellulose
polysaccharides and lignin. They may also contain
some proteins and lipids. But in general, BSG is rich
in proteins, along with minerals, vitamins, and
amino acids. That’s why you often see that BSG is
used in addition to regular wheat flour.
Nevertheless, there are some limitations when it
comes to replacing wheat flour by BSG flour, due
to its color and flavor. BSG has a brown color,
when moist, and thus can only be used in products
with an off-white color. Moreover, because of
modification in the flour, the physical properties
will vary from normal wheat flour and only small
quantities can be incorporated.
2.2 Size Distribution
Öztürk et al. showed the incorporation of BSG of
different particle size (fine, <212 μm; medium, 212
to 425 μm; and coarse, 425 to 850 μm) at 5 to 25%
level into wheat flour for the production (2002).
The results indicated a proportional increment
between the particle size of the BSG and the
dietary fiber content. However, is not a good idea
that adding BSG as much as possible. Although the
incorporation of BSG significantly improved the
dietary fiber but encountering the main difficulty of
achieving a good structure and high loaf volume.
Besides, increasing the level of dietary fiber
significantly increased dough development time,
dough stability and crumb firmness but decreased
the degree of softening and loaf volume.
Normally, 10% of the BSG is milled (Perten
Instruments AB, Kungens Kurva, Sweden) to a
particle size smaller than 355 lm, 59.5% of the BSG
flour consisted of particles between 355 and 250
μm (Ktenioudaki, 2012). Under this circumstance,
the balanced high nutritional value with good
bread characteristic, including loaf volume,
mouthfeel, flavor and so on can be achieved.
2.3 Circular Economy
Nowadays, in the current linear economy, a
product is thrown away after being used; not
realizing that we might be able to recycle it. In the
circular economy, rest streams get a second
chance to be reused in products. Materials keep
their nutrition’s or they are being ‘upcycled’ for
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reusing. With recycling rest streams money can be
saved and it is much more environmental friendly.
Brewers spent grain hailed from beer brewers is
used in the circular economy. By using BSG in
addition, and as a replacement, in bread
manufacturing, more than a quarter of materials
are saved. Besides BSG, also another rest stream
from the beer brewery can be used in the bread
baking industry.
The main wastes in the brewing process are beer
spent grains and waste yeast, but also diatomite
sludge and a small amount of waste protein. A
large number of by-products and waste products
produced by beer brewery and waste, if not
utilized well, will result in a huge waste of
resources and serious pollution to the surrounding
environment. Recycling of beer waste cannot only
reduce the pollution of the environment but also
develop potentially high value-added products,
greatly enhance the economic efficiency of
enterprises.
Waste yeast is a treasure, containing 50% of
protein, 6-8% of ribonucleic acid, 2% of vitamin B,
8 essential amino-acid for the human body and a
variety of nutrient. Through the autolysis of edible
waste yeast, that is using endogenetic enzyme of
the fungus, such as protease, nuclease,
carbohydrate hydrolase, etc., the macromolecule
substance in the bacteria is decomposed into small
molecule soluble substance. Including free chloric
acid (20 species), nucleotides, peptides, sugar and
so on. At the same time, it does not contain
cholesterol and saturated fatty acids. Among them,
the content of amino acids is rich, the components
are balanced, the ratio between essential amino
acids and the human needs model is quite close to
the formulate, especially the high content of lysine,
which is conducive to make up for lack of the
amount of levulinic acid in bread. Aspartic acid and
glutamic acid have an umami taste, and the serine,
threonine, alanine have a sweet taste, which has
the function of enhancing freshness and flavoring
to the mellow taste of the BSG bread. Besides, that
chloric acid can mask the smell and odor of spent
grain in the bread.
By reusing the beer brewing spent grain and waste
yeast, a recycle, ring model is built to achieve both
effective utilization of resources as well as profit
growth. This sustainable development is fitting the
concept of circular economy. Within these beer
and bread industries, the factory has played a
"producer", "decomposer" role. Waste generated
during the production process has been almost
completely absorbed within the entire industrial
chain, basically achieving "zero emissions”.
3. Methodology
The BSG manufacturing process is first developed
on small scale, and that process is upscaled to an
industrial process. The overall production process
doesn’t differ in the lab scale compared to the
industrial scale. Only the amounts are upscaled
while aiming to keep the rest as much the same as
possible.
3.1 Overall Production Process
During the bread production, there are several
steps. These steps and their function are described
below.
3.1.1 Milling
In the brewery, the grains used are separated from
the liquid after the boiling step. With filtration, the
grains are removed from the liquid and can be
seen as waste or byproduct for the beer brewery.
The liquid fraction is produced further to beer, the
solid fraction is dried and BSG is obtained and
transferred to the bread baking industry.
Normally bread consists of regular flour, but in
context of the circular economy, some BSG is
added. Before the BSG can be used it must be
converted into powder by milling machines. By
milling the BSG, the hulls around the grain will be
removed (Hassona, 1993; Miranda et al., 1994a,b;
Öztürk et al., 2002).
3.1.2 Sieving
After the BSG is milled, the impurities must be
removed to prevent the bread of physical and toxic
hazards such as bacteria’s and kennels/hulls from
the grain.
In general, the goal of sieving the flour (milled BSG)
is:
- To aerate the flour;
- To remove coarse particles and impurities;
- To make the flour homogeneous (the
same particle size).
3.1.3 Mixing
Before the mixing, all ingredients are weighed in
the right fraction (see table 1). When making the
BSG bread, a fraction of flour is substituted with
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BSG. This is done in different fractions. Different
used fractions where regular flour is substituted
with BSG could be 5%, 10% or 15% as stated by
Dreese, and Hoseney (1982).
In table 1, is chosen for 15% BSG flour in context of
the circular economy.
Ingredients Percentage
Regular wheat flour 85
Brewers Spent Grain 15
Yeast 2-4
Salt 2
Sugar 6
Fat 2
Water 60
Table 1, general fractions of the ingredients (A.M.
Samuel, 1996)
These different fractions affect the characteristics
of the final bread.
The bread consists of different ingredients (see
table 1). Sugar, salt, oxidizing agents, and yeast are
added in solution form and in a sequence way. By
every addition, the previous addition must be
completely solved to get an optimal dispersion of
all ingredients.
Mixing the regular flour and the BSG with the other
ingredients provides the dough for development.
The development of the gluten starts with the
hydration of the ingredients by the addition of
water. During the hydration, the gluten network
will expand in the dough. By the time the dough
will be stickier and one coherent substance due to
the maximum point of consistency will be formed.
The dough must develop a well-structured dough
network in order to retain the CO2 gas inside the
dough.
Mixing time.
The time of mixing the ingredients with each other
depends on the constituents of the dough, type of
mixer, the particle size of the flour, and kind of
gluten in the flour and the presence of salt or other
substances.
In case the mixing time is to short the dough will
be over mixed and when it is too long it will never
reach its optimal point of mixing so there won’t be
a good coherent substance of dough.
As said before the kind of gluten (flour) is very
important in the mixing degree. In case of flour
with weak gluten, the mixing time will be shorter
than flour with strong or extra strong glutens. The
gliadin proteins and its subgroups are the factors
behind the mixing time. Gliadin proteins differ in
size and due to the size of the proteins, the mixing
time differs. In case of small proteins, the mixing
time will be shorter.
Kneading.
All ingredients are well mixed and a bulk of dough
has formed. Before the fermentation stage, the
