Dough Cert Study Guide 2013 Final

Dough Certification
Revised October, 2013

Dough Certification
Table of Contents
Module 1: Hygiene ............................................................................................................... 1-1

Overview and Performance Objectives .............................................................................................................. 1-1
Importance of Hygiene ....................................................................................................................................... 1-2
Purpose of Domino's Pizza Hygiene Standards .................................................................................................. 1-2
Main Sources of Contamination ......................................................................................................................... 1-2
Domino's Pizza Commissary Hygiene Standards ............................................................................................... 1-3
Hygiene .................................................................................................................................................... 1-3
Jewelry ..................................................................................................................................................... 1-3
Hair .......................................................................................................................................................... 1-3
Facial Hair ............................................................................................................................................... 1-3
Uniforms .................................................................................................................................................. 1-4
Production Uniforms for a Class "C" Commissary .............................................................................. 1-4
Production Uniforms for a Class "A" and "B" Commissary ................................................................ 1-4
Shirts ............................................................................................................................................. 1-4
Pants .............................................................................................................................................. 1-4
Footwear........................................................................................................................................ 1-5
Apron ............................................................................................................................................ 1-5
Warehouse Team Member ................................................................................................................... 1-5
Delivery and Service Team Member .................................................................................................... 1-5
Disease Control ........................................................................................................................................ 1-5
Employee Practices .................................................................................................................................. 1-6
Hand Washing .................................................................................................................................................... 1-6
Hygiene Summary .............................................................................................................................................. 1-7
Knowledge Questions ......................................................................................................................................... 1-8
i
Module 2: Sanitation............................................................................................................ 2-1
Essential Components of a Master Sanitation Schedule ..................................................................................... 2-2
Management Support ........................................................................................................................... 2-2
Organization ......................................................................................................................................... 2-2
Scheduling ............................................................................................................................................ 2-3
Training ................................................................................................................................................ 2-3
Supervision ........................................................................................................................................... 2-4
Materials and Supplies ......................................................................................................................... 2-4
Storage of Cleaning Equipment & Supplies ......................................................................................... 2-5
Cooperation .......................................................................................................................................... 2-5
Methods of Cleaning .......................................................................................................................................... 2-6
Steps to Cleaning ................................................................................................................................................ 2-7
Classes of Cleaning Compounds ........................................................................................................................ 2-8
Alkaline ................................................................................................................................................ 2-8
Complex Phosphates ............................................................................................................................ 2-8
Surfactants ............................................................................................................................................ 2-9
Chelating .............................................................................................................................................. 2-9
Acids .................................................................................................................................................... 2-9
Factors that Influence the Effectiveness of Detergent ...................................................................................... 2-10
Sanitizing .......................................................................................................................................................... 2-11
Methods of Sanitizing ....................................................................................................................................... 2-11
Heat .................................................................................................................................................... 2-11
Chemical ............................................................................................................................................ 2-11
Types of Chemical Sanitizers ........................................................................................................................... 2-12
Chlorine .............................................................................................................................................. 2-12
Quaternary Ammonium Compounds ................................................................................................. 2-12
Factors that Influence the Effectiveness of Sanitizers ...................................................................................... 2-13
Safety Concerns When Using Chemicals ......................................................................................................... 2-13
Monitoring ........................................................................................................................................................ 2-14
Methods for Monitoring ................................................................................................................................... 2-14
Visual Inspection of Area, Equipment and Personnel ........................................................................ 2-14
Chemical Testing................................................................................................................................ 2-14
Verification Checks ............................................................................................................................ 2-15
Three Compartment Sink.................................................................................................................................. 2-16
Requirements for Automatic Tray Washers ..................................................................................................... 2-17
Pest Control ...................................................................................................................................................... 2-18
ii
Contracted Pest Control Company ................................................................................................................... 2-18
Internal Rodent Traps ....................................................................................................................................... 2-18
External Rodent Traps ...................................................................................................................................... 2-18
Birds ................................................................................................................................................................. 2-19
Controlling Birds .............................................................................................................................................. 2-19
Insects ............................................................................................................................................................... 2-20
Stored Product Pests ......................................................................................................................................... 2-20
Other Common Insects Found in Food Processing Facilities ........................................................................... 2-20
Insect Light Traps ............................................................................................................................................. 2-21
Production Area Sanitation Checklist ............................................................................................................... 2-22
Equipment Cleaning Frequencies Checklist ..................................................................................................... 2-23
Sanitation Summary ......................................................................................................................................... 2-25
Knowledge Questions ....................................................................................................................................... 2-26
Quiz 1 ................................................................................................................................. Q1-1
Module 3: Safety .................................................................................................................. 3-1

Facility Safety ..................................................................................................................................................... 3-2
Safety Tasks Pertaining to Equipment ................................................................................................................ 3-3
Rules for Lifting Safely ...................................................................................................................................... 3-5
Common Injuries in Dough Production .............................................................................................................. 3-5
Major Strains ........................................................................................................................................ 3-5
Slips and Falls ...................................................................................................................................... 3-6
Personal Protective Equipment (PPE) ............................................................................................................... 3-6
Examples of PPE .................................................................................................................................. 3-6
Production Room Safety ..................................................................................................................................... 3-7
Production Room Electrical Safety .................................................................................................................... 3-8
Facility Security.................................................................................................................................................. 3-8
Safety Summary ................................................................................................................................................. 3-9
iii
Module 4: Production Equipment ...................................................................................... 4-1
Production Equipment ........................................................................................................................................ 4-2
Dough Mixer ...................................................................................................................................................... 4-3
Dough Divider .................................................................................................................................................... 4-3
Dough Rounder .................................................................................................................................................. 4-3
Work Tables ....................................................................................................................................................... 4-3
Scales .................................................................................................................................................................. 4-4
Yeast Scale ........................................................................................................................................... 4-4
Flour Scale ........................................................................................................................................... 4-4
Check Weighing Scale ......................................................................................................................... 4-4
Ingredient/Portion Scale ....................................................................................................................... 4-4
Receiving Scale .................................................................................................................................... 4-4
Thermometers ..................................................................................................................................................... 4-5
Cooler Thermometer ............................................................................................................................ 4-5
Freezer Thermometer ........................................................................................................................... 4-5
Production Room Thermometer ........................................................................................................... 4-5
Water Meters ...................................................................................................................................................... 4-5
Water Chillers ..................................................................................................................................................... 4-6
Vegetable Slicer .................................................................................................................................................. 4-6
Tray Washers ...................................................................................................................................................... 4-6
Heat Sanitizing ..................................................................................................................................... 4-6
Chemical Sanitizing ............................................................................................................................. 4-6
Three Compartment Sinks .................................................................................................................................. 4-7
Refrigeration Equipment .................................................................................................................................... 4-7
Freezer .................................................................................................................................................. 4-7
Storage Cooler ...................................................................................................................................... 4-7
Dough Cooler 4-7
Temperature Control for Storage Cooler .............................................................................................. 4-7
Condensing Unit for Storage Cooler .................................................................................................... 4-8
Outdoor Condensing Units ................................................................................................................... 4-8
Compressors ......................................................................................................................................... 4-8
Evaporators .......................................................................................................................................... 4-8
Refrigeration/Exterior Construction ..................................................................................................... 4-8
Strip Curtains ...................................................................................................................................................... 4-8
Refrigerated Transport ........................................................................................................................................ 4-9
Non-Refrigerated Transport................................................................................................................................ 4-9
Commissary Vehicle Sanitation ....................................................................................................................... 4-10
iv
Receiving of Product ........................................................................................................................................ 4-10
Commissary Equipment File ............................................................................................................................ 4-11
Maintenance Checklist ..................................................................................................................................... 4-12
Multi-pocket Dough Divider .............................................................................................................. 4-12
Cylindrical Rounder ........................................................................................................................... 4-13
Production Equipment Summary ...................................................................................................................... 4-14
Quiz 2 ................................................................................................................................. Q2-1
Module 5: Ingredient Management .................................................................................... 5-1

Flour ................................................................................................................................................................... 5-2
Flour Requirements ............................................................................................................................................ 5-2
Flour Specifications ............................................................................................................................................ 5-3
Flour Sample ...................................................................................................................................................... 5-3
Bulk Flour Receiving.......................................................................................................................................... 5-4
Bulk Inspection .................................................................................................................................... 5-4
Bagged Flour Receiving ..................................................................................................................................... 5-4
Trailer Inspection ................................................................................................................................. 5-4
Shelf Life and Storage ........................................................................................................................................ 5-5
Parts of a Wheat Berry........................................................................................................................................ 5-6
Bran ...................................................................................................................................................... 5-6
Endosperm............................................................................................................................................ 5-6
Germ..................................................................................................................................................... 5-6
Milling Process ................................................................................................................................................... 5-7
Components of Flour .......................................................................................................................................... 5-8
Vital Wheat Gluten ............................................................................................................................................. 5-9
Uses ......................................................................................................................................................... 5-9
Water ................................................................................................................................................................ 5-10
Water Requirements ......................................................................................................................................... 5-10
Water Specifications ......................................................................................................................................... 5-10
Water Analysis ................................................................................................................................................. 5-10
Water's Function in Dough ............................................................................................................................... 5-11
Water Characteristics that Affect Fermentation ............................................................................................... 5-11
Soybean Oil ...................................................................................................................................................... 5-13
v
Bulk Oil Receiving ........................................................................................................................................... 5-13
Bulk Inspection .................................................................................................................................. 5-13
Oil's Function in Dough .................................................................................................................................... 5-13
Soybean Oil Specifications ............................................................................................................................... 5-14
Shelf Life and Storage ...................................................................................................................................... 5-14
Premix .............................................................................................................................................................. 5-15
Minor Ingredient Receiving .............................................................................................................................. 5-15
Shelf Life and Storage ...................................................................................................................................... 5-15
Ingredient List for Premix ................................................................................................................................ 5-15
Sugar .................................................................................................................................................. 5-15
Salt ..................................................................................................................................................... 5-16
Sodium Stearoyl Lactylate Emplex (SSL).......................................................................................... 5-16
Whey .................................................................................................................................................. 5-16
Amylase.............................................................................................................................................. 5-16
Ascorbic Acid ..................................................................................................................................... 5-17
L-cysteine Hydrochloride ................................................................................................................... 5-17
Yeast ................................................................................................................................................................. 5-18
Types of Yeast .................................................................................................................................................. 5-18
Compressed Yeast ................................................................................................................................. 5-18
Compressed Yeast Receiving ...................................................................................................... 5-18
Shelf Life and Storage ................................................................................................................. 5-18
Active Dry Yeast (ADY) .................................................................................................................................. 5-19
Active Dry Yeast Receiving ........................................................................................................... 5-19
Shelf Life and Storage .................................................................................................................... 5-19
Instant Active Dry Yeast(IADY) ...................................................................................................................... 5-20
Instant Active Dry Yeast Receiving ............................................................................................... 5-20
Shelf Life and Storage .................................................................................................................... 5-20
Fermentation ..................................................................................................................................................... 5-21
Factors Affecting Fermentation ........................................................................................................................ 5-21
Proofing ............................................................................................................................................................ 5-23
Reasons for Proofing ........................................................................................................................................ 5-23
Proofing Depends on ........................................................................................................................................ 5-23
Gas Production ................................................................................................................................... 5-23
Gas Retention ..................................................................................................................................... 5-23
Conditions of Dough Proofing.......................................................................................................................... 5-24
Ideal Proofing ..................................................................................................................................... 5-24
Over-Proofed ...................................................................................................................................... 5-24
Under-Proofed .................................................................................................................................... 5-24
vi
Ingredient Management Summary.................................................................................................................... 5-25
Dough Evaluation Guide .................................................................................................................................. 5-27
Module 6: Procedures for Cold Dough Processing ........................................................... 6-1

Cold Dough Ingredients...................................................................................................................................... 6-2
Cold Dough Preparations.................................................................................................................................... 6-3
Cold Dough Processing Procedures .................................................................................................................... 6-4
Cold Dough Labeling ....................................................................................................................................... 6-10
Rework Procedures ........................................................................................................................................... 6-11
Procedures for Cold Dough Processing Summary............................................................................................ 6-12
Quiz 3 ................................................................................................................................. Q3-1
Module 7: Dough Troubleshooting..................................................................................... 7-1

Identifying Dough Problems............................................................................................................................... 7-2
Dough Problem Checklist at the Commissary ...................................................................................... 7-2
Dough Problem Checklist (Delivery/Store Cooler).............................................................................. 7-2
Dough Problem Checklist at the Store ................................................................................................. 7-3
Crust Bubbles During Baking ............................................................................................................................. 7-4
Crusted Dough .................................................................................................................................................... 7-4
Crust Has Poor Volume After Baking ................................................................................................................ 7-5
Inconsistent Dough in the Same Delivery .......................................................................................................... 7-5
Poor Dough Shelf Life in Stores (Over-Proofed) ............................................................................................... 7-6
Dough Slow to Proof, or Does Not Proof (More than 4 Hours) ......................................................................... 7-7
Dough is Difficult to Work With at the Store ..................................................................................................... 7-7
Baked Crust is Streaked ...................................................................................................................................... 7-7
Sticky Dough ...................................................................................................................................................... 7-8
Poor Taste ........................................................................................................................................................... 7-8
Poor Texture (Low Center Heights after Baking)............................................................................................... 7-9
Dough Troubleshooting Summary.................................................................................................................... 7-10
vii
Glossary ................................................................................................................................ 8-1
Answer Keys ................................................................................................ Key-1 through 10
viii
Module 1: Hygiene
Hygiene
Overview
Most of the microbial issues in a food processing plant stem from Team Members with improper
hygiene habits. Maintaining proper personal hygiene is an important measure against foodborne
illness and product contamination. The module on hygiene will explain Domino’s Pizza Hygiene
Standards.
Performance Objectives
Upon completion of this module, you will be able to:

• Understand the importance of personal hygiene.
• Know the standards set by Domino’s Pizza for good hygiene.
Dough Certification 1-1 2013

Module 1: Hygiene
Importance of Hygiene
Personal hygiene is very important in dough manufacturing. Domino’s Pizza is made and
shipped fresh, running a greater risk of becoming contaminated. Personal hygiene means,
essentially, good health and cleanliness. All persons working in direct contact with food, food
contact surfaces, and food packaging materials should conform to hygiene standards to protect
against possible product contamination. It is essential that everything surrounding the dough
making process is clean and safe. This includes the production room, storage areas, Team
Members, and each piece of equipment.
The Domino’s Pizza Hygiene Standards have been created to maintain cleanliness and eliminate
sources for potential contamination. These standards are based off of the Current Good
Manufacturing Practices (cGMP). The cGMP are published in the 21 Code of Federal
Regulations (Part 110 21 C.F.R). The purpose of these regulations is to ensure a safe and sanitary
food supply. Check with all federal and local laws about their hygiene standards and make sure
that they are met at the commissary.
Purpose of Domino’s Pizza Hygiene Standards

• Establish guidelines for personnel in order to reduce the risk of product contamination or
adulteration.
• Motivate Team Members to assume responsible behavior through educational standards.
• To manufacture Domino’s Pizza dough that is safe and wholesome.
• To understand the impact a Team Member’s handling can have on finished products.
Main Sources for Contamination

• People: Most microbial problems in a food processing plant stem from Team Members with
improper hygiene habits.
• Faulty processing or practices.
• Raw ingredients.
• Defective equipment or environment.

Module 1: Hygiene
Domino’s Pizza Commissary Hygiene Standards
All personnel entering the dough processing area need to follow all the stated hygiene standards.
This applies to management, visitors, contractors, truck drivers, and Team Members.
Hygiene
• Team Members are to report to work clean, having taken proper precautions to ensure body
odor will be kept to a minimum. Bacteria can gather on skin and in the hair.
• Team Members must practice good personal hygiene habits at all times.
• Due to various health department regulations, all Team Members working in the preparation
and production areas are not to wear lotions on their hands, as it may leave residue on the
product.
• Perfume and aftershave should not be worn.
• Fingernails must be neatly trimmed, clean and not to exceed ¼ inch beyond the finger tip.
• Nail polish is not permitted.
• False fingernails are not permitted unless covered with an approved glove.
Jewelry
• Due to various health department regulations, all Team Members working with food
preparation are restricted from wearing jewelry, other than a plain wedding band, unless
prohibited by plant policy or local government. It is recommended; however, for safety
purposes, that it not be worn.
• Watches, necklaces, bracelets, earrings, and any other form of jewelry are prohibited in the
production area. Jewelry is difficult to maintain clean and sanitized as they easily harbor
bacteria. Jewelry items can also come off and fall into the product, or become a safety hazard
by getting caught in the machinery.
• Supervisor should be informed if a Medic Alert bracelet needs to be worn.
Hair
• Hair is one of the leading adulterants of food and is objectionable to the customer.
• Hair must be washed on a regular basis.
• All production personnel hair must be under restraint with a hairnet. A hair bonnet provides
more protection against hair falling out.
• Hairspray is not an acceptable form of hair restraint.
• Baseball caps are not an acceptable form of hair restraint as they do not restrict all hair from
falling out and also caps are not cleaned on a regular basis.
• If a knit hat is worn while working in the cooler or freezer a hairnet need to be worn on top of
it.
• Class “C” commissaries are allowed to wear a store hat. This hat can only be used in the
production area. In no instance shall hair be unkempt, left loose, or unrestrained.

Module 1: Hygiene
Facial Hair
• Facial hair must be clean shaven or a beard net, also known as a snood, is required. A beard
net can eliminate the possibility of facial hair dropping into the dough.
• One days beard growth requires a beard net.
• A mustache is allowed, but it must be neat, trimmed and clean. It cannot exceed the width of
the mouth, or extend below the top of the upper lip, otherwise it must be covered by a beard
net.
• Sideburns need to be covered above the ear lobe. If sideburns are below the earlobe they need
to be covered with a beard net.
Uniforms
Production Uniforms for a Class “C” Commissary
 Uniforms can be a smock or apron over a clean store uniform. Uniforms must have a
clean appearance and must be laundered before each use.
 In lieu of the preceding, a standard uniform may be covered with a smock while Team
Member is in production area.
Production Uniform for a Class “A” and “B” Commissary
 Uniform will be specifically changed into at the start of each shift, worn only within
the confines of the commissary operation and maintained clean throughout the shift.
 Outside contamination to the uniform can be limited if Team Members change inside
the commissary.
 Color should be white or light in color in order to show if there are any stains which
could lead to possible contamination.
Shirts
 Only shirts with snaps are permitted, no buttons.

 No pockets above the waist; if present, the pockets must be sewn shut. Items
such as pens, tools, keys, or cigarettes can fall out of the pockets when leaning
over, causing contamination to the product or food contact surface.
 Cut-off shirts or sleeveless shirts of any type are not allowed.
Pants
 Must be neat, clean and serviceable.

 No holes or patches allowed.
 Must be long-legged; hemmed, without cuffs at the bottom and must cover the
ankle.

Module 1: Hygiene
Footwear
 Types of shoes must comply with local, state, and federal safety regulations.
 Must be neat, clean, and serviceable.
 Shoe must completely enclose foot, no open toes, holes or sandal types.
 Socks must be worn with shoes.
Aprons (if used)
 Must be neat, clean and serviceable.

 Can be a disposable type.
 Must be bib type.
Warehouse Team Members

 Must wear an approved uniform, jumpsuit type coveralls or shop coat while working in
the warehouse area. These outfits must have a clean appearance and must be laundered
before each use.
Delivery and Service Team Members
 Delivery personnel must wear a full uniform.

 Must be neat, clean, and serviceable.
 Must have a logo patch on the shirt.
 An approved Domino’s Pizza hat must be worn.
 Ankle supporting steel-toe, non-slip, non-marring sole type shoe must be worn.
 Socks should cover the ankle.
Disease Control
• Team Members must exercise reasonable personal hygiene so that exposed parts of the body
(face, neck, arms, and hands) do not constitute a threat to exposed food.
• Team Members are to refrain from coughing, sneezing and spitting over the product.
• No person having infected boils, sores, unprotected wounds, open cuts or abrasions will be
allowed to handle raw or finished goods without taking proper precautions to prevent
contamination of food products. A metal detectable bandage should be used and covered by a
sanitary glove, since Staphylococcus bacteria are prone to proliferate in cuts, further
contaminating food and causing illnesses.
• No person should be in the production area if they are contagious with bacteria that can be
transmitted through food. Common symptoms may be, but not limited to, diarrhea, cramps, or
vomiting.
• No person having a cold or respiratory infection will be allowed to handle raw or finished
goods without taking proper precautions to prevent contamination of food products. These are
referred to as communicable diseases as they are transmitted directly or indirectly from one
human to another.
• Dough should never touch a Team Member’s face or neck.

Module 1: Hygiene
Employee Practices
• Eating should be in designated areas only, for example, in the break room.
• Food and food containers should not be stored in the locker room.
• Team Members must not eat, drink, use chewing tobacco, or smoke in the food processing
area or warehouse. Also, these items may not be stored in these areas.
• Personal items, such as, jackets, shoes, purses or bags should not be stored where food,
ingredients or equipment is exposed. These items need to be stored in designated areas, like,
the locker room.
• Certain office supplies, such as mechanical pencils, wood pencils, pens with caps, paperclips,
staples, correcting fluid, etc., should not be brought into the dough production room.
Hand Washing
• Hand washing can be the most important measure in reducing the possibility of
microbiological product contamination. Hand washing removes visible and invisible dirt.
• Hands and wrist must be scrubbed with an antimicrobial soap and hot water each time upon
entering the production room, after you have gone to the lavatory, touched your mouth or
when hands get dirty or contaminated.
• The use of a nail brush can reduce the possibility of contamination. If a nail brush is used or
required it must be cleaned on a regular basis, otherwise, it can be a source of contamination
to all Team Members.
• Wearing gloves does not replace hand washing. Gloves need to be kept clean, in good
condition, and replaced often.
• Instant hand sanitizer can be used after hands have been washed and dried, but it cannot be
used in place of hand washing. Hand sanitizing reduces the level of microorganisms to a safe
level.

Module 1: Hygiene
Hygiene summary
In the processing area, it is critical to take all necessary and or required precautions to protect
against contamination of food, food contact surfaces or food packaging materials.
The module on hygiene is important as it describes the standards Domino’s Pizza International,
Inc. has set to help prevent the potential for contaminating the dough. Contamination hurts us all-
in terms of our company’s image, our customers’ confidence in us and money spent to replace the
contaminated product.
A review of the hygiene standards applying to anyone who enters the production room:
• Wear clean, correct size uniform with no buttons or pockets.

• Approved shoes worn, no open toes or sandals.
• Display good personal hygiene.
• Do not store clothing or personal belongings in areas where food, ingredients or equipment
are stored.
• Hands and arms should be free of cuts, abrasions, sores, etc.
• Bandaged injuries to the hand shall be covered by sanitary gloves.
• Wash hands before starting work, before leaving the restroom, etc., to remove soil and
contaminants.
• Do not carry items such as pens, pencils, cigarettes, lighters, or mechanical tools in shirt
pockets.
• Do not wear hand lotion, fingernail polish or fake nails.
• Do not wear jewelry.
• Hair nets are required, and must cover all hair. Beards are allowed, but must be covered with
a beard net (snood). One days beard growth requires a beard net.
• No food, candy, gum, cigarettes, or tobacco in the production room.
• Do not enter the production room with any communicable disease that present a risk to the
sanitation and safety of the manufactured product.
• Smoking is only allowed in designated areas.

Module 1: Hygiene
Knowledge Questions
True or False
1. Team Members must report to work clean?
2. Open toed shoes can be worn in the production room?
3. A Team Member should handle dough with exposed sores?
4. Hand sanitizer can be used in place of hand washing?
5. Eating is allowed in the production room?
Short Answer
6. Explain why hygiene is important?
7. Give two reasons why jewelry is not to be worn in the production room.

