11.

MACHINERIES REQUIRED FOR A BAKERY UNIT

Introduction: Successful bakery production is connected with efficient use of bakery
machinery. Machine can work more efficiently, speedy and at cheaper rate (depending
on labour cost) hence in large scale bakery unit machines are preferred for most of the
work. Therefore, mechanical as well as technical knowledge is essential for the baker.
The machines used in bakery units can be divided into four parts:
1. Ingredients handling equipment’s: It includes storage bins, weighing balance, sifter,
conveyer system etc.
a. Storage bin: These are used to store flour, sugar etc. dry bulk raw material. They are
available in various sizes and shape (mostly cylindrical or square). They are generally
underground. Its bottom is slanted at one end, which helps to remove flour / other
material. They are generally made – up from stainless steel or mild steel covered with
corrosion resistant and weather proof external coating. The interior surface may be
either polished steel or a synthetic coating that is smooth, non toxic, non abrasive and
free of odour and taste.
b. Ingredient conveying system: Ingredient transfer from storage bin to production
area or at any other place by conveyor belt. The belt moves continuously with constant
speed hence when material is placed on the belt, it automatically get transferred.
c. Unloading system: To unload the truck trolley, the material is transferred directly to
storage bin through tube, operated by electric motor. In this device, arrangement is
made to switch the machine off automatically, as soon as the truck gets emptied or the
bin gets filled.
d. Dump bin and blender: Bakeries that receive flour in bags are generally equipped
with dump bin / blender where bags are emptied. From there, it is transferred to
production area by conveyor belt. Dump bin is rectangular metal cabinets whose bottom
slopes toward conveyor belt.
Cabinet containing two or more compartments are known as blender. Hence,
two or more different types of flour can be mixed. Normally, blender can blend 50:50,
25:75, 33:67 and 40:60 flours. However, it can be made according to specific need.
e. Flour sifter: Flour sifter sieves are made up of metal, which vibrates mechanically. So
the flour is divided into different categories according to particle size. It is generally
placed at the end of conveyer belt where flour is transferred from dump bin. Sifters are of
various types like cone sifter, vibrating screens type etc.

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f. Centrifugal machine: In most of the flour mills and in few large - scale bakeries
specialized centrifugal machine is used to destroy the insects (particularly in egg form)
are known as rotors. In this machine, the flour is forcefully thrown to the walls of machine
by central shaft, hence flour colloides with wall forcefully. So, the eggs of flies, insects or
any other unsound material are broken down without affecting flour quality.
g.Weighing Machine: It is used to weigh raw materials and finished products. The
accurate quantity of ingredients according to the product formula is essential for the
desired quality of finished products. Hence, various types of automatic/ semi - automatic
weighing machines are developed. Out of them, electronic weighing system is the most
effective means, at present.
2. Dough processing machines: It includes mixer, divider, moulder, prover etc.
a. Mixer: It is advisable to use mixer when at least 90 kg flour is used everyday in the
bakery. A unit producing bread, cake, biscuits i.e. assorted bakery products on small
scale should install heavy duty type multipurpose cake mixer because it would be useful
for bread dough kneading and cake mixing as well as egg beating and sugar - fat
creaming. Generally, high speed, low speed, variable speed vertical / horizontal mixers
are marketed.
Horizontal mixer: This is normally high speed heavy duty type mixer machine. It may
be of two categories namely, stationery bowl machine and tilting bowl machine. In the
former case, dough is removed by hand while in later case the bowl separated from
machine. Mixers are generally made up of sturdy frame of cast iron, tubular steel or
channel steel welded construction, whose upper portion houses the mixing bowl.
Normally, the bowl fabricated of stainless steel, is transverses by a single agitator shaft
that is provided with one or more mixer bars either straight or of various configurations.
Some mixers, intended for processing exceptionally stiff dough, are equipped with dual
agitator shafts. Power is provided by an electric motor located at the base of the mixer
frame. The bowls are trough - like shape with a curved bottom and flat ends and sides.
High speed mixer machine produces a lot of heat through friction
hence they are provided with jacket, which keeps the dough cool, which is essential for
uniform dough development. Modern high speed mixers are provided with the facility for
self lubrication. As a precautionary measure, push button switch should be provided to
the operator.
Double arm / reciprocating arm mixer: In this machine, mixing action akin to the hand
mixing. Where two agitator arms are mounted vertically on circular planes. As these

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arms rotate at moderate speed, the agitators traverse intersecting elliptical paths in a
shallow and slowly revolving bowl. As they do so, they impart a gentle kneading,
stretching, lifting and folding action to the dough. Due to slow speed, the dough
temperature increases very little, hence there is no need of refrigeration cold jacketing.
Because of this, these machines are suitable for temperature sensitive dough, such as
for pies and pastries in which the preservation of discrete shortening particles is
important. It is also useful for dough’s containing nuts and fruits which may breakdown in
high speed mixing.
Vertical mixer: It may be used for multipurpose function (beating egg, aerating batter,
kneading etc.) hence it is useful to small bakeries preparing different products. They
consist of essentially a vertical frame of variable height with a horizontally - extended
head which houses the drive mechanism that actuates the vertical shaft with the beater
attachments. The mixer head may be either horizontally stationery (in which case bowl is
elevated into mixing position), or it may be equipped with a motor drive (for raising and
lowering as required), or to spiral mixers (which may be tiltable so the beater can be
moved free of the bowl). The motor itself, which may be either of the geared
transmission or variable - speed type is enclosed in a base of frame. The arm may be
attached with different attachments, meant for beating, aerating purpose.
The frame of any mixer is made up of mild steel / cast iron, which is
mounted with electric motor of 0.33 to 10 hp (mainly 0.5 to 1.5 hp for small bakeries) as
per requirement. They usually possess a gear system hence the speed can be changed.
The capacity of bowls may vary from 10 to 200 kg and are made up of stainless steel.
The speed of arms varies from 70 to 370 rpm(Revolutions per minute) for slow speed
and high speed, respectively, The arm shape is made in such a way that it can carry out
folding, kneading and stretching action ( in case of bread dough) and aerating ( in case
of creaming purpose ) or just simple mixing( in case of cookies and biscuits dough
preparation).
b. Liquid ferment equipment: The large scale bakery industry should possess
equipment’s necessary to prepare and keep yeast slurry or flying ferment. It is generally
equipped with temperature control, agitator, sanitary pump, value etc. A tank made up of
stainless steel having capacity of 200 to 250 liters is used for this purpose.
c. Dough divider: This machine divides the bulk dough volumetrically into individual
dough pieces that confirms as closely as possible to a preset weight. Hence, the dough
density (which is highly affected by the extent of fermentation) should be even otherwise

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the weight might change. Now - a - days, such dough dividers are available which can
make 1 to 8 pieces at a time and also ,make 20 to 30 strokes / minutes (however, it is
considered the best practice to run machine have 15 to 18 strokes / minutes). It is
advisable to purchase dough divider when 40 to 50 flour bags are used weekly.
Normally, a labour can cut 500 to 600 pieces in an hour; hence it is also again advisable
to purchase a divider on comparative economic calculations.
d. Rounder: Rounding machines basically consists of an external or internal revolving
surface against which the freshly scaled dough piece is held by a spiral track or trough.
As the surface revolves, it carries the irregularly - shaped dough piece upward in the
spiral rounding trough, imparting to the dough a rolling motion. This motion results in
uniform rounded dough ball with a thin, smooth and dense skin that not only eliminates
the stickiness of the cut dough surface, but also serves as a carbon di oxide gas
retaining membrane. The revolving surface may have the form of a conical bowl, an
umbrella or a drum.
e. Intermediate proover: Intermediate proover generally consists of overhead
enclosures that house an endless, tired conveyer that supports dough carriers in the
form of either trays or canvas loops. In these enclosures dough pieces are rested for 10
to 15 minutes. They are equipped with temperature and humidity controller.
f. Moulder: It is economically viable for a baker to purchase a moulder when he is using
25 to 30 bags of flour per week
g. Final poover: After moulding and panning the dough loaves are carried to a steam
box, which is just like a steam - room. The accurate control system for temperature and
RH is established as it may change the quality of products. The final proover are made
up of stainless steel. The proover can be of two types:
Manual: Proof box, intended for manual loading, with castered racks moving on fllor
tracks should be limited to a depth of four racks to facilitate their movement through the
box. Where greater capacity is involved, suspending the racks from monorails for easier
handling generally provides a satisfactory solution. In the instances, where box depth
exceeding seven racks is required, motorized monorails will be found to be most
effective in facilitating rack movement.
Automatic: They are several kinds: Tunnel proover : This is the simplest type of
automatic proover. It requires a long floor due to its length (27.5 m to 91.5 m) that may
be costlier particularly in case of high land cost. The problem of length can be alleviated
by designing the proover in two adjoining parallel sections with a cross - conveyer at one

