Food Production - Assignment

Topic name :- Bread Faults

Group members :
Mohd. Imran Ansari - 1741103105
Nav Kiran Virdi - 1741103106
Nayanika Chakraborty - 1741103107
Neha Kumari - 1741103108
 Food Production - Assignment

Bread Faults
Introduction :-
To understand the concept of bread faults we first need to understand what
is bread and the process of bread making.
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Bread is a food consisting of flour that is moistened, kneaded into dough,
and often fermented using yeast, and it has been a major sustenance since
prehistoric times. Not only is it an important source of carbohydrates,
it’s also portable and compact, which helps to explain why it has been
an integral part of our diet for thousands of years. Basically, it’s a paste
of flour and water, cooked over or surrounded by heat.
Did you know the invention of fluffy breads was actually an accident?

In the prehistoric times the breads that were made were actually flatbreads.
One day an Egyptian woman made the flour and water mixture and forgot
to pack it inside. The mixture was left overnight on the table. The next day
the woman, amazed with the volume of the dough, tried baking it. After
baking, came out, a fluffy loaf of bread. The people back then thought it
was a miracle. They started preparing the mixture and leaving it overnight
to let the magic happen overnight. It was much later that the thing they
actually considered magic was actually yeast. Yeast, which was present in
the air, helped the mixture to rise up which led to the perfect dough for a
fluffy, risen-up bread loaf. And thus, the tradition of mixing yeast to the
mixture of flour and water, to make the perfect fluffy bread, started.

History of BREAD
Recent evidence indicates that humans processed and consumed wild
cereal grains as far back as 23,000 years ago in the Upper Paleolithic
period. From the Neolithic period 9500 BC simple stone mechanisms were
used for smashing and grinding various cereals to remove the inedible
outer husks and to make the resulting grain into palatable and versatile
food.

As humans evolved we mixed the resulting cracked and ground grains with
water to create a variety of foods from thin gruel, to a stiffer porridge. By
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simply leaving the paste to dry out in the sun, a bread-like crust would be
formed.

This early bread was particularly successful when wild yeast from the air
combined with the flour and water, this started a fermentation process
which slightly raised the crust. These ancient breads would however be
unpredictable depending on the type of grain, the flour texture, the liquid,
the availability of wild yeast and especially the weather.

 Breads in Egypt

The Egyptians were curious why the effect of the bread ‘rose’ and
attempted to isolate the yeast, to introduce directly into their bread. They
also found that they could take a piece of dough from one batch and save it
for the next day’s batch of dough, this was how the origin of sourdough
came about and is a process still used today.

Records also show that the Egyptians were baking bread as far back as
2500 years ago and sometimes paid their officials with good bread.

The Egyptian hieroglyphics above read:

"let me live upon bread and barley of white my ale made of grain red".

 Roman Empire with Breads

Baking flourished in the Roman Empire from as early as 300 BC but it

wasn’t until 168 BC that the first Bakers Guild was formed, within 150 years
there were more than three hundred specialist pastry chefs in Rome.

The whole craft was incorporated in a guild of bakers - COLLEGIUM

PISTORUM - and was of so high repute in the affairs of the state that one
of its representatives had a seat in the Senate. The ruins of Pompeii and
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other buried cities have revealed the kind of bakeries that existed in those
historic times.

The Romans enjoyed several kinds of bread, with interesting names.

Lentaculum, made originally flat, round loaves made of emmer, (a cereal
grain closely related to wheat flour) with a bit of salt were eaten. There was
also oyster bread (to be eaten with oysters); 'artolaganus' or cakebread;
'speusticus' or 'hurry bread', tin bread, Parthian bread and the Roman Style
Slipper Loaf

Breads were made richer by adding milk, eggs and butter, but only the
wealthy and privileged could afford these. The Egyptian grammarian and
philosopher Athenaeus, who lived in the 3rd century A.D., has handed
down to us considerable knowledge about bread and baking in those days.

He wrote:

“the best bakers were from Phoenicia or Lydia, and the best bread-makers
from Cappadocia.”

 Breads in Ancient Greece

In ancient Greece, keen rivalry existed between cities as to which produced

the best bread. Athens claimed the laurel wreath, and the name of its
greatest baker, Thearion, has been handed down through the ages in the
writings of various authors.