dough must be kneaded to aerate the dough for
two purposes:
Provide a gas nucleus for CO2 formation during the
fermentation stage. Provide oxygen to enter the
dough for optimal yeast activity and oxidation of
the dough.
3.1.4 Fermentation
After the viscoelastic substance is mixed well and
formed, the most important step of the bread
making process can begin. During the fermentation
of the dough, the sugars are converted into carbon
dioxide (CO2) and ethanol. The formed CO2 exit
the bread through the dough and affect the
structure of the final bread. During the solid
fermentation phase, the fermentation contributes
to the taste and structure of the bread.
The conditions of fermentation.
First of all, the presence of a certain yeast S.
cerevisiae is important for the breakdown of the
sugars. Besides the yeast, the temperature and
humidity play also an important role in the activity
of yeast and the gas production. The surrounding
temperature must not be too high (above 40°C) in
order to prevent that the yeast cells will be killed
or distort. The right temperature of fermentation is
30-35°C with a humidity of 85% or higher.
The optimal pH degree where the yeast activity is
optimal is from 4-6. Is the pH degree lower than 4,
the yeast activity will decrease due to the
deformation and distort of the yeast cells. In case
of a higher pH, the activity will be lower as well.
Knockback.
During the fermentation some periods of rest of
the dough are used to knock back, normally after
5
2/3 of the fermentation time is over. By pushing
the dough together (knockback), the inside of
formation of gas will be released and temperature
will be spread around and in the dough. By pushing
the dough together, some oxygen will also enter
the dough. The incoming oxygen stimulates the
yeast activity and so the fermentation.
Furthermore, the knockback also provides the
gluten with some mechanical extension by folding
or stretching. This prevents the dough from
becoming one hard and sticky substance.
3.1.5 Dough Make-Up.
After the first main fermentation, the dough
becomes a fermented bulk. The goals of the dough
make-up are:
- To shape the dough already to its
intended design.
- To divide the dough into uniform pieces.
- Improve the grain and texture of the
bread.
- Improve appearance and acceptability of
the final bread.
The dough make-up is consisting out of four parts:
1. Scaling;
2. Rounding;
3. Intermediate proofing;
4. Molding;
Scaling
The bulk of dough is divided by a divider into slices
to predetermine the intended weight and size. To
prevent the yield loss, 12% extra weight of dough
is taken into consideration.
Rounding.
After the dough sliced into different pieces, the
sizes of the slices are still difficult to handle on an
industrial level. The chance of contamination is
also greater with sticky sizes. Therefore the goal of
a rounder is to change the surface of the slices and
retain the gas inside and give the dough more
strength. The stickiness of slides will also be
reduced by making the surface hard.
Intermediate proofing.
Although by the rounding most of the gas will
remain in the dough, some gas has left the dough
sideways due to the machine and the divider. As
results of the degassing of the dough, the dough
will tear more easily and will lose it flexibility. To
prevent the problem by molding the dough will
rest during the fermentation.
The machine (intermediate proofer) consists of
trays where the dough is lying on. The rate of trays
is predetermined and is driven by a chain with a
constant rate of stages. The duration of a stage is
around 5 – 20 minutes.
Molding
In the last step of the dough make-up, the dough
must be shaped and placed in the purposed pans
for the baking step. Before the dough is placed into
the pans, pushing the power of 2 or 3 closed rolls
with different sizes degasses the dough. The
different does have different diameters to provide
a good degassing and grain and structure of the
dough. The biggest roll is about 0.25”, which degas
the most the CO2 out of the dough. The other rolls
of 0.125” and 0.06” provide a good grain texture.
Then to give the dough a good cylindrical form, the
dough will enter the woven mash chain. The dough
must be very tight to prevent that some air from
outside will enter the dough.
3.1.6 Proofing Process
Before the dough bulk ready to be baked, the
dough is transferred into pans. The important
point of transferring the dough into pans is that
the seam must be at the bottom of the pan.
This is to prevent that the dough will break open
during the baking phase. The temperature of the
dough during panning is 32°C.
Proving or proofing process refers to the last step
of the fermentation. Proving is a resting period of
the dough in the fermentation step where the
dough rises to its desired and intended height.
The optimal parameters of the rising stage:
- Temperature 30-35°C
- Humidity 85%
- Time 55-65 minutes.
In optimal conditions, the size of the dough will rise
by a rate of 3-4. The humidity is an important
factor during the rising stage; the wet content in
the dough will evaporate under higher
temperature. In case of a low humidity, the dough
will not rise to its indented design due to the loss
of wet content and will result in a crusty bread. On
the other hand, a high humidity will lead to
condensation of the dough.
6
3.1.7 Baking
After the dough is made up and the fermentation is
done, the baking process can begin. The most
important parameter of the baking process is the
temperature.
The oven must be suitable for a temperature of
220-250°C. To ensure that the bread is baked well
the inside temperature must be around 95°C. This
temperature must be accomplished to prevent the
bread from becoming soppy. Different forms of
heat transferred this heat to get well-baked final
bread.
Heat transfer in the dough.
The heat provided by the oven is transferred by
different ways of heat transfer:
- Convention, heat transfer due to gasses.
- Radiation, electromagnetic radiation
generated by thermal motion.
- Conduction, heat transfer due to solid
materials.
- Condensation of steam.
- Evaporation of water.
In the dough, there is a formation of evaporation,
conduction, and condensation of steam are the
occurring forms of heat transfer.
The time of baking depends on the size of the
bread. Normally it takes around 25-30 minutes.
3.1.8 Packaging
After the dough turned out into bread. The bread
must be cooled down before packaging. The right
temperature for packaging is around 35-40°C.
The way of packaging differs from company to
company. Normally the bread is already divided
into slices.
3.2 Lab/kitchen scale
In the kitchen, BSG bread has been made on small
scale. During this kitchen trial, the following recipe,
and procedure were followed. There were four
types of bread made. Three BSG-breads each with
a different type of BSG milling, and one normal
bread.
3.2.1 kitchen scale recipe
850 gram Whole wheat flour
150 gram BSG
40 gram Yeast
600 ml Water
20 grams Salt
60 gram Sugar
For the normal bread to compare the results in the
survey, 1000 grams of whole wheat flour was used
replacing the BSG-and-whole wheat flour
combination.
3.2.2 kitchen procedure
Extended information on the theory behind the
kitchen scale steps can be found in chapter 3.1, the
following steps were followed during the kitchen
trial.
1. The BSG was first milled in the correct size, for
this experiment, also the optimal milling
technique was investigated. Therefore, three
milling techniques were used. The following
milling equipment was used for the following
bread types: (1) Magimix, (2) Mortar and
pestle, (3) Beer brewing miller. The milling
equipment is further explained in chapter
3.2.3.
2. After the milling, the BSG was mixed with the
whole wheat flour. In the correct ratio, as can
be found in chapter 3.2.1.
When the BSG and wheat flour were mixed, the
‘normal bread making procedure’ could be
followed.
3. The yeast was then dissolved in 300 ml of
semi-warm water. And let it acclimate to the
new environment.
2
4. of the needed amount of BSG/wheat flour
3
was weighted and put in a bowl, with a small
pit in the middle.
5. Next, the yeast was added, together with the
rest of the water. And let it rest for 10
minutes.
6. After the waiting time, the salt, and sugar was
added. And this mixture was kneaded for
around 10 minutes.
7. The dough rested for a while with a
temperature around 30-35°, in a high humidity
environment. To build this environment, a
kitchen towel is wetted and hung over the
dough.
8. Now, the dough was knocked back. And the
oven was preheated at 190°C.
