CEREALS AND BREAD

Design of packaging material,

equipment and storage.

SUBMITTED BY-
AKSHITA(CH15502)
ANJALI(CH15504)
ANKIT(CH15505)
ANUJ(CH15506)
INTRODUCTION
• CEREALS
Cereals belong to the monocot families ‘Gramineae’ and
are cultivated widely to obtain the edible components of
their fruit seeds.
These fruits are called ‘caryopsis’ and are structurally
divided into endosperm, germ, and bran.
Cereal grains are cultivated in huge quantities and provide
more food energy than any other type of crop, therefore,
they are known as staple crops.
• BREAD
Bread is usually made up from wheat flour and water, by
baking.
Staple food and one of the oldest man made foods, having
been of significant importance since the dawn of
agriculture.
The virtually infinite combinations of different flours and
differing proportions of ingredients has resulted in wide
variety of types, shapes, sizes, and textures available
around the world.
PACKAGING CONSIDERATION
AND SELECTION
The packaging must contain and preserve a certain quantity of
product as efficiently as possible and must protect its content
from external threats including spoilage, breakage, damage from
external environmental conditions and theft.

Primary, secondary and tertiary packaging must be designed so

that the product stays in perfect conditions until it reaches its
end users.
LEVEL OF PACKAGING
PACKAGING CONSIDRATION & SELECTION

• Choosing packaging materials for cereal products should be

related to the major indices of cereals, which include loss of
crispness, lipid oxidation and nutrient loss.
• Protection against environmental conditions like humidity,
temperatue etc
• Packaging material should be able to withstand mechanical
hazards during transportation and facilitate stacking several
tiers high so as to optimize the use of available space.
• To protect the content from spoilage
• To protect the content from insect infestation
• Easy to handle
• Economical and easily available
PACKAGING MATERIAL
Paper, paperboard, and printed fiberboard

• Most cereals are packaged with paper-board materials

made from wood fibers.
• Microflute corrugated paperboards have good strength,
excellent shock absorbing ability, good aesthetic
appearance and print properties.
• White board in suitabe for food and is coated with LDPE,
PVC or wax.
Plastic films

• Biaxially oriented films are widely used

• Films are coated with other polymers or aluminium to
improve the barrier properties or to impart heat stability.

Metals
• Rarely used for cereals and products due to cost, despite
of perfect barrier properties, convinience and extreme
strength
• Aluminium is non toxic, protects from sun damage
PACKAGING EQUIPMENTS
1. BAGS – manufacturing, filling and closing

• Pre-fabricated wrapper that only needs product and closure to

complete the pack
• Useful for handfilling operations
• These are of many types-

i. Paper bags – flat, gasseted, self opening, and rose bottom.

Made in various types and weights according to size, weight
and purpose. Sulphite papers, particularly the machine
glazed paper bags are used where strength is essential.
ii. Film bags – provide more protection than paper bags While
some films give visibility to the product. Films such as LD or
HD polyethylene may be extruded in tubular form.
Bag filling and closing equipments-
There are 4 operations involved in bagging:
1. Feeding the flat bag to loading ppint
2. Opening the bag and keepind it open
3. Loading the product
4. Making the closure
2. Cartoning-

3 main operations are used

i. Forming or erecting – material may be fed to the carton forming
point as a continuous web
ii. Loading or filling – in the continuous web fed and top loading
system tha container has only one face open at the moment of
filling
iii. Closing or sealing
When forming, filling and closing must be carried out on one machine
in a single operation, fully automatic machinery is used. The division
between semi-automatic or fully automatic machines relates
principally to how the filling or loading of the carton is carried out.
Storage of cerials
• Grain storage is carried out basically to maintain the quality of
grain after harvest
• 2 methods for storing the cereals-
1. bag storage
2. loose in bulk storage
• Different regions of Asia and Africa have different climatic
conditions, local construction materials and traditional storage
systems.
• Modern system can be classified on the bases of storage
structure or container, facilities of loading and unloading and
method for controlling the storage atmosphere
These systems are—
•  bagged storage system
• silo storage system
• airtight storage system
• aerated storage system
• low‐temperature storage system
• controlled atmosphere storage systems
• damp grain storage system with chemicals.
BREAD
Basic requirements for packaging-
1. Be attractive and maintain shelf life
2. Run on automatic machinery
3. Be strong
4. Inexpensive
5. An adequate moisture barrier
6. Protects the shape of the bread
• Packaging material—
Aluminium foil because of its compatibility and resistance,
hygiene, durability, strength, multi-mode heating, sustainability,
good presentation.

• Types of packaging techniques—

1. Modified atmosphere packaging (MAP)-
CO2 and N2 are the most common gases in gas
packaging. Nitrogen is effective if residual O2 percentage is
low. CO2 is soluble in water and fat producing carbonic
acidand lowers the pH of product. In this, the antimicrobial
effect may be lost if headspace oxygen concentration
increases by 0.5-1%
2. Vacuum packaging –
This involves evacuating most of the oxygen (less than 1%).
Low oxygen concentration prevents the growth of aerobic
organisms and reduces the rate of oxidative rancidity.

3. Flushing with inert gases—

Nitrogen is the inert gas and is used as the filler gas. It can
delay the oxidative rancidity in low water activity products. It
has also brought improvements in barrier properties of
packaging material and in sealing performance.
Use of this technique has doubled or trippled the shelf life of
bread.
Other types of packaging materials
• Flexible packaging (laminates, wrappers) – most common
method providing tear tape at the top which opens like a
thread .

• Display boxes – flexible packets arranged in display boxes

manually then the boxes are shrinked wrapped

• Vertical pouches – bread pieces are arranged in trays to

prevent any damage at the ease to handle and store.

• Polybags – these polybags are tied through twist and tie bands
or stickers. Majority of white bread available in market is
stored in this.
Storage of bread
Bread actually goes stale faster in the refrigerator than at room
temperature. Best way to store bread-
1. Wrap the bread in plastic or aluminium foil to keep it from
drying out and getting hard.
2. Keep yhe bread at room temp for not more than 2 days where
room temp shoud be around 20 degree celcius. Keep it away
from direct sunlight
3. Freeze the extra bread because drop in the temperature will
stop the starch from crystallising and getting stale.
4. Don’t put the bread in refrigerator because it will draw out the
moisture and bread will become stale 3 times faster than it woul
do at room temp.
5. Thaw frozen bread at room temperature. Crisp in the oven or
toaster to restore crustiness.