Internship Report: Merit Bread

Burhan Aslam
Roll No. 39 (Regular)
B.Sc. (Hons.) Food Science & Technology

Institute of Food Science and Nutrition (IFSN)

University of Sargodha, Sargodha.
INTERNSHIP REPORT

MERIT BREAD
Outline

Introduction to industry
Merit’s products
Equipments used in the merit bread
Raw material and their functions
Bread manufacturing
Bread faults
Continued…

Fruit bun manufacturing

Fruit bun faults
Rusk manufacturing
Bakery section and role of ingredients
General recipe for muffins
General recipe for mini cake/fruit cake
Steps in bakery production
Continued…

Recipe for shwarma manufacturing

Recipe for burger manufacturing
Fast food section (pizza manufacturing)
Hygiene conditions
Conclusions
Products
Introduction and History
 One of the most famous bread industries of
Pakistan
 Makes: bread, bun, Rusk, biscuit, cake, burger
bun, and baker khani etc.
 It started work in Lahore; its head office is also in
Lahore Kala Shah Kaku.
 This plant started production in 2002.
Continue…
 Products are currently available in

◦ Gujranwala, Gujarat,

◦ Sargodha , Mianwali, Jhang,

◦ Easakhel, Khanewal,

◦ Multan, Okara,

◦ Sialkot, Jhelum,

◦ Faisalabad, Toba Take Sing & Surrounding area

only.
Continue…
Groups of Merit Bread

 Head office Kala Shah Kaku.

 ISLAH (Pvt.) Ltd. Kot Lakh Pat Lahore.
 Team Enterprises Faisalabad unit.
 Marry Gold Bread (Ramna foods (Pvt.) Limited is
sister concern of merit bread)
 HISBIZ (Pvt.) Limited Faisalabad
Merit’s Products

Shwarma
Burger Section
Biscuits
Cakes
Bread Section
Buns
Rusk
Fast Food Section
Continue…
Shwarma Types

Shwarma large
printed

Shwarma small
printed

Shwarma plain large

Shwarma plain small

Continue…
Burger Section

Roll

Round

Jumbo

Mac

Royal
Continue…
Biscuits Types

Almond

Nipple

Almond special

Choora

Cookies large
Continue…
Cakes Types

Fruit cake
Mini cake
Queen cake
Muffins
Kulfa cake
Plain cake
Cup cake
Continue…
Bread Section

Milky open top bread

(standard)
Large bread (white)

Standard bread (white)

Milky mini bread

Sandwich bread (white)

Milky plain standard
bread
Bran bread (diet bread)
Continue…
Buns Types

Fruit bun

School bun

Burger rolls (long)

Burger bun (round)

Sheer mall
Continue…
Rusk Types

Pillow pack rusks

Simple ruks (open top &

plane)

Goal rusk

Tikky pack
Continue…
Fast Food Section

Pizza
Shwarma
Drumstick
Zinger
Pratha roll
Sandwich
Spring roll
Chicken roll
Equipments Used In Merit Bread
1. Mixers
Spiral Mixer (bread, bun and Rusk mixing)
• of a rotating steel bowl and an Axel which also rotates
• mixing is done due to their combination of rotation

Z- Mixer
• Mixer is usually wheel-mounted, heavy tub with vertical
sides, round ends, and flat bottom.
• Spindles are lowered into mixer, move in either
planetary or stationary, circular motion when activated.
• Blades are designed to provide cutting action of dough.
Equipments used in Merit Bread
Continue…
2. Weighing Balance: Weighing balances is used
to weigh different bread ingredients.
Two types of weighing balances at plant.

Mechanical Balances
• These are used to weigh flour and sugar etc.

Electronic scales
• Used to weigh different ingredients in small
fractions (Yeast, improver, salt)
Equipments Used In Merit Bread
Continue…
3. Ovens (Swing type oven)
• 8 wings which have trays suspended between the iron-
wheels.
• Below these trays, there are gas burners for baking.
4. Rusk oven (Tunnel type oven is used for Rusk drying)
5. Flour Sifter (Remove the undesirable foreign particles, dust)

6. Steam Boiler (Steam for proofing)

7. Slicer (Knives cut the loaves without tearing the crust)

8. Packaging machines(Automatic machine,wrap
product)
9. Sealing machine (Electric heating rod, 120˚, Seal P.M)
Baking Ingredients

Major Minor Optional

• Flour • Shortening (Fat • Fats or
• Sugar or Oil) shorting
• Yeast • Antimicrobial • Improver
• Water agents • Additives
• Emulsifiers • Emulsifier
• Additives • Milk powder
• Salt • Eggs
• Bread • Honey
Improvers • Fruits
• Milk • Spices
• Aroma
compounds
Functions Of Major Ingredients
Flour
• Provides proteins (gluten) that provide
strengthening and structure to the bread
• Provides the final volume to the bread
• During baking dough protein coagulates and
hydration starch partially gelatinizes to from
structure of bread