9. When the dough has risen enough, the bread
was formed.
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10. When the bread had a nice shape, it was put in
the oven at a temperature of 190°. Also, a
bowl with a little bit of water is placed in the
oven to make an environment with a high
humidity.
11. After around 25-30 minutes, the bread is
ready. This can be checked by knocking on the
bottom of the bread. When it sound hole
inside, the bread is finished.
3.2.3 Particle Size Distribution
During the kitchen trial, BSG was milled with three
different types of equipment as mentioned before.
The first milling technique used was the Magimix.
This is an electronic mixing device with a sharp
knife which cuts everything inside the machine.
The second milling technique was milling using a
mortar and pestle.
And lastly, the third milling technique was the beer
brewing miller.
The result of the particle sizes can be found in
chapter 4.2 and in Appendix. A
3.3 Industrial Scale
The main downstream steps in the industrial
processing of BSG bread doesn’t differ from the
Lab/kitchen scale.
3.2.1 Characteristics of food processing equipment
and industrial process
The steps of the bread making process are
described below. These steps are when bread has
to be made on small scale (lab/kitchen scale).
When wanting to produce bread on an industrial
scale, this process must be upscaled while
maintaining these steps.
All industrial steps are illustrated in the Process
Flow Diagram in appendix D Also is a list of
equipment provided in the appendix.
At the start of the process wet BSG is coming from
a beer brewery, this enters a filter to remove big
particles and waste that entered the BSG before
entering the bakery. Since wet BSG from a brewery
contains 70-80% of water, and further contains
large amounts of polysaccharide, and proteins, this
must be dried to prevent microbiological growth
(Kunze, 2010). Therefore, the wet BSG is dried
using an electric oven to lower the water content
in the BSG, to prolong the lifetime of the BSG. The
moisture content is lowered to around 10% since
that is the optimal amount to prevent microbial
growth according to Woods et al. (1994).
Also, is it the case that during the drying step, the
BSG won’t be entirely dried but the water content
will be adjusted so that the rest of the process can
continue with the same recipe. Therefore, the
bakery can produce bread in a continuous process
without having to adjust the recipe everything, and
so creating a constant product.
For the preservation by drying, multiple options
are possible among them are oven-drying, freeze-
drying, and the use of superheated steam. An oven
dryer is used since according to Kieran et al. freeze-
drying is not economically attractive and
superheated steam is not investigated properly but
on small scale, it was attractive to use (2016).
Therefore, oven drying is preferred at no warmer
than 60°C.
After the drying, the BSG is stored in a storage
tank, T-101. According to Robertson et al.
autoclaving was most suitable for long-term BSG
storage (2010). When the BSG is frozen or
autoclaved at 120°C for 1 hour it is made sure that
no microbial growth was taken place, while when
stored at 4-20°C there was some microbial growth.
But since the microbial activity is very low, and the
BSG is not stored for an extremely long time, and
the cost of autoclaving or constant freezing is
relatively high. In the bakery the BSG is not
autoclaved but immediately stored at around 4°C
(Lynch, 2016).
After the storage, the bread making process can
begin. The BSG is milled with techniques similar to
the mortar and pestle technique and reduced to
the same mean diameter with a standard deviation
as low as possible.
After the milling, the BSG moves to a filter, which
filters the BSG particles that fall outside the error
margin and moves those to the milling phase
again.
The BSG is then moved to a mixer, where BSG and
whole wheat flour are mixed in the correct ratio
described before. While, at the same time, water
and sugar are mixed, in a separate mixer and yeast
is added to this mixer.
The solution of water, sugar, and yeast is then
added to a separate mixer with the BSG and whole
wheat flour. And this is mixed until it is more or
8
less a compact dough. Then this dough is moved to Lastly, the bread is ready to be shipped to stores,
the kneader, where the same types of handling or warehouses.
must be recreated on the industrial scale. The type
3.2.2 Sanitation and Cleaning
of kneading of the bread plays a major role in the
quality of the final product and must, therefore, be Produced bread will be sold throughout the
recreated as similar to the lab scale as possible. An country, if the product has any quality problems,
industrial kneader must, therefore, be used. The ranging the company will get consumer
kneader must have enough access to oxygen from complaints; heavy will lead to food poisoning and
the outer air outside the kneader. other serious food safety incidents, may result in
the closure of manufacturing enterprises. When
The dough is then moved to an area with a high
healthy people eat moldy and rotten bread,
humidity, which can be done through recycling the
nausea, vomiting, diarrhea and other symptoms
steam from the oven-drying step. In this area, the
appear. These are the signs of food poisoning
dough will rise for some time. The bread enters
(Peng, 2014).
this area in trays.
Environmental health conditions in the production
The choice has been made to use water vapor, that
process are poor, the number of microorganisms,
leaves the process at the drying, to recycle in the
microbial contamination of baked goods, baking
process to create an environment with a high
bakery food is the main cause of mildew. To truly
humidity during the rising/fermentation. The heat
implement the GMP system at bakery facilities, air,
exchanger, E-102, used in the process to cool the
walls, floors, ceilings, equipment, etc. in
steam coming from the drying step in E-101, can
production environments, especially in clean work
also be done through natural cooling. When the
areas, must also be sterilized using the right
length of the pipeline is long enough, and the
methods. Regularly fully open and clean each
insulation is not too high, the water can cool down
machine from the workshop and then reinstall
without having to pass a heat exchanger.
(Peng, 2014).
After some time, the dough must be knocked-back
Prior to the production of cereal food, the food
and this is done by a sort of kneader. This machine
assessment agency first checks the presence or
must recreate the knocking back with a hand, and
absence of pesticides and fertilizers in the wheat
therefore a machine must be picked that can make
production process and removes any sand and
these movements.
debris prior to storage. However, brewer’s spent
When the dough is knocked back, the dough is grain is used to produce bread, so it is not
moved to the rising area again with a high humidity necessary to check the raw cereal, but before
before shaping the dough into bread. The bread entering the processing plant, it is necessary to
enters the rising area in trays. check whether the raw material moldy (Peng,
2014).
In the shaping step, with machine X-104, the bread
is shaped into a normal shape. This machine will Grooves or irregularities appear in the inner wall
make sure the bread looks good and can move to of the pipe may lead to a build-up of raw materials
the oven. or food in the pipe. If they are not cleaned in time,
the accumulated food or raw material in the
After the shaping, the bread must be baked, at the
pipeline may be spoiled, bacteria may grow inside
same temperature and time as in the kitchen scale.
the system, resulting in pollution of the entire BSG
After the baking, the bread must be cooled, to
bread production process. The entire BSG bread
reduce the cooling time, cool air is used to cool the
production process is a food processing, it is
bread before cutting it since warm bread is more
necessary to ensure that all materials sanitation
fragile when cutting it.
safety (Peng, 2014).
In the cutting phase, the bread is cut into slices and
According to the Good Manufacturing Practices
then moved to the packaging where the bread gets
(GMP) regulations of the Food Factory, the
a nice package, which can be made with using
processing plant must have appropriate sanitation
alternative materials of rest streams of other
facilities and a reasonable layout as follows:
industries and implementing the circular economy
principle. 1. Sanitation configuration