During the friendly rivalry between the towns, Lynceus sings the praises of
Rhodian rolls.

“The Athenians', he says, 'talk a great deal about their bread, which can be
got in the market, but the Rhodians put loaves on the table which are not
inferior to all of them.

When our guests are given over to eating and are satisfied, a most
agreeable dish is produced called the "hearth loaf", which is made of sweet
things and compounded so as to be very soft, and it is made up with such
an admirable harmony of all the ingredients as to have a most excellent
effect, so that often a man who is drunk becomes sober again, and in the
same way, a man who has just eaten is made hungry by eating of it.”
The island of Cyprus had a reputation for good bread.
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The tradition of Bread Making -

The bread making process originated in ancient times. The basis of the
operation is to mix flour with other ingredients, for example, water, fat, salt
and some source of aeration followed by baking. As long ago as 2,000 BC
the Egyptians knew how to make fermented bread. The practice was to use
a little old dough, or leaven, to "start" the new dough. These two dough
were mixed together and allowed to ferment (rise) for some hours before
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baking. They made an astonishing 50 varieties of bread, paid wages with
bread, and painted bread making scenes in their tombs.
A variety of methods have since been developed in making leaven. The
Baker's Patent required the fermentation of hops and scalded malt for at
least two to three days.
In the early 1900's it was discovered that traditional long fermentation times
could be reduced from 18 to 3-4 hours by the use of very small amounts of
certain chemicals, called oxidants, in bread or flour. Oxidants, when added
to dough, not only speed up the process but also produce a superior loaf.

History of Bread Production in New Zealand

Bread was the subject of many of New Zealand's earliest food regulations
such as the Sale of Bread Act and Bread Ordinance in 1863. At the turn of
the century, seventy bake houses were established in the Canterbury
Settlement, which were mostly family businesses and baked through the
night.
In those days, dough was mixed in a wooden trough by plunging arms into
the mixture, punching and kneading it until all ingredients were mixed. This
task required considerable strength.
Ovens have developed dramatically since the first European settlers used a
camp oven ( a round cauldron) which stood over the hot embers of an open
fire. Early bakeries used small 'beehive' direct fired ovens heated by
lighting a fire in them. When the oven was hot enough the fire was drawn,
or taken out and the batch inserted.
With the help of technology, bread baking methods have changed
considerably. Most of the tedious manual work associated with bread
baking has now been eliminated.
In New Zealand there are two main processes for making bread. One of
these is called the Bulk Fermentation (BF) method and the other the
Mechanical Dough Development (MDD) method. In the BF method, the
mixed dough is left to rise for approximately two hours until it is ready to be
divided into loaf size pieces. It is then given a final rising and baked, In the
MDD method, the dough is mixed at very high speeds and has higher
levels of some essential ingredients. This cuts down the amount of time the
dough needs to rise from two hours to ten minutes. The dough is then
divided, molded into loaf size shapes, given a final rising and baked. About
80% of the bread made in New Zealand is made by the MDD method.

How was bread first made?

According to history, the earliest bread was made in or around 8000 BC in
the Middle East, specifically Egypt. The quern was the first known grinding
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tool. Grain was crushed and the bakers produced what we now commonly
recognize in its closest form as chapatis (India) or tortillas (Mexico). ...
Booze and bread, people.
The science behind bread making :-

Bread is the product of baking a mixture of flour, water, salt, yeast and
other ingredients. The basic process involves mixing of ingredients until the
flour is converted into a stiff paste or dough, followed by baking the dough
into a loaf.
The aims of the bread making processes used in New Zealand (mechanical
dough development, bulk fermentation and no-time dough are to produce
dough that will rise easily and have properties required to make good bread
for the consumer.
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To make good bread, dough made by any process must be extensible

enough for it to relax and to expand while it is rising. A good dough is
extensible if it will stretch out when pulled. It also must be elastic, that is,
have the strength to hold the gases produced while rising, and stable
enough to hold its shape and cell structure.
Two proteins present in flour (gliadin and glutenin) form gluten when mixed
with water. It is gluten that gives dough these special properties. Gluten is
essential for bread making and influences the mixing, kneading and baking
properties of dough. When you first start to bake bread, learning to mix the
ingredients is very important.
Bread making involves the following basic steps:
Mixing ingredients
Rising (fermentation)
Kneading
Second Rising
Baking
Cooling

The bread making ingredients :-

To form a perfect dough for the perfect loaf of bread there are 3 very
important things. They are -
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 Enzymes
 Starch
 Yeast
This is how the above three elements are important-

Enzymes
Enzymes are proteins which catalyze, or speed up, biological reactions.
Several enzyme catalyzed reactions occur during bread making. First,
starch has to be broken down into sugar. The sugar then has to be broken
down into simple sugars to allow yeast to react with these sugars during
the process called fermentation (rising).