Module 2: Sanitation
Sanitation
Overview
A commissary facility is a food manufacturing plant. It should be built in such a manner that
allows for easy cleaning and maintenance. Since food is being manufactured in the facility, it is
critical that it is maintained in an acceptable sanitary condition at all times. This makes good
business sense because our customers demand it and it is required by federal and local
governmental agencies. Sanitation is the responsibility of every Team Member in the plant.
A comprehensive sanitation program is essential to each and every commissary. Cleaning and
sanitizing may be the most important aspects of a successful sanitation program. The main
reason for creating a sanitation program is to reduce or prevent contamination from microbes,
pest activity or foreign material. A commissary not maintained in a sanitary manner may
experience many problems and may compromise product safety.
All federal and local government should be consulted when developing a sanitation program.
When it comes to the use of chemicals always think and act safely. Team Member safety is
always paramount when using chemicals.
Sanitation needs to become a way of life in the commissary. There are two methods for
maintaining a sanitation program at a facility: preventive and corrective. An effective sanitation
program will spend 80% on preventive sanitation and 20% on corrective sanitation.
Preventive Sanitation is established to reduce the possibilities of issues arising. The use of a
Master Sanitation Schedule is an example of preventative sanitation.
Corrective Sanitation eliminates an undesirable issue once the issue has been discovered. For
example, clean up after a spill occurred.
• Become familiar with equipment and structured housekeeping cleaning frequencies and
requirements.
• Understand the components needed to develop and maintain a successful sanitation program.
• Understand why pest control is a necessary part of a comprehensive sanitation program.

Essential Components of a Master Sanitation Program
Sanitation is a way of life as it applies to the food industry. It involves a combination of factors:
personal hygiene, respect for the food produced, clean and organized appearance, soundness of
equipment and facilities, and pest control. To insure success of the sanitation program, there are
several important and essential components of the program that must be present:
• Management Support.
• Organization.
• Scheduling.
• Training.
• Supervision.
• Materials and Supplies.
• Storage of Supplies.
• Cooperation.
Management Support
A commissary will only be as clean as the general manager or highest ranking official
wants it to be. Without key management support, it is impossible to maintain a successful
sanitation program. Management provides leadership, organization and training. They
supervise, document completed jobs/tasks, provide cleaning equipment, chemical supplies
and safe areas to store them. They will ensure that the program can be executed as
designed. Their leadership and participation are essential for a sanitation program to be
effective.
Organization
Organization of the housekeeping job must follow certain principles:
 Removal of flour and processing dust at least every three weeks. This helps prevents
mold.
 Daily cleaning of product zones which are high in moisture and oil.
 Thorough cleaning of all portions of every piece of equipment weekly (except for flour
handling equipment).
 Cleaning of flour handling equipment every four weeks.
 Cleaning of electrical switch boxes every four weeks.
 Cleaning of product zones and the immediate vicinity of equipment should be
performed by the individual who operates the machine.
 Cleaning of all other areas.
 Thorough, even if less frequent, cleaning of the premises.

Scheduling
When it comes to scheduling, written schedules are more effective than verbal ones, as
they are proven to give the best results.
 Utilize a Master Sanitation Schedule. A Master Sanitation Schedule should list all jobs
that need to be completed, the frequency and the person(s) or department responsible.
The schedule should include outside grounds, the building, production areas, drainage,
utensils, equipment and storage areas. Every piece of equipment, utensil, surface
(floors, walls & ceiling) and all other areas must be included on the Master Sanitation
Schedule.
 A Master Sanitation Schedule must be realistic taking into account manpower,
production schedule, and the special requirements needed to clean each piece of
equipment.
 A Daily Sanitation Schedule should also be created for areas, equipment and parts that
need to be cleaned on a daily basis. All team members need to be informed of their
cleaning responsibilities. It is important to remember that cleaning frequencies are
estimated and they can be adjusted if the area is being over or under cleaned.
 Document all procedures. The written information should also include the cleaning
frequency, type of cleaning, name of chemicals to use, chemical concentration,
cleaning and disassembling steps, and safety equipment (PPE – Personal Protection
Equipment) required for the specific job.
 Since cleaning and sanitizing may be the most important aspects of a successful
sanitation program, sufficient time should be given to outline proper procedures and
parameters. Detailed written cleaning procedures need to be developed for all food-
contact surfaces (equipment and utensils, etc.) and non-product surfaces and areas.
This may include equipment, overhead structures, walls, floors, drains, coolers,
warehouse and outside grounds.
Training
Training is a critical element of a successful sanitation program. Team Members must
have a complete understanding of what is required of them. They must be fully trained in
the proper and safe way to perform a cleaning task and the amount of time required to
complete it. Proper training explains the objective of each task, shows the correct
procedure, and allows the Team Member to successfully complete the task under
supervision until the skill is mastered. Training each Team Member to better understand
the importance of their role in maintaining the sanitation program is essential for success.

Supervision
Supervision is another component to a successful cleaning program. All jobs must be
supervised at some level. Department supervisors need to make sure all Team members
have been trained in the sanitation requirements and procedures for their areas.
Supervision is necessary on a continual basis to ensure that the area has been properly
cleaned. This is often done through inspections of equipment and the immediate area. It is
not enough to just check the finished job, as checking assures thoroughness but permits
inefficiency. The plant sanitarian must actively supervise the various cleaning jobs to
make sure they are being performed thoroughly and efficiently. At such times, the alert
supervisor makes a time study of the job. Supervisors also need to continually monitor
cleaning methods and frequencies to ensure areas are not being over or under cleaned.
Materials and Supplies

Some of the equipment necessary for cleaning a modern commissary:
 An industrial vacuum cleaner.

 An assortment of attachments including the overhead pipe cleaning attachment.
 Sufficient electrical outlets so that the vacuum cleaner can be used anywhere in the
plant.
 Air hoses with an OSHA (or equivalent) approved valve and wand (air pressure must
be limited to 30 psi).
 Large industrial type push brooms, pails (mop buckets) with wringers, hand brushes,
non-metallic scrubbies and squeegees (window and floor types).
 “Utility” and “Heavy Duty” detergents and sanitizers.
 Material Safety Data Sheets (MSDS) for all cleaning products – especially sanitizers
and solvents.
When commissary size permits, consideration should be given to the purchase of:
 Steam Jet Cleaners.

 Scrubbing machines.
 Sweeping machines.
 Wall washing machines.
 Adjustable, portable scaffolds.
 Hot water – compressed air jets.
 Rack washers.
 Pan washers.
 Custom installations for performing difficult washing jobs.
 Vacuum cleaner with necessary attachments and permanent vacuum tubes installed if
necessary, to reach remote areas.

Storage of Cleaning Equipment & Supplies
Cleaning chemicals, sanitizers and pesticides need to be labeled and stored in a locked
compartment away from production and food storage areas. This helps protect against
contamination of food, food contact surfaces, or food packaging materials. Consult all
federal, state, and local government agencies for the regulations/laws governing the
application, use, or storage of these products.
 Gloves and garments should be stored in a clean, dry area away from soiled items.
 Cleaning utensils should be cleaned and sanitized after use.
 Chemicals should be stored off the floor in a designated area. Ideally, in a cabinet
away from the processing area.
 Brushes, brooms, utensils should be color-coded and used in designated areas only.
For example, black brushes could be used to clean floor drains and white brushes to
clean food contact surfaces. This reduces the possibility of the same brush being used
to clean a drain and then used on the equipment.
Cooperation
Cooperation represents the final component of a sanitation program. It relies on the

teamwork of everyone in the commissary – management, production, warehousing,
delivery and service, and especially maintenance and engineering. All Team Members
must know their individual role in the cleaning and sanitizing operating plan. They must
be aware of their goals and responsibilities. They need to organize a master plan so that it
can be executed flawlessly. The Team Members will need the right tools to do the job, and
must have training and supervision – someone who cares about the outcome and how it
impacts the commissary operation. All Team Members must be held accountable for
positive and negative results. This will enable them to achieve the common goal of having
the cleanest and safest commissary possible.

Methods of Cleaning
Foam
Produced through the introduction of air into a detergent solution as it is sprayed onto the
surface to be cleaned. The types of foaming equipment are portable, wall mounted, central
systems and automated. Foam cleaning will increase the contact time of the chemical
solutions, allowing for improved cleaning with less mechanical force and temperature.
High Pressure Cleaning

Used to increase the mechanical force,thus, aiding in soil removal. In high pressure
cleaning, chemical detergents are often used along with increased temperature to make soil
removal more effective.
Clean in Place (CIP)

This type of cleaning is a system in which the cleaning and sanitizing of interior surfaces
of pipes, process equipment, tanks, and various fittings (i.e. filters) is performed without
disassembling of equipment (closed circuit) . This method of cleaning is often used to
clean the interior surfaces of tanks and pipelines of liquid processing equipment. A
chemical solution is circulated through a circuit of tanks and/or lines and returned to a
central reservoir allowing for reuse of chemical solution. Time, temperature, and
mechanical force are manipulated to achieve maximum cleaning.
Clean Out of Place (COP)
This method of cleaning requires the disassembling of equipment into component parts or
units to be cleaned in another area, such as a three compartment sink. Utilized to clean tear
down parts of fillers and parts of other equipment which require disassembly for proper
cleaning. Parts removed for cleaning are placed in a circulation tank and cleaned using a
heated chemical solution and agitation.
Mechanical Cleaning
Normally involves the use of a brush either by hand or a machine such as a floor scrubber.
Mechanical cleaning uses friction for food soil removal. This type of cleaning requires
Team Members to take pride in their work and often a lot of chemical is used.

Steps to Cleaning
Cleaning is the process of removing soil (dirt) from a surface with or without the use of a
cleaning chemical. Cleaning should always be done from top to bottom to avoid re-
contamination of a surface that was just cleaned.
1. Dry Cleaning
 Scraping, brushing or squeeging excess particles from the surface prior to the use of
water. This helps decrease water consumption, clogged drains and the spread of
particle to other areas of the room.
2. Pre-Rinse
 Water is used to remove most of the remaining particles and prepare surfaces for
detergent application.
3. Chemical Application
 Aids in the removal of all particles.

 Water alone can be a good cleaning agent if there is enough external energy (typically
referring to heat and applied force). However, cleaning compounds are normally used
to decrease the amount of external energy needed and increase the internal energy of
the water.
 Cleaning solutions are typically made up of 95-99% water.
 The goal for cleaning compounds is to make the water work more efficiently.
 There are four requirements for a cleaning compound
 Penetrate the soil.

 Displace the soil from the surface.
 Dispersion of the soil in the solvent.
 Preventing the soil from coming back to the surface.
4. Rinse
 Removes detergent and soil and prepares the surfaces to be sanitized.
5. Sanitizing
 Application of a sanitizer according to chemical manufacturing specifications.

Classes of Cleaning Compounds
The cleaning compounds needed to clean a commissary tend to include a combination of
chemicals to achieve a specific purpose. There is no single chemical that can effectively and
completely clean a food manufacturing facility.
For example, an all purpose or general purpose cleaner is effective for lightly soiled surfaces and
typically requires a decent amount of manual effort and contact time. Therefore, it is normally
not an effective cleaner for the entire facility. A cleaning chemical should be effective in;
penetrating the soil, displacing, dispersing and preventing the soil from coming back.
Along with meeting these requirements a quality cleaning compound should also soften the water,
dissolve quickly and completely, and be non-corrosive to the surfaces applied. Ideally, the
compound should be non-toxic (if possible), cost effective and stable for handling and storage.
Below is a list of the different types of cleaning compounds most commonly used in food
manufacturing facilities:
Alkaline
 Are solutions with a pH above seven (neutral).
 If you are trying to clean soil that is acidic (pH below 7), than the cleaner needs to be
an alkaline (pH above seven). Most food items are acidic, therefore, an alkaline
cleaner is needed.
 The pH of the alkaline cleaner has a direct relation with cleaning strength. Increasing
the pH from 7 to 9 increases the cleaning strength by 100 times. The pH is a
logarithmic scale; each measure of one unit is ten times stronger or weaker than the
previous number. It can be used in a very broad range of temperatures.
 Major functions:
 Soil displacement/emulsifying
 Saponifying – changing fats into soaps
 Peptizing – ability to attack and disperse protein
Complex Phosphates
 Soften water and provide a desirable level of alkalinity (increasing pH) which is
helpful in cleaning.
 Emulsify oily and greasy soils by breaking them up into tiny globules. Many
phosphates can actually peptize or suspend loosened soil and keep it from settling back
on the cleaned surface.
 Soil displacement by emulsifying and peptizing.
 Dispersion of soil.
 Water softening.
 Prevention of soil depositions.

Surfactants
 An important part of any cleaning agent.

 They are chemicals that when dissolved in water or another solvent orient themselves
at the interface (boundary) between the liquid and a solid (the soil that is being
removed) and modify the properties of the interface.
 When soil is present (hydrophobic in nature) the surfactant can be either a soap or a
synthetic detergent.
 Wetting and penetrating soils.
 Dispersion of soils.
 Prevention of soil redepositions.
Chelating
 One of the major concerns in dealing with cleaning compounds is water hardness. The
metal ions in the water interfere with the cleaning ability of detergents. They act like
soil and use up the surfactants, making them unavailable to act on the surface that
needs to be cleaned.
 A chelating agent combines itself with the metal ions in the water, making it
impossible for the metal ion to be precipitated with the surfactants. Therefore, chelated
metal ions remain tied up in solution in a state where it will not interfere with the
industrial cleaning compounds.
 Mineral deposit control.
 Soil displacement by peptizing.
 Prevention of redepositioning.
Acids
 Includes organic and inorganic acids and are often used in a two-step sequential
cleaning regime with alkaline detergent.
 They are often used for the prevention and removal of stone films.
 Mineral deposit control.

Factors That Influence the Effectiveness of a Detergent
Contact Time
 Depending on the type of particles and detergent used, it will take time to release these
particles from the surface.
Temperature
 Most chemical activity increases with increasing temperatures.
 If water is too hot it can bake the particles on to the equipment or become a safety
hazard for sanitation employees.
Physical Disruption (scrubbing)

 May be needed to remove all the particles, especially in hard to reach areas.
Water Chemistry
 Impurities in the water can change the effectiveness of cleaning chemicals.
 If the commissary has hard water, the calcium and magnesium salts can interact and
reduce its effectiveness.
 Water used for cleaning and sanitizing must be potable and pathogen-free.
Concentration
 Type and amount of chemical used to remove the soil.
Soil
 An unwanted matter on a surface that can be visible or invisible. The “stuff” the
cleaning chemical is trying to remove.
 Organic soil: Includes food soils such as fat, grease, protein, carbohydrate, living
matter such as mold, yeast, bacteria and petroleum soil. Most organic soils can be
removed by the use of alkaline cleaners or solvents.
 Inorganic soil: Includes rust, scale, hard water deposits and minerals (sand, silt, and
clay). Often acids can be used to remove rust and scale and a general purpose cleaner
for minerals.
 Combination soil: The most challenging since it is a combination of both organic and
inorganic components. Proper identification is critical for removal.
Surface
 Certain chemicals can damage or interact with the surface it is applied to. For
example, an oxidizing agent can destroy a stainless steel surface.
 Always make sure that the cleaning chemical is safe to use on the surface to be
cleaned.

Sanitizing
Sanitizing is the process of reducing the number of microorganisms on a clean surface to safe
levels. It is primarily used on food contact surfaces. To be effective, cleaning and sanitizing is a
two step process. A thorough cleaning is essential before using a sanitizer. A sanitizer is less
effective when food particles or dirt are present on equipment surfaces. Use only approved
sanitizers for food processing plants.
Methods of Sanitizing
Heat
 Sanitizing a surface using heat is achieved through steam, water or air.

 The higher the heat, the shorter the time required to kill the microorganisms.
 If using a tray washing machine, it might rely on hot water to sanitize the trays
(although most use a chemical sanitizing rinse).
 The temperature of the final sanitizing rinse must be at least at 180°F (82°C), with
enough dwell time to heat the surface to a minimum temperature of 160°F (72°C).
Chemical
 Sanitizing by the use of chemicals is typically done one of two ways:

 First - by immersing a clean object in a specific concentration of sanitizing solution
for a required period of time.
 Second - rinse, swab, or spray an object with a specific concentration of sanitizing
solution. Examples of chemicals sanitizers are chlorine bearing compounds, iodine
complexes, quaternary ammonium compounds, acid-anionic, peroxyacetic acid, dual
halogen or chlorine dioxide.
 The most commonly used are chlorine and quaternary ammonium compounds,
commonly referred to as “quat” sanitizers.

Types of Chemical Sanitizers
Chlorine Compounds
 Chlorine, in its various forms, is the most commonly used sanitizer in food processing
and handling applications.
 Commonly used chlorine compounds include: liquid chlorine, hypochlorites, inorganic
chloramines, and organic chloramines.
 In properly diluted form, they are non-staining, nontoxic, nonirritating to the skin,
stable and economical.
 Chlorine sanitizers are often easy to prepare, apply and leave minimal residue on
surfaces. The activity of chlorine is affected by pH, temperature, water hardness, and
organic load. Chlorine is less affected by water hardness when compared to other
sanitizers. It can also be corrosive to metal surfaces at high temperatures. This can be
a problem when used in a tray wash machine, as it can be very corrosive on the
stainless steel equipment.
 The maximum allowable level for no-rinse applications is 200 ppm available chlorine,
but recommended usage levels may vary. Concentration is measured in parts per
million (ppm) using a test kit designed for a specific type of sanitizer. These are
usually available from the chemical supplier.
Quaternary Ammonium Compounds (Quat or QAC)

 Quaternary Ammonium Compounds are based on the active ingredient benzalkonium
chloride.
 In their properly diluted form they are odorless, colorless and nontoxic.
 They are often stable at high temperatures, over a wide pH range, and in the presence
of organic materials.
 They are effective against many types of bacteria.
 It should also be noted that detergent residue can negatively affect the sanitizing
results.
 The maximum no-rinse concentration is 200 ppm and can be tested with a specific test
strip.

Factors That Influence the Effectiveness of Sanitizers
Concentration
 Generally, the activity of a sanitizer increase with increased concentration. However, a
leveling off occurs at high concentrations.
 A common misconception regarding chemicals is that "if a little is good, more is
better".
 Using sanitizer concentrations above the recommended level does not necessarily
sanitize better. In fact, it can be corrosive to the equipment, making it even more
difficult to clean and sanitize.
 Also, excess residue can possibly contaminate the product.
Temperature
 Generally, sanitizers are most effective at temperatures between 55°F and 120°F
(13°C and 49°C).
Contact Time
 In order for the sanitizer to kill the microorganisms, it needs to be in contact with the
object for a specific amount of time.
 See the manufacturer's label for the time required.
Safety Concerns When Using Chemicals

• Working with chemicals poses a risk to both the product and Team Members using them.
• It is the responsibility of the employer to ensure chemicals are properly stored, handled and
meet all regulatory guidelines.
• Personal Protective Equipment (PPE) should be provided if needed. Typically, this would
include goggles, gloves, rubber boots, etc.
• Information, such as the Material Safety Data Sheet (MSDS) and product labels should be
available to all Team Members.
• Strong acids and alkalis are highly corrosive to skin. Always take appropriate precautions,
and use the correct Personal Protective Equipment (PPE) whenever handling these types of
chemicals.
• When diluting sanitizers, always add concentrated sanitizer to water; not water to sanitizer.
Adding water to a concentrated sanitizer may rapidly generate heat.

Monitoring
The purpose of an adequate monitoring program is to assure that the processing areas, food
contact equipment and non-contact equipment are properly maintained in a clean and sanitary
manner. It is also important for Team Members to maintain clean uniforms and use the PPE that
is appropriate for their job.
What to Monitor
 Condition of the food contact surfaces.
 Design and cleanliness of equipment. For example, the rounder, divider, conveyor belt.
 Correct cleaning procedures being followed.
 Type and concentration of chemicals and sanitizers used.
 Condition of employees uniforms and gloves (if applicable).
 PPE is in good working condition.
Methods for Monitoring

Visual Inspection of Area, Equipment and Personnel
 A self inspection program should be implemented at the commissary.
 A self inspection audit should be conducted at least once a month, including all
areas inside and outside of the facility.
 Self inspections help identify issues before they have the opportunity to become
potential problems. For each issue noted, a corrective action needs to be
recorded listing the problem, how to resolve it, the person responsible for the
corrective action, and the date of completion.
 A record of the inspection should be kept on file for at least 12 months.
 Daily pre-operational inspections should also be conducted and the results recorded.
Chemical Testing
 Monitor chemical concentration using test strips.
 Test strips change color when dipped into the appropriate sanitizer, the amount
of color change representing the concentration of the sanitizer.
 This method can quickly provide a concentration range in a short period of time,
and are reasonably accurate.
 They are often available through the chemical supply company.
 This method is quick, easy and inexpensive.
 Measure sanitizer concentration with a colorimetric test kit.
 This method requires a mixing of chemicals to provide a more precise reading.

 This is a more complex method that requires some training prior to use.

Verification Checks
 Microbiological testing:
 Swab or plate testing determines the presence of a specific type of organism.

 The disadvantages are it only tests for a certain type of microorganism and it
takes a long time (often weeks) for the results.
 Microbiological enumeration:
 Testing the effectiveness of equipment cleaning by determining the presence of

any non-specific organic matter on a surface.
 An example of this type of testing is bioluminescence ATP (Adenosine
Triphosphate). They provide rapid results, but can be expensive.

Three Compartment Sink
• For clean and sanitized trays, a three compartment sink needs to be used if there is not an
automatic tray washer in use.
• The sink must have three separate compartments for manually washing, rinsing and sanitizing
dough trays and utensils.
• The sink compartments need to be large enough to submerge the dough trays to ensure proper
cleaning and sanitizing.
Steps for Using a Three Compartment Sink (sinks are to be set up left to right):
1. Rinse and/or scrape all items prior to washing.
2. Wash items in the first sink in water at least 110°F (43°C) with an approved
detergent.
 The water temperature can and should be checked with a thermometer.

 A brush, cloth or scrubber can be used to loosen debris.
 Steel wool or metallic scrubber should not be used as it can leave metal pieces on the
dough trays or damage the trays.
 The water and detergent should be replaced when the water cools off, suds are gone or
water is dirty.
3. Rinse
 Wash the items in the second compartment by either submerging them in clean rinse
water or spraying them with rinse water.
 The water temperature should be at a minimum of 110°F (43°C).
 The items should be rinsed until there are no visible signs of dirt, old product or
detergent.
4. Washed and rinsed items need to be sanitized in a chemical sanitizer.
 The two most common types of chemical sanitizers are quaternary ammonium and
chlorine.
 Generally, sanitizers work best between 55°F and 120°F (13°C and 49°C).
 Quaternary ammonium sanitizers (quats) should be at 200 ppm and chlorine at 50-
200ppm.
 If the concentration is too high, add more water.
 To ensure accuracy, use test strips to verify the concentration is correct.
 Please follow all local, state or federal regulatory agencies for the concentration
requirements for the sanitizers.
5. The washed, rinsed and sanitized items should then be placed on a clean drain board
to air dry.
 Using towels can possible contaminate the items.

 Trays should be allowed to air dry and should not come into contact with the floor, or
any other surface that is not clean and sanitized.

Requirements for Automatic Tray Washers
Dough trays are considered food contact surfaces and must be washed and sanitized prior to use.
The trays must be free of soil.
• Measure and record the concentration of the detergent being used. Concentration must adhere
to local, state, or federal agencies and must be checked prior to use and throughout the day.
The tray washing parameters must be recorded three times a shift: at the start up, middle and
the end of the day.
• Proper wash and rinse cycles as required by local board of health.
• Machine must be capable of meeting NSF requirements.
• Must have an accurate, self-contained thermometer to monitor temperatures for all cycles.
• Must include a device that allows the operator to check the pressure of the water in the wash
and final rinse cycles.
• Must be compatible with dough trays to allow easy loading and unloading.
• Must have an automatic soap dispensing unit with an automatic warning device to indicate a
low supply of detergent or sanitizer.