9
a. The production plant should be set
according to the process and hygiene
requirements in order to avoid the cross-
contamination of the process and the raw
material and clinker;
b. Dressing rooms, disinfection rooms, raw
material warehouses, semi-finished
products workshops, processing
workshops, packaging workshops, testing
rooms, finished goods libraries and offices
should all have their own independent
locations.
c. Plant area should be sufficient for the
placement of sanitary facilities,
production equipment, facilitate
personnel operations, storage of raw
materials. Establish special sanitation
facilities for storing foodstuffs and
utensils;
d. There should be a certain width between
the equipment in the processing
workshop or between the equipment and
the wall to facilitate the operation and
passage.
2. Zoning isolation baking food production
and a number of venues, different places
on the hygiene cleanliness requirements
are not the same, food processing
enterprises should be strictly separated
and isolated these places, according to the
bakery processing process, divided into:
a. General work area, including raw material
warehouse, tool warehouse, raw material
processing place;
b. Quasi-clean operation area, including
processing conditioning, semi-finished
products warehouse, packaging material
preparation room, buffer room;
c. Cleaning work area, including the
decoration and packing of high-moisture
active baking food, the cooling and
storage place and the inner packing room
after the processing field and food
packaging before packing;
d. General work area, including outer
packaging room, finished product
warehouse;
a. Non-food processing areas, including the
laboratory, office, dressing and hand-
washing disinfection room, bathroom.
Yeast, flour and water are essential for most baking
projects. But if bakery do not clean their
production equipment properly, these three
ingredients can also act as a medium for bacterial
growth. Dangerous food pathogens can
contaminate products and cause unmanageable
problems. "Efficient bakery plant management
requires CIP (cleaning-in-place) practices of most
production equipment," says Evan Reyes, Specialist
for the food service industry at Goodway
Technologies (2016). CIP reduces the frequency of
having to partially dismantle the device, including
the removal of the conveyor belt (Reyes, 2016).
However, some materials are not suitable for CIP
and therefore at some places cleaning out of place
(COP) is required. Scenarios are described below
on the cleaning procedures.
The specific cleaning tasks are described in
Appendix E, in table 5. The information was found
from Essential industries website, and these are
the procedures how they clean their equipment.
Because we are all bread processing enterprises,
we can consider using the same cleaning
procedures.
Cleaning Procedures
Bake ovens
Weekly spray cleaning procedure – Interior
 Preheat the oven to 150ºF then turn heat
off.
 While oven surfaces are still warm, spray
interior walls with strong solution of hot
water and food service degreaser solution
and let soak in.
 Let solution stand on soil for two to five
minutes to permit chemical cleaning
action to take place.
 Baked-on grease or carbonized food soil
may need to be loosened with a stiff
brush or scraper.
 Use a damp cloth to pick up the dissolved
and loosened soil.
 Rinse with clear water and let air dry.
Weekly spray cleaning procedure – Exterior
 Spray outside of the oven with a warm
solution of food service degreaser.
 Use a damp cloth to pick up the dissolved
and loosened soil.
 Rinse with clear water.
10
  Wipe dry with a clean, dry cloth.
 Keep the sides, front and back of the oven
clean at all times to avoid odors (Karsten,
2016).
Range hoods with removable filters
Weekly spray degreasing
 Range must be cool enough to permit
your hand to touch any part of the top.
 Remove filters and clean in the
dishwashing machine or by manual
method (see following procedure).
 Fill hand held sprayer with warm food
service degreaser.
 Spray all inside and outside hood surfaces.
 On heavily soiled areas or where grease is
baked on, loosen soil with a brush until
the grease and soil is dissolved and loose.
 Clean out drain trough around the lower
inside edge of the hood as well as the
channels which hold the filters.
 Flush off soil and solution with clear, hot
water. Allow inside surfaces to air dry and
wipe dry outside surfaces.
 Replace clean filters.
Removable hood filters
Dishwashing Machine Method
 Once a week, take out the filters to the
dishwashing machine after all dishes are
washed for the day.
 Make sure that filters will easily go
through the machine without jamming.
 Lay each filter flat in a dish rack or on
conveyor. Do not stack them. Put each
through the full wash and rinse cycle.
 Examine each filter as it comes from the
machine. If not thoroughly clean, run it
through again.
 Stack filters on drain board until dry, then
replace in the hood.
Manual Cleaning Method
 Once a week, remove the filters to the
multiple-compartment sink and soak in a
hot solution of food service degreaser.
The hotter the water, the faster the
grease will be loosened for removal from
the filter.
 Flush filters thoroughly under hot tap
water to remove cleaning solution and
grease.
 Stack on the drain boards to air dry.
Replace in the hood (Karsten, 2016).
Vertical Cutter – Mixer
Daily Cleaning Procedures
 Disconnect electrical power from unit to
avoid accidents.
 Take out removable parts and the cover.
 Wash in multiple-compartment sink, using
a hot solution of Liquid Detergent.
 Rinse with clear water and dip in a Quat
Rinse sanitizing solution. Allow to air dry.
 Fill half full the bowl with hot solution of
Liquid Detergent.
 Brush clean inside and outside of bowl.
Wipe clean all other surfaces.
 Tip bowl to remove solution, rinse with
clear water and fill with warm Quat Rinse
sanitizing solution.