Water
• Dissolve the ingredients forming homogenous
mixture and Important for yeast activity
• Helps in swelling of starch granules
• Medium for many chemical reactions
occurring in bread making
• Help in transforming the protein of the flour
into gluten
Function Of Major Ingredients
Sugar
• Promotes fermentation and browning
• Provides sweetness & food for yeast activity
• Gives appetizing color due to Caramelization
• Also affects the volume of loaf
• Make the bread tender because of its property
to retain moisture
• Improves the texture of bread.

Yeast
• Production of carbon dioxide
• Causes dough maturation
• Development of fermentation flavor
Functions Of Minor Ingredients
SHORTENING (Fat or Oil)
Used to soften or tenderize the bread
Confers the moisture on bread and hence retard
staling
Assists in gas retention by making the gluten
more airtight thus giving better volume and
crust

Anti microbial agents

Calcium propionate and 4% Acetic acid is
used
They kill the microbes and increase shelf life
Checks the growth of bacteria as Bacillus
subtilis and Bacillus mesentricus by
decreasing the pH
Functions Of Minor Ingredients
Continue…
Emulsifiers
Mono and triglycerides are widely employed as
emulsifiers in hydrogenated shortenings
Other Polysorbate, Glycerin mono sterate
They act as softener agent.
They also perform as dough conditioners to
increase dough tolerance

Additives
These additives may be added as
preservatives as antibacterial and antifungal.
Calcium and ammonium salt added in bread
to supply the nutrient needs of yeast cells
Functions Of Minor Ingredients Continue…
Salt
Natural antioxidant
Boost the flavor
Tightening the gluten structure
Adding strength
Helps loaf to hold on to carbon dioxide gas
Slows down fermentation

Bread Improvers (combination of enzymes)

Softness
Whiteness
Shining Strength
Crumb texture
Functions Of Minor Ingredients Continue…

Milk
used in milky bread
enhance the food value
enhances the crust color and crumb color
gives taste
enhances the volume of bread
Bread Manufacturing
Ingredients

Flour Ravi yeast Sugar Oil

Ca.Propionat
Salt Soft improver Acetic acid
e

Banaspati Vanilla
Ca.Acetate Safe yeast
ghee powder

Lemon
Muraba Food color
essence
Bread Manufacturing
 Steps in BREAD Production

Aging Sifting Weighing Mixing

Dividing Fermentation
(10-15
Panning Molding min, 25–
3000C)

Proofing Baking De panning,

Damping
(35C-40C) (220-250˚C, 30 Cooling
(15-20 min)
R.H 82-85% min) (10-20 min)

Dispatch Packaging Slicing

Bread Faults

External Internal

• Volume too small • Holes in Crumbs

• Volume too large • Yellow-Gray Streak
in crumb
• Crust color • Coarse Crumb
• Thick Crust Structure
• Wrinkle Side
• M-Form (in large
bread)
• Dent in Bread
Fruit Bun Manufacturing
 Ingredients

Flour Ravi yeast Sugar Oil

Mix. (120)
Salt Ca.Propionate Soft improver
improver

Banaspati
Acetic acid Ca.Acetate Safe yeast
ghee

Lemon
Vanilla powder Muraba Food color
essence

Orange Crown
essence improver
Fruit Bun Manufacturing
Continue…

 All the steps are same as described above in bread

production.

 There is a difference in mixing, temperatures etc

and all of important polishing is done in fruit bun.

Steps in Fruit Bun Production

Mixing
Aging Sifting Weighing

Dividing

Panning Molding Fermentation

Proofing Baking De panning Cooling

Dispatch Packaging Polishing

Bun Faults

Holes under the White crust on the

top crust top crust

Cracks at the
Flat bun
sides

Coarse crumb Large irregular

structure holes
Rusk Manufacturing
 Ingredients

Flour Ravi yeast Sugar Oil

Salt Ca.Propionate Soft improver Acetic acid

Banaspati
Ca.Acetate Safe yeast Vanilla powder
ghee

Orange Crown
Milk powder
essence improver
Steps in Rusk Production

Aging Sifting Weighing Mixing Fermentation

Panning Baking Proofing Molding Dividing

Damping De panning Cooling Slicing Drying

Dispatch Packing Cooling

Bakery section
Role of Ingredients in Bakery Section

Flour
• Provides the basic structure
• Has ability to form strong dough, retains gas,
produces light aerated baked products.

Sugar
• Increase tenderness
• Crust color, volume,
• Moisture retention

Shortening
• Impart desirable eating qualities
• Interact with starch components to alter
hydration and swelling properties
• Plays a part in “baked flavor”
Role of Ingredients in Bakery Section
Continue…
Eggs
• Affect texture as a result of their emulsifying,
tenderizing, leavening and binding actions.
• Structure
• Add nutritional value

Leavening agents
• Causes the flour mixture to rise (CO₂ production)
• Leavener may b biological (Yeast) or chemical
(baking powder)

Glucose
• Used to prevent sugar crystals formation
• Give moderate sweetness
• Participate in formation of characteristics brown
color.
Role of Ingredients in Bakery Section
Continue…
Milk Powder
• Combines with gluten in wheat to produce soft
and moist product after baking
• Combines with reducing sugar to give color and
browning effect

Salt
• Flavor enhancer
• Controls the fermentation
• Aids in suppressing undesirable bacteria by
osmosis process

Flavors
• used in small amounts
• important effects on sensory and physical
qualities of bakery products.
Role of Ingredients in Bakery Section
Continue…
Water
• Hydration of flour proteins and starch
• Dissolving sugars, salts and various leavening
chemicals
• Aids in ingredient distribution

Potassium sorbate

• Acts as mould inhibiter in bakery products

Sorbic acid
• Used as preservative
• Lowers down the ph of products
• Inhibits the growth of micro-organisms
Bakery Section, Muffins
 Ingredients

Flour Sugar Oil Margarine Salt

Baking Food Milk

Butter Eggs
powder colors powder

Condense Chocolate Potassiu

milk Peanuts Choora powder m sorbate

Sorbic
Essence Muraba Corn flour
acid
Bakery Section, Mini cake/Fruit cake
 Ingredients

Flour Sugar Oil Margarine

Baking
Salt Butter Eggs
powder

Food Milk Condense

colors powder milk Peanuts

Choora Sorbic acid Essence Muraba

Bakery Section, Steps in Bakery
Production

Grinding of Mixing
Weighing
sugar (5-7 min)

Baking
Cooling (200˚C, 18 Molding
min)

Packing
Shwarma Manufacturing
 Ingredients

Bread
Sugar Dry yeast
improver

Flour Guar gum Salt

Oil
Shwarma Manufacturing
Continue…

Weighing Packing

Mixing Baking
(10 min) 26-27 (280-2850C,
degree Celsius 10min)

Proofing
Molding
(35-400C, 120-
(10 minutes)
125 minutes )
Burger Manufacturing
 Ingredients

Flour Water Sugar Gluten

Xanthan
Dry yeast Cmc Guar gum
gum

Oil Salt
Burger Manufacturing:
Steps
Mixing
Weighing (25˚C, 16 Molding
min)

Damping Baking Proofing

(25-30 minutes (2350C -2400C, (120 minutes
to cool) 16 min) 36-40˚C)

Slicing Packing
Products of Fast Food Section

 38 total products in Fast Food Section

 Some of them are given below:-
◦ Pizza

◦ Spring roll

◦ Zinger burger

◦ Chicken burger

◦ Chicken roll

◦ Chicken donuts
Products of Fast Food Section
Continue…
◦ Drum sticks

◦ Sandwich

◦ Chicken pratha

◦ Pratha roll

◦ Shwarma

◦ Hot wings

◦ Chicken tikka

◦ Chicken shami
Pizza Manufacturing
 Ingredients for pizza dough

Flour Yeast Improver

Salt Sugar Water

 Procedure for dough

1. Mixing 2. Molding
Pizza Manufacturing Continue…
 Pizza sauce Ingredients
Black
pepper Tomato Ketchup Vinegar

Red chili Xanthum Orange

dry Salt gum color

 Pizza sauce procedure

Mixing
(2min)

Cooking
(30 min)
Pizza Manufacturing Continue…
 Pizza topping ingredients

Capsicum Tomato Cheese

Chicken tikka Black olive Pizza sauce

Pizza Manufacturing Continue…

Pouring
Pizza Pizza
Molding pizza
dough topping
sauce

Proofing
De Cooling Baking (15 to 20
(8-12 min,
panning (few min)
240-250˚C) min, 35 to
40˚C)

Polishing
(using oil at Packaging
edges )
Hygiene conditions

 Consideration is given to proper sanitation and

cleaning conditions
 Hygiene of workers
 Sanitization of industry
 Environment

 Inspection of workers
Conclusions

 Report is integration of our practical and theoretical

efforts that we have done in industry

 Report tells all the details of processes being

exercised in the industry

Questions