Pest Control
A necessary part of a successful sanitation program is the control of pests in and around the
building. A documented and complete Pest Control Program needs to be established for the
facility. This must be handled through a reputable pest control company. All local, state, and
federal guidelines must be followed for the pest control program used. It is important to
remember that preventative pest control is the best and most effective approach. Do not wait
until a problem exists to act. The first step to controlling all types of pest is by improving the
sanitation program.
Contracted Pest Control Company

A contracted pest control company should provide the following information to each commissary.
• A contract stating the services provided, frequency of visits, and methods used to control each
form of pest.
• Documentation of pesticides and rodenticides applied inside or outside the building. This can
be achieved using log format showing the material used, amount, targeted pest, area where
pesticide is applied, method of application, date, time and person applying the pesticide.
• A copy of the sample label and Material Safety Data Sheet (MSDS) needs to be available for
each pesticide applied at the commissary.
• A current map should be available showing the location, and number of each pest control
device used (i.e. internal traps, external traps and insect light traps).
• A copy of the pest control technician’s license and proof of insurance should be on file.
Internal Rodent Traps

• Mechanical traps (Ketch-All or Tin-Cats), extended trigger traps, or glue boards should be
used inside the facility, unless prohibited by regulatory requirements.
• Poison should never be used in a food manufacturing facility. If these traps are prohibited by
law, non-toxic feeding station can be used for monitoring purposes. These stations should be
constructed in a durable material, locked and secured in order to minimize the possibility of
potential contamination of food products or material in storage.
• Mechanical traps used for internal monitoring should be placed every 20 – 40 feet
(6.5 - 13 meters) along exterior walls, each side of an exterior overhead or pedestrian door, or
where there is a chance of a pest entering the building.
• The traps or glue boards should be identified.
• Traps need to be inspected at least twice weekly with findings recorded.
External Rodent Traps

• Bait stations can be installed around the exterior perimeter of the building every 50 – 100 feet
(15-30 meters) to control rats and mice.
• The stations should be properly positioned, tamperproof, secured to the ground and labeled.
• Only an approved rodenticide or monitoring feeding block (non-toxic) should be used as bait
inside these stations.
• The stations should be inspected at least monthly or more frequently if high activity is noted.
• Bait stations should not be used inside the facility.

Birds
There are many species of birds out there; however, three are known pests at food processing
facilities:
• English Sparrow (Passer domesticus)

• Starling (Sturnus vulgaris),
• Pigeon (Columbia livia).
They are considered pests for their presence, ability to spread diseases, and to damage property.
Their presence increases the chance of them entering the commissary. If a bird enters they have
opportunity to contaminate all the stored food. A few diseases they are known to spread are
Histoplasmosis, Ornothosis, and Salmonellosis. Examples of some of the property damage can
be clogged gutters, roof leaks and defacing of the building from their droppings.
Controlling Birds
• The first step to controlling birds should be through sanitation.
 Their food and water sources need to be removed. Clean area around the building,
especially around the dumpster.
 Make sure the dumpster lid is kept closed in between uses.
 Standing water also needs to be eliminated.
• The next step is to eliminate the possibility for roosting or nesting sites.
 This can be accomplished through ensuring all outside openings are maintained and
kept closed if not in use.
 Temporary control can be obtained by visual devices (i.e. fake owls or scare balloons),
sound devices, structural modifications (netting or chimney caps), and roost alteration
(spiked wires or ropes).
• The use of avicides is strongly discouraged, and often illegal.
 This must be done by a certified Pest Control technician and follow all regulatory
requirement.
 Their use should only occur when there is no other practical control.

Insects
There are many types of insects and pests that are of concern to the modern food manufacturing
plant. In order for insects to survive, they require a source of food, moisture, temperature and
time to develop. Maintaining a clean commissary and properly rotating products (First In First
Out – FIFO) can be the best way to prevent infestations. Making sure your facility is sealed is
also critical in keeping pests out. The use of pesticides should only be a supplement to a
thorough preventive pest control program.
Stored Product Pests
• One of the more common groups of pests is known as pantry pests.

• They include several types of beetles, moths and mites that can infest and contaminate whole
grain or processed foods.
• Pheromones are often used to monitor their presence and assess their numbers – they are not
used for controlling or killing.
• There are two types of stored product pests: external and internal feeders.
 External feeders
 They are strong fliers, are attracted to light, and penetrate packaging.
 They can be found on product spillage on stored items or on old equipment.
 Examples of external feeders are cigarette beetles and Indian meal moth larva.
 Internal feeders
 They are invaders as they cannot attack whole or undamaged grains.

 Examples of internal feeders are flour beetles and sawtoothed grain beetles.
Other Common Insects Found in Food Processing Facilities

• Sanitation and proper stock rotation are the best ways to limit either of these pests.
• If activity is found in the commissary, inform the contracted pest control company
immediately.
• In general, the greater the number of insects seen, the older the infestation problem is, and the
more difficult it will be to resolve.
Cockroaches
 Cockroaches will eat almost anything and like to stay as close as possible to food and
moisture sources.
 Common species found in food processing facilities are German, Oriental and
American.
Ants
 Ants can be similar to cockroaches in the fact they will eat almost anything to survive.
 The Carpenter ant likes to feed on a wide variety of foods, especially other insects.

Insect Light Traps
• Can be an effective way to identify issues with flying insects.
• Careful consideration is needed when installing these. Units should not attract insects from
the outside into the building, or be placed within ten feet of exposed product.
• The light trap units need to be cleaned out regularly and more frequently during high activity
months.
• The bulbs should be shatterproof and changed annually.

Production Area Sanitation Checklist (Sample)

Date :________/________/________
Team Members on shift: _____________________________Shift Leader: ________________________ ____________
Shift Time: __________
To __________________________________________________________________________________
PRODUCTION ROOM PRODUCTION EQUIPMENT
 Second half of table top clean  Mixer: hood inside, paddles, scraper & outside
 Small hand sink clean  Divider: pistons, ram, knife & inside clean
 Hand sink holders clean & filled  Hopper & outside of divider clean
 Soap dispenser & paper towels filled  Oil drain jugs empty & clean
 Scale shelf & control boxes on wall #1 clean  Divider conveyors & belts
 All shelves clean  Bowl elevator carriage clean
 Electrical Cords Frame around window clean  Outside of bowl elevator clean
 Wall #2 clean  Mixer control panel clean
 Pipes overhead clean  CO/4 or CO/5 drum, rails, base, cord top & panels clean
 A/C unit, pipes & filters clean  Round-a-matic auger, cylinder base, cord, outside & table clean
 Wall #3 clean
 Scale rack & all control boxes clean
 A/C unit, pipes & filters clean
 Wall #4 clean INSIDE COOLER
 Cooler door & frame clean  Conveyor & floor underneath clean
 Display monitors & pipes clean
 Back up water meter & pipes drain hose clean
 Scale read out clean
 Strip curtain & door frame clean
TRAY WASH ROOM

 Floor & front of tray washer swept & cleaned  Blower fans clean
 Front of tray washer cleaned  Table top conveyor clean
 Screens cleaned  All walls in tray room clean
 Front tank clean  Floor in tray room clean
 Center section clean  Three compartment sink clean
 Back tank clean  Water chiller clean top, behind and around
 Screens clean  Ceiling in tray room clean
 Top of tray washer clean  Doors to production room clean
 Behind tray washer clean include walls & floors  Drain grates and pits clean
 Floor under tray washer clean & sanitized  Tanks refilled & burners turned on
 Conveyor chain in tray washer clean  Empty trash container, sanitize & place new liner inside
 Outside of tray washer clean

Equipment Cleaning Frequencies Checklist
DAILY EACH EVERY EVERY

EQUIPMENT CLEANING WEEK 3 4
WEEKS WEEKS
FLOUR EQUIPMENT
Conventional flour handling equipment X
Bulk flour equipment - all pneumatic
X
(under controlled conditions– 6 weeks)
Bulk System Breather bags X
SIFTER
Tailings
X
(check every 4 hours during shift, & at end of production run)
Screens (break down & clean) X
MIXER
Product Zone X
Scrape & Wash (*preferably) *X X
Water Inlets X
Housing X
WATER COOLERS/CHILLERS
Non-sealed chilled water tanks X
Yeast slurry systems X
INGREDIENT CONTAINERS
Wet X
Dry X
Mixing bowl (inside) X
DIVIDER
Product Zone X
Housing X
ROUNDER
Product Zone X
Housing X
WALK-IN COOLER
Floor X
Fans X

Housekeeping Cleaning Frequencies Checklist
DAILY EACH EVERY 2 EVERY 3 EVERY 4
HOUSEKEEPING CLEANING AREAS WEEKS WEEKS WEEKS
WEEK
FLOOR AREAS
Production X
Restrooms X
Shipping X
Flour Storage X
Storage (other) X
Garage X
PIT AREA (IF APPLICABLE)
Scale – Production X
Scale – Receiving X
Elevator X
Damp or Wet X
Dry X
Sump X
PIPES AND OVERHEADS X
Structures X
Walls X
Rough walls (or as needed) X
FLOOR DRAINS X
WINDOWS (dusty areas) X
ELECTRICAL FIXTURES X
CEILINGS (as needed) X
LOCKERS X
STRIP CURTAINS
Production X
All others X

Sanitation Summary
Sanitation needs to become a way of life in the commissary. Implementing a master sanitation
program can be the most effective way of achieving that goal. The essential components of a
master sanitation program are: management support, organization, scheduling, training,
supervision, material and supplies, storage of supplies and cooperation.
The methods for cleaning are foam, high pressure cleaning, Clean in Place (CIP), Clean Out of
Place and mechanical cleaning. No matter what method is used, cleaning should always be
preformed top to bottom. The steps to cleaning are: dry clean, pre-rinse, chemical application,
rinse and finally sanitize. Selecting the correct detergent to use for each job can be difficult, there
are many factors involved in how effective it will be.
After cleaning is completed, it is then time to sanitize the surfaces. Sanitizing is the process of
reducing microorganisms to a safe level. The two methods for sanitizing are heat and chemical.
The two most common types of chemical sanitizers used in a commissary are chlorine and
quaternary ammonium (quat). These sanitizers should only be used in the approved
concentration.

Knowledge Questions
True or False
1. Training is a critical element of a successful sanitation program?
2. Clean in Place (CIP), often involves the use of a brush either by hand or a machine such as a
floor scrubber?
3. The impurities in water can change the effectiveness of a cleaning chemical?
4. The concentration of a chemical sanitizer is not important, as long as it is enough?
5. When diluting sanitizers always add the concentrated sanitizer to water?
Short Answer
6. What are the two methods for maintaining a sanitation program?
7. What are the five steps to cleaning?
8. What are the two methods for sanitizing?
9. How often should the bulbs in insect light traps be changed?

Quiz 1
HYGIENE AND SANITATION QUESTIONS
MODULES 1 AND 2
TRUE OR FALSE
1. Poison bait traps are acceptable inside the commissary?
2. Wearing gloves does not replace the need for Team Members to wash their hands?
3. All containers should be labeled?
4. Sandals can be worn in the production room, if the person is just walking through the
area?
5. Dough trays are not considered food contact surfaces, therefore, cleaning and
sanitizing them is not important?
6. Team Members with open sores should not touch the product?
7. Only Team Members have to follow the hygiene standards while in the commissary?
8. Scheduling, training and supervision are three examples of the essential components
to a master sanitation program?
9. The two most common types of chemical sanitizers used in food processing facilities
are chlorine and quaternary ammonium?
10. Insects need food, moisture, temperature and time to develop?
11. Verbal schedules are effective for cleaning and sanitizing?
12. A knit hat can be worn in place of a hairnet?
13. Generally, chemical sanitizers work best between 30°F to 40°F (1°C to 4°C)?
14. The steps to cleaning are: sanitizing, chemical application and rinse?
15. Earrings and necklaces should not be worn in the production area, but watches can be
worn?
Dough Certification Q1-1 2013

Quiz 1
FILL IN THE BLANKS
16. The first step to controlling all forms of pest should be through?
17. An easy way to check the concentration of a chemical sanitizer is through the use of?
18. What type of water should be used to wash hands with?
19. Mechanical traps should be placed every how many feet or meters along exterior
walls?
20. If a Team Member has facial hair growth of one day or more, it should be covered
with?
21. The use of what reduces the levels of microorganisms to a safe level on a Team
Member hands?
22. Most microbial problems in food processing are the result of Team Members with?
23. What is the frequency for changing the bulbs in insect light traps?
24. At least how many times a day should the automatic tray washing detergent and
sanitizer concentrations be checked and recorded?
25. What does MSDS stand for?

Quiz 1
CHOOSE THE BEST ANSWER
26. Internal mechanical traps should be checked and recorded at least?
a. Monthly
b. Weekly
c. Twice a week
d. Never
27. Hands should be washed with what type of soap?
a. Antibacterial/germicidal
b. Hand sanitizer
c. Soap is not needed
d. Water only
28. Examples of the different types of monitoring are?
a. Temperature, rinse and verification checks

b. Visual inspection, chemical testing and verification checks
c. Foam, time and visual inspection
d. None of the above
29. Fingernails should be?
a. Clean
b. Trimmed, not exceeding a ¼ inch
c. Free of nail polish
d. All of the above
30. Written cleaning procedures should include?
a. Cleaning frequency
b. Cleaning procedures
c. Chemicals and concentrations
d. All of the above

Quiz 1
Notes

Module 3: Safety
Safety
Overview
Domino’s Pizza’s goal is to keep all Team Members safe on the job. The following module will
give a better understanding of our safety standards.
This module will cover the safety standards for a commissary. Occupational Safety and Health
Administration (OSHA), and Domino’s Pizza want to prevent accidents before they occur. The
goal of these organizations is to assure health and safety for all workers by establishing strict
standards and training.
There are two major categories of injuries occurring in dough production: slips and falls and
major strains. In this module you will learn ways to protect against these problems.
• Understand the safety requirements in the commissary.
• List at least seven safety-oriented tasks pertaining to equipment.
• Describe the safest way to lift something.
• List at least two ways to reduce injuries involving slipping and falling.
• Explain what PPE is and list examples.

Module 3: Safety
Facility Safety
Below you will find many of the safety requirements employed in our commissary system.
• Each Team Member and visitor shall comply with all occupational safety and health standards
and rules, as well as regulations and orders that are applicable to their own action and conduct.
• Outside vendors, contractors and other suppliers are expected to abide by the company’s
safety rules and regulations when they are on company property.
• Hair restraints must be worn at all times in designated areas.
• Observe all warning and danger signs.
• Team Members working in maintenance and production areas may not wear jewelry of any
type.
• Those unsafe acts which endanger the health of Team Members or visitors will not be
permitted.
• Alcohol or drugs are not permitted on the premises.
• Only authorized personnel shall operate lift trucks.
• Use proper exits from all platforms.
• Eye protection is mandatory for Team Members and visitors involved in or around welding or
grinding operations, or in areas where required.
• Hearing protection must be worn in designated areas.
• Always watch and stay clear of moving fork trucks.
• Hard hats must be worn in the warehouse area of the facility, and whenever construction is
present.
• Safety goggles are to be worn in designated areas and wherever appropriate.
• Smoking is only permitted in designated areas; do not smoke outside of the designated areas.
• No jumping off docks, use ramps and stairs.
• Use wet floor signs as necessary.
• Horseplay, scuffling, teasing and other distracting practices are dangerous and shall not be
engaged in.
• Keep hands and clothing away from moving parts on operating machines.
• Use Lockout/Tagout procedures when servicing and cleaning machines.
• Passengers are not permitted on fork lifts or hand trucks.
• Chock trailers while loading or unloading.
• Do not block or obstruct doors or exits. They must be kept clear.
• All unsafe conditions should be reported to a supervisor at once. First Aid supplies are
available in designated areas. All injuries should be recorded on an accident report or on a
First Aid Log.
• Good housekeeping throughout the facility is directly connected with, and is essential to,
safety, efficiency and satisfactory working conditions.
• Use prescribed safety equipment when necessary to do a job.
• Never enter a confined area such as a hopper, bin tank, or silo without following proper
confined space entry procedures.

Module 3: Safety
Safety Tasks Pertaining To Equipment
• Attach safety guards to all equipment. All machine pinch and shear points need to be
identified and guarded.
• Before reaching into or cleaning machinery, always unplug any electrical machinery. Be sure
to grasp the plug to disconnect- NEVER pull the cord.
• Always lockout/tagout all equipment before cleaning or maintaining. Even if the machine is
turned “off,” an electrical malfunction can happen. OSHA and Domino’s Pizza require
lockout/tagout procedures to be followed to reduce personal injury.
• Think safety when using the mister (spray bottle) to apply the correct amount of mineral oil
when coating the divider hopper. Use no more than 57 grams (2 ounces) of oil for this
process. Excess oil can collect on the equipment or drip on the floor and causes slips and
falls.
• Maintain all equipment on a daily basis by making sure it is operating effectively. Equipment
that malfunctions is more likely to cause an accident and can be dangerous to the operator.
• To prevent slipping and falling accidents, cleaning tools must be stored in approved location.
• Inspect electrical cords regularly. Replace cords that are cracked, frayed or damaged in any
way. Replace plugs with bent or damaged prongs, or those with missing ground prongs.
• Take care when setting up equipment that cords are protected (do not set equipment on them
or stretch, bend or twist them). Make sure that cords do not create a tripping hazard.
• Do not use spray type cleaning fluid, steel wool, or excessively wet cloths to clean around
wiring or electrical devices.
• Water and electricity do not mix. Keep floors as dry as possible. Be certain electrical cords
do not come into contact with water.
• Do not operate equipment you are not authorized and trained to operate. If in doubt, ask or
check written instructions. It is a good idea to have operating instructions and tips posted for
each piece of equipment. Be sure these instructions are updated when needed and that all
controls are clearly identified and labeled.
• Always be especially careful when cleaning equipment. Sharp edges can cut and heavy,
slippery pieces can fall or be dropped if not handled with care.

Module 3: Safety
• Use extreme caution when cleaning silos. Follow all manufacturer’s recommendations and
instructions related to maintenance, service or repair. When cleaning a flour silo, always work
in teams of three, one in, one outside, and one on the ground. These are some safety tasks that
will assist you when working in a flour silo:
Inside Silo – Person 1 Silo Safety Rules

-Empty pockets and remove all metal objects -Do not use tools that could produce a spark or static
(such as belt buckles and jewelry, coins or electricity. The danger of a confined space is the potentially
cigarettes, necklace) explosive atmosphere. Flour dust mixed with air, a condition
created by entering and cleaning the silo, is highly explosive.
-Use only explosion proof electrical devices (i.e. extension
cord, light fixtures etc.)
-Never do anything to introduce a spark or ignition source to
set off an explosion
-Limit items taken into the silo to reduce potential product
contamination.
-Special precautions must be taken before doing any welding
or cutting operations in or near a silo.
-NO SMOKING must be strictly enforced
-Wear Safety Harness attached to a Lifeline that -Make sure Power Switch outside the bin is locked in the OFF
you control. position
-Eye Protection -Wear Eye Protection (snug fitting goggles).
-Wear respirator mask -Minimum: - respirator mask that covers both nose and -
mouth.
-Inside must be able to see and hear outside and -Person 1, 2 and 3 must be able to hear each other at all times.
grounds person at all times.
-Start cleaning at the top and work your way -Use stable structure for climbing. Normally ladders and
down. platforms that are already built in the silo.
-Special precautions must be taken before doing
any welding or cutting operations in or near a
silo.
Outside Silo–Person 2 Silo Safety Rules
Must attend Person 1’s Lifeline at all times. Must be able to see and hear inside and grounds person at all
times.
On the Ground–Person 3 Silo Safety Rules
Must be able to see and hear inside and outside Person 1, 2 and 3 must be able to hear each other at all
person at all times.
times.

Module 3: Safety
Rules for Lifting Safely
In your daily routines you may often find it necessary to lift large, awkward shaped, or heavy
objects. Back and stomach muscles may be strained if you are not careful. Pay special attention
when reaching overhead, handling oversized or heavy loads, long objects and bags or sacks.
Rules for Proper Lifting

• Leg muscles do the work instead of back and stomach muscles.
• Get a good footing.
• Place your feet about shoulder width apart.
• Bend knees to grasp the weight.
• Keep body over the load.
• Keep back straight.
• Get a firm hold.
• Keep the back as upright as possible and then lift gradually by straightening the legs.
• Get help if weight is too heavy or bulky to lift.
When unloading, lower the load slow, using your legs and not your back muscles.
Common Injuries in Dough Production

Major Strains
There are several ways that can cause back strain in the commissary.
 Lifting something over your waist, such as trying to take heavy supplies from a high
shelf. Most people do not think about back strain when they are arranging supplies.
Store heavy supplies on lower shelves.
 Twisting back muscle. This condition can result if the production line is not set up
correctly. For example, if the production line is set up in a way that one must twist
around sharply, this may cause a back strain problem.
 Lifting a load that is out of balance. This happens if you try to cut too much dough out
of the mixer at one time. Also, make sure you know where your fingers are in relation
to the knifewhen you are cutting dough in the bowl. Trying to be too quick in
completing a job can cause Team Members to forget about safety. Cutting smaller
chunks of dough will make a load easier to handle.
 Do not bend and turn at the same time. Stand up straight first and then turn in the
desired direction.
 When lifting a stack of empty dough trays, test the weight of the stack before you pick
it up. Often these are trays full of dough, water, or other material mixed in with
apparently empty trays making the stack much heavier than it appears.

Module 3: Safety
Slips and Falls
Injuries in the commissary can also result form slipping and falling.
 Do not run. WALK. You may not see obstacles if you are moving too quickly.
 Use only stable structures for stepping and climbing. Dough trays are not to be used
for standing or climbing on. An unstable structure can topple or break and you can
easily fall.
 Clean-up spilled oil or any liquids immediately. Do not use more than the approved
amount of oil to coat the divider hopper (57 grams (2oz.)). Clean and dry floors lessen
the chance of slipping or falling.
 Be especially careful when moving stacks of dough trays. Stacks of dough trays
appear to be a stable unit, but they are in fact not. They often come apart from each
other and can fall on Team Members, causing injuries as well as loss of product.
Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) is worn to minimize exposure to specific occupational

hazards. The use of PPE is only part of a complete safety program. PPE does not reduce the
hazard itself nor does it guarantee permanent or total protection. Controlling a hazard at its
source should be the first choice because this method will eliminate it from the workplace or
isolate it from the Team Member. When a hazard cannot be removed or controlled, PPE must be
used if the work process is to continue.
Examples of PPE
 Shoes- Recommend that approved safety shoes be worn to protect your feet. Shoes
should be steel toes with non-slip bottoms.
 Hard Hats or Bump Caps- Should be worn in designated areas; visitors are included
in this requirement.
 Eye Protection- Proper eye protection must be worn when the activity presents a
potential eye or face injury. Typically, this occurs when working with chemicals (tray
washing).
 Gloves- Appropriate gloves and aprons shall be worn when handling hazardous
chemicals and abrasive materials. Gloves should be replaced when the signs of wear
are apparent.
 Back Support Belts- When coupled with the correct method of lifting, it can be
effective in eliminating or reducing back strains and injuries.
 Ear Plugs- The result of prolonged exposure to excessive noise can result in a
permanent loss of hearing. Ear plugs protect your hearing from damaging decibels.
 Respiratory Equipment- Approved respiratory equipment shall be worn when the
worker is exposed to inhalation hazards. Servicing a flour silo (inside) is a good
example of when this type of equipment is necessary.

Module 3: Safety
Production Room Safety
The production and tray washing areas have the majority of the activity during a typical work
day. Both of these areas have a lot of different types of equipment. There are mixers, elevators,
dividers, and conveyors to name a few. Safety and sanitation are one and the same. Chances are
if a piece of equipment or floor is not cleaned properly it can be unsafe.
Useful tips that can be used to make an area safe:

• Lockout/Tagout all equipment prior to cleaning or maintaining.
 A lockout/tagout program protects against unexpected startup of equipment during
service or maintenance activities. Locking the equipment in a safe position (“OFF”)
prevents equipment from being turned on without the use of a key or other unlocking
mechanism. The Team Member that is performing the work holds the only key that
can restore power to the equipment.
• Install a semi-rough floor surface, such as “Stonhard”
 This is a seamless, sanitary and easy to clean flooring surface that can stand up to
cleaning chemicals and does not harbor bacteria or dirt. It also has a non-slip surface.
• Ensure there is adequate room to perform maintenance on the equipment.
• Do not work on equipment between the machine and a hard place (i.e. wall)
• Install “kill” switches on equipment (commonly referred to as E-stops or emergency stops).
 A security device used to shut off equipment in an emergency situation-with the touch
of one button (red stop button). Kill switches, or emergency stops, must be operational
on all pieces of equipment.
• Label all containers to avoid confusion.
 All chemicals and containers need to be clearly and correctly identified as to type. If
the original label is missing or illegible, then a new label should be placed on the
container. This helps prevent Team Members from using the wrong chemicals, or
possibly contaminating product by using a non-food designated container.
• Do not wear jewelry.
• Wear steel-toes shoes with non-slip soles.
• Use proper lifting procedures.
• Adhere to all cleaning and equipment Preventative Maintenance schedules.
• Discard broken dough trays.
 Broken trays need to be removed from the system when they present a safety hazard
when handled. They also need to be removed if the integrity of the container is
breached.
• Keep a First Aid Kit nearby.
• Have at least one Team Member certified in First Aid in the facility per shift.