 Rinse all surfaces with this solution, tip
bowl to remove solution and wipe dry
inside of bowl allowing other surfaces to
air dry (Karsten, 2016).
Quat Rinse sanitizing solution is designed for use
on floors, walls, food-processing equipment and all
hard surfaces. It is perfect in food preparation
settings such as supermarkets, dairies, schools,
hospitals, nursing homes, restaurants and
meat/poultry- handling operations. The specific
properties of Quat Rinse sanitizing solution:
 Type: Quaternary Ammonium Sanitizer
 Form: Liquid
 Odor: Bland
 Color: Colorless
 Weight Per Gallon: 8.29 Lbs.
 pH: 7.0 – 8.0
 pH 1%: 7.5
 Foam Height: Low
 Active Quat: 10%
 Hard Water Tolerance: 500 ppm
 Viscosity: 0-5 cps.
 Typical Dilution (food service, dairies):
1:512
 Typical Dilution (food processing plants):
1:256 – 1:512 (Karsten, 2016)
11
3.2.3 Sanitation and Cleaning
Recommendation
There are some bread food factories that use
ultraviolet light and chemicals to sterilize the
production floor, but both methods have some
drawbacks: (1) UV penetration is weak, the
irradiation distance is not long, the disinfection
effect is not ideal. (2) Fumigation with chemical
disinfection, although the effect is better, there is a
big smell, also there are residual pollution and
other issues, adverse to human health and
environmental protection, the residue will
continue to contaminate food (Peng, 2014).
The use of ozone on the bread food factory
disinfection can be a good choice. Ozone has a
significant role in sterilization, disinfection and
eliminates the peculiar smell. Is widely used in the
pharmaceutical industry disinfectant (Peng, 2014).
Ozone is a strong oxidant, the sterilization process
is a biochemical oxidation reaction, sterilization
principle is the oxidative decomposition of bacteria
required for the metabolism of glucose, the
bacteria inactivation of death; infiltration of
membrane tissue, invasion into the cell membrane,
acting on the outside Membrane lipoprotein and
the internal lipopolysaccharide, the bacteria
permeability distortion, dissolution and death;
directly with bacteria, viruses, destroy their
organelles and "DNA, RNA", the bacteria
metabolism is destroyed, leading to its death
(Peng, 2014).
Ozone disinfection of space, the effect was
significant at room temperature 15℃, 73%
humidity, the ozone concentration of 0.08-0.6ppm,
for 30 minutes to kill 99.99% of Staphylococcus
aureus in the air. By using ozone for disinfection,
the kill rate of E. coli was 100%, the killing rate of
Pseudomonas aeruginosa was 89.8%, and the
killing rate of Staphylococcus aureus was 99.7%.
With 5.5 mg/m3 of ozone for 45 minutes, a dripped
Bacillus subtilis black mutant in the 100ml plastic
bottle will be 100% killed (Peng, 2014).
Ozone sterilization is a bacteriolytic grade,
bactericidal thorough, broad-spectrum, no residue,
almost all germs, molds, fungi and protozoa,
oocysts have significant inactivation effect and can
damage botulinum toxin. Ozone sterilization speed
is very fast, is 300-600 times chlorine, ultraviolet
light 3000 times. The high redox potential of ozone
determines its widespread use in oxidation,
decolorization, and deodorization. (Peng, 2014)
Ozone sterilization is a bacteriolytic grade that is
thoroughly bactericidal, broad-spectrum, free of
residues and has a significant inactivation effect,
can almost destroy all germs, molds, fungi,
protozoa, oocysts and botulinum toxin. Ozone
sterilization speed is very fast, is 300-600 times the
speed of chlorine, which is 3000 times that of UV
light. The high redox potential of ozone determines
its widespread use for oxidation, decoloration, and
deodorization. Ozone dissolves in water and
virtually eliminates all harmful substances in the
water such as iron, manganese, chromium, sulfate,
phenol, benzene and oxides. Organic matter and
algae can also be decomposed (Peng, 2014).
Due to the poor stability of ozone, it quickly
decomposes into oxygen or a single oxygen atom.
A single oxygen atom combines itself with oxygen
molecules without any toxic residues. It is a
pollution-free and environment-friendly
disinfectant. Ozone is a gas that quickly diffuses
throughout the sterilizing space (Peng, 2014).
4. Results and Discussion
4.1 Survey
During the experimental part of BSG bread making,
as stated in chapter 3.2, two trials took place. The
first trial was effectuated using already provided
dried BSG and during the second trial only wet BSG
was used. Each time 4 diverse types of bread were
made, by using various kinds of milling methods.
The milling types were the following: 1st type - food
processor, 2nd type - mortar and pestle and the 3rd
type - beer brewing miller. In Appendix F can be
seen pictures of the breads obtained as well as of
some equipment that has been used during the
kitchen trial.
Unfortunately, as it was the first time of bread
making there were minor mistakes that have been
made which might have affected the quality of the
final product. If these mistakes might have had an
influence on the characteristics of the bread, they
will be mentioned further in the chapter.
To find out the best qualities of each kind of bread
a survey was intended to be made, however for
the second trial there were not enough answers
gathered to give a structured answer report. For
the first trial where dry BSG was used 35 people
12
were questioned regarding individual
characteristics of the bread.
The questions that were asked can be found in
Appendix F. Out of the whole number of
individuals interrogated, 42,9% are male and the
rest are woman. As can be seen in figure 3. The
significant majority of the people questioned are of
age until 25 years old. 25,3% are of age between
25 and 50 years old and the remaining 14,35% are
above 50 years old. In order to understand the
worldwide preferences, the nationality was also
taken into account, where 40% are Dutch people,
25,7 % are Europeans, but non-dutch, and the