Starch
Starch belongs to a group of chemical compounds called carbohydrates.
Pure dry starch is a white granular powder. Wheat flour contains 70-73%
starch and most commonly anywhere between 8 -14.5% protein.

Yeast
Yeast belongs to the fungi family. It is a very small single cell micro-
organism. Like all other fungi it doesn't have the power to produce food by
photosynthesis. Instead it ferments carbohydrates (sugars) to produce
carbon dioxide and alcohol which gives bread it's texture, colour and
aroma.
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TYPES OF BREAD

There are three main kinds of bread in the

world:
 those that rise highest and so have to
be baked in pans,
 those with a medium volume, like rye
and French breads, and
 those that hardly rise at all and
consequently are called flatbreads.
Whole meal bread
Whole meal and wheat meal breads are
popular. Any bread containing whole meal
flour can be called ‘whole meal’ as long as the
percentage of whole meal flour is shown in the
ingredient list as it is the characterizing
ingredient of the bread.
Processing of these differs in two ways from that of white bread. During
mixing the amount of water added to make an optimum dough consistency
needs to be increased because the bran in the whole meal absorbs more
water. The dough is weaker because the bran particles break up the strong
protein bonds in the bread dough, and this weakens the dough structure.
This means the dough could collapse when it rises. Extra protein, called
gluten, is added to make the dough stronger and stop it collapsing.
Whole meal bread contains higher concentrations of minerals and vitamins
than white bread as it retains the bran and germ of the wheat.
It is an excellent source of dietary fiber, containing twice that of white bread
and more than multigrain breads.
Multigrain and kibbled Bread
Mixed or multigrain breads are made from a
mixture of whole meal, white or rye flour and
may contain wheat germ, honey, gluten, non-
fat milk solids, cracked and whole grains of
wheat and other cereals such as rye, oats,
corn, barley, rice millet and triticale.
A wide choice of multigrain breads can be
achieved by blending various grains,
vegetable pieces, nuts, seeds, fruit and spices.
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There are "light" and "heavy" multigrain breads.
"Light" multigrain's have an openness similar to white bread, with small
kibbled grains, oats or other wheat mixed through the bread.
"Heavy" multigrain breads are characterized by small volume, dense
texture and a high grain content.
"Light" breads are similar to white bread in terms of composition, whereas
"heavy" breads are similar to or denser than whole meal bread.
Multigrain bread contains whole grains of different types. Kibbled bread
contains kibbled grain which is grain that has been broken into smaller
pieces. Many types of grain can be added to the bread including rye,
barley, oats, corn, millet, soya, alfalfa and rice. The grain should be soaked
in water for several hours before mixing because unsoaked grain in bread
is hard enough to break teeth. This bread also needs extra protein (gluten)
to make the dough stronger and hold up the extra weight of the grains.
Rye Breads
Rye bread is a whole meal bread made from rye or a mix of rye and wheat
flour. It was originally developed in Europe and is made in a wide variety of
styles and shapes.
Rye flour is different from ordinary flour. It contains only small amounts of
dough strengthening proteins, therefore producing weak dough. Rye flour
also has more amylase enzyme which breaks down starch into sugars.
Rye dough's are made with less water than dough from ordinary flour, so
they are stiff and keep their shape. Molding, proving and baking also need
to be modified to handle the weak, sticky dough. As with most grain and
meal breads, some white flour or gluten can be used to improve the dough
strength.
The traditional way of making this bread includes several proving stages to
raise the acidity and kill the amylase. This stops the bread being doughy
and sticky. The sour dough method is the most popular means of making
bread the traditional way.
Fruit Bread
Fruit breads use a normal bread recipe to which fruit and often sugar are
added. Popular fruits used are raisins, currants, dates, orange peel and
dried fruits such as apricots. Hot cross buns, eaten at Easter, and many
fruit breads, also have spices added. Ingredients used to enhance
appearance and flavor of breads include cinnamon, nutmeg, egg wash and
sugar/water wash.
If you would like to learn more about the nutritional properties of these
types of bread then click through for information on the Nutritional
Properties of Bread, which is included in the Nutrition section.
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Now to understand the concept of bread faults another thing u need to
know is, 'What do you mean by "Good Bread"?'
There are few parameters by which a professional judges the quality of the
breads. Those parameters are as follows.
1. Volume
2. Bloom of crust/shine
3. Colour of crust & crumb
4. Texture and structure
5. Shape
6. Moistness
7. Flavour
8. Taste
9. Oven break etc.
Now we will be discussing about ideal bread according to those parameters
mentioned above.
1. Volume – it has to be considered with the relation to its weight (we can
say specific volume). Too much volume will
make the bread stale or crumbly where as less volume will turn the bread
less flavored and heavy.
2. Bloom of crust/shine – this is a really delicate quality of bread. a dull
bread will reduce the eye appeal of bread
and an artificially shined bread will clearly indicated presence of chemical in
bread which again can be repulsive for
the guests.
3. Colour of crust & crumb – crust colour supposed to be attractive golden
brown. Preferred crumb colours are like
white or light brownish according to the grade of wheat.
4. Texture & structure – crumb texture has to be light, soft, fluffy & consists
of small even gas pocket networks
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(gluten networks). Any unusual hole, damages in crumb should be avoided.
Similarly a smooth, even crust is
desired in good bread.
5. Shape – symmetry in shapes is a characteristic of good quality bread.
6. Moistness – quality of bread is judged by the amount of moisture present
in bread crumb.
7. Flavour – taste of any bakery product could be fully appreciated only
when it is accompanied by matching flavour.
A number of acids, bi-products and alcohols are responsible to produce
right flavour for bread. These products are
generally produced during fermentation only. So it is very important to give
proper fermentation time to get good
breads.
8. Oven break – when open top bread is getting baked, then upper and
side surface crust forms earlier than the
bottom surface. At that stage gas that has produced inside the crumb
escapes out through the part where the crust
yet to form (or you can say weaker part). Escaping of gas also can create
some openings which technically known
as “oven break”.