Module 3: Safety
Production Room Safety-Electrical
Inspect electrical outlets regularly for the following:

• Check outlets and extension cords to make sure they are not overloaded.
• Examine electrical cords to make sure they are not frayed, damaged, or placed under rugs or
floor mats.
• Do not use devices with damaged cords or plugs.
• Do not use electrical devices in wet locations.
• Keep electrical devices clean and free of dust or grease accumulation.
• Turn off electrical devices when they are not in use.
• Make sure that the proper wattage light bulbs are being used in light fixtures and lamps.
• Use extension cords only on a temporary basis and not in place of permanent wiring.
• To remove a cord, grab at the plug; do not pull on the cord.
• Do not modify electrical equipment except in accordance with manufacturer’s specifications.
• Electrical covers and panels are in place.
• Electrical wires, flexible cords and hoses are off the floor and affixed properly.
Facility Security
• Assign a responsible person to be in charge of issuing all keys to the facility.

• No unauthorized entry into the building.
• A visitor log should be maintained current with every visitor signing in each day when they
arrive and sign out when they leave.
• Secure coolers and freezers at all entrance point when the facility is closed.
• Develop a Building Evacuation plan and practice evacuation drills.
• Conduct Safety Committee meetings on a regular basis with issues discussed being recorded.
The Safety Committee should be formed with a representative from every department.
• All visitors should be escorted while in the facility.
• Challenge unescorted visitors for proper identification.
• Be familiar with Material Safety Data Sheets (MSDS).

Module 3: Safety
Safety Summary
Safety standards have been created to protect every Team Member working in a commissary.
They need to be adhered to at all times to prevent accidents and possible injuries. No short cuts
can be taken in terms of safety.
Major strains and slips and falls are the two most common accidents in a commissary, but can be
avoided through training and proper equipment. Personal Protective Equipment (PPE) should be
used to reduce the exposure to a specific hazard, but it will not eliminate it. Examples of PPE are
safety goggle, ear plugs, steel-toed shoes and bump caps.

Module 3: Safety
Knowledge Questions
True or False
1. Safety should only be practiced once in a while?
2. It is safer to perform maintenance or cleaning on equipment while it is running?
3. Running in the commissary may lead to a slip and fall accident?
4. Most of your lifting ability comes from the use of your back?
Short Answer
5. What does PPE stand for?
6. List three examples of PPE?
7. Explain the correct way to lift a heavy object?

Module 4: Production Equipment
Production Equipment
Overview
Equipment can “make or break” your operation. Proper equipment maintenance on a daily basis
can be a major factor to good dough production.
Equipment used by commissaries must meet Domino’s Pizza standards and should be updated on
a regular basis. Well maintained, clean, updated equipment will enhance quality and productivity
in dough production.
• List the necessary production equipment used in a commissary.
• Learn how to check a thermometer.
• How to set up a commissary equipment file.
• Requirements for maintaining commissary equipment.

Production Equipment
Domino’s Pizza Team Members take pride in producing a quality product for our customers,
therefore, we strongly encourage our commissaries to purchase the equipment listed below:
• Dough Mixer
• Dough Divider*
• Dough Rounder*
• Dough Trays
• Work Tables
• Scales
 Yeast scale- (digital-weighs in ounces or grams)
 Flour Scale
 Scoop
 Adjustment flour container
 Check weighing Scales
 Receiving Scale
• Thermometers
 Cooler Thermometers
 Freezer Thermometers
 Production Room thermometers Stem thermometers – Dough (battery operated digital)
• Water Meter
• Water Chiller
• Vegetable Slicer
• Containers (marked for mixing yeast and water making yeast slurry)
• Dough Conveyor or sharp knife for cutting dough from mixer (plastic handles only- no wood
handles)
• Label Gun and materials or Ink-jet label system
• Large Whisk (marked for mixing yeast & water when making yeast slurry)
• Yeast Viability Kit
Other Equipment
• Tray Washers
 Automatic
 Three Compartment sink
• Refrigeration Equipment
 Freezer
 Storage Cooler
 Outdoor condensing units
 Compressors
 Evaporator
 Refrigeration/Exterior Construction
 Strip Curtains
• Refrigerated Transport
Note: *Items may not be required in a Class “C” commissary.

Dough Mixer
• Mixer with automatic discharge must be compatible in size and design with other dough
production equipment so that removal of all dough from the mixer can take place within two
(2) minutes.
• The minimum mixer capacity must be able to utilize at least twenty-five (25) pounds (11kg) of
flour.
• Mixers must be: Baking Industry Sanitation Standards Committee (BISSC), or approved to
use in food manufacturing (i.e. National Sanitation Foundation (NSF)), or the international
equivalent.
• Mixer must be of a type for pizza dough.
• A backup mixer of no less than 30 quarts (28.4 liters) may be used during emergencies.
However, the primary mixer must be returned to use within a reasonable time, allowing for the
delivery of repair components and the scheduling of service personnel.
Dough Divider
• Divider must achieve consistent and accurate portioning allowance variance in dough weight
of plus (+) or minus (-) no more than one percent (1%) of Domino’s Pizza established dough
weight.
• Divider must be self-oiling and oil line should be self-maintained.
• Dough pieces from the divider must be nearly round or “soup can” shape. Separation of the
individual dough pieces must be maintained.
• Divider must be capable of processing the dough at least as fast as the mixer produces the
dough to maintain product flow.
• Divider must be BISSC, or the international equivalent, or approved to use in food
manufacturing.
Dough Rounder
• Rounder must achieve complete rounding and sealing of the dough piece. The rounding
action will result in skin formation over the surface the of the dough piece.
• Rounder must be capable of providing for separation of the dough pieces during transfer from
the divider and during the rounding process itself.
• Rounder will have the capacity to process at least the same amount of dough as the divider.
• Rounder must allow for not more than 0.25% dough loss, while dough is going through
rounding process.
• Rounder must be BISSC, or the international equivalent, or approved to use in food
manufacturing.
Work Tables
• Work Tables must be stainless steel, including legs. Stainless steel frames with replaceable
plastic inserts are acceptable.
• Must be approved to use in food manufacturing (i.e. NSF) or the international equivalent.

Scales
• The capacity of all scales must be such that the lower limit of its range of use will not be less
than twenty-five percent (25%) of the total weighing capacity and the upper limit of its range
of use will not be more than seventy-five percent (75%) of its total weighing capacity.
• A commissary must have scales on hand to ensure accuracy and to perform the following
functions:
Yeast Scale
 Yeast scales must measure in one (1) gram increments. If scale measures in ounces,
the scale must read to the hundredth of a pound 0.00 pound (lb.) or international
equivalent.
Flour Scale
 Commissaries with mixers capable of one hundred (100) pounds (45.3 kilos) of weight
or more, the scale must read to a tenth of a pound (0.0 lb or international equivalent).
 Commissaries with mixers capable of smaller amounts of weight, the scales must read
to a hundredth of a pound (0.00 lb or international equivalent).
 The accuracy of the scales must be such that 0.5% accuracy is maintained over the
entire range of the scale. If computerized measuring systems are utilized, a mechanical
backup system is required.
Check Weighing Scale

 Scales used to check or weigh product (dough and vegetables, if applicable) must read
to a hundredth of a pound (0.00 lb or international equivalent).
Ingredient/Portioning Scale
 Scale used to weigh dough ingredients read to a hundredth of a pound (0.00lb or

international equivalent).
Receiving Scale
 Commissaries must have two or more scales to perform the receiving function. Scale
must read to a hundredth of a pound (0.00lb or international equivalent).

Thermometers
• Thermometers must be capable of measuring the temperature accurately with the range being
used (accurately is defined as plus [+] or minus [-] one degree 1°F )
• Thermometers may not be made of mercury or have a glass shaft.
• All thermometers must be approved to be used in food manufacturing i.e. NSF, or
international equivalent.
• Always keep two extra thermometers at the commissary.
• Checking the thermometer should be done before production begins each day or any time the
thermometer has been dropped.
 To check for accuracy, compare the thermometer with a certified bulb thermometer or
by placing the thermometer in a container of water and ice. The thermometer must
register between 32°F (±1°F).
 Stem thermometers may be recalibrated by realigning the face of the thermometer with
the pointer.
Cooler Thermometer
 Two (2) thermometers are required, having a range of at least 0°F to 80°F (-18°C to
27°C) with at least two (2°F) degree (1°C) divisions.
 Type or style must be such that convenient and proper placement is allowed for easy
and accurate reading or monitoring on a daily basis.
Freezer Thermometer
 Two (2) thermometers required which will have a range of at least -40°F to 40°F
(-40°C to 4°C) with at least two degree (2°F) or 1°C divisions.
Production Room Thermometer
 Two (2) thermometers required which will have a range of at least 30°F to 120°F
(-1°C to 49°C) with at least two degree (2°F) or 1°C divisions.
Water Meters
• Meters must deliver water consistently and accurately in one (1) pound increments (.45kg)
with allowable variance of one tenth of a pound (0.10lb or international equivalent).
• Meters must have a read-out of poundage delivered, which can be adjusted by one (1) pound
increments (1.0lb. or international equivalent).
• Meters must have an automatic shut-off when correct poundage is delivered.
• Meters will have clear, flexible food grade tubing with which to dispense the water.

Water Chillers
• Water chillers must be able to produce water as cold as 40°F (4°C).
• Water chillers must be the proper design and size that will produce the required temperature
water throughout the entire day of production.
• Water chiller must be able to dispense the amount of chilled water required for efficient dough
production.
• Water chiller must have accurate self-contained thermometers to read the leaving water
temperature.
Vegetable Slicer
• Slicer must have a blade capable of being removed for professional sharpening, and/or slicer
blade must have sharpening capabilities.
• Slicer will be Underwriters Laboratories (UL) and NSF, or the international equivalent, or
approved to use in food manufacturing.
Tray Washers
• Tray washers must have proper wash and rinse cycles as required by the local board of health.
• Tray wash machines must be approved to be used in the food manufacturing (i.e. NSF or the
international equivalent)
• Tray washers must have accurate self-contained thermometers to monitor temperatures for all
cycles.
• Tray washers must have a device that allows the operator to check the pressure of the water in
the wash and final rinse cycles.
• Loading racks of the tray washer must be compatible with dough trays to allow easy loading
and unloading.
• Tray washers must have an automatic soap dispensing unit, where such unit will have an
automatic warning device to indicated low supply of detergent.
• Trays must be properly sanitized using on of the following methods:
Heat Sanitizing
 A surface temperature of no less than 170°F (77°C) must be obtained.
 The dwell time must be checked prior to use and periodically during use.
Chemical Sanitizing
 The parts per million (ppm) must be to Domino's Pizza standard and within the range
recommended by the manufacturer.
 The sanitizing concentration must be checked prior to use and periodically during use.
 Sanitizer must be dispensed automatically.
 The water temperature must be a minimum of 75°F (24°C).

Three Compartment Sinks
• Sink compartments must be large enough to submerge dough trays.

• Additional information about three compartment sinks can be found in the sanitation module.
Refrigeration Equipment
• No trailer or containerized shipping unit will be utilized as a regular storage unit.
Freezer
 If a freezer is present, the freezer must be capable of maintaining product temperatures

of -10°F to 0°F (-23°C to -18°C).
Storage Cooler
 A storage cooler must be used for primary refrigerated food storage; temperature range
of 33°F to 38°F (1°C to 3°C) to maintain consistent internal temperatures of 35°F
(2°C) for food product.
 Size is to be based on estimated volume with minimum exterior dimension of eighty
(80) square feet (7.43 square meters) of floor space.
 R rating must be no less than R=30
 Strip curtains must be on primary doors of storage cooler.
 Must be approved to be used in food manufacturing (i.e. NSF or the international
equivalent)
 Exterior walls must be approved to be used in food manufacturing (i.e. NSF or the
international equivalent)
 All refrigeration units must be kept clean, serviceable and free of structural defects.
Dough Cooler
 Must meet all the same criteria as a storage cooler.

 Needs to be strong enough to cool down dough to 1-4°C within 2 ½ to 4 hours.
Typically dough coolers may require additional refrigeration and cooling fans. They
must be designed properly to ensure time and temperatures requirements are met for
dough cool down.
Temperature Control for Storage Cooler
 Control must be a thermostat operating from a solenoid valve and installed as close to
evaporator as possible.
 System must have an automatic cycle function. Normally, close contacts shall be
wired in series with thermostat operating the liquid line solenoid valve.

Condensing Unit for Storage Cooler
 Condensing units must be sized for proper load.
Outdoor Condensing Units
 Units that will be operating below ambient temperatures of 50°F (10°C) at any time of
the year must have a crankcase heater and a head pressure regulating control.
 Outdoor units must be equipped with an outdoor housing cover that will protect
compressor and components from the elements and which is easily removed for service
on compressor and components.
Compressors
 Compressor must have a manual reset, high head pressure cut out control. This may be
combined in a dual pressure control or proper range for the system being used.
Evaporators (for dough cooler-required)
 Evaporator must be sized for 8°F to 10°F temperature differences.

 Units must be capable of maintaining a minimum of eighty-eight percent (88%)
relative humidity.
 Dough cooler system must be capable of cooling dough to below 40°F in less than (4)
hours without causing a crust or hide to form on the dough pieces.
Refrigeration/Exterior Construction
 If pallets will be used:

 Storage cooler will be sixty (60) inches (152 centimeters) wide.
 Area of cooler exposed to pallet traffic must be fitted with door guards, cooler
corners, and side guards anchored securely to floor.
Strip Curtains
• Strip curtain are not required at access doors between cool processing rooms, which maintain
70°F (21°C) or less, and walk-ins.

Refrigerated Transport
• All regularly scheduled commissary deliveries or regularly scheduled pickups at the

commissary of perishable and/or potentially hazardous items must be made in refrigerated
vehicle. All products, including dough and sliced vegetables, must be transported in a
refrigerated vehicle.
• A perishable and/or potentially hazardous item is one which requires refrigeration as specified
in the "Shelf Life Guide".
• A refrigerated vehicle is one which utilizes a source of mechanical temperature control for the
cargo and is independent from that servicing the passenger compartment.
• Exceptions are emergency situations as defined by critical inventory levels within a store. If
an emergency situation arises, product must be transported in an insulated cooler which will
keep temperature control below 40°F (4°C).
• If during transport product temperatures exceed 40°F (4°C), Domino's Pizza reserves the right
to require the use of a refrigerated vehicle.
• Non-refrigerated products shall not be transported in the refrigeration section.
Non-Refrigerated Transport
• All regular scheduled commissary deliveries or regularly scheduled pickups at the commissary
shall have a separate non-refrigerated section in the trailer.
 A thermal barrier shall separate non-refrigerated product from refrigerated product.
This barrier shall be bulk head type or double curtain type.
• Store cleaning chemicals are to be transported in spill proof plastic type totes or in the trailer's
belly box.
• Non-refrigerated products shall not be transported in the refrigeration section.

Commissary Vehicle Sanitation
• Only the following items may be transported in a commissary vehicle simultaneously with
food product:
 Food product picked up en-route for return or re-sale; provided they are sealed
containers.
 Recycled dough trays and other food containers (i.e. veggie tubs).
 Store equipment; providing its condition is not a source of possible contamination.
 Packaging material; providing its condition is not a source of possible contamination
(i.e. boxes)
• All reasonable steps must be taken to segregate returned items from food products being
delivered to minimize the possibility of cross contamination.
• The storage compartment in which food products are carried during regularly scheduled
commissary deliveries must be able to be washed, rinsed, and sanitized.
• Prior to loading food products in a commissary vehicle for delivery to stores, the interior
surfaces of the storage compartment must be:
 Cleaned of all loose material, debris, spills, and removable dirt that could provide a
source of possible contamination.
 Washed, rinsed, and sanitized; or if sufficiently pressurized water is available, pressure
rinsed, and sanitized.
 An exception is allowed for the second one if outside temperatures are below
freezing. However, in this case, all reasonable steps must be taken to provide a
sanitary environment prior to loading.
Receiving of Product
• All product incoming to a commissary will be date coded and used on a First-In, First-Out
(FIFO) basis.
• All product received by the commissary are to be free of damage or infestation, within
required product specifications, which could render them unwholesome or injurious to
consume.
• All receiving and storage of raw and unfinished goods are to conform to the current Quality
Assurance Standards.

Commissary Equipment File
In order to construct a complete equipment file, please include the following information:
• Owner's manual
• Purchase information (i.e. date, dealer, receipt)
• Copies of Work Orders or Invoices for service performed on the equipment
• Warranty information
• Completed in-house Preventive Checklist
 Develop a Preventive Maintenance Schedule based on recommendations in the owner's
manual. Assign regular maintenance functions to specific individuals. Have a
checklist initialed and dated each time work is performed. Maintain follow up on a
regular basis.
 A regular schedule of maintenance is long term protection and prevention of
unscheduled equipment failures.
• Maintain a contact list with daytime and nighttime phone numbers for emergency repairs on
equipment. Make sure service personnel are on call 24 hours. This will save time and money.
• Develop a written contingency plan in case of breakdowns.
 Know where you can rent or borrow equipment.
 Know what alternate types of equipment will get the job done.
 Know how to keep things going without the equipment.
 Have alternative power sources.
 Have some idea of the cost of various contingency measures as well as advantages and
disadvantages so you can make the best choice quickly.
 Unforeseen breakdowns and too much time for repairs can mean a stoppage in
production.
 Be sure backup equipment is in working order. The time to check is not after the
regular machine breaks. This will prevent costly downtime.
• Update the equipment list periodically giving brand, model and serial number. Have a
realistic idea of what repairs your own crew should or should not attempt by themselves. This
will allow you to order parts with little effort.

Maintenance Checklist
Multi-pocket Dough Divider
Daily (immediately after production)
 Daily/Weekly equipment maintenance is essential for good operation.

 Equipment must be lockout/tagout prior to maintenance. This is to avoid injury
from accidental starting or electrical shock.
 Stop slide just before top position; remove volume pistons and partitions.
 Stop slide just past lowest position; remove knife and section piston.
 Scrub chambers (don't forget top), pistons, knife, etc. with "Scotch Brite"
scouring pad and warm water.
 Re-assemble parts in reverse order as in 1, 1/1, 2 with light oil film; parts should
move easily.
 Check oil level in oil tank; refill only with clean mineral oil.
 Remove and clean both oil drip trays.
 Drain water from air regulator unit.
 Check position of divider conveyor to rounder drum. Belts should just clear
drum.
Weekly
 Check tension and tracking conveyor belts.

 Check oil level in air regulator unit.
 Check free stroke suction piston rod (1 to 1-1/2).
 Check oil pump function and oil lines.
Quarterly
 Check oil level gear reducer(s).

 Check tension and condition of V-belts.
 Check tension and lubricate drive chains.
 Lubricate wheels and casters.
 Check bail and sleeve bearings.
 Check position, shape and function of scraper blade.
Annually
 See operating manual.

Cylindrical Rounder
Daily: after final production
 The rounder is critical to production. It pays to keep it maintained.

 Always lockout/tagout equipment before maintenance
 Clean drum with acrylic scraper, do not use scraper on Teflon surfaces.
 Blow or wipe out dough chips form tracks. Start from the top and clean
downwards.
 Check if all tracks are locked and in proper position.
 De-activate flour duster, if applicable.
 Check position of discharge chute in relationship to the proofer infeed.
Quarterly
 Check tension and condition of V-belt from motor to gear reducer.

 Check oil level in gear reducer.
 Lubricate wheels, caster and the thread of hold down pad adjustment.
Annually
 See operating manual.

Production Equipment Summary
In this module, you have learned how extremely important it is to keep equipment well
maintained.
In addition to the Team Members who use the equipment, the equipment itself will play a key
role in the dough produced. Knowing the equipment limitations and how to maintain it will save
time and money.

Knowledge Questions
1. How can you check the accuracy of a thermometer?
2. What are two functions of a dough rounder?
3. What material must the work surface be made of?
4. What temperature must water chillers be able to produce?
5. What is an acceptable percentage of dough loss from the rounder?
6. What are two common types of scales used in the dough making process?

Notes

Quiz 2
SAFETY AND
PRODUCTION EQUIPMENT QUESTIONS
MODULE 3 AND 4
TRUE OR FALSE
1. The three compartment sink should be large enough to submerge a dough tray?
2. Safety should only be practiced once in a while?
3. Work tables can be made of any material, ideally wood?
4. If space is limited a trailer or containerized shipping unit could be used as a regular

storage unit?
5. Most of your lifting ability comes from the use of your legs?
6. The dough divider must achieve consistent and accurate portioning within plus or
minus 10% of the established Domino’s Pizza dough weight?
7. Food products, like dough and vegetables, do not need to be transported in

refrigerated vehicles?
8. The goal of organizations such as OSHA or OSH is to assure health and safety to all
workers by establishing strict standards and training?
9. It is okay to use broken dough trays?
10. Always pull the cord when unplugging equipment?
11. A commissary only needs one scale to weigh everything?
12. Only serious injuries should be reported to a supervisor at once?
13. The rounding action of a dough rounder will result in skin formation over the surface
of the dough piece?
14. The use of a PPE reduces the hazard itself and guarantees permanent or total
protection against it?
15. Proper equipment maintained on a daily basis can be a major factor to good dough
production?

Quiz 2
FILL IN THE BLANKS
16. What should separate non-refrigerated product from refrigerated products?
17. What are the two common injuries in dough production?
18. What does PPE stand for?
19. A security device used to shut off equipment in an emergency situation with the touch
of one button is known as?
20. What should be done to all equipment prior to cleaning or maintaining it?
21. What type of plan should be developed in case of equipment breakdown?
22. These two areas in a commissary have the majority of activity during a typical work
day?
23. What equipment needs to be capable of processing the dough at least as fast as the
mixer produces dough in order to maintain product flow?
24. What are the two reasons for only using no more than 57 grams (2 oz.) of oil to coat
the divider hopper?
25. What should be attached to all equipment and are there for your protection?

Quiz 2
26. This is developed based on the recommendations from the owner’s manual for each
piece of equipment?
a. The color of the equipment

b. Preventative maintenance schedule
c. How to manufacture pizza dough
d. None of the above
27. The dough rounder must allow for not more than what % dough loss?
a. 1%
b. 10%
c. 0.25%
d. 5%
28. The capacity of all scales must be such that the lower limit of its range of use will not
be less than what percent of the total weighing capacity and the upper limit of its
range of use will not be more than what percent of it total weighing capacity?
a. 1% and 99%
b. 10% and 80%
c. 25% and 75%
d. 45% and 65%
29. Thermometers are needed in?
a. Offices and restrooms

b. Coolers, freezer and production room
c. No thermometers are needed in a commissary.
d. Warehouse only
30. Examples of PPE are?
a. Safety shoes
b. Hearing and eye protection
c. Hard hat or bump cap
d. All of the above

Quiz 2
Notes

Module 5: Ingredient Management
Ingredient Management
Overview
High quality dough is the foundation of any pizza that hopes to satisfy the customer. Developing
a quality pizza starts with the ingredients used to make the dough. There are five main
ingredients in the manufacturing of Domino’s Pizza dough. The receiving, storage and
specifications for each ingredient affect the outcome of the dough.
This section will cover the main ingredients and their function in the development of Domino’s
Pizza dough. The five main ingredients are:
♦ Flour
♦ Water
♦ Premix
♦ Soybean Oil
♦ Yeast

• Name the ingredients that are in pizza dough.
• Explain the interaction of the ingredients in pizza dough.
• Know the three parts that make up a wheat berry.
• Understand the steps to flour milling.
• Understand the function of water in dough.
• Understand the function of soybean oil in dough.
• List the ingredients in Domino’s Pizza premix.
• Understand the types of yeast and their differences.
• Understand the importance of fermentation and the factors affecting it.
• Learn why dough is proofed.