remaining are people of other cultures. Another
aspect that was taken into consideration is
whether people have tasted spent grains bread
before and turns out that 60% from the people
who filled in the survey have never tasted this kind
of bread before.
Figure 3, Percentage of males and females
in the survey population
Analyzing the answers regarding the first type of
bread, its corresponding milling type was using the
food processor, the characteristics of this certain
bread can be formed. 69,3% from the people
questioned found the aroma of the bread to be
pronounced (5-6 on the scale of 7). However, to
the question whether the smell would make them
eat the bread 30,8% answered no and 15,4%
answered yes. The rest were not sure if they like or
not the smell and the answer chosen is maybe.
Another characteristic that was analyzed is the
texture of the crumbs, which plays a vital role in
how people appreciate the bread. The survey
shows that an estimated 54% of the respondents
found the bread crumbs to be smooth and moist.
Despite of this, when rating the bread on the
mouth feel scale, almost 77% answered it to be
lightly abrasive. This can be since during the bread
making the dry BSG should have been milled in the
food processor for a longer period, which might
have led to smaller sizes of the grains. This shows
us that the milling of the BSG using the food
processor wasn’t good enough for it to be smooth
and not cause discomfort to people tasting it.
According to the survey, almost everyone found
the intensity of the bread flavor to be at 4 to 6
pronounced on the scale of 7.
The last question is how much the person liked the
tasted bread and the answers vary, however none
scaled the bread neither to like extremely nor to
dislike very much. The answers given can be found
in Appendix F, Table 5 along with the answers of
the other types of bread.
The survey shows the aroma of the 2nd type of
bread (milling type: mortar and pestle) to be the
most pronounced in comparison with the other
kinds, where almost 70% rated it to be around 5-7
on a scale of 7. Further 40% of interviewed people
said that the smell makes them want to eat the
bread. Analyzing the tables with the answers,
Appendix F, it can also be observed that the
crumbs texture is found to be mildly coarse and
dry. The survey also shows almost half of the
people who filled in the survey to find the bread
moderately abrasive. 40% of answers of the
intensity of the flavor are scaled 4 on the scale of 7
to be pronounced. Further, 10% of the people
chose the answer to be “like extremely”.
For the 3rd type of bread (milling type: beer
brewing equipment) 62,5% found the aroma of the
bread to be pronounced and only 12,5% answered
that the smell would play the factor of them
wanting to eat the bread. The crumbs texture can
be described as mostly smooth and dry on account
of the fact that nobody chose it to be very coarse
and dry. In comparison with the other two types of
bread, this one is found to be the most
nonabrasive one, as 50% of people who filled in
the survey chose to scale it 1-2 on a scale of 7 of
how abrasive it is. The flavor intensity is found to
be mildly pronounced as almost all the answers
were situated between 3 and 5 on the scale to 7.
In conclusion, analyzing all the results obtained
following the survey, the characteristics for each
kind of bread can be pointed out. From the three
kinds of breads, according to the survey the most
nonabrasive and smooth one was the 3 rd type,
which used the beer brewing miller. Meanwhile
the 1st type of bread was found to be the most
13
abrasive. However, the flavor was the most intense When calculating the energy consumption due to
felt during the tasting of the 1 st type of bread. Also the milling, the Bond’s index and the
analyzing the Figure 10 in Appendix G, it can be corresponding formula is used. Below is the
observed that most of the people, who filled in the following formula used:
survey, placed the 2nd type of bread on the highest
dE −3
marks on the scale. Further, the 2nd type of bread =−C D x , where x=
was the one whose smell was found to make most dD 2
of the people want to eat the bread. It can be This can be rewritten as:
deduced that this is due to the fact that the smell
100 1
of the bread was not found to be too pronounced
neither was left unfelt.
E=Ei
√ D2 (
1− 0.5
q )[ kgJ ]
If it was to choose the best bread according to the Where Ei is the bonds work index, which has been
survey obtained, it is needed to take a look at determined to be 80 KJkg -1, which is equal to
Table 6 in Appendix G, which indicates the average 80*103 Jkg-1.
marks for each type of the bread. Type 2, which is
the bread that used the mortar and pestle as a D 1 3.01
And, q= = =3.83
milling technique, is found to have the highest D 2 0.785
average mark from all of them, which means that
The diameter before the milling (D 1) was
this is the bread that was appreciated the highest.
experimentally determined to be 3.01 mm, and the
In addition to this, the size distribution, Table 4 in
diameter after the milling (D2) is experimentally
Appendix E, and the theory research that was
determined to be 0.785 mm.
effectuated showed that the second type of bread
had the best particle size, which corresponds with 100 1 J J K
answers obtained. If it was to take into
consideration the flavor of the second type of
E=80∗103
√ ( 0.785
1−
3.83 0.5 )[ ]
kg
= 4.4∗105
kg [ ]
= 440
k
bread, it could be said that it was mildly So, the energy consumption due to the milling
pronounced, which is a good characteristic process is 440 KJkg-1.
because people usually find the taste of the BSG
bread unpleasant. To sum up, after analyzing the 5. Conclusion
results of the survey it can be assumed that the
best type of milling is the mortar and pestle.
4.2 PSD Different milling techniques
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Appendix A, Particle Size Distribution graphs