Some common bread faults

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FAULTS SYMPTOMS REASONS

1. Flying  Here the 1. Inadequately
Tops- top conditioned gluten
also known as crust instead of rising 2. Insufficient proofing
exaggerated break, wild gradually burst open 3. Excessive heat in the
break or flaked crust under the pressure of oven
**************** expanding gas. 4. Lack of diastolic
activity in flour
5. Lack of humidity in
proofing chamber
6. Bread is not covered
during proofing which
may lead to skin
formation
on the top of the bread,
especially in molded
breads like loafs, and
that
skin will give an
unsatisfactory bloom of
the crust
1. Lack of Having blind 1. In an over fermented
shine appearance, less dough gluten will
on the crust/ lack of glossy appearance. loosen its resistance
break shred power and
will have excessive
elasticity; in such a
case gluten will not
produce any
break shred during
baking.
2. An under kneaded
dough
3. Over proofing
2. Condensati Dark colour patches on 1. If the bread is not
on crumb cooled properly before
marks packing some of the
water vapours will
deposit in the crumb.
3. Uneven 1. Over fermented
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texture dough
2. Under fermented
dough
4. Stales/  Rapidly 1. Too cool oven, due
dries drying of to which baking time is
rapidly the crumbs prolonged hence more
evaporation of moisture
2. Too high dough
temperature which
again causes
undesirable
evaporation of moisture
3. Over fermented
dough with open
structure which enables
rapid drying
4. Too tight dough with
less fermentation time
5. Use of milk without
related changes to the
ratio of fat & liquid
6. Excessive use of
mineral improvers.
1. Sticky/ over 1. When flour is milled
moist from sprouted wheat, it
crumb will have excessive
diastolic activity, means
excess formation of
sugar & dextrin which
can
impart gumminess.
2. Excessive humid
proofing chamber.
2. Close/dens  Tight & 1. Using excess milk,
e dense as milk has tightening
crumb crumb effect on gluten.
2. Excessive fat
3. Excessive oxidizing
improvers
4. Over molding
5. Under proofed dough
6. Tight dough
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7. Too high oven
temperature
1. Crumblines  This bread 1. Due to too over or
s of crumbs will under fermented
not slice neatly, and dough.
may break into 2. Too slack dough
fragments by the 3. Too tight dough
pressure of slicer 4. Excessive fat or too
blades low amount of fat
5. Excessive mineral
improvers
6. Low salt content
7. Poor quality of flour
8. Under mixed dough
9. Under baked bread
1. Lack of 1. Too over fermented
colour on dough
crust 2. Insufficient sugar
3. Insufficient salt
2. Too dark 1. Excessive sugar in
crust colour formula
2. Too much diastolic
activity in dough
3. Un ripened
dough/young dough
4. Too high oven
temperature
5. High salt content
6. Too cold temperature
7. Lack of humidity in
the oven
3. Leathery 1. Under fermented
crust dough
2. Used too strong flour
without giving enough
time mature gluten
strands
3. Excessive humidity
in oven or proofing
chamber
4. Too slack dough
4. Blisters  Air bubbles 1. A very humid
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on proofing room can
the crust deposit droplets of
water on the crust of