Flour
Flour is a key ingredient to the manufacturing of pizza dough. Flour plays several different roles
in the formation of dough. The flour should be made of sound hard spring wheat. The terms
spring and winter refer to seasons, while hard and soft refer to the protein content of the wheat.
This blend is needed to provide the physical and rheological requirements for Domino's Pizza
Cold Dough formulation.
Wheat is one of the few cereal grains that contain gluten proteins that help make our dough.
Domino's Pizza requires the flour to have a high protein level. Gluten when mixed with water
has the ability to form an elastic mass that can be stretched or extended. The gluten permits the
dough to retain gas allowing it to rise and expand in the baking process.
There are several important characteristics (properties) of high protein flours that allow for good
pizza dough formation. Higher protein content gives greater tolerance to fermentation (allow
dough to rise during fermentation and maintain its shape and volume after baking), provides
better stability, and influence crispiness. The higher the protein, the crispier the final product will
be.
Flour Requirements
 Flour must be unbleached, unmalted and unchlorinated.
 Free of potassium bromate* and other added oxidants.
 Free of sprout damage, butter, musty or other undesirable flavors or odors.
 Certificate of Analysis is recommended for each lot and reviewed, signed and dated by
receiving Team Member.
*Note: Potassium bromate has been banned in several countries as a carcinogen. Potassium
bromate should not be used in Domino's Pizza flour.

Flour Specifications
Attribute Amount Interaction/Function

Moisture 14% Flour moisture amount is important for several reasons:
- Once the moisture level surpasses 14%, bacteria may form.
- Stability of flour in storage is affected by its moisture content.
- If moisture content of flour shipment exceeds the specified
limit, then the excess moisture is paid for at the rate of flour.
Protein 12.5 % - Protein when mixed with water forms the gluten.
13.75%
Ash 0.56% High ash will result in increased or accelerated browning in the
maximum dough. The ash content is the mineral residual left in the flour and
is a measurement of milling efficiency. The lower the ash content,
the whiter and more refined the flour is because it has a greater
percentage of starchy endosperm.
Amylograph 1000 Bu Determines the amount of amylase activity.

minimum
Falling 325 seconds Indicates the amount of damaged starch present in the flour. It
number minimum gives an indication of the amount of sprout damage that has
occurred within a wheat sample.
Farinograph Farinograph Absorption: 60.5 to 65%

Farinograph Mixing Peak: 6 to 8 minutes
Farinograph Stability: 12 to 18 minutes
Farinograph MTI: 20 to 40 BU
A farinograph measures the flour’s water absorption before dough

reaches a definite consistency. It measures the length of time
required to mix dough to a definite consistency and the dough’s
tolerance to over mixing.
Flour Sample
An annual 1 kg flour sample should be sent to:
Domino’s Pizza World Resource Center
Attention: DPI QA
30 Frank Lloyd Wright Drive
Ann Arbor, Michigan, 48105
U.S.A
If a sample cannot be sent directly to the World Resource Center it should be sent to a Domino’s
Pizza International regional office.
The sample will be evaluated to ensure it meets the flour specifications stated above.

Bulk Flour Receiving
Every incoming shipment of flour is to be thoroughly inspected before it is received into the
facility. The mill’s certificate of analysis numbers must be within the approved
specification.
Bulk Inspection
 Check the general appearance of the trailer.
 Inspect both the inside and outside of the flexible transfer hose. Look for worn spots,
filth, mold, etc.
 Check the trailer’s discharge outlet and the facility’s receiving inlet. Look for mold,
insect activity and filth.
 Check all seals to ensure seal numbers match what’s in the bill of lading.
 Visually inspect all hatch seals for tampering.
 Examine the area around the trailer’s air relief socks. Pay close attention to the folds
and seam for any possible live insects.
 Document each inspection as to all findings in the Receiving Log.
 Receive flour into the facility.
 If the integrity or cleanliness of the trailer is in question or if contaminants are
identified do not receive the flour and contact the Team Leader.
Bagged Flour Receiving
• Receipt dates must be displayed on the lower corner of the pallet. The date should not be
recorded on the shrink wrap.
• Use First In, First Out (FIFO) method of stock rotation. Prolonged storage can result in
excessive moisture lost in the flour.
• If pallets are stacked, a slip sheet is required between pallets. Slip sheets reduce the
possibility of wood slivers getting into the bags.
• If a full pallet is not received, every bag must be dated.
• Always store product on clean pallets and never store on the floor.
• All ripped or torn bags should be discarded to prevent any possible product contamination.
Trailer Inspection
 Trailer must be free of damage and odors.
 Non-food items and food items must be properly stored.
 Trailer and pallets must be free of pests or insect evidence.
 Flour bags should be free of pest evidence and damage.

Shelf Life and Storage
• Flour should be stored between 35°F - 90°F (3°C - 32°C).

• In the summer seasons, do not stack pallets over two high.
• Allow for proper air circulation around the pallets.
• Heat will decrease the shelf life of flour.
• Flour should be used within 90 days.
• Once opened, it should be used within 30 days.
• As flour sits unused, its moisture content decreases.
• Flour should always be properly stored in between uses.
• Flour absorbs odors, so it should be stored away from strong smelling items.

Parts of a Wheat Berry
• Wheat flour can be made from about 72% of the wheat berry. This means that out of every
45kg (100 pounds) of wheat that is harvested, 33kg (72 pounds) of flour will be obtained.
• The wheat berry is about 6mm (1/4 in) in length and 3mm (1/8in) in diameter and consists of
three main parts:
Bran
 Bran consists of about 15% of the wheat berry; it is the tough, woody coat which
covers the endosperm and the germ.
 There are five layers of bran over the center portions of the wheat berry.
 The three top layers can be regarded as protective coverings.
 The fourth layer contains the coloring matter which distinguishes the berry as being red
or white.
 The fifth layer is called aleurone and is actually the outer layer of the endosperm.
Endosperm
 The endosperm is in the center of the wheat berry and is the source of all the flour used
in our pizza dough.
 This is the most important section of the berry.
Germ
 The basic function of the germ is only in the initial growth of the berry.
 The germ is located at the lower end of the wheat berry and is discarded during
milling.
 The germ contains a substance called glutathione that weakens the flour.
 Although the germ has no function in the dough making process, it does perform a
very important function in wheat production.
 Once the berry is planted, it is the germ portion which starts to grow.
Source: dontwastethecrumbs.com

Milling Process
• The milling process determines the quality and functionality of the flour.
• The end product of the milling process has a direct effect on how the pizza dough will
perform.
Six Main Steps to Milling Wheat
1. Reception and storage of wheat
 Incoming wheat is received and stored in the part of the mill known as an elevator.
 Upon arrival wheat is weighed, sampled and tested.
 The wheat is then sent to a receiving separator to remove some of the foreign materials
that may be present.
 Wheat is then stored depending on class, grade and protein content.
2. Cleaning the grain
 The wheat still needs more detailed cleaning.

 It passes through a series of equipment to remove the impurities based on size, specific
gravity and weight.
 During this process the wheat passes through a series of magnets to eliminate any piece
of ferrous metal.
3. Conditioning
 The conditioning, or tempering, of wheat is the controlled addition of water to toughen

the outer layer (bran).
 This allows for an easier separation from the endosperm during the milling process.
 The amount of conditioning needed is dependent on the class of the wheat being
milled, and the specifications desired from the end product.
4. Milling separation
 Milling is the separation of the wheat kernels into flour and by products by grinding
and separating.
 The grain is opened and the endosperm removed from the bran.
 The endosperm is then ground into flour meeting specific requirements.
5. Treatment of flour
 Flour can be treated with a combination of additives to achieve changes in gluten

characteristics.
 Flour can also be fortified by adding minerals or vitamins to meet nutritional standards.
 The legal types and amounts of additives vary by country.
6. Packing and storing

Components of Flour
Protein
 Protein is a key component for successful dough formation.
 Protein is the reason for dough volume and satisfactory texture.
 Gluten is formed with the addition of water during the mixing stage. Imagine gluten as
many tiny balloons. These properties are special to wheat proteins and give pizza
dough many of its important characteristics. If the dough is underdeveloped, the
balloon fabric is coarse and not elastic enough to become inflated to its full potential. If
the gas produced from fermentation is pumped into the little balloons, the balloons will
not stretch and rupture causing the gas to escape. On the other hand, if the dough is
over mixed, the balloons become overstretched and weak. When the gas enters the
balloons the gluten structure collapses causing the gas to escape.
 The protein content of flour is estimated by the Kjeldahl method. This method actually
determines the amount of nitrogen contained in the flour, and the value obtained is then
multiplied by the factor 5.7 to yield the amount of protein. This method identifies only
the amount of protein present in the flour and not its quality.
Starch
 Flour is about 70-75% starch.
 Starch is the main carbohydrate found in flour and is a source of food for the yeast.
 Starch has both intact and damaged granules as the result of the milling process.
 The main function of the starch granules is to absorb water.
 Damaged granules absorb three times more water than that of undamaged starch
granules.
 The starch in the flour also provides structure during baking.
Sugar
 Sugar needs to be present for fermentation.
Fat/Oil
 Natural fat or oil usually accounts for 18% of the flour.
Water
 In every 45 kg (100 pounds) there is approximately 6 kg (14 pounds) of water.
Ash
 The ash content is the criteria for judging how well the wheat has been milled.
 High ash content may result in accelerated and/or increased browning of the dough.
 Ash represents most of the mineral elements obtained by the plant from the soil.

Vital Wheat Gluten
Vital wheat gluten can be added if first approved by Domino's Pizza International Quality
Assurance. The allowable range is 0.5% to 3% flour weight basis. Vital wheat gluten is light tan
in color and almost flavorless. It is the natural protein found in wheat with the starch removed. It
is extracted through a mechanical water washing process where no chemicals are used or added.
It contains about 75% protein; therefore, it increases the protein amount in lower protein flours.
The United States Department of Agriculture (USDA) has approved it for use as a dough
strengthener, however, check with local or federal requirements prior to use.
Uses
 Improves the texture and elasticity of the dough.
 Can produce consistent and uniform dough.
 Excellent visco-elasticity properties that help put spring into dough.
 Helps increase dough strength and shelf life.
 Improves the dough's tolerance to abuse.
 Increases crispiness and toughness in the crust.

Water
Water is often an overlooked ingredient in the dough manufacturing. Domino’s Pizza dough
formula calls for about 55% water depending on the formula used. The water accounts for almost
half of the dough weight.
Water Requirements
• Water used for dough manufacturing must be potable, meaning it is safe to drink.
• Be aware of plumbing to ensure separation or incoming water lines from waste/sewage lines.
• Back flow prevention should be installed on all water lines used in production.
• If possible, iron or copper water lines should be avoided in dough production.
Water Specifications
Attribute Amount Interaction/Function
pH 7 +/-1 -High Alkalinity slows fermentation
Hardness 50 to 150 ppm -Soft water produces sticky dough.

-Hard water produces stiff dough.
Chlorine Less than 0.2 ppm -Chlorine can inhibit yeast activity at high
levels.
Types of Chlorine found in water:
Free chlorine: when chlorine is being added to
the water it is in the form of free chlorine
Combined chlorine: When free chlorine
combines with contaminants it becomes
combined chlorine.
Total Chlorine: Sum of free chlorine plus
combined chlorine.
Water Analysis
• It is recommended to have a Water Quality Analysis conducted at least annually by an
independent certified lab.
• If facility is on a well the test should be performed at least every six months. Well water may
also be tested for nitrates.
• Production water should be tested and documented daily for pH, hardness and chlorine levels.

Water's Function in Dough
• Water acts as both a solvent and dispersing agent for all the dough ingredients (salt, sugar, and
yeast). It activates the yeast, allowing for proper fermentation, and forms the gluten in the
flour.
• During baking, water combines with the starch in the flour to form the pliable structure of
dough.
• Amount of water affects the consistency of the dough. Changing the amount will cause the
dough to change its consistency from very soft to stiff.
• Aids in the freshness and eating quality of the baked pizza.
• The water temperature also affects the exit dough temperature and quality.
Water Characteristics that Affect Fermentation

Amount
 The amount of water used affects the consistency of the dough and amount of
fermentation activity. Maximizing the amount of water added to the dough leads to a
softer dough and higher fermentation activity.
 The amount of water also contributes to the functional properties of the dough (i.e.
plasticity, extendibility and stickiness).
Temperature
 The temperature of the production water is critical to controlling the temperature of the
final dough. For example, if the water temperature is too hot there is a good chance the
exit dough temperature will possibly be too high.
Water Quality
 Water with a bad flavor or odor will cause the dough to have bad flavor and/or odor. A
water filter can remove bad taste and smell, but it will not eliminate unwanted
chemicals like chlorine. However, reverse osmosis equipment may improve water
quality.

pH
 The pH is an important aspect of dough making because it affects chemical and
biological reactions. Ideally the water should have a pH of 7 which is considered
neutral.
 The most important effect pH has on dough is changing the rate of amylase enzyme
performance (converting starch to sugar), therefore, changing the rate of fermentation.
The ideal pH for fermentation is about five, which is slightly acidic. This pH is best
achieved by using water with a pH between 6.0 and 8.0, with 7.0 being ideal.
 Dough ferments faster in an acid medium with a pH of 5. Flour is slightly acidic and
when mixed with water has a pH of approx. 6. Upon fermentation the pH balance
decreases to 5.6. As we go up the water scale to a pH of 8 or above (less acidic),
fermentation is slowed.
 Having production water with a pH below 6.0 is not very common. This pH can
corrode pipes.
 It is more common to have water with a pH 8.0 and above. Water with a higher
alkalinity tends to reduce the fermentation rate of dough.
Amount of Dissolved Minerals

 The water used for dough manufacturing should be 50-150 ppm, typically considered
to be medium hard water. This type of water is often the best for dough as it contains
the proper amounts of mineral salts (mostly of calcium and magnesium). These
minerals help strengthen the gluten and also can provide nutrients for the yeast.
 Hardness or softness of water will effect dough formation. The levels of water
hardness will vary by location and type of source such as wells, rivers, or reservoirs.
 Hard water: is referred to as water that contains levels exceeding 150 ppm of mineral
salts, as carbonates, nitrates, sulfates and chlorides of calcium and magnesium. Since
hard water has a higher mineral content, this will result in more fermentation activity
and stronger dough. Hard water with levels exceeding 200 ppm and higher can elevate
the pH of the dough, causing a retarding effect on yeast and enzyme activity.
 Soft Water: Soft Water is defined as water that either naturally contains a low mineral
content, particularly of calcium and magnesium salts, or whose levels of such salts
have been reduced by demineralization. Soft water, because of the absence of minerals,
will result in slower fermentation and dough with a tendency to lose strength. Soft
water (0 to 15 ppm) is undesirable because it tends to soften the gluten and produce
slack, sticky dough and a finished product with a more open grain.

Soybean Oil
Soybean oil is edible oil extracted from soybean that is an excellent source of good quality
protein. It is rich in polyunsaturated fatty acids and contains no cholesterol. Soybeans are also a
good source of calcium, iron, zinc, phosphate, magnesium, B vitamins and folate.
Refined, Bleached and Deodorized Soybean oil is used in dough production. RBD soybean oil is
refined vegetable oil made from selected soybean oil. It is very light in color (clear at room
temperature) and bland in flavor and odor.
Other types of oil (rapeseed, canola, and sunflower) may be used in

dough production upon approval from DPI QA.
Bulk Oil Receiving

Every incoming shipment of oil is to be thoroughly inspected before it is received into the
facility. The oil product code and P.O. must match approved supplier information.
Bulk Inspection
 Check the general appearance of the trailer.
 Inspect both the inside and outside of the flexible transfer hose. Look for worn spots,
filth, mold, etc.
 Check the trailer’s discharge outlet and the facility’s receiving inlet. Look for mold,
insect activity and filth.
 Check all seals to ensure seal numbers match what’s on the bill of lading.
 Visually inspect all hatch seals for tampering.
 Examine the area around the trailer’s air relief socks. Pay close attention to the folds
and seam for any possible live insects.
 Document each inspection as to all findings in the Receiving Log.
 Receive oil into the facility.
 If the integrity or cleanliness of the trailer is in question or if contaminants are
identified do not receive the oil and contact the Team Leader.
Oil's Function in Dough

• Accounts for 3.8% of the dough formulation.
• Affects the volume, crumb structure, flavor and the texture of the dough.
• Has a lubricating effect on the gluten’s meshwork.
• Allows dough to stretch more easily.

Oil Specification
Analytical information Values
Free Fatty Acid 0.05 maximum as oleic acid
Iodine Value Peroxide Value: 2.0 meq/kg maximum
Lovibond color red 2.0 maximum
Cold Test (hours) 15 minimum
Smoke Point (°F) 440
Moisture Dry, less than 0.1%

• Oil should be stored between 50°F to 90°F (10°C to 32°C).
• Oil should be used within 6 months from the manufacturing date.

Premix
Premix is only for commissaries manufacturing Domino’s Pizza Cold Dough. The premix
contains dough additives that allow the dough to maintain shelf life, color and texture.
Minor Ingredients Receiving

• Is the container damaged?
• Is the pallet/bag of minor ingredients marked with receipt date?

• Premix should be stored below 90°F (32°C).
• Premix should be used within six months from the manufacturing date.
• Always store premix on the pallets and never directly on the floor.
• Do not stack the pallets two high when the temperature of the room is above 32°C.
• Allow for air circulation around the pallets.
Ingredient List for Premix

Sugar
 Although the amount of sugar added to the dough formulation is small, it plays an
important role.
 The type of sugar used in our pizza dough is sucrose (table sugar) which is a
compound sugar (glucose + fructose). The sucrose is converted into simple sugars then
consumed by the yeast.
 The sugar performs the following functions in the dough:
 Aids in browning the crust during baking.
 Is a source of energy (food source) for the yeast.
 Improves flavor without actually sweetening the dough.
 Increases the fermentation tolerance.
 Refines and smoothes the texture and grain of the dough, since there is more
sugar available for continued yeast activity.
 Acts as a tenderizer because sugar retains moisture.

Salt
 Salt controls (slows) yeast growth and therefore gas production necessary for
fermentation.
 The type of salt used in the pizza dough formulation is sodium chloride which is better
known as table salt.
 Salt performs a three fold function in dough:
 Stabilizes fermentation; it retards and regulates fermentation. If too much is
added, it will reduce the volume and the lightness of the dough. If there is not
enough added, the dough can have poor texture and a flat taste.
 Provides a strengthening effect on gluten by increasing bond strength.
 Improves flavor.
Sodium Stearoyl Lactylate Emplex (SSL)

 Sodium stearoyl lactylate is an emulsifier added to the premix. It strengthens the
dough and makes it more extensible. This allows for more gas to be trapped in smaller
bubbles, reducing proofing time, thus, giving a softer, more even textured dough.
 A widely used dough conditioner that is a sodium salt of stearoyl lactylic acid, a
compound that is obtained by reacting stearic acid with lactic acid.
 It is a free-flowing powder that is insoluble in water, but readily soluble in hot fats and
oils.
 When used at the recommended levels, it measurably increases dough absorption,
strengthens the gluten structure, and improves mixing tolerance, machinability, and the
overall quality of the baked dough product.
Whey
 It is a dough additive that aids in better crust color and crispiness.
 Also called milk serum, is the liquid that remains as a by-product of cheese production
and has several commercial uses. It is composed of water-soluble vitamins and
minerals, lactose and noncasein proteins.
 Sweet whey is obtained from the making of rennet-coagulated cheese, while acid
whey is obtained from the making of acid-coagulated cheese.
 Sweet dairy whey used in Domino’s Cold Dough Premix contains about 70% lactose.
 Spray-dried whey forms the base ingredient of several dairy-substitute blends in which
it is combined with varying proportions of caseinate, nonfat dry milk, soybean flour,
corn flour, and mineral salts, both singly and in various combinations.
Amylase
 Amylase is an enzyme found in flour that breaks down starch and its polysaccharide
components into fermentable sugars.
 They are differentiated according to the particular starch chain location they act upon
(α and/or β linkages); hence the name α-amylase, β-amylase, and glucoamylase, to
name a few. These amylases are naturally found in humans, plants, fungi, and bacteria.
 Amylases derived from different sources will vary in such characteristics as their
molecular weight, pH optimum, activation energy, optimum temperature, and heat
stability.
 It is added to the premix as a crust color improver.

Ascorbic Acid
 Ascorbic acid, also known as Vitamin C, is added to the premix as an oxidant

 It strengthens proteins to improve gas retention.
 Found naturally in citrus and various other fruits and vegetables; can also be
synthesized artificially.
 Chemically, it acts both as a reducing agent and as an oxidizing agent. The reducing
action takes place mainly under anaerobic conditions, similar to the conditions that
exist in the developer-mixer section of some continuous dough mixing systems. Once
it is oxidized to dehydroascorbic acid by atmospheric oxygen during conventional
dough mixing, it functions as an effective oxidizing agent.
 It is used as a maturing agent in flour and as a dough improver.
L-cysteine Hydrochloride
 L-cysteine is a reducing agent that helps to weaken the protein to reduce mixing time
and elasticity.

Yeast
Yeast is an essential ingredient in Domino’s Pizza dough. The main purpose of yeast is to serve
as a catalyst in the fermentation process. Yeast is responsible for proofing dough and also adding
a special flavor. Saccharomyces cerevisiae, also known commonly as Baker’s Yeast, is the
species of the yeast used in dough making. Yeast is a group of very small organisms that can be
found growing nearly everywhere on earth. One pound of yeast contains approximately 3200
billion yeast cells.
Types of Yeast
Compressed Yeast
 Also known as “wet” or “fresh” yeast and is found in cake form in compact blocks.
 This yeast is characterized by having a moisture content of about 70% and is ready to
use immediately.
 If handled properly, the yeast should have excellent proofing properties.
 It is flavorful and adds to the assurance of proper distribution of the yeast in the dough.
Compressed Yeast Receiving
 Julian code date on the container checked?

 Julian code date recorded in Receiving Log.
 Check-in temperature below 7°C (45°F)?
 Time the yeast is placed in the middle section of the cooler immediately and
away from the door?
 Store in a cooler with constant temperature of 1°C to 3 °C (33°F to 38° F).

 Compressed yeast should be used within 21 days.
 Store the yeast in air tight container.
 If the yeast has dark edges or white mold, discard the yeast.
 Remove the yeast from cooler 15 minutes before use.
 If not used within 15 minutes, throw away.

Active Dry Yeast (ADY)
 Active dry yeast comes in granular forms or in small beads and is in a semi-dormant
state.
 The color should be creamy white to tan.
 The texture should be fine and have free flowing particles.
 The ADY goes through a drying process called dehydration lowering the moisture to
4-8%.
 Provides a longer shelf life than compressed yeast, which is critical for consistent and
optimum yeast activity.
 It is stable at ambient temperatures making it easier to use in parts of the world where
higher temperatures and humidity are present.
 Reactivation of yeast is achieved by rehydrating in luke warm water from 95 to 110°F
(35 to 42°C), with 100°F (38°C) being the optimum temperature. The hydration step is
very critical for consistent and optimum yeast activity.
 Always keep yeast in wrapper until ready for use. Exposure to air will damage the
yeast.
Active Dry Yeast (ADY) Receiving

 Check-in temperature below 21°C (70°F)
 Yeast should always be stored in a sealed container after opened.

 Rotate new stock using FIFO method.
 Cross stack yeast cases on pallet to provide for air circulation.