Mass Percentage dry BSG vs Particle Size

80
70
60
percentage (%)

50
40 Magimix
30 moltar and pestle
20 beer brewing miller
Mass

10
0
<0,063 0,063<S 0,09<S< 0,18<S< 0,25<S< 1<S<1,4 1,4 < S 2 < S < >4
<0,09 0,18 0,25 1 <2 4

Particle size (mm)

16
Graph 1, Dry BSG Mass percentage vs particle size

Mass Percentage wet BSG vs Particle Size

50

40
percentage (%)

30
Magimix
20 Moltar and pestle
beer brewing miller
Mass

10

0
<0,063 0,063<S 0,09<S< 0,18<S< 0,25<S< 1<S<1,4 1,4 < S < 2 < S < 4 >4
<0,09 0,18 0,25 1 2

Particle size (mm)

Graph 2, Wet BSG Mass percentage vs particle size

Mass dry BSG vs particle size

80
70
60
Mass (gram)

50 Magimix
40 Moltar and pestle
30 Beer brewing miller
20
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Particle Size (mm)

Graph 3, dry BSG particle size of BSG after milling

Mass wet BSG vs particle size

50
45
40
35
Mass (gram)

30 Magimix
25 Moltar and pestle
20 beer brewing miller
15
10
5
0
0 1 2 3 4
Particle Size (mm)

Graph 4, wet BSG particle size of BSG after milling

17
 Cumulative mass percentage dry BSG vs Particle size
100
90
80
70
Percentage (%)

60 Magimix
50 Moltar and pestle
40 beer brewing miller
Mass

30
20
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Particle Size (mm)

Graph 5, Cumulative mass percentage dry BSG vs particle size

Cumulative mass percentage wet BSG vs particle size

100
90
80
70
Percentage (%)

60 Magimix
50 Moltar and pestle
40 beer brewing miller
Mass

30
20
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Particle Size (mm)

Graph 6, Cumulative mass percentage wet BSG vs Particle size

Appendix B, Percent composition of Whole-wheat flour compared to

BSG flour
Cereal grain Protein As Crude fiber Crude fat Acid Detergent Fiber Cellulose Ligni
h n

Whole- wheat flour 16.8 2.1 2.0 2.4 7 2.1 2.1

BSG flour 34.4 3.6 14 8.3 36 10 17

Table 2, Percent composition of Whole-wheat flour compared to BSG flour

This table shows some qualities of whole-wheat flour and BSG flour. Overall you can see that BSG flour contains
more percentage of each of these qualities.

18
Appendix C, Differences between the bread made from whole wheat
with BSG

The table shows the farinograph and extensive graph data for the whole-wheat flour and the flours containing
5% and 10% BSG. The absorption of the flour blends is increasing with the slightly increasing amount of
contained BSG. The dough development time was similar with each other in BSG case, but still taking longer
time compared with using whole wheat. Adding more BSG under certain range of temperature enhances the
stability of the dough. The proportional number, obtained by dividing the resistance to extension by
extensibility gets higher as the level of BSG increased. This result is quite coordinate with the decrease in loaf
volume (%).

Appendix D, Process Flow Diagram

19
 Yeast
Sugar

FC FC

Water
MV-101

Whole wheat M-103

P-101 flour
Salt V-104
V-102 V-103
Unwanted materials Steam Water vapour Carbon dioxide
FC
Big BSG particles E-102 Oxygen

FC FC
P-2 P-4 P-9 P-16
Wet BSG
P-17
V-101

F-101 X-101 F-102 K-101

T-101 M-101 M-102
X-102
E-101

X-105 X-103 K-102

E-103 X-104
E-104

X-106 Shipping

Figure 4, Process flow diagram of BSG manufacturing process

Equipment list M-103 Mixer

F-101 Filter
F-102 Filter X-101 Miller
X-102 Waiting area for rising step
E-101 Oven-dryer X-103 waiting area for rising step
E-102 Heat Exchanger
E-103 Oven MV-101 Mixing valve
E-104 Cooling
P-101 Centrifugal pump
M-101 Mixer
M-102 Mixer T-101 Storage tank
X-104 Shaping
X-105 Cutting
X-106 Packaging