the bread, that droplet
can increase the
elasticity of gluten due
to
presence of excess
moisture at that point,
which may cause
blisters
during baking.
2. Too slack dough
which is not mixed
properly
3. Air pockets present
in the dough
1. Hard or  Very hard 1. Using too strong flour
flinty crust crust without giving adequate
breaks like an egg shell proofing time.
2. Too tight dough
3. Too much use of
oxidizing improvers
1. Too thick Less amount of oven
crust spring can cause this
problem.
Less amount of oven
spring can happen due
to
1. Lack of diastolic
activity
2. Lack of sugar & fat in
the formula
3. Poor quality or too
strong flour
4. Over fermented
dough
5. Lack of moisture in
the oven
2. Less 1. Too tight a dough
volume 2. Too little or excess
yeast.
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3. Under fermentation
4. Crusting of dough
5. Excessive slat or
sugar
6. Under proving
7. Too less amount of
salt
8. Over or under mixed
dough
3. Excessive 1. Too slack a dough
volume 2. Lack of oven
temperature
3. Lack of salt
4. Too much of yeast
5. Excessive proving
6. Loose molding
4. Holes and  Elongated This happens if some
tunnels holes or gluten strands get
tunnels in damaged, they also try
crumb to damage
all neighboring gluten
strands, until gluten
starts to coagulate
under the
action of heat. Reasons
for damaging gluten
strands may be:
1. Too soft flour.
2. Too strong flour with
high yeast content.
Actually too strong flour
needs
to be fermented for
longer period to
condition the gluten
properly,
otherwise gluten
strands break because
of the excess gas
produced by
the extra yeast.
3. If enriching
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ingredients (like milk,
eggs, fat) are not mixed
properly or
form lumps in dough.
These lumps can
create extra pressure
on gluten
strands in order to
damage them.
4. Too hot oven sole
forces the lower part to
set faster, but the inner
part of
dough will still rise and
create holes.
5. Improper knock
back. Large gas
cell/pockets presents in
dough can
burst during baking to
create this fault. These
large gas pockets need
to
be removed during
knock back.
6. Excess flour that has
used to dust the dough
if folded in flour that
also
can create holes or
tunnels in side.
1. Cores  Hard spots 1. Uneven mixing of
can dough
be felt by touching the 2. Incorporation of
bread crumb small pieces or bits of
dough that has
collected by
scraping the work table
or mixing machine long
time after the main
dough has already set
for fermentation.
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3. Sometimes if dough
was not covered with a
damp cloth during
fermentation, skin
forms on the dough.
This skin can create
this problem
if mixed in to the dough.
1. Seams  Dense 1. Too hot or too cold
moist bread mould can arrest
layer on the outer the activity of yeast of
crumb area, especially the
near the top crust. This area of the dough
faults happens only to which is in contact with
molded or tinned the mould.
loaves. 2. Weight of dough is
more than the capacity
of the mould.
3. Careless handling of
a final proved dough
4. Disturbing the
position of bread mould
too much in oven.
1. Sourness 1. Over fermentation
2. Excess yeast
3. Less amount of salt
4. High room or proving
chamber temperature.