Instant Active Dry Yeast (IADY)
 IADY is dried and must be re-hydrated prior to use as per Domino’s Pizza
manufacturing procedures.
 The yeast is added to water to ensure consistency in the Domino’s Pizza Cold Dough
formulation.
 Not following the slurry procedure can result in inconsistent dough formation. Slurry
procedure for IADY requires the yeast to be hydrated in water at four times of the
weight of the yeast. The slurry water temperature is 13°C to 18°C (55°F to 65°F).
Whisk the water and yeast and let it stand for 2 minutes. Whisk well and add to water
(mixing bowl). Remember to rinse out the slurry container to ensure all the yeast has
been added to the dough.
Instant Active Dry Yeast (ADY) Receiving

 Check-in temperature below 21°C (70°F)
 IADY should be stored in dry ambient temperatures of 33°F to 90°F

(0.55°C to 32.33°C).
 Shelf life is 12 months from the production.
 Shelf life decreases if stored in extreme heat or sunlight.
 Follow the expiration date on the package if less than a year.
 Opened shelf life of the yeast is 7 days refrigerated at 33°F to 38°F
(0.55°C to 3.33°C) and tightly covered and air removed.
IADY is the only approved yeast for the use in Domino’s Pizza dough formulation.

Fermentation
Fermentation, in its simplest form, is the physical and chemical change which takes place when
yeast is active and provided with food. The yeast consumes the sugars and excretes its waste
products, primarily carbon dioxide gas, alcohol and flavor components. This is what causes the
dough to ferment and proof. Once the yeast cells consume the food supply, the yeast will begin to
die off. This life cycle determines the shelf life of the dough.
An important activity involved in the process of fermentation is the interaction of substances

called enzymes. They break down the complex sugar in the dough into simple sugars so it can be
used by the yeast as a source of food. Yeast can feed only on simple sugar, which are present only
in small quantities in the flour. Without enzymes, there would be no transforming of sugar and
very little fermentation activity.
Amylase is the enzyme naturally found in flour. It breaks down the starch and the polysaccharide
components of the flour into fermentable sugars. The amount of amylase is important and can be
measured by the falling number in flour. Too little amylase results in low fermentation and too
much results in a sticky crumb and possibly a gummy layer in the crust.
Glutathione is a tripeptide made up of the amino acids (glutamine, glycine and cysteine) that acts
as a strong reducing agent on gluten. It is present in wheat germ as well as in yeast cells which
release it when they undergo autolysis. Its presence in a dough results in low volume and poor
quality. These adverse effects can be overcome by the proper use of oxidants.
Factors Affecting Fermentation

There are many factors that affect the rate of fermentation. Therefore, it is critical to always
follow the dough formula as small changes can result in inconsistent dough formation.
Temperature
 Dough temperature is an important factor in affecting the fermentation rate. This is the
reason behind requiring an exit dough temperature of 80°F ±2°F and needing to record
the results.
 Yeast works slowly at 33°F. As the temperature increases so does the yeast activity.
 Within the range of temperatures in which yeast is operative, every degree rise in
temperature increases the rate of yeast fermentation by 3-5%.
 A decrease of one degree will cause a similar decrease in the rate of fermentation.
Salt
 Salt inhibits yeast activity at levels above 1%.
 Salt slows fermentation by stabilizing yeast activity.

Sugar
 In small quantities it supplies food for the yeast.
 In larger quantities it slows fermentation because sugar absorbs water thus making less
water available for proper functioning of the yeast.
 Gas production can be increased with sugar levels of about 5%, but reduced at higher
levels because of osmotic pressure.
Acidity
 A pH scale measures how acidic or basic a substance is with a range from 0 to 14. A
pH of 7 is neutral, less than 7 is acidic, and greater than 7 is basic.
 Yeast thrives in a slightly acidic pH (pH 5-6). At the onset of fermentation, the pH will
decrease due to the presence of carbonic acid (carbon dioxide dissolved in water) and
other organic acids.
 The pH can have little effect on yeast fermentation unless it drops below 4.0.
Water
 With the addition of water, the soluble solids are diluted and the osmotic pressure on
the yeast cells is reduced. This causes an increase in yeast activity and the overall rate
of fermentation.
Amount of Yeast
 The more yeast added the faster the fermentation process.
Fermentation Time
 The amount of time yeast gets to act on the sugars present. The longer the
fermentation time, the higher the degree of fermentation.
 The rate of fermentation declines with time at a constant temperature but it does not
completely stop.

Proofing
Proofing is the physical and chemical change in the dough brought about by the yeast organism
added during mixing. It is the act of holding doughballs in trays for the appropriate time, under
controlled temperature and humidity conditions that are conducive to optimum yeast
fermentation.
The dough expands in volume as the yeast organism ferments the available sugars. During
fermentation, enzymes (catalysts) in the yeast and flour break down the sugar that is added during
mixing plus the sugar that is naturally present in the flour into simple sugars, which is then
consumed by the yeast. As the enzymes work and the yeast feeds, proofing occurs. This produces
carbon dioxide gas bubbles, which are trapped by the gluten proteins in the dough. As more gas is
produced, the dough keeps expanding until finally the gluten becomes overstretched, weakened,
and collapses.
When baked, the trapped gas expands, resulting in a proofed bread textured product. It is
important to use the dough when it is in the right stage of proofing.
Reasons for Proofing Dough

• The characteristic flavor, texture, and volume of the Domino’s Pizza dough results from the
proofing (fermentation) action of the yeast microorganism. There is no flavor, texture, or
volume unless the dough has been properly proofed.
• An improperly proofed doughball is more difficult and time consuming to make up and may
result in more time spent on oven tending.
Proofing Depends on
In ideal fermentation, carbon dioxide gas is being produced at the same rate as the ability of the
gluten to retain it. Proofing expands doughball equally upward and outward.
Gas Production
 The ability of yeast to generate carbon dioxide gas during dough fermentation and
thereby effect the aeration or leavening of the dough.
Gas Retention
 The ability of the gas cells in a dough to retain the carbon dioxide generated by yeast
during dough fermentation.
 Adequate gas retention is an important attribute of dough that will ensure good final
volume. Poor gas retention will result in baked products with a dense grain and a
reduced volume.
 Good strong gluten structure to entrap gas relates to high gluten (protein) flour and
proper mixing/dough consistency.

Conditions of Dough Proofing
Ideal Proofing
 The pizza dough begins proofing from the time it is made. It is slowly proofing all the
time in the cooler. In fact, the cold temperature in the cooler is what allows the store to
keep fresh dough for several days without loss of quality or overproofing.
 A stack of 2°C (35°F) dough will take a long time to warm to 16°C (60°F), at which
temperature it will proof more rapidly. So in cold weather, the store should avoid
putting the dough in cold, drafty areas which are frequently found along outside walls
under the make area.
Over–Proofed
 When a doughball no longer bakes with good volume to the crust. When the dough is
over-proofed it should not be used.
 Working with this dough, it is often difficult to get rid of the large air bubbles,
especially those at the rim.
 The dough stretches out quickly, but often unevenly. The elastic gluten structure of the
dough becomes incapable of holding the carbon dioxide bubbles; when the pizza is
itemized and baked, it deflates like a flat tire, leaving only a thin dough base under the
items.
 If you taste the rim portion of the pizza, you will note it has a fragile, cracker-like
texture and a slightly sour taste.
 As the dough begins to overproof, the sides of the individual doughballs begin flowing
together.
 The surface of the balls become sticky and eventually large, wet gas bubbles will push
out from the surface.
Under-Proofed
 An under-proofed doughball is very elastic and will take longer to stretch to fit the
pizza screen. There will be more shrink back than with properly proofed dough.
 The gluten structure will trap the gas so well that in baking, large bubbles will swell up
on the pizza, causing sauce, cheese and items to slide off.
 The finished product will be tough, dense and tasteless.
 An under-proofed ball has not had the gluten structure thinned or stretched enough.

Ingredient Management Summary
The five main ingredients used in dough and their functions were covered in this module.
Flour: The flour should be made of sound wheat with a high protein content. Wheat is the only
cereal grain which contains gluten proteins which make our dough. Gluten is the elastic material
formed when water is mixed with wheat flour.
Water: Water unites with the protein and forms the gluten. It also aids in dissolving and
dispensing the yeast and other ingredients for proper uniformity and consistency.
Yeast: Yeast is the most essential ingredient in the dough. Yeast is responsible for proofing the
dough, its texture, volume and flavor.
Oil: Soybean oil acts a tenderizer and improves the texture of the dough.
Premix: Premix is used for commissaries manufacturing Domino's Pizza Cold Dough. The use of
premix allows the dough to maintain shelf life, color and texture. The premix contains the
following ingredients: Sugar, Salt, Sodium Stearoyl Lactylate Emplex (SSL), Whey, Amylase,
Ascorbic Acid, L-cysteine hydrochloride.

Knowledge Questions
True or False
1. The five main ingredients in Domino's Pizza Cold Dough are flour, water, soybean
oil, yeast and cornmeal?
2. The main component of flour is protein accounting for nearly 70-75%?
3. The pH of water used in dough should be 7 ±1?
4. As long as water is potable there are no other characteristics that will affect
fermentation?
5. Oil allows dough to stretch more easily?
6. The three common types of yeast used for baking are compressed, active dry yeast
and instant active dry yeast. However, only instant active yeast is approved for use by
Domino's Pizza?
7. Higher fermentation temperatures increases yeast activity?
8. Under-proof dough will have a cracker like texture and a slightly sour taste?
Short Answer
9. What are the three parts of a wheat berry?
10. Name at least 4 of the ingredients found in the premix?
11. What in its simplest form is the physical and chemical change which takes place
when yeast is active and provided with food?

Dough Evaluation Guide

Notes

Module 6: Procedures for Cold Dough Processing
Procedures for Cold Dough Processing
Overview
This module provides you with in-depth knowledge pertaining to the dough making process. You
will learn about the entire dough making process from checking the equipment to shipping. It is
important to follow the exact formulation and procedures, as small variances can lead to big
differences in the final product.
• List the steps for the entire dough production process.
• Explain reasons for combining slurry, minor ingredients and flour.
• Describe the proper way to measure dough temperature.
• Identify restrictions on reworking dough.
• Describe the procedure used in placing doughballs on a dough tray.
• Describe the best way to round dough.
• Identify downstacking and dough tray labeling procedures.

Cold Dough Ingredients
Flour Specification for Flour for Pizza Dough
pH = 7.0 +/- 1
Water Hardness = 50 to 150 ppm
Chlorine = 0.2 ppm maximum
Oil 100% RBD (Refined, bleached and deodorized) soybean oil.
Yeast “SAF” - Instant Active Dry Yeast is the only approved yeast.
Premix From suppliers approved by Domino’s Pizza International QA.
Vital Wheat Allowable range 0.5% to 3% FWB (Flour Weight Basis)

Gluten (VWG) If needed and approved by Domino’s Pizza International QA.

Cold Dough Preparation
1. Calibrate all of your metering equipment and scales.
 Calibrating equipment is essential for accurate measurements.

 This should include thermometers, scales and water meters.
 Scales must be check weighed equal to its usage and documented prior to production.
Adjustments need to be made prior to start up if required. Inaccurate scales used for
weighing ingredients can have a big impact on the quality and consistency of the
dough.
 Calibration records should be kept on file.
2. Dust off the flour bags.
 This removes any foreign objects which could get into the dough and possibly
contaminate it.
3. Set the water meter to the proper temperature and volume, or zero the scale and
weigh out the water.
 Water is an important ingredient in the dough making procedure. The wrong

temperature or amount can change the consistency of the dough.
4. Tare the floor scale or zero out the platform scale.
 To tare a scale, deduct the weight of the container from the total weight to determine
the weight of the contents. This allows accurate measurements of added ingredients.

Cold Dough Processing Procedures
Used with approved DPI QA formula and premix
1. Add water into mixing bowl.
2. Re-hydrate yeast for two minutes.
 The yeast water hydration range is 13°C to 18.3°C (55°F to 65°F).

 Amount of water is 4 times the weight of yeast being re-hydrated.
3. Subtract amount of re-hydration water (step 2) from the total water added to the
bowl.
 Remember to rinse out the slurry container with the running water to make sure all of
the yeast slurry is added to the dough.
4. Add Cold Dough Premix as per the approved formula.
 This can be done once half of the water has been added.
 There must be an adequate amount of water in the bowl to prevent the salt from
shocking the yeast.
 Do not allow the minor ingredients to sit in the bowl for an extended time, as the salt
and sugar will settle out causing inconsistent dough.
5. Add re-hydrated yeast slurry.
6. Whisk all ingredients into water, distributing well.
 Whisk without oil to keep from encapsulating ingredients.
7. Add Oil.
 Do Not Whisk If a whisk is used the oil will coat the yeast cells and prevent the
hydration of yeast cells, reducing the rate of fermentation.
8. Add Flour.
 *Vital Wheat Gluten to be added if approved by DPI QA.

9. Mix all ingredients to full development.
 All of the ingredients must blend together as thoroughly as possible with the liquid to
prevent any lumping in the mixture. If the slurry, minor ingredients and flour do not
blend well, the dough will not proof consistently.
 Mixing can affect the color, texture, volume, flavor and shelf life of the finished
product.
 During the mixing, the starch and protein molecules in the flour absorb water, hydrate
the dough, and supply the yeast cells with water needed for fermentation.
 Mixing times will vary depending on type of mixer used.
 Low speed: The initial mixing at low speed allows the ingredients to hydrate
and disperse evenly. The yeast begins to feed on the sugars and generate carbon
dioxide and other flavor components.
 High Speed: The mixer is switched to high speed to develop gluten and allow
air pockets to incorporate into the dough. The mixing agitation creates air cells
that can be expanded during baking, resulting in good oven spring.
Example of Mixing Times:

Required end bake characteristics and shelf life must be maintained. Approval of
lower mix time is required.
 Benier/Wendel: 5 to 6 minutes
 Benier Spiral: 6 to 8 minutes
 Hobart HCM or VCM (high speed cutter/mixer): 1.5 to 2 minutes
10. Take the dough temperature and record it in the production report.
 Exit temperature of the dough should be 25.5°C to 27.7°C (78°F to 82°F).

 This is the ideal temperature for the fermentation.
 If the dough is too warm, it will speed up the fermentation process, and if too cold it
will slow it down.
 The accuracy must be ±1°F during the shift. Measurements and recording of your
processing parameters will allow you to make necessary adjustments.
 A targeted dough temperature insures consistency from batch to batch.
 Using a digital battery operated thermometer gives a faster, more accurate readout than
a probe thermometer.
 Dough should be removed from the mixer within two minutes.
11. Make a proof sample from each batch.
 The sample should be at least 6 ounces (170 grams) and proofed prior to shipping to
ensure the dough performs as expected.
 The samples should be uniform in size and identifiable for recall purposes.
 Allow the doughballs to proof and record the results.
 If any of the test proof doughballs fail to proof (rise), inform the Production Team
Leader right away.
 The dough should not be shipped if it fails this test.
 A log needs to be maintained, recording the proofing results for each batch.
 Dough must not be shipped prior to proof check verification.

12. Divide the dough.
 This portions the dough consistently whether mechanically or by hand.

 A mister is used to lightly coat the hopper with mineral oil. A mister gives an even
spreading of the oil in the hopper. This helps to lubricate the hopper so the dough will
slide easily into the divider.
 To coat the hopper, use only 57g (2 oz.) of mineral oil per divided batch. If more than
the required amount is used to coat the hopper, oil will collect on the exterior of the
doughball and burn during baking. Excess oil can also build up on the equipment and
create an ideal environment for bacteria to grow. The excess oil could also drip on the
floor and increase the hazard of slip and fall accidents.
 Place the dough in the divider hopper either manually or by using a bowl lift. Make
sure the divider is set at the right scaling weight. Dough weights as specified per size
must not exceed a tolerance of 1% of its total weight. Weights must be spot checked a
minimum of once per batch. Adjustments must be made when needed. Pockets must
be logged for weights on all size changes or at least twice if sizes are never changed.
 Information on the current dough weights and doughball placement (in trays) can be
obtained from DPI’s Quality Assurance Department.
 If there is rework to be added from the previous batch, it is added at the divider hopper.
For more information regarding rework, please refer to the rework section at the end of
this module.
13. Round the dough.
 Allow several “clean-up” doughballs to pass through the rounder before rounding
begins. This picks up any debris left in the rounder.
 Doughballs must be as round as possible. To achieve the right shape, doughballs will
probably have to be rounded twice.
 The skin (outer surface) of the doughball should be smooth, with no creases, lumps,
curls or unclosed centers. Round doughballs make it easier, and therefore faster, for
the pizza maker at the Domino’s Pizza store to properly size and shape the dough.
 Any doughballs contaminated with grease or dirt from the rounder should be thrown
away. Do not attempt to pick out the grease or dirt.
 The rounder must be able to handle the flow from the divider.
 If too many “doubles” (two doughballs that are bunched together) are occurring at the
rounder, and you cannot speed up the rounder, then you must slow down the speed of
the divider. Often times, the moving belts are not adjusted properly, which can cause
the doughballs to double up in the rounder.
 If using an AMF belt rounder, the doughball must turn 90 degrees between the first and
second set of channels. This is critical to avoid a “tunnel” from being formed within
the dough piece. Doubles cause reduction in profitability and affects both quality and
efficiency.
 After the doughballs drop off the rounder, the Team Member places them in the dough
trays.
Note: The acceptable way to rework these doubled doughballs depends on the type of dough
being made and the type of divider used.

14. Place doughballs into trays.
 When placing the doughballs, provide ample space to allow for proper proofing.
 Ninety percent of all trays must have good placement or the dough cannot be shipped.
 Procedures used when placing doughballs on a dough tray:
 Use a clean, sanitized, dry and cool dough tray. Dough trays are to be approved
by DPI QA.
 Outside and inside of the dough trays should be free of breaks, foreign matter
and old dough stickers.
 Warm dough trays cause the bottom of the doughballs to dry out, which makes it
difficult to make quality pizzas.
 Wet dough trays cause doughballs to slide together in the dough tray, and when
proofing will run together and slow down the pie making process.
 Dough placement template will help avoid doughballs touching the corner or
sides of the dough trays. Make sure not to dislodge the doughballs when the
template is removed. Templates are designed to be used only in conjunction
with an automated production line (tray and doughball conveyors).
 Doughballs placed too close to each other can cause them to flow together in the
proofing process. Cutting the doughballs apart (in the tray) alters the weight and
slows down the pizza maker.
 Doughballs too close to the corners or the sides causes straight edges after
proofing which makes it impossible to make a round pizza.
 Proper placement of the doughballs in the dough tray is critical, and allows for
uninhibited proofing in the tray.
15. Label each dough tray.
 Label each dough tray with the date & time made, and use-by date. All processed food
items are required by law to carry a production date and batch number (code), which
allows you to track each batch of dough you manufacture in case of a product recall. It
also provides a way for stores to rotate their stock. Lastly, it allows stores and
commissaries to know the shelf life of the dough.
 All dough manufactured is required to have the following information attached to the
dough tray:
 First day of use

 Last day of use
 Expiration date (two digit month/two digit day)
 Dough size
 Shelf life (Cold Dough Formulation – i.e. CD 5 or CD 6)
 Batch number/code/time of production

16. Dough Cool Down.
 Crisscrossing the dough trays allows for faster cooling within the appropriate time
frame. The internal core temperature of the dough needs to be between 1-4°C and
achieved within a 2½ to 4 hour period.
 Place the dough trays on the cart (dough dollies) with a clean bottom tray. Trays
should never touch the floor. Keeping the dough trays off the floor reduces the chance
that any foreign material will get in the dough tray and contaminate the product.
Bottom trays are distinguishable from other dough trays by color or visible markings.
 Cross-stack the dough trays into stacks that are NO HIGHER THAN 25 dough trays
high. Cross-stacking allows the air to circulate around and through the dough trays,
and cools down the dough faster. The height of the stacks is limited to 25 for both
safety reasons, and because there is still enough room for air circulation.
 Place the stacks of dough trays in the dough cooler. Make sure they are at least 8cm
(3”) from the wall of the cooler and from other stacks of trays. Putting the dough
trays in the cooler within 15 minutes helps ensure that the proof time will be
consistent. Keeping dough trays away from the walls allows for increased air
circulation. A clean, empty tray needs to be placed on top of the stack to protect
against product contamination.
 The temperature of the cooler where the dough is stored should be maintained between
1°C to 3°C (33°F to 38°F). This helps maintain an internal temperature of 4°C (40°F)
or less in the dough. The design of the cooler must allow for uniform cool down for all
areas within the cooler.
 The dough temperature should be checked with a digital battery operated thermometer.
Remember that the internal temperature of the dough should be consistent with the pre-
established processing parameters and shelf life requirements. If processing
temperatures are not monitored, and the product is not properly cooled, the proofing
will be inconsistent and the shelf life may be compromised.
 When checking the temperature, start by taking the temperature of the tray in the center
of the stack. Also check for any evidence of crusting during the cool down process.
17. Down stack the Dough Trays.
 Down stacking occurs after the appropriate temperature of the dough is achieved.
 The dough trays need to be down stacked from the cross-stacked position for storage
and shipping.
 Before down stacking, put a clean, empty dough tray on the bottom for sanitary
reasons.
 When moving the stacks of dough use caution. Handling a stack of dough trays as if it
were a stable unit can be a real hazard. Trays tend to come apart and fall without
warning, causing injury, damage or loss of product. Make sure the stack has a clean
cover tray on top.
 Make a final visual check of each stack of dough trays assuring dough trays are nested
together securely. Dough trays not properly seated or nested can be easily dislodged
and fall, a real potential for injury, as well as causing the product to dry out (crusting).
 Record results on the Downstacking Log. Document the time produced, time down
stacked and the temperature of each stack. Inform the Production Team Leader if the
target temperature is not achieved within the four hour time frame.

18. Shipping
 If shipping, ship within your pre-established processing parameters to meet your usage
and shelf-life requirements.
Cold Dough Labeling

Dough Labeling Instructions - Distribution Center Production
Cold Dough 6 - New Dough Tags
If production is:
Monday……… use Wednesday to Sunday labeling
Tuesday……… use Thursday to Monday labeling
Wednesday…… use Friday to Tuesday labeling
Thursday……… use Saturday to Wednesday labeling
Friday………… use Sunday to Thursday labeling
Saturday……… use Monday to Friday labeling
Sunday……….. use Tuesday to Saturday labeling
Example:
Cold Dough 6 (CD 6) Day Can the dough be used?

Sunday, Production No
Monday 1 No
Tuesday 2 Yes
Wednesday 3 Yes
Thursday 4 Yes
Friday 5 Yes
Saturday 6 Yes
Rework Procedures
A rework procedure needs to be established to ensure only a maximum of 10% of the flour’s
weight is reworked. Rework is clean unadulterated food that has been removed from processing
for reasons other than unsanitary conditions. For example, a double doughball can be reworked,
but a doughball that has fallen on the floor cannot.
• A sanitary bucket or container should be identified for rework. It should be able to hold no
more than 10% of the flour’s weight per batch. For example, if the dough batch uses 100
kilos of flour, then only 10 kilos of rework can be used from each batch.
• If rework has been collected it should be added at the divider hopper of the following batch.
• It also must be added within 15 minutes of being collected, otherwise the dough will begin to
proof.
• Rework dough greater than 10% of the flour weight batch or older than 15 minutes needs to be
discarded.

Procedures for Cold Dough Processing Summary
Complete dough preparation steps.
1. Start water meter and add water into bowl.
2. Re-hydrate yeast for two minutes.
3. Subtract amount of re-hydration water from the total water added to the bowl.
4. Add cold dough premix.
5. Add re-hydrated yeast slurry.
6. Whisk all ingredients into water.
7. Add oil. Do not whisk.
8. Add flour. (Add vital wheat gluten here if approved by DPI QA)
9. Mix all ingredients to full development.
10. Take the dough temperature and record it. It must be 25.5°C to 27.7°C (78°F to 82°F).
For consistency, the accuracy must be ±1°F during the shift.
11. Make a proof sample from each batch.
12. Divide the dough.
13. Round the dough.
14. Place doughballs into trays.
15. Label each dough tray.
16. Dough cool down.
17. Downstack the dough tray.
18. Ship the dough.