K-101 Kneader
K-102 Knock back

Appendix E, Cleaning Tasks

20
 Daily Cleaning Tasks  Clear the Decks
 Multiple-Compartment Sink
 Mixers
 Walls Behind Mixers and Sink
 Freezers/Retarders
 Donut Fryer and Sanitary Donut Machine
 Work Bench Tops
 Work Bench Shelves, Legs and Frames
 Spice Cabinet and Scaling Bench
 Ingredient Bins
 Microwave Ovens
 Can Opener – Manual Bench Type
 Hand Tools
 Mixing Bowls, Attachments, Sheet Pans
 Scales
 Proof Box
 Sheeter, Rounder, Divider
 Decorating Station
 Showcases and Back Bar
 Telephones
 Wrapping Station
 Floor
 Drains
 Cleaning Tools

Weekly Cleaning Tasks

 Hoods and Filters

 Storage Shelving and Floor Pallets
 Reach-In Retarders and Freezers
 Walk-In Freezer
 Sheeter
 Pan Washer
 Racks
 Cream Case

Table 4, Cleaning tasks

Appendix F, mean diameter before and after milling

21
 BSG before milling Mortar and pestle dry
Sieve size Gram in sieve sieve size*gram in sieve Sieve size Gram in sieve sieve size*gram in sieve
0.0315 0 0 0.0315 0.06 0.00189
0.0765 0 0 0.0765 0.7 0.05355
0.135 0 0 0.135 1.16 0.1566
0.215 0.01 0.00215 0.215 1.25 0.26875
0.625 0.66 0.4125 0.625 13.6 8.5
1.2 1.88 2.256 1.2 2.84 3.408
1.7 6.85 11.645 1.7 1.46 2.482
3 28.43 85.29 3 0.75 2.25
4 14.67 58.68 4 0 0
Sum 52.5 158.28565 21.82 17.12079

Table 5, Mean diameter experimental results

Appendix G, Photos of the breads during the kitchen trial

22
Figure 5. The dough before going into the oven Figure 6. The baked breads right out of the oven

Figure 9, The mortar and pestle

Figure 7, The texture of the obtained bread Figure 8, The food processor used

23
Appendix H, Survey Questions and answers
i. Survey questions:
1. What is your gender?
o Woman
o Men

2. What is your age group?

o <25
o 25-50
o >50

3. What is your nationality?

o Dutch
o European, but non-dutch
o Other

4. Have you ever tasted spent grain bread (bread made from beer brewing waste grains)?
o No
o Yes

5. How would you rate the aroma of the bread? ( 1 = mild; 7 = pronounced )
□1 □ 2 □3 □ 4 □ 5 □6 □7
6. Does the smell make you want to eat the bread?
o Yes
o No

7. How would you describe the crumbs texture? ( 1 = smooth and moist; 5 = coarse and dry )
□1 □ 2 □3 □ 4 □ 5
8. How would you rate the bread on the mouthfeel scale? ( 1 = nonabrasive; 7 = abrasive )
□1 □ 2 □3 □ 4 □ 5 □6 □7
9. On a scale from 1 to 7, how would you rate the intensity of the bread flavor? ( 1 = imperceptible; 7 =
pronounced)
□1 □ 2 □3 □ 4 □ 5 □6 □7
10. How would you rate this bread taking into consideration all the factors above? ( 1 = dislike very much; 2 =
dislike moderately; 3 = dislike slightly; 4 = like slightly; 5 = like moderately; 6 = like very much; 7 = like
extremely;)
□1 □ 2 □3 □ 4 □ 5 □6 □7

24
 ii. Survey answers:
  Gender     Age      
  M F   <25 25-50 >50  
Type 1 (13) 53,80% 46,20% Type 1 69,20% 23,10% 7,70%  
Type 2 (10) 30% 70% Type 2 50% 30% 20%  
Type 3 (8) 37,50% 62,50% Type 3 37,50% 37,50% 25%  
  Nationality       Tasted    
  Dutch European Other   Yes No  
Type 1 46,1% 23,1% 30,8% Type 1 38,5% 61,5%  
Type 2 40% 20% 40% Type 2 40% 60%  
Type 3 37,5% 25% 37,5% Type 3 37,5% 62,5%  
  Aroma            
  1 2 3 4 5 6 7
Type 1 0 15,4% 7,7% 7,7% 38,5% 30,8% 0
Type 2 0 0 20% 10% 50% 10% 10%
Type 3 0 12,5% 25% 0 50% 12,5% 0
  Smell            
  Yes No Maybe        
Type 1 15,4% 30,8% 53,8%        
Type 2 40% 10% 50%        
Type 3 12,5% 0 87,5%        
  Crumbs text            
  1 2 3 4 5    
Type 1 15,4% 38,5% 7,7% 30,8% 7,7%    
Type 2 0 30% 10% 50% 10%    
Type 3 12,5% 25% 25% 37,5% 0    
  Mouth feel            
  1 2 3 4 5 6 7
Type 1 7,7% 15,4% 0 0 46,1% 23,1% 7,7%
Type 2 0 20% 20% 10% 10% 30% 10%
Type 3 25% 25% 0 25% 25% 0 0
  Intensity            
  1 2 3 4 5 6 7
Type 1 0 7,7% 0 30,8% 53,8% 15,4% 0
Type 2 0 20% 10% 40% 20% 10% 0
Type 3 0 12,5% 12,5% 25% 50% 0 0
Table 5. General answers to the survey

How would you rate this bread taking into consideration all the factors above?
Averag
  1 2 3 4 5 6 7 e mark
Type 1 0 15,4% 15,4% 23,1% 30,8% 15,4% 0 4,2
Type 2 0 0 20% 20% 30% 20% 10% 4,8
Type 3 0 12,5% 12,5% 12,5% 25% 37,5% 0 4,6
Table 6. The rating of each type of bread taking into consideration the characteristics analyzed.

25
 0.00%

1
0
0.00%

15.40%

2
0
12.50%

Figure 10, Rating of different types of bread

15.40%

3
0.2
12.50%
Type 1

4 23.10%
0.2
Type 2

12.50%

30.80%
Type 3

0.3
25.00%
RATING OF THE BREAD

15.40%
6

0.2
37.50%

0.00%
7

0.1
0.00%

26