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end. The pan - carrying conveyor in this type of proover is generally the grid design.
Where the unproved dough enters from one end and exists from the other end within a
specific time limit. Tray proover: In this type of proover stabilized trays are conveyed by
continuous drive a chain that travels through the length of proofing chamber in a series
of three or six laps or passes. In this type of proover, the trays, on being loaded, are
elevated to the top tier and preceded horizontally back and forth in descending stages
until they reach the discharge level. One of their major advantages is the relatively small
floor space required. Rack proofer: It is just similar to rack oven. Where hot air is
replaced by the steam.
h. Baking Oven: Oven is sometime referred to as the heart of the bakery. The
construction and design of modern ovens depend on types of products to be baked,
nature of the fuel to be used, system of heat application and mode of its transmission,
flexibility for controlling the amount and intensity of heat and the cost of oven
construction, operation and maintenance. Looking to all the above factors most of the
small and medium scale bakeries in India use fire – wood oven. But the main drawback
of this type of oven is no facility of controlling the temperature hence it requires long
experience to maintain and handle such ovens. The large scale baking units may use
the electric oven but the operating cost is too high, hence it is not preferred much.
However, it will be much popular in high class small scale bakeries like bakery division of
five star hotels. Diesel fired ovens are preferred as they are cheaper than electric fuel for
large scale operations. However, wherever gas (LPG) supply is easily available, gas
oven can also be used. Recently, microwave ovens are introduced for baking purpose.
But their use is still limited to the household baking as it is quite costly and requires lots
of research. It is important to note that, in the case of microwave oven, the
caramelization of sugar does not take place hence there is no browning of the products,
therefore it is not accepted because of colour consciousness of the consumers. Some of
the modern ovens are:
Reel oven: They consist of a reel structure that revolves vertically around a horizontal
axis within the baking chamber and supports the baking trays in fly - wheel fashion. They
require large baking chamber and more heat consumption hence not accepted by
bakers. Moreover, the heat distribution is not proper and moisture may condensed on
top portion of the oven hence baking of product is not proper. Reel ovens are normally
heated by direct firing with electricity or gas.

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Traveling tray oven: In this type of oven, two parallel endless chains are replaced to
reel of oven, which carry trays through the baking chamber, the third chain acting to
stabilize the trays horizontal position during baking cycle. These ovens may be single -
lap or double - lap.
Tunnel oven: It features a long, low baking chamber through which a motor - driven
conveyor, carrying the baking hearth, passes in straight line. The length of the chamber
may be of 30 to 12m that is divided into 1 to 8 heat zones each zone with 9 to 18 m
length. Each zone has a specific control on temperature and Rh. The product is loaded
from one end and is unloaded from the opposite end. This kind of oven has several
advantages: A). It possess flat and continuous hearth hence any size and shape of pan
can be used. B).Zone temperature control is facilitated by providing separate control for
both top and bottom heat and for balancing the heat across the oven width). Optimum
steam conditions are established easily and effectively. D).The problem of tray
stabilization is entirely eliminated. These features render the oven particularly effective
for cookie and cracker baking.
Conveyerized oven: This is developed when integrated approach for continuous
proofing and baking is adopted. The oven consists of an enclosure formed by insulated
panels., supported by a steel frame. It houses an endless conveyer, which is arranged
either in ascending or descending spirals or tiers about the periphery. Depending the
particular design, the panned product enters the oven through a small opening either at
the top or the bottom of the unit. It travels the total length of the interior conveyer as it
bakes and then exits again at either a high or low level. Because every pan passes
through the same path, a high degree of uniformity of bake is achieved.
Rack oven: It consists basically of a vertical baking chamber into which a special rack
carrying as many as 100 trays of product is wheeled. The rack rests on a turn table that
rotates during the baking phase and thereby exposes the product to uniform convection
heating. They may be heated by electricity, gas, or fuel oil, and may feature
computerized programmable controls for regulating temperature, steam condition and
baking cycle.
3. Product handling machine: After baking the bakery products are depanned, cooled,
sliced and packed. The equipments required for all these processing are:
a. Bread cooler: At present, room of suitable conditions is used for cooling the bakery
products so that atmospheric conditions does not affect on cooling. The different types of
coolers are: Continuous belt cooler: This cooler consists of endless, multiple - tier

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overhead conveyers that travel in straight flights with 180◦ turns at the end of each flight,
which transport the bread through a 60 to 90 minutes cooling cycle. The flights are
generally open on all sides, with an overhead fan exhausting the heat radiating from the
loaves to the exterior or they may be enclosed with panels to form a tunnel like structure
and use a counter current air movement to accelerate the cooling action. Tray cooler: In
this cooler, trays replace the conveyer belt. It usually consists of stainless steel grills
mounted on steel frames that are attached to parallel standard roller chains with the
drive sprockets located at the conveyer loops. In loading this type of bread cooler, the
loaves being fill continuously from the depanner must be grouped and material for
transfer onto the trays or pallets. Rack cooler: This is similar to rack oven of bread
processing. It is generally air conditioned and hence enclosed and frequently the exterior
panels of rack coolers are omitted. This facilitates the flow of natural convection air
currents through the racks. However, the usually dense concentration of loaves that is
found in rack coolers during operation may require forced air circulation to improve the
cooling rate. Vacuum cooler: This is relatively a new cooling system. Here cooling is
carried out by modulated vacuum which brings about very rapid reduction in product
temperature. The system consists of a conveyer within a tunnel that serves as the
vacuum chamber and whose ends are provided with vertical doors that form an airtight
seal when closed. A pivoting bridge conveyer at each end of the tunnel affects the
transfer of the product onto the interior conveyer and to the discharge conveyer.
b. Slicer: Despite many precautions, the bread loaf cannot be sliced properly by hand;
hence every bread producer must purchase bread slicer. Generally reciprocating slicers
are used for slicing purpose. In which, straight blades are mounted (at intervals that yield
the desired slice thickness) on two frames which move up and down in opposite
directions at a high speed. This reciprocating motion is imparted to the frames by a small
electric motor through a crank - shaft and levers. Slicing is performed by gently pushing
the loaf through the oscillating blades. The frames may be mounted either vertically, in
which case the bread conveyer feeding the cutting zone is slatted at a downward angle
or they may be tilted toward the feed side, in which case the conveyer is then on a level
plane. The purpose is to obtain angle cutting and to have the top crust of the loaf contact
the cutting blades first.
The other types of slicers are continuous band slicer, disc slicer etc.
c. Packing machine: Normally, the bakery products packed in a polyethylene bags at
present. The cottage scale baker seals the bag with candle but it does not look

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attractive. Instead of that a plate type electric heater is attached to a table, which seals
the bag when a touch is recommended. The machines are developed on the same basis
which can either be foot or hand operated. It seals the bag in between two arms of the
machine.