Knowledge Questions
1. How often should you calibrate your metering equipment?
2. How do you prepare an Instant Active Dry Yeast (IADY) slurry?
– Re-hydrate yeast for ____ minutes. The yeast water hydration range is 13°C
to _____°C (55°F to 65°F).
– Amount of water is _____times the weight of yeast being re-hydrated.
– Subtract amount of re-hydration water from the total water added to the bowl.
– Remember to rinse out the slurry ______ with the running water to make sure
all the yeast slurry is added to the dough.
3. List in order the 6 steps for Cold Dough preparation.
4. What is the proper way to measure the Cold Dough temperature after mixing?
5. What percent of a dough batch can you rework?
6. What information must appear on tray labels?
7. What is the maximum number of dough trays that should be in a stack?

Notes

Quiz 3
INGREDIENT AND
DOUGH PROCESSING PROCEDURES
MODULES 5 AND 6
TRUE OR FALSE
1. Amylase is the enzyme found in flour that breaks down sugars in the dough so they
can be used by the yeast?
2. The initial mixing at low speed allows the ingredients to hydrate and disperse evenly?
3. Ten percent (10%) of the flour weight per batch can be reworked?
4. FIFO stands for First In, First Out?
5. The dough should be whisked after the oil is added?
6. The presence of chlorine in water can inhibit the yeast activity at high levels?
7. The germ is the most important section of a wheat berry?
8. Higher ferment temperatures increases yeast activity?
9. It is important to remember to rinse out the slurry container with running water to
make sure all of the yeast slurry is added to the dough?
10. A proof sample of at least 6 ounces (170 grams) should be taken once a day?
11. Understanding the milling process of flour is important because the end product has a
direct effect on how pizza dough will perform?
12. The two main factors for proofing dough are gas production and gas retention?
13. Metering equipment should be calibrated monthly?
14. The falling number, on the flour specification, determines amount of moisture in the
flour?
15. Salt performs a three fold function in dough, it stabilizes fermentation, strengthens the
gluten and improves flavor?

Quiz 3
FILL IN THE BLANKS
16. How much mineral oil per batch should be misted on the divider hopper?
17. Name at least three ingredients in the premix?
18. At least what percentage of dough trays must have proper placement in order to be
shipped?
19. What piece of equipment must be able to handle the flow from the divider?
20. How long should yeast be re-hydrated for when making a yeast slurry?
21. This content is the criteria for judging how well the wheat was milled. Also, high
content of it will lead to accelerated and/or increased browning?
22. What are the five main ingredients in Domino's Pizza cold dough?
23. What is the time frame that dough should be cooled down?
24. What does RBD stand for in RBD Soybean Oil?
25. This technique allows for faster cooling of the dough trays within the appropriate
time frame?

Quiz 3
26. The hardness of water used to make dough should be in what range?
a. 0 to50ppm
b. 150 to200ppm
c. 200 to 400ppm
d. 50 to150ppm
27. What when mixed with water has the ability to form elastic mass that can be stretched
or extended?
a. Gluten
b. Yeast
c. Sugar
d. Cornmeal
28. What should the exit dough temperature be after mixing for cold dough?
a. It does not matter

b. 26 to 28°C (78 to 82°F)
c. 1 to 3°C ( 34 to 37°F)
d. 20 to 40°C (68 to 104°F)
29. What type of yeast is the only approved yeast for Domino's Pizza dough formulation?
a. Compressed
b. Active Dry Yeast (ADY)
c. Instant Active DryYeast (IADY)
d. All of the above
30. Dough weights should be checked at what frequency?
a. Weekly
b. Daily
c. At start up, after lunch, and at the end of the shift
d. A minimum of once per batch

Quiz 3
Notes

Module 7: Dough Troubleshooting
Dough Troubleshooting
Overview
This module should identify problems that arise pertaining to the dough. Although many of the
problems may be observed in the store, this impacts the commissary very strongly. In fact, many
of the solutions regarding these problems will be remedied in the commissary. Please remember
quality dough making is extremely critical. The work in a commissary affects the store and
customer greatly. Dough is the foundation for pizza, and without great dough there cannot be a
great pizza.
• Successfully troubleshoot, diagnose and repair faulty dough.
• Identify the possible causes and solutions for the most common complaints pertaining to the
dough.

Identifying Dough Problems at Facilities

Dough Problem Checklist at the Commissary
 Are the Domino’s Pizza International dough procedures being followed?
 Are the ingredients added in the correct order?
 Is the amount accurately weighed or metered?
 Flour analysis (flour meets our specifications)?
 Water hardness (should be 50-150 ppm)?
 Check weigh all scales?
 Check premix expiration dates?
 Water temperature?
 Yeast slurry temperature?
 Mix times: low and high speeds?
 Exit dough temperatures?
 Amount of divider oil used?
 Cool down time?
 Cool down temperatures?
 Loading time to the trucks?
 Rounder efficiency?
 Are dry trays being used?
Dough Problem Checklist (Delivery/Store Cooler)
 Proper truck temperatures being maintained?

 Dough temperature being maintained?
 Proper length of time for unloading?
 Placement of dough in the store coolers?
 Cooler condition (correct temperature & adequate size)?
 Cover trays being used?
 Bottom trays being used?

Dough Problem Checklist at the Store

Often, if only one store is having trouble with the dough, the issue might be at the store
level. The following are some suggestions a commissary might share with the store in
order to resolve the issue.
 Follow proofing guidelines.
 Bubbles: Caused by using under-proofed, over-proofed or expired dough.
 Follow proper stretching technique: improper stretching technique could result in thin
centers.
 Place the dough soft side up when stretching a pizza: the skin side should be touching
the table.
 Finger arrangements (oven): Improper finger arrangements in the oven could lead to
under baked or over baked pizzas.
 Remove the doughball from the dough tray using the correct method. Improper
removal of doughball could result in dough tails.

Crust Bubbles During Baking

POSSIBLE CAUSES SOLUTIONS
Proof dough according to dough proofing
Dough not properly proofed. guidelines.
Check yeast viability and yeast hydration

Yeast does not meet specifications. temperatures.
Reduce the amount of water used in 0.5%

Too much water used in formula: proofed increments based on flour weight and
dough may exhibit a large, sticky bubble. appropriate water range to meet dough shelf
life.
Maintain proper temperatures for exit dough

Temperature abused. temperature, storage and transportation.
Have flour sample sent to Domino’s Pizza

Weak or strong flour. International Quality Assurance department for
testing.
Note: There is expected to be some bubbling with the screen dough. This is due to the
formulation giving us a light and airy product.
Crusted Dough

Use only high humidity unit suitable for dough
storage to avoid crusting; no crust should form
Insufficient humidity in cooler. on cross-stacked dough in proper cooler.
Straight stack dough when it meets your pre-
established process temperature.
No cover tray used on dough in make area or Use a cover tray.
cooler.
Dough cooler must be able to cool down dough
in 2-4 hours. Check cooling system for
Down-stacking time running greater than four problems; maintain and service regularly.
hours. Cool down time excessive. Increase horsepower on system or increase
cooling capacity, if needed.

Crust Has Poor Volume After Baking

Reduce water in formula to give equal outward
Too much water in dough: dough pancakes in and upward rise, an increase of about 25% in
tray, or rises outward more than upward. height and width.
Use colder water during production to bring

Dough from mixer too hot; over 29°C/85°F. dough temperature down.

Yeast does not meet specifications. temperatures. Use only good quality, fresh
yeast.
Store below 32°C (90°F). Heat will cause flour

Improper flour storage. to lose moisture.
AMF Divider “working” dough too much, Check to make sure vacuum and head pressure
stressing the gluten structure. are running accurately.
Reduce the amount of time dough is mixed on

high speed. If dough is mixed too long on high
speed the dough will become tight and allows
Mixed on high speed too long. fewer air cells to form; therefore, reducing the
amount of oven spring. Over-mixing can also
weaken the gluten structure.
Inconsistent Dough in the Same Delivery

Monitor the dough maker. Be sure yeast is
dispersed in water before adding other
Strict formula and procedures not followed. ingredients. Ensure all scales are weighing
accurately ingredients.
Use thermometer to monitor each batch of

Finished dough batches vary more than 2 °C dough; correct water temperature to bring
(5 °F). dough into range.

Poor Dough Shelf Life in Stores (Over-proofed)
The dough does not meet shelf life requirements, often has excessive bubbles and is too soft to
handle during pizza making.

Yeast does not meet specification. temperatures.
Use colder water during production to bring

Dough too hot from mixer 29°C (85°F). dough temperature down.
Quickly move trays to cooler in less than 15

Dough is out too long in production room. minutes.
Lower production room temperature 20°C to

Production room is too warm. 24°C (68°F to 75°F).
Lower cooler temperature to 1°C to 3°C (33°F

to 38°F). Place plastic strip curtain over inside
Cooler too warm, either at store or commissary. of door opening. Clean cooler unit. Have
cooler unit professionally serviced at least
twice yearly.
Stack trays at least three inches from walls of

Inadequate air circulation around tray stacks. coolers and allow air circulation around sides,
top and bottom of stacks.
Warm up of dough between commissary cooler Load and unload quickly, strip or air curtains
and store cooler. on coolers and trucks.
Improper truck temperature during loading Must maintain truck temperature from 1°C to
and/or delivery. 3°C (33°F to 38°F).
Loading dough at temperatures greater than Dough must be at temperature less than 4°C
4°C (40°F) onto the truck. (40°F) prior to loading.

Dough Slow to Proof or Does Not Proof (More than 4 hours)

Yeast does not meet specifications or temperatures. Follow approved formula and
insufficient quantity added. ensure that all scales are weighing accurately.
Make sure the cooler is running at the proper

Dough cooler is too cold. temperature.
Dough is Difficult to Work With at the Store

Too little water is used in batch. Increase water to meet the shelf life of dough.
Get flour analyzed and rework the gluten

Inferior quality of protein in flour. amounts if necessary. Too much gluten could
result in under-proofing.
Increase water/flour temperatures to meet exit

Exit dough temperatures are too low. dough temperatures.

Yeast does not meet specifications. temperatures.
Baked Crust is Streaked

Only use 57 grams (2 oz.) of oil per batch with
Excessive use of divider oil in hopper. mister (spray bottle) to spread evenly.
Increase time to get complete mix and gluten

Mix time too short. development.

Sticky Dough
Dough is too soft and sticky to handle. There is often moisture in the dough tray and the dough
pancakes in the tray.

Reduce water to meet shelf life requirements.
Too much water in dough.
Moisture condensed on doughballs while Cross-stack for 15 minutes.
straight stacked.
Increase low speed mix to allow gluten to
Too short mix time. properly develop.
Check the hardness of water, it may require

Soft water. some form of conditioning.
Poor Taste
The majority of flavor complaints (blandness) are caused by the dough not being proofed
properly prior to baking.

Recheck formula and procedures.
Formula not followed.
Use sprays carefully. The odors can
Use of sprays for eliminating pests. contaminate food products and
containers/packaging (trays).
Check ingredients.
Foreign substances in ingredients.
Grease equipment carefully. Regularly
Careless lubrication of equipment or faulty schedule maintenance and repair. Ensure
equipment. maintenance Team Members are trained in
food safety and sanitation.
Eliminate cause; inspect and document all

Fumes from trucks. trailers prior to loading and unloading.
Break down equipment completely for cleaning

Unsanitary equipment. each day.

Poor Texture (Low Center Heights after Baking)

Dense dough due to under-proofed dough. temperatures.
Make sure store is following the proofing

Young dough being used in the stores. guidelines. Proof to double the size.
Follow exact dough weight specifications.

Dough weight is not exact – undersized.

Dough Troubleshooting Summary
The troubleshooting process is important not only to the commissary, but also to the stores.
Throughout this module, troubleshooting problems, causes and solutions have been highlighted.
The key is to be able to make quality dough the first time and every time, thus, alleviating the
need to troubleshoot.
However, in the event that problems do arise (and they always do), you must know the causes and
solutions to the various problems you will encounter.

Glossary
AIB International American Institute of Baking, a not-for-profit

corporation that provides technical and educational
programs to protect the safety of the food supply.
Absorption The amount of water required by the flour to produce

a dough of the desired consistency. This is based on
the flour's protein content and protein quality,
although other factors, such as damaged starch, play
a role in the absorption value.
Acid A compound that ionizes in water to produce

hydrogen ions. It readily donates protons to other
substances. They often taste sour; examples are
lemon juice and vinegar. They have a pH below the
neutral point of seven and turn litmus paper red.
Acids are often used in toilet bowl cleaners, rust
removers and on hard water stains.
Active Dry Yeast Yeast that has been dehydrated to a moisture level of
4 to 8%, the low moisture content greatly prolongs
the yeast's storage stability without the need for
refrigeration. It requires the restoration of its
moisture in tempered water prior to its addition to
dough.
Adequate The amount required to accomplish the intended task

while maintaining good public health.
Adulteration The intentional or unintentional addition of foreign

substances, making a food product impure, unsafe, or
unwholesome.
Alkaline A solution containing more hydroxide ions than

hydrogen ions, also referred to as basic. They have a
pH value above the neutral point of 7, turn litmus
paper blue and feel soapy. Often used in degreasers
and cleaners to assist in soil removal. Baking soda is
a common alkaline substance.
Amylase An enzyme found in flour that breaks down starch

and its polysaccharide components into fermentable
sugars. It is added as a dough conditioner in the
premix.

Glossary
Amylograph A machine that measures and records the apparent

viscosity of a flour-water slurry at either a fixed or
uniformly rising temperature. The viscosity tends to
increase as the starch in the flour undergoes
gelatinization with rising temperatures, while the
hydrolyzing action of α-amylase exerts a
counteracting effect. The height of the curve is taken
as an index of amylase activity and of the flour's
baking potential.
Anion A negatively charge atom.
Arrival time The time required for the top of the curve to reach the
500 BU line after the mixer has been started and
water introduced. This value is a measurement of the
rate at which the water is taken up by the flour. The
arrival time increases as protein amount increases.
Ascorbic Acid Also known as vitamin C. It is added to the premix as

an oxidant. It strengthens proteins to improve gas
retention.
Ash The criteria for judging how well the wheat has been
milled. High ash content may result in accelerated
and/or increased browning of the dough. The lower
the ash content, the whiter and more refined the flour
because it has a greater percentage of starchy
endosperm. Ash represents most of the mineral
elements obtained by the plant from the soil.
Autolysis The breakdown of all or part of a cell as the result of

its own enzymes present. Dead or dying cells are
most susceptible to it.
BISSC Baking Industry Sanitation Standards Committee,

was formed in 1949 to develop and publish voluntary
standards for the design and construction of bakery
equipment which today are recognized as the
definitive sanitation standards for equipment used in
the baking industry.
Bacteria Very small, single celled organisms that use organic

matter for their food and produce waste products as a
result of their life process. They reproduce very
quickly and some can cause infections and diseases.
The presence of bacteria is why cleaning is so
important in order to eliminate their possible food
sources.

Glossary
Biofilm Forms when bacteria attaches to a surface that is

exposed to a small amount of water and begins to
excrete a slimy, glue-like substance. In food
processing the presence of a biofilm can lead to
contamination. They tend to require more
sophisticated cleaners which are amended with
oxidizing agents for removal.
Bran The outer, multi-layered seed coat or husk of wheat.

It is high in fiber and separated out during milling by
sifting.
cGMP Current Good Manufacturing Practices. They are the

criteria used in part to determine whether a food has
the possibility of adulteration. They are published in
the 21 Code of Federal Regulations (C. F. R) Part
110. The main purpose of these regulations is to help
ensure a safe and sanitary food supply.
CIP Clean-in-Place. System in which the cleaning and

sanitizing of pipe lines and tank interiors is
conducted within a closed circuit. Disassembly of
equipment is not required.
COP Clean-Out- of- Place. Cleaning requiring the

disassembling of equipment into component parts or
units to be cleaned in another area, such as a three-
compartment sink.
Calibration To check, adjust, or determine by comparison with a

standard.
Carbohydrate Organic compounds consisting of carbon, oxygen and

hydrogen. They can be simple or complex
carbohydrates. Sugars and starches are the most
efficient source of food energy by providing four
calories per gram. Stored in muscles and liver as
glycogen and in the blood as glucose.
Cation A positively charged atom.
Caustic Strong alkaline substance which irritates the skin.
Celsius Scale (°C) A temperature scale that is based on 0° for the

freezing point of water and 100° for its boiling point
at sea level. It is in general use in those countries
where the metric system is used. Temperatures on the
Fahrenheit (°F) scale can be converted to the Celsius
(°C) scale by the following formula:
°C = 5/9 (°F - 32).

Glossary
Check Weights Test weights used to make sure your scales are
accurate.
Chelating The ability to prevent deposition of undesirable

mineral salts on surfaces being cleaned. Therefore,
hard water cannot interfere with the cleaning process.
Chlorine The most commonly used sanitizer due to its low cost
and effectiveness. Chlorine kills a wide range of
microorganisms. However, soil can quickly
inactivate chlorine solutions, and they can be
corrosive to some metals when used improperly.
Cleaning The removal of soil or unwanted matter from

surfaces to which it clings.
Combination soil The most challenging soil to remove from a surface

since it is both organic and inorganic components.
Proper identification is critical for removal.
Communicable disease An illness that is transmitted directly or indirectly

from one human to another.
Compressed Yeast Yeast that has been pressure-filtered into a semisolid

form with a moisture content of about 70% and
typically packaged in one-pound cakes. Unlike other
yeast, it requires storage at refrigerator temperatures
to retain its fermentative activity.
Cross-contamination Occurs when microorganisms are transferred from

one surface or food to another.
Cross-Stacking Criss-crossing the dough trays to allow for faster

cooling.
Crusting The formation of a dry layer or skin on dough being

proofed in a low-humidity environment. This leads
to moisture loss on the outside surface of the dough.
Usually caused by leaving a cover tray off too long or
having a cooler with air that is too dry. Crusting can
result in torn edges, dry dough, difficulty in
stretching and a dry texture.
Damaged Starch Starch granules that have sustained mechanical

damage during flour milling by fracturing or cracking
their granular structure. Such damage greatly
increases their water absorption capacity. However,
excessive levels of starch damage have an adverse
effect on the baking performance of flour.

Glossary
Degreaser A product that removes grease and oily soils from a

surface.
Departure Time The time required from the first addition of water
until the top of the curve leaves the 500 BU line.
Longer times indicate stronger flours.
Detergent A synthetic cleaning agent resembling soap that has

the ability to emulsify oil and remove dirt.
Disinfectant A chemical agent which is capable of destroying

bacteria or pathogens, but not spores.
Dispersing Agent A material that reduces the attraction between like

particles.
Dissolving The power of the detergent for both inorganic and/or

organic solids so as to speed the transfer into
solution.
Divider A machine that divides bulk dough volumetrically

into individual dough as closely as possible to a
predetermined weight. They must achieve consistent
and accurate weights within one percent of the
Domino’s Pizza established dough weights.
Divider Oil A lubricant used on the internal surfaces of the

divider that come into contact with the dough. It
normally consists of pure oil that is tasteless and
odorless, and resists oxidation and does not support
bacterial or fungal growth. Must be FDA or food-
grade approved.
Domino’s Pizza Cold Dough Created to require less dough management by the use
of specially formulated premix. The exit dough
temperature being a range of 78°F to 82°F (25. 5°C
to 27. 8°C).
Dough Development Time Also referred to as peak time or mixing time; is the
time between the addition of water and the
development of the dough’s maximum consistency.
The maximum of the curve is commonly considered
the point at which the dough is optimally developed
and best able to retain gas. Higher protein content
gives higher peak times.
Dough Tray A flat, shallow container or receptacle, usually with

raised edges used for holding, transporting, proofing
dough.

Glossary
Elasticity The ability of a dough to go back to its original shape
after stretching.
Emulsification The act of breaking up fats, oils and other soils into
small particles which are suspended in a solution.
Emulsifier (sanitation) An aqueous additive used to keep solids disperse

throughout the cleaning fluid.
Emulsifier (dough conditioner) Allows for fat and water to mix and form a stable
mixture. Stearoyl lactylates (SSL) effectively
strengthen the dough and make it more extensible.
This results in trapping more gas in smaller bubbles,
reducing proofing time, giving a softer more even
textured bread. The added “stretch” also makes the
dough more tolerant to over or under mixing.
Endosperm The nutritive and energy-rich portion of wheat that

makes up 85% of the whole kernel. It is composed
largely of starch and some protein and represents the
primary source of the flour obtained in milling.
Enzyme A protein that accelerates the rate of chemical

reactions. They are catalysts that promote reactions
repeatedly without being damaged by the reaction.
Enzyme categories of special significance in baking
are carbohydrases which include the amylases that
degrade starch into simpler carbohydrates;
proteinases that modify the proteins present in dough;
and lipases that hydrolyze the fats of wheat and flour.
Extensibility The degree to which the dough can undergo

stretching by the application of force before it
ruptures or breaks. It is an important factor in a
dough’s baking performance, especially during
shaping. A strong dough is not very extensible but is
very elastic. A weak dough is very extensible but not
very elastic. A strong dough will be difficult to shape
due to the lack of extensibility.
FDA Food and Drug Administration. An agency within

the United States Department of Agriculture that
issues and oversees regulations pertaining to the
safety, purity and wholesomeness of food, drug, and
cosmetics in order to safeguard public health.

Glossary
Fahrenheit (°F) A temperature scale which 32°F represents the
freezing point of water and 212°F its boiling point
under standard atmospheric pressure. General use of
this scale is now limited chiefly to the United States.
Interconversions of the Fahrenheit (°F) and Celsius
(°C) scales are as follows:
°C = 5/9 (°F - 32); °F = (9/5 x °C) + 32.
Falling Number A method for measuring the level of amylase activity

in flour. The number is based on the time it takes for
a rod to sink or drop through a flour slurry heated in a
boiling water bath. This is important because flour
contains many active enzymes that help in the
breakdown of starch. A high amount of amylase
activity can lead to excessive browning, lower
volume, undesirable crusts and sticky crumbs. Low
falling numbers indicate a degraded gel. The higher
the falling number, the better the remaining viscosity
and processing characteristics. A low falling number
is accompanied by a high level of amylases naturally
present in the grain; it is an indication of sprouting.
Farinograph An instrument for measuring the resistance of a

dough to mixing. It consists of a small high-speed
mixer that is connected to an oscillating
dynamometer whose movements are transmitted by a
lever to a recording system that produces a chart or
farinogram. The resultant chart provides information
on flour’s water and mixing profile, two important
physical properties of flour.
Fermentation Is the physical and chemical change that takes place

when yeast is active. The yeast consumes the sugars
and excretes its waste products, primarily as carbon
dioxide (CO 2 ) gas, alcohol and flavor components.
This is what allows the dough to ferment or proof.
Once the yeast cells consume the food supply, the
yeast will begin to die off. This life cycle determines
the shelf life of the dough.
Flour The finely ground meal of wheat that has been

milled. The starches in the flour provide food for the
yeast. When mixed with water it forms gluten.
Flour Analysis A form received from the flour supplier on tests

preformed on the flour to ensure it is within
Domino’s Pizza specification.
Flour Quality The essential capacity of a flour to produce dough of

good quality under both favorable and less favorable
processing conditions.

Glossary
Foam A mass of bubbles formed on liquids by agitation.

They can be unstable, transient or stable depending
upon the presence and nature of the components in
the liquid.
Food Any substance intended for use or for sale in whole

or in part for human consumption, including ice and
water.
Foodborne infection An illness that results from eating food containing

pathogens, which grow in the intestine and cause
illness. Typically, symptoms do not appear
immediately.
Food-contact surfaces Any surface of equipment, containers, utensil, and

wrappings that come into direct contact with food.
Gas Production The ability of yeast to generate carbon dioxide gas

during dough fermentation, thus, affecting the
aeration or leavening of the dough.
Gas Retention The ability of the gas cells in a dough to retain the
carbon dioxide generated by yeast during dough
fermentation. Adequate gas retention is an important
quality attribute of dough that will ensure good final
volume, whereas poor gas retention will result in
baked dough with a dense grain and a reduced
volume.
Gelatinization The process where starch granules take up water and

swell in an aqueous suspension upon being heated to
progressively higher temperatures, thus, transforming
the suspension into a viscous paste. Ultimately, with
continued heating, the cell walls of the granules burst
and release their contents into the suspending
medium which, as a result, loses some of its earlier
viscosity that is attributable to the swollen starch
granules.
Germ In wheat, the embryo that represents the rudimentary

plant and forms part of the seed or kernel. It normally
contains high levels of protein, fat, vitamins and ash.
It generates high enzymatic activity during
germination (the first stage in the development of a
plant from a seed).
Gliadin A major protein of wheat flour that once hydrated

and mixed associates with glutelin to form gluten.
Gliadin is insoluble in water.

Glossary
Glutathione A tripeptide made up of the amino acids (glutamine,
glycine and cysteine) that has as a strong reducing
effect on gluten. It is present in wheat germ and in
yeast cells, which release it when they undergo
autolysis. Its presence in a dough results in low
volume and poor quality. These adverse effects can
be overcome by the proper use of oxidants found in
our premix.
Gluten The protein group (gliadin and glutenin) in flour that

forms the structure of dough when mixed with water.
It holds the carbon dioxide produced by the yeast and
expands during fermentation to provide the elasticity
and extensibility (stretch) in dough.
Glutenin A protein that makes up about 40% of the protein

present in wheat flour and is primarily responsible for
the visco-elastic properties of dough. Associates with
gliadin to form gluten once the flour is hydrated and
mixed.
Hard Water Water that contains soluble salts calcium, magnesium

and sometimes iron. Can be measured by exceeding
100-200 ppm. Hard water can inhibit the action of
some surfactants and reduce the effectiveness of the
cleaning process.
Hopper A container that is positioned over a piece of

equipment for the purpose of holding material to be
fed to the equipment below. The hopper above a
dough divider holds a supply of dough.
Humidity The measure of moisture in the atmosphere. It

depends on the temperature and is higher in warm air
than cold air.
IPM Integrated Pest Management. Program using

prevention measures to keep pest from entering the
facility and control measures to eliminate any pest.
Iodine Sanitizer effective at low concentration and not as

quickly inactivated by soils as chlorine. It is
somewhat corrosive to surfaces and is less effective
that chlorine.
Infestation Situation that exist when pest overrun or inhibit the

facility in large numbers.
Inorganic soil Includes rust, scale, hard water deposits and minerals
(sand, silt and clay). Typically acids are used to
remove rust and scale, while general purpose cleaner
is used to clean minerals.

Glossary
Insolubility The inability of one substance to dissolve in another.
Instant Active Dry Yeast The only approved type of yeast by Domino’s Pizza
International. Yeast, retaining over 87% of the
gassing power of compressed yeast , has its moisture
content reduced to less than 5%. It is packaged under
a vacuum in a heat-sealed pouch, does not require
refrigerated storage. Its loss of activity will normally
not exceed 1% per month of storage.
Julian Date A calendar created by Julius Caesar where each day

of the year is numbered consecutively from 001
through 365. For example January 1 is 001, March 31
is 090, and December 31 is 365.
L-cysteine A reducing agent added to the premix as a dough

relaxer. It weakens the protein in order to reduce the
mixing time and elasticity.
Life Cycle The phases the dough passes through, which can be
defined by how useful it is for making pizzas. Dough
that is too young is often called green. Dough in the
middle of its life cycle is ready to use. Dough that is
no longer useful is called expired or blown.
MSDS Material Safety Data Sheets. Informative sheets

provided by the chemical supplier listing the
chemical, common names, potential physical and
health hazards, usage instructions, storage and
handling, and other important information. OSHA
requires a copy of an MSDS for each chemical stored
or used in a facility.
MTI Mixing Tolerance Index. The difference between the

top of the curve at the peak and the top of the curve
measured five minutes after the peak is reached. A
low MTI the flour had good tolerance to mixing and
a high MTI indicates a weak flour.
Microbe A general term for microorganism. They cannot be

seen with the naked eye.
Mixer A machine capable of a stirring or rotating motion for

combining various ingredients, both dry and liquid,
into mixtures that assume the character of a dough.
Mixing Profile A profile of the mixing behavior of the dough,

therefore, allowing for consistency among each batch
of dough.

Glossary
NSF National Sanitation Foundation. Their seal is affixed
to food service equipment which indicates that the
equipment meets certain standards to be used for
food processing.
Neutral A chemical state that is neither an acid nor alkali. A

pH of seven is considered neutral. An example is
distilled water.
OSHA Occupational Safety and Health Administration. A

US Federal Agency that establishes and enforces
standards relating to health and safety of industrial
workers in the US.
Organic soils A broad range that includes food soils such as fat,
protein, carbohydrates, grease and living matter such
as mold, yeast, bacteria and petroleum soils. Most of
the organic soils are best removed by using alkaline
cleaners or solvents.
Oxidizing Agents (dough) Remove hydrogen atoms from the sulfur-hydrogen

(sulfhydryl) linkages allowing for more sulfur
availability for the gluten strengthening disulfide
bond. Oxidizing agents strengthen dough. Ascorbic
acid, also known as vitamin C, is an example of an
oxidizing agent used in the premix.
Oxidizing Agents (sanitation) Give up oxygen easily or can readily oxidize other
materials. Examples are chlorine and peroxide
compounds. They are the opposite of reducing
agents and should be stored away from flammable
solvents. Their major functions are destaining and
improves peptizing.
PCO Pest Control Operator. Licensed professional who

uses safe, up-to-date methods to prevent and control
pests.
pH A measurement of the acidity or alkalinity of a

substance, expressed in a number range from 0-14.
Zero being a powerful acid and 14 being a powerful
alkali. Distilled water is seven, neutral.
Pancaking When proofing dough has a flat appearance and only

spreads sideways instead of evenly upward and
outward.
Pathogen A microorganism capable of causing disease in its

host.
Peptizing Power The ability to attack and disperse protein.

Glossary
Platform Scale A heavy duty weighing machine, also called platform

balance, that is equipped with a low, flat platform on
which heavy objects may be placed for weighing.
Phosphate A substance that is added to a detergent to increase

its water softening ability.
Porous A surface that has many tiny openings.
Potable Safe to drink, as in describing a water supply.
Precipitation Removing metal ions from solution as insoluble

materials.
Preproofing A method of proofing used by the stores. The dough

is slightly proofed and then placed back in the walk-
in. This shortens the amount of time to have the
dough optimally proofed when it is needed.
Proofing The act of holding doughballs in trays for the

appropriate time under controlled temperature and
humidity conditions that are conducive to optimum
yeast fermentation.
Protein A large complex molecule of one or more chains of

amino acids. Proteins perform a wide variety of
activities in a cell. The type of structure found in a
specific protein category depends on the type of
bonding that links the individual amino acids. In
wheat flour, gliadin and glutenin are the two major
proteins involved in gluten formation in dough.
Gluten plays a vital role in determining the quality of
the baked product.
Quaternary Ammonium Compounds Also known as quat, is a group of sanitizers all

having the same basic chemical structure. Quats are
non-corrosive to surfaces and remain active for short
periods of time after they have dried. However, quats
may not kill certain types of microorganism and are
easily affected by detergent residue.
RBD Soybean Oil Refined, bleached and deodorized soybean oil. It is

an edible oil extracted from soybean. It is rich in
polyunsaturated fatty acids and contains no
cholesterol. It is very light in color (clear at room
temperature) and bland in flavor and odor. It acts as
a lubricant, flavor contributor and tenderizer.

Glossary
Reducing Agents Have the opposite effect of oxidizers; they break the
disulfide bonds of protein molecules, weakening the
protein structures. They encourage the development
of gluten, therefore, shortening the mixing time and
decreasing the amount of mixing needed. L-cysteine
is the reducing agent used in the premix.
Residual Sugar Any sugar that was added to dough but not fully used
by the yeast during fermentation. It survives into the
finished baked product, where it ultimately
contributes to physical quality attributes such as taste,
crumb texture, and crust color.
Rework Clean, unadulterated food that has been removed

from processing for reasons other than insanitary
conditions, or one that has been successfully
reconditioned by reprocessing and is suitable for use
as a food.
Rinse The use clean potable water after washing to remove

excess detergents.
Rounder A machine consisting basically of a rotating surface

of either conical, bowl or drum shape against which
the freshly divided dough piece is held by a
stationary spiral trough. As the surface rotates, it rolls
the dough piece upward in the spiral trough and
transforms it into a rounded ball, imparting to it a
thin, smooth and dense skin.
SSL Sodium stearoyl lactylate. An emulsifier added to the

premix. It strengthens the dough and makes it more
extensible. This allows for more gas to be trapped in
smaller bubbles, reducing proofing time and giving a
softer, more even textured dough.
Saccharomyces cerevisiae A species of yeast which serves as the principal

fermentative agent in baking. It is a unicellular
microorganism that metabolizes sugars and other
nutrients into carbon dioxide, alcohol, and other by-
products.
Salt An inorganic salt, sodium chloride (NaCl), used

universally as a seasoning in foods. It stabilizes gas
production in the dough, slows growth, strengthens
gluten and serves as a flavor enhancers.
Sanitize The process of reducing microorganisms to levels

considered safe from a public health viewpoint.
There are two methods for sanitizing surfaces: heat
and chemical sanitizing.

Glossary
Sanitizer Capable of killing 99.9% of a specific bacterial test

population within 60 seconds. Chlorine bearing
compounds and quaternary ammonium compounds
are the two most common chemical sanitizers used in
food manufacturing facilities.
Saponifying Power The ability of the detergent to saponify (turn fats into
soaps) fats.
Sequesteration Holding metal ions in solution.
Shelf Life The length of time an ingredient or product can be

used under ideal conditions.
Silo A storage bin, usually cylindrical in shape, for

holding bulk quantities of such dry ingredients as
flour. It may be located either outdoors or inside the
production area and is normally provided with
pneumatic conveying systems.
Skin Side The side of the dough that is exposed to air on the
dough tray. This side should be facing down when
stretching a pizza.
Soft Side The side of the dough that touches the dough tray.
This side should be facing up when stretching a
pizza.
Soft Water Water that either naturally contains a low mineral

content, particularly of calcium and magnesium salts,
or whose levels of such salts has been reduced by
demineralization.
Soluble The ability of being dissolved in a solvent, such as

water or another liquid. For example, sugar is
soluble in water.
Solvent A liquid which dissolves another substance. Water is

the most common solvent.
Spores Bacteria that have formed protective layers in order

to survive until conditions are favorable again. Not
all bacteria can form spores, some examples are
Bacillus and Clostridium.
Sugar Serves as the food for yeast. Sugar is a tenderizer

and browning agent through a process known as
caramelization.

Glossary
Surfactants Components in detergent that reduce surface tension
at the points where the detergent meets the soiled
surface, allowing the detergent to quickly penetrate
and disperse the soil.
Stability The difference in time between the point at which the

top of the curve first intercepts the 500 BU line
(arrival time) and the point at which the top of the
curve leaves the 500 BU line (departure time).
Standard A measure used as a comparison for quality to

determine the degree or level that a requirement is
met.
Starch It is a carbohydrate consisting of glucose units that is

the major component of flour. Pure starch is a white,
odorless and tasteless powder
Starch Retrogradation The formation by the linear amylose fraction within

partially gelatinized starch granules of crystalline
aggregates. It is accompanied by a loss of the
fraction's gel-like character. Retrogradation is
involved to a major degree in staling reactions.
Sterilize The statistical destruction and removal of all living

organisms.
Surface Tension The attractive forces which liquid molecule have for
each other.
Suspending The ability to emulsify fat and suspend other solids in

solutions.
Suspension The process of a cleaning agent holding insoluble dirt

particles in the cleaning solution and keeping them
from redepositioning.
Synergistic Chemicals that when combined have a greater effect

than the sum of the two independently.
Synthetic detergents Also know as soapless detergent. They are typically

made from byproducts of refining crude oil. They do
not form a scum in hard water and lather better than
soaps.
Tare or Zero Out To deduct the weight of the container from the total
weight to determine the weight of the contents.

Glossary
Thermometer An instrument for measuring the temperature. A
digital thermometer is a battery-powered food grade
thermometer that reveals the internal temperatures of
food products with a digital display that is accurate to
0.1 degree.
Troubleshooting Locating and eliminating sources of trouble in

procedures and operations.
UL Underwriters Laboratories. A company that tests and

certifies products for public safety and compliance.
Vital Wheat Gluten Vital wheat gluten can be added, if first approved by
DQII QA, in the allowable range of 0.5% to 3%
FWB. It is the natural protein found in wheat with
the starch removed. It is extracted through a
mechanical water washing process where no
chemicals are used or added. Vital wheat gluten is
light tan in color and almost flavorless. It contains
about 75% protein, therefore, it increases the protein
amount in lower protein flours. This provides
additional qualities to the dough when the flour alone
is not enough. Vital wheat gluten absorbs nearly
twice its weight of water and retains a portion of it in
the final product, therefore, increasing the yield. The
USDA has approved it for use as a dough
strengthener, however, check with local or federal
requirements.
Water It is an odorless, tasteless, colorless and transparent

liquid that freezes to a solid state at 0°C (32°F) and
boils (100°C) 212°F. It is the most important solvent
in nature. In dough formation it aids in dissolving
ingredients, activates the yeast and combines with the
proteins in flour to form gluten.
Water Absorption The amount of water required for dough to reach a

definite consistency. Adsorption increases with the
level of protein and quality. Therefore, spring wheat
tends to have higher adsorption. Adsorption is also
equal to the amount of yield, more water in the batch
produces more product.
Water Meter Any device that indicates and measures the amount
of water that passes through it. In the bakery, it
serves to automatically control the amount of water
that is added to the mixer during dough mixing.
Water Treatment Various procedures applied to process water, such as

chlorination, filtration, demineralization, etc., to
bring the water to the required quality standard.

Glossary
Wetting The ability to lower the surface tension of the water

medium so as to increase its ability to penetrate soil.
Whey Also called milk serum, is the liquid that remains as

a by-product of cheese production and has several
commercial uses. It is composed of water-soluble
vitamins and minerals, lactose and noncasein
proteins. Sweet dairy whey used in Domino’s Cold
Dough Premix contains about 70% lactose. It is a
dough additive that aides in better crust color and
crispiness.
Yeast A microscopic, unicellular microorganism that

belongs to the genus Saccharomyces and includes a
number of species. Saccharomyces cerevisiae is the
most common species used in baking. The organism
reproduces by budding and also by sporulation and is
capable of converting certain sugars into alcohol and
carbon dioxide by fermentation.

Knowledge Questions Answer Key
Module1: Hygiene
1. True
2. False
3. False
4. False
5. False
6. Explain why hygiene is important?
♦ Protects against possible product contamination.
♦ Is an important measure against food borne illness and product contamination.
♦ Helps reduce the possibility for contaminating products.
♦ Contamination hurts us all-in terms of our company’s image, of our customers’
confidence in us, in terms of the money we spend to replace the contaminated
product.
7. Give two reasons why jewelry is not to be worn in the production room.
♦ Cannot be kept clean, often harboring bacteria.
♦ Can become a safety issue, if it gets stuck on a piece of equipment.
♦ Jewelry can fall off and into the product or equipment.
1. True
2. False, Mechanical cleaning.
3. True
4. False, too much sanitizer can leave a residue on the food contact surface.
5. True
6. Preventive and Corrective.
7. Dry cleaning, pre-rinse, chemical application, rinse and sanitizing
8. Heat and chemical
9. Annually
Key-1
Module 3: Safety
TRUE OR FALSE
1. False
2. False
3. True
4. False, legs
5. Personal Protective Equipment
6. Examples are:
♦ Safety shoes
♦ Eye protection
♦ Hearing protection
♦ Hard hats of bump caps
♦ Respiratory equipment
♦ Back belts
7. Proper way to lift heavy objects is
♦ Your leg muscles doe the work instead of your back and stomach muscle.
♦ Get a good footing
♦ Place your feet about a shoulder width apart
♦ Bend a the knees to grasp the weight
♦ Keep body over the load
♦ Keep back straight
♦ Get a firm hold
♦ Keep the back as upright as possible and then lift gradually by straightening the
legs
♦ Get help if the weigh is too heavy or bulky to lift.
Key-2
1. To check for accuracy, compare the thermometer with a certified bulb thermometer
or by placing the thermometer in a container of water and ice. The thermometer
must register between 32°F (±1°F).
2. Functions of a dough rounder are:
♦ Rounder must achieve complete rounding and sealing of the dough piece.
♦ The rounding action will result in skin formation over the surface the of the
dough piece.
♦ Rounder must be capable of providing for separation of the dough pieces
during transfer from the divider and during the rounding process itself.
♦ Rounder will have the capacity to process at least the same amount of dough
as the divider.
3. Work Tables must be stainless steel, including legs. Stainless steel frames, with
replaceable plastic insert, are acceptable. Must be approved to use in food
manufacturing (i.e. NSF) or the international equivalent, approved.
4. 40°F or 4°C
5. Not more than 0.25% dough loss
6. Yeast scales, Flour scales, check weighing scales and ingredient scales.
1. False flour, water, soybean oil, yeast and premix

2. False, flour is about 70-75% starch.
3. True
4. False, Amount, Temperature, Water Quality, pH, and amount of dissolved
minerals.
5. True
6. True
7. True
8. False over-proof
9. Bran, endosperm, and the germ
10. Sugar, Salt, SSL, Whey, Amylase, Ascorbic Acid and L-cysteine hydrochloride.
11. Fermentation or proofing
Key-3
Module 6: Cold Dough Processing Procedures
1. Every day prior to production.

2. 2 minutes; 18°C (65°F); 4 times; container
3. The steps are:
♦ Calibrate metering equipment and scales
♦ Check for leaks in the yeast viability test kit
♦ Run the yeast viability test
♦ Dust off the flour bags and weigh the flour
♦ Set the water meter to the proper temperature and volume
♦ Tare the floor scale or zero platform scale
4. Using a digital battery operated thermometer, take the internal temperature of the
dough which should read between 26°C to 28°C (78°F to 82°F). For consistency,
the accuracy must be +1/– 1°F. Record the temperature.
5. 10% of flour weight per batch.
6. Answer:
♦ First and Last Day of Use
♦ Expiration Date
♦ Dough Size
♦ Shelf Life (Cold Dough Formula)
♦ Batch number/code/time of production
7. 25
Key-4
Quiz Answer Key
Quiz 1
TRUE OR FALSE
1. False, outside only, mechanical traps, such as tin cats, can be used inside.
2. True
3. True
4. False, all people entering the commissary need to, including visitors and
contactors.
5. False, they are considered food contact surfaces.
6. True
7. False, open toed shoes or sandals are not allowed by any person entering the
dough production or warehouse area.
8. True, Organizing, Material and Supplies, Storage facilities and Cooperation are the
others.
9. True
10. True
11. False, detailed written schedules are most effective.
12. False, if one is worn it must be under a hair net.
13. False, 55-120°F (13-49°C)
14. False, dry cleaning, pre-rinse, chemical application, rinse and sanitizing.
15. False, no jewelry can be worn
FILL IN THE BLANKS
16. Improved sanitation

17. The appropriate sanitizer test strip
18. Warm or hot water
19. 20-40 feet (6.5-13 meters)
20. A beard net or snood
21. Hand sanitizer
22. Team Members with improper hygiene standards
23. At least annually
24. Three, start up, middle of the shift and end of shift.
25. Material Safety Data Sheets
Key-5
26. C. Twice a week

27. A. Antibacterial/germicidal
28. B. Visual inspection, chemical testing and verification checks
29. D. All of the above
Key-6
Quiz 2
TRUE OR FALSE
1. True
2. False, all the time
3. False, must be stainless steel.
4. False, trailers or containerized shipping unit should never be used as a regular
storage unit.
5. True
6. False, 1% of the established dough weight.
7. False, all perishable or potentially hazardous foods need to be transported in a
refrigerated vehicle.
8. True
9. False, they need to be discarded when they present a safety hazard when
handled.
10. False, always pull the plug
11. False, several scales are needed, yeast scale, flour scales, check weighing scales,
ingredient scales and receiving scales.
12. False, all injuries need to be report to a supervisor.
13. True
14. False
15. True
FILL IN THE BLANKS
16. A thermal barrier

17. Major strains and slips and falls
18. Personal Protective Equipment.
19. Kill switch, Emergency stops or E-stop
20. Use the lockout and tagout program
21. Contingency plan
22. Production and tray washing
23. Dough divider
24. One. Excess oil can collect on the equipment 2. can drip on the floor and cause
slips and falls.
25. Safety Guards
Key-7
26. B. Preventative maintenance schedule

27. C. 0.25%
28. C. 25% and 75%
29. B. Coolers, freezer and production room
Key-8
Quiz 3
TRUE OR FALSE
1. True
2. True
3. True
4. True
5. False, if a whisk is used the oil will coat the yeast cells and prevent the hydration of
yeast cells, therefore, reducing the rate of fermentation.
6. True
7. False, Endosperm
8. True
9. True
10. False, every batch
11. True
12. True
13. False, daily
14. False, the falling number determines the protein quality.
15. True
FILL IN THE BLANKS
16. No more than 57 grams or 2 ounces

17. Sugar, salt, SSL, Whey, Amylase, Ascorbic Acid, and L-cysteine hydrochloride
18. 90%
19. The rounder
20. Two minutes
21. Ash
22. Flour, water, premix, soybean oil and yeast.
23. 2½ to 4 hours
24. Refined, Bleached and Deodorized
25. Crisscrossing or cross stacking
Key-9
26. D. 50-150ppm
27. A. Gluten
28. B. 26 to 28°C (78 to 82°F)
29. C. Instant Active Dry Yeast (IADY)
30. D. A minimum of once per batch
Key-10

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Dough Certification

Revised October, 2013

Module 1: Hygiene ............................................................................................................... 1-1

Quiz 1 ................................................................................................................................. Q1-1

Module 3: Safety .................................................................................................................. 3-1

Quiz 2 ................................................................................................................................. Q2-1

Module 5: Ingredient Management .................................................................................... 5-1

Module 6: Procedures for Cold Dough Processing ........................................................... 6-1

Quiz 3 ................................................................................................................................. Q3-1

Module 7: Dough Troubleshooting..................................................................................... 7-1

Answer Keys ................................................................................................ Key-1 through 10

Upon completion of this module, you will be able to:

Dough Certification 1-1 2013

Purpose of Domino’s Pizza Hygiene Standards

Main Sources for Contamination

Dough Certification 1-2 2013

Dough Certification 1-3 2013

Production Uniforms for a Class “C” Commissary

Production Uniform for a Class “A” and “B” Commissary

 Only shirts with snaps are permitted, no buttons.

 Must be neat, clean and serviceable.

Dough Certification 1-4 2013

Aprons (if used)

 Must be neat, clean and serviceable.

Warehouse Team Members

Delivery and Service Team Members

 Delivery personnel must wear a full uniform.

Dough Certification 1-5 2013

Dough Certification 1-6 2013

• Wear clean, correct size uniform with no buttons or pockets.

Dough Certification 1-7 2013

1. Team Members must report to work clean?

2. Open toed shoes can be worn in the production room?

3. A Team Member should handle dough with exposed sores?

4. Hand sanitizer can be used in place of hand washing?

5. Eating is allowed in the production room?

6. Explain why hygiene is important?

Dough Certification 1-8 2013

Dough Certification 2-1 2013

Dough Certification 2-2 2013

Dough Certification 2-3 2013

Materials and Supplies

 An industrial vacuum cleaner.

 Steam Jet Cleaners.

Dough Certification 2-4 2013

Cooperation represents the final component of a sanitation program. It relies on the

Dough Certification 2-5 2013

High Pressure Cleaning

Clean in Place (CIP)

Clean Out of Place (COP)

Dough Certification 2-6 2013

 Aids in the removal of all particles.

 Penetrate the soil.

 Removes detergent and soil and prepares the surfaces to be sanitized.

 Application of a sanitizer according to chemical manufacturing specifications.

Dough Certification 2-7 2013

Dough Certification 2-8 2013

 An important part of any cleaning agent.

Dough Certification 2-9 2013

Physical Disruption (scrubbing)

 Type and amount of chemical used to remove the soil.

Dough Certification 2-10 2013

 Sanitizing a surface using heat is achieved through steam, water or air.

 Sanitizing by the use of chemicals is typically done one of two ways: