Diploma in Production of

Value Added roducts from

.Cereals, Pulses' and
••........ - .•.. -

Oilseeds
(DVPCPO)
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The Diploma programme on "Production of Value Added

Products from Fruits and Vegetables" has been developed
by the School of Agriculture, Indira Gandhi National
Open University, New Delhi under the project "Open
Learning Interventions for Development of Customized
Open Learning Education/Training Packages for
Development of competent and productive Human
Resources for Food Processing" Sponsored by the
Ministry of the Food Processing Industries, Government
of India.

"Education is a liberating force, and in

our age it is also a democratising force,
cutting across the barriers of caste and
class, smoothing out inequalities imposed
by birth and other circumstances. "

\ - lndira Gandhi
 Indira Gandhi BPVI-034
t®J
~ National Open University
School of Agriculture Baking and Flour
Confectionery

PRACTICAL MANUAL
EXPERIMENT 1
Determination of Flour Colour/Dullness of Flour By
Flour Colour Grader 5

EXPERIMENT 2
Determination of Gluten Content in Wheat 8

EXPERIMENT 3
Determination of Falling Number 11

EXPERIMENT 4
Determination of Dough Raising Capacity 13

EXPERIMENT 5
Preparation of Bread and Its Evaluation 15

EXPERIMENT 6
Determination of Effect ofIngredients - Yeast, Fat and Sugar 22

EXPERIMENT 7
Effect of Additives, Potassium Bromate, Ascorbic Acid,
Cereal Malt and Fungal u-amylaste; Gluten; Glycerol
Mono Stearate (GMS); Sodium Stearoyl-2-Lactylate (SSL);
Diacetyl Tartaric Acid Esters of Monoglycerides (DATEM)
and Guar Gum 26

EXPERIMENT 8
Different Bread Making Methods-Straight Dough, Sponge
and Dough, Activated Dough Development 32

EXPERIMENT 9
Preparation of Variety Bakery Products-Buns, Rusk,
Rolls, Doughnuts, Pizza, Puff Pastry 38

EXPERIMENT 10
Baking of Biscuits 46

EXPERIMENT 11
Determination of Effect of Ingredients-Sugar, Fat, Gms,
Starch, Lecithin 50

EXPERIMENT 12
Baking of Cakes-Sponge Cake and Decoration 55
PROGRAMME DESIGN COMMITTEE
Prof. Panjab Singh, vc Shri A.N.P. Sinha, Addl Secretary
Banaras Hindu University, Varanasi Ministry of Food Processing Industries,
New Delhi - I 10049
Dr. S.M. Jlyas, VC
A N Dev University, Dr. N.C. Saha, Professor & Head
Faizabad - 224229 Laboratory Division, lIP, Mumbai-400093
Dr. Satish Bal, Dept. of F & AE
Sh. Kumar Bhatia
lIT, Kharagpur .,..721302
Former MD, National Seeds Corporation Ltd.
Pusa, New Delhi -110012
Dr. C.K Teckchandani, Dean,
Agri. Engg. Dr. G. Yenkateswara Rao, Head, ISMBCT
JNKVV, JabaJpur- 482004 CFTRT, Mysore - 570020
Dr. R.R Lal, IIPR
Dr. M.M. Krishna Kanpur - 208024
Former CMD, Modern Food Industries
India Ltd., New Delhi Dr. B.O. Kaushik
IARI, Pusa, New Delhi -110012
Dr. P. Haridas Rao
Former Head, ISMT & Bakery CFTRI, Sh. B.B. Pattanaik
Mysore MD, National Seeds Corporation Ltd.
Dr. H.V. Narasimha Pusa, New Delhi - 110012
Former Head, Cereal Science CFTRI
Mysore Faculty Members (SOA, IGNOU)
Dr. M.K. Salooja, Professor
Mr. K.K. Maheshwary Dr. S.K. Yadav, Reader
Ministry of Food Processing Industries Sh. Mukcsh Kumar, Lecturer
Khel Gaon Marg Dr. Praveen Kumar Jain, Lecturer
New Delhi - 110049 Dr. Mita Sinhamahapatra, Lecturer
Dr. P. Vijayakumar, Lecturer
Dr. S.K. Saxena, Director Sh. Kumar Bhatia, Sr. Consultant
Centre for Analysis Research and Training Or. D.S. Khurdiya, Sr. Consultant
New Delhi - 110048 Sh. Jaya Raj, Sr. Consultant
Dr. S.D. Kulkarni, Director, CTAE Sh. N.S. Dhama, Sr. Consultant
Bhopal- 462038 Sh, Rajesh Singh, Consultant

PROGRAMME COORDINATORS
Dr. M.K. Salooja and Sh. Kumar Bhatia

BLOCK PREPARATION TEAM

Dr. G. Venkateswara Rao, Editor Dr. D. lndrani
Head, Flour Milling Baking and Scientist, FMBCT Dept.
Confectionery Technology CFTRI, Mysore - 570020
Department, CFTRI
Mrs. Jyothsna Rajiv
Mysore -570020
Scientist FMBCT Dept.
Mrs. M.L. Sudha CFTRI, Mysore - 570020
Scientist, FMBCT Dept.
CFTRI, Mysore - 570020

COURSE COORDINATORS
Dr. M.K. Salooja, Sh. Mukesh Kumar and Sh. Kumar Bhatia

MATERIAL PRODUCTION
Mr. Raj iv Girdhar Ms. Hiteshi Verma
Section Officer (Publications) (VVord Processing)

September, 2006

© lndira Gandhi National Open University, 2006.

ISBN: 81-266-2556-2
All rights reserved. No part of this work may be reproduced in any form, by mirneograph or
any other means, without permission in writing from the Copyright holder.
Further information on the Indira Gandhi National Open University courses may be obtained
from the University's office at Maidan Garhi, New Delhi-1I0 068 or the official website of
fGNOU at www.ignou.ac.in.
Printed and published on behalf of Indira Gandhi National Open University, New Delhi by
Director, School of Agriculture.
Laser typeset by : Rajshree Computers, V-166A, Bhagati Vihar, Uttam Nagar, New Delhi-l l 0059
Paper Used: Agrobased Environment Friendly
Printed at : Younl! Printing Press, 2626. Lane No. 7, Bihari Colony, Shahdara, 0elhi'1l0032
BPVI-034 BAKING AND FLOUR
CONFECTIONARY
This course is designed to make you familiar with some basic quality characteristics
of wheat flour and practicals for the preparation of bread, biscuits and cakes as well
as methods for making varieties of other bakery products. The twelve experiments
have been divided in three types.

The first part deals with experiments relating to physical characteristics of flour like
sieve analysis and colour and chemical characteristics offlour like gluten, falling
number and dough raising capacity.

The second part deals with test baking of bread, effect of ingredients and additives
on the quality of bread, different bread making methods, variety breads and variety
of bakery products like buns, rusk, rolls, doughnuts, pizza and puff pastry.

The third part the test baking of biscuits and the effect of ingredients, baking of
sponge cakes and their decoration, bar cake, cup cake and plum cake have been
described.

Objectives
After reading this course and carrying out the experiments set for you to do, you
should be able to:

• understand the physical and chemical characteristics of flour

• understand the effect of ingredients and additives on quality of various bakery

products like bred, buns, rusk, rolls etc.

• estimate the baking requirements of cakes and similar products.

Study Guide
The Practical Course involves 10 counselling sessions (4 hours each) of intense
work. During the counselling the guided and unguided experiments will be performed
by the students.
The practical evaluation shall be done under two components: (i) guided experiments
and (ii) unguided experiments. The guided experiments shall be performed during
the counselling sessions under the guidance of the counsellors. The unguided
experiment shall be undertaken by the students in the last session. For unguided
experiment, student shall hot be provided any guidance while performing the
experiments(s).
Both the components will be evaluated. The weightage of70 per cent will be assigned
to guided experiments and 30 per cent is for unguided experiments. Each experiment
performed by the student would be evaluated. The student performance would be
assessed by the counsellors covering various aspects like manipulative skills,
observation and their understanding ofthe basic concepts related to the experiment.

Laboratory Note Book

An important part of your scientific training is the maintenance of a complete and up
to date record of your laboratory work. For writing and reporting the experimental
data, a notebook of 50 pages is required that is available in market.
You should prepare tables for recording the data as given in the manual. For, each
experiment, you should write down the type of sample, title of the experiments to be
conducted, procedures, observations and results.
EXPERIMENT 1 DETERMINATION OF
FLOUR COLOUR!
DULLNESS OF FLOUR
BY FLOUR COLOUR
GRADER
Structure
1.1 Introduction
Objective

1.2 Experiment
Principle
Requirements
Procedure
Observations
Results

1.3 Precautions

1.1 INTRODUCTION
Millers and bakers desire a quick method and a simple method for measuring the
colour of flour that is colour as affected by grade and the amount of bran powder
present in the flour; Kent-Jones, Amos and Martin described a direct reading in-
strument with its own empirical scale. The instrument is a re-designed optical sys-
tem and the empirical scale from -5 to +18. Very good high ratio flours have a
minus reading. The higher the figure, the duller the flour and lower the grade. Re-
sults are reported to nearest 0.25 limit. Similar to ash, colour grade value is an index
of extraction rate of flour and gives the extent of bran contamination. It is directly
related to ash content.
Objective
After studying and performing the experiment you should be able to
• determine the extent of bran contamination in the flour.
(Scope: Applicable to wheat flour and atta)

1.2 EXPERIMENT
1.2.1 Principle
A known amount of flour is mixed with certain amount of water to make a suitable
paste which is taken in a standard cell and the light reflected from its surface is
compared with that of a standard surface to determine the colour grade value.
1.2.2 Requirements (Eq uipments/Machinery /Instrument/and
Chemicals/Material)
• Balance (Accurate to O.Olg)
• Kent-Jones and Martin colour grader
• 250 ml beaker
• Glass rod
• Stopwatch 5
Practical Manual
1.2.3 Procedure
• Switch on the instrument 15-20 min prior to reading.

• Check the Galvanometer indicator points to zero, if not make the necessary
adjustments by turning adjust zero control.

• Open sample cell cover of the grader, transfer working reference surface
(W.R.S) into the position with its frosted surface outward. Carefully close the
cover.

• Turn the thumbwheel to bring the galvanometer indicator to the WRS value.
The instrument is standardized.

• Check that the front face of the glass cell is clean and perfectly dry.

• Weight out 30g of flour sample into a 250mL beaker.

• Measure 50mL of water and add to flour.

• Mix water and flour immediately with a glass rod for 45 sec.

• Hold the sample cell '\t a slight angle, frosted side uppermost, and carefully
pour-in the paste upto a level between the two marked lines.

• This will ensure that any air bubbles in the mixture will rise away from the
measured surface of the cell.

• Open the sample cell cover and remove the W.R.S and place the sample cell in
the position.

• Close the cover arid turn the thumb wheel to bring the galvanometer indicator
back to zero.

• Read the colour grade value from the main dial.

• The time of test from the commencement of mixing to the reading is 90-120
sec.

1.2.4 Observations
Note the colour of the flour from the main dial of the colour grader and report in
absolute unitless values. Repeat two to three times.

1.2.5 Results
Dullness of flour or flour colour measured using Kent-Jones, Amos and Martin
colour grader is expressed in absolute unitless values.

The approximate range of colour grade values for different types of flours are given
below

Type of flour Colour grade value

High grade patent flours -1.0 to 0.5

Long patent flours 0.5 to 1.25

72% Extraction flours 2.0 to 4.50

80% Extraction flours 5.0 to 7.5

83% Extraction flours 8.0 to 12.5

6
 Determination of Flour
1.3 PRECAUTIONS Colour/Dullness of Flour
By Flour Colour Grader

• See that all the flour is wetted.

• Flour paste should be smooth so as to flow easily.

• The sample cell and holder should be kept clean.

• Wash out the sample cell immediately after a test has been made.

• Test should be performed within 90-120 sec.

• Iflonger time is taken over the test, the grade value will be rather on the higher
side.

7
 EXPERIMENT 2 DETERMINATION OF
GLUTEN CONTENT
IN WHEAT
Structure

2.1 Introduction
Objective

2.2 Experiment
Principle
Requirements (EquipmentslMachinery/lnstrumentland Chemicals/Material)
Procedure
Observations
Results

2.3 Precautions

2.1 INTRODUCTION
The strength of the flour is associated with the amount of gluten present in the flour.
The dough obtained by mixing wheat flour with water possesses the characteristics
of viscosity. Plasticity and elasticity which are significant during handling the dough
as well as in its end performance. These properties are due to the interaction of
water soluble proteins of wheat with water. The albumins, globulins and other smaller
proteins as well as starch are washed along with water leaving behind a cohesive,
elastic and rubbery mass called as "Crude wet gluten". Colour of the gluten varies
from pale yellow to greenish grey. Weaker gluten generally have yellow colour,
while strong gluten will have deeper greenish colour. Gluten from strong wheat are
generally extensive and elastic. Hydrated glutenin and gliadin differs in their mechanical
property. Gliadin is viscous, sticky mass which is extensible; while glutenin is tough,
rubbery elastic mass. Gliadin is more extensible, but less elastic. Gluten exhibits the
properties of both the components.

Objective
After studying and performing this experiment, you should be able to
• Determine the gluten content.
(Scope: It is applicable to wheat flour, semolina and atta)

2.2 EXPERIMENT
2.2.1 Principle
Gluten ina sample offlourcan be estimated by hydrating the flour with water and
later washing the dough free of starch, sugars, water soluble proteins and other
minor components. The wet cohesive, visco elastic mass obtained is referred to as
wet gluten while the dried product obtained from it is referred to as dry gluten.
2.2.2 Requirements (Equipments/MachinerylInstrument/and
Chemicals/Material)
• Hot air oven
• Aluminium dishes/petri plates (small)
8 • Analvtical balance (least count 0.001 g)
• Dessicator Determination
Content
of Gluten
in Wheat

• Aluminium foil

• Plastic bowl

• Measuring cylinder

• Glass rod

• Fine sieve

2.2.3 Procedure

• Weigh out 25g flour into a plastic bowl.

• Add lSmL water, mix to get a dough ball.

• Immerse the dough ball in water for one hour to ensure proper hydration.

• Wash out the starch by kneading gently in a gentle stream of water over a fine
sieve.

• Continue washing till the washed out liquid is clear.

• Squeeze the washed water into clean water.

• If water turns turbid, continue washing.

• The cohesive mass obtained is called wet gluten

• After pressing as dry as possible place in a petri dish containing a small piece of
aluminium foil.

• The wet gluten so obtained is dried in a hot air oven at 100DCfor 24 hr.

• Weigh the gluten to constant weight.

• The dried gluten is called as dry gluten.

2.2.4 Observations

Weight of flour taken 2Sg

Let the weight of empty petri dish wash WI

Weight of petri dish + wet gluten W2

(before drying)

Weight of petri dish + dry gluten W3

(After drying)

Wet gluten (%)

25

Dry gluten (%) WfW1 x 100 - B

25 •

On 14% moisture basis

9
Practical Manual
Wetgluten(%)= 100 -14 X A
100 - IM

Dry gluten (%) = 100 - 14 x B

100 - IM

Where IM - Moisture content of flour

A- Wet gluten content

B - Dry gluten content

2.2.5 Results
Calculate gluten content (wet and dry) using the above formulae. The results are
displayed along with the moisture basis. Wet gluten for good bread flour falls in the
range ofJO- 36%. Dry gluten for good bread flour falls in the range of 10-12%.
While biscuit and cake flour has dry gluten in the range of7 -10.0%.

2.3 PRECAUTIONS
I' 'r

• Never touch the petri plates with wet hands.

• The dough ball should be completely immersed in water for one hour.

• Dough ball should be washed till it is completely free of starch.

• Wet gluten to be pressed as dry as possible before taking the weight.

• Wet gluten to be dried to constant weight.

10
EXPERIMENT 3 DETERMINATION OF
FALLING NUMBER
Structure
3.1 Introduction
Objective

3.2 Experiment
Principle
Requirements (Equipments/Machinery/lnstrumentiand Chemicals I Material)
Procedure
Observations
Results

3.3 Precautions

3.1 INTRODUCTION
Wheat flour contains different enzymes which are important in bread making. Diastatic
enzymes which include both a-amylase and ~amylase produce sugars during
fermentation by hydrolyzing starch. These sugars are consumed by yeast to produce
carbon-di-oxide (C02) and alcohol. The amount of CO2 gas produced depends
on the sugars formed which in turn are influenced by the enzymes present. The CO2
gas produced is responsible for the leavening ofthe dough. The optimum amount of
these enzymes is desired for good quality bread. The excess enzymes as found in
rain damaged wheat, produces sticky dough and bread with dark crust colour and
sticky crumb. Flour with low level of enzyme produce bread with poor loaf volume
and dull crust colour. Falling number gives an idea about enzyme activity in flour.

Objective

After studying and performing this experiment you should be able to

• Determine the soundness of grain with respect to germination and estimate the
a-amylase activity.

(Scope: It is applicable to wheat flour and atta)

3.2 EXPERIMENT
3.2.1 Principle
The time in seconds required to stir and allow a viscometer stirrer to fall a fixed
distance through a hot aqueous flour suspension being liquified by the enzyme in a
standardized apparatus.

3.2.2 Requirements (EquipmentslMacbinerylInstrument/and

Chemicals / Material)
• Falling number apparatus from Falling Number, Sweeden

• Kamas/Udy-Lyc1onemill

• Balance (Accurate to O.Olg)

• 25 ml pipet, 1I
Practical Manual

3.2.3 Procedure
• Fill water bath to water level control fixed at 1 inch below cover.

• Put on the heater of falling number apparatus and allow water to boil.

• Pipette out 25 mL water into the falling number tube.

• Weigh 7g of flour into the tube.

• Insert rubber stopper and shake the tube in upright position 10 times.

• Scrape the flour and suspend in water with viscometer stirrer.

• Place the tube in falling number water bath and start the timer.

• The stirrer automatically stirs the flour suspension for 60 sec.

• After 60 sec. the stirrer is released on top of the gel.

• The stirrer slowly falls down depending upon the enzyme activity.

• The apparatus gives a buzzer sound and records the time on the completion of
the stirrer falling a fixed distance through the liquified gel.

• Repeat till the data are within ± 20 sec.

• Falling number is inversely proportional to alpha amylase activity of flour.

3.2.4 Observations

Falling number = x sec.

Falling number = 100-14 x x

(on 14% moisture basis) 100-IM

Where IM is moisture content of the sample.

3.2.5 Results
Calculate falling number using the above formula. Results are displayed along with
the moisture basis.

3.3 PRECAUTIONS
• Sample to be weighed accurately

• Water to be pippeted out exactly

• Flour water to be mixed in upright position for 10 times uniformly

• Test to be performed only when the water has started boiling

• Tube dimensions and weight of the stirrer are significant variables in FN test

12
EXPERIMENT 4 DErrERMINATION OF
DOIJGH RAISING
CA-PACrfY
Structure
4.1 Introduction
Objective

4.2 Experiment
Principle
Requirements (Equipments/Machinery/lnstrumentJand Chemicals I Material)
Procedure
Observations
Results

4.3 Precautions

4.1 INTRODUCTION
When dough is made by mixing flour, yeast, sugar and water and packed in a cylin-
der, expansion takes place. The raise in dough for a particular period is indicative of
its gas retaining property. This property in turn depends on both quantity as well as
the quality of protein present in flour,

Objective

After studying and performing this experiment you should be able to

• Determine the dough raising capacity of flour that is suitability of yeast for
satisfactory fermentation,

(Scope: Applicable to wheat flour)

4.2 EXPERIMENT
4.2.1 Principle

Yeast both dry and compressed differs in their ability to produce carbon-di-oxide in
dough. The difference in abilities is due to the difference in activities. The activity of
a yeast sample further depends on the strain, processing and storage conditions.
Dough raising capacity of yeast determines the suitability of yeast for a satisfactory
fermentation.
4.2.2 Requirements (Equipments/Machinery/Instrument/and
Chemicals/Material)

• Balance (Accurate to 0.01 g)

• Plastic bowl

• 500mL measuring cylinder

• Wooden stick

• Watch glass / petriplate

13
Practical Manual
4.2.3 Procedure

• Accurately weigh the following ingredients as given in the table

Wheat flour 100g
Sugar 1.5g

Baker's yeast (compressed) 4.00 g

or or
Baker's yeast (dried) 1.00g

Water 55mL

• Dissolve sugar and disperse yeast using specified amount of water

• Add to the flour and make a dough ball
• Pack the dough into a 500 mL measuring cylinder without any air bubble
• Cover the cylinder with a watch glass/petri plate and keep for 1hr at 27°C
• Note the initial reading
• Note the final reading after one hour

4.2.4 Observations

Dough raising capacity B - A x 100

A

Where A Height of the dough before fermentation

B = Height of the dough after one hour offermentation

The material shall be deemed to have satisfied the test, if the raise in level is atleast
80% of the original for dry yeast and 110% for compressed yeast.

4.2.5 Results
Calculate dough raising capacity using the above formula. Results are displayed
along with type of yeast used in the experiment.

4.3 PRECAUTIONS
• If dried yeast is used, it should be dispersed using luke warm water.
• Dough should be kneaded well and should be free oflumps.
• Dough to be packed in the measuring cylinder without any air bubbles.
• Cylinder should be covered so that the upper layer ofthe dough does not get
dried.
• Reading in the measuring cylinder to be taken for the upper most raise of the
dough.

14
EXPERIMENT 5 PREPARATION OF
BREAD AND ITS
EVALUATION
Structure
5.1 Introduction
Objective

5.2 Experiment
, Principle
Equipments
Procedure
Evaluation
Results

5.3 Precautions

5.1 INTRODUCTION
One of the advantages of bakery products is its amenability to produce varieties
with different taste and texture. Hence, several varieties of breads are produced
world over. These varieties are produced either by (i) Adding newer ingredients (ii)
Changing the processing conditions (iii) Varying shape and size (iv) Altering the
ingredient level etc. The varieties available in India are very few. Hence, there is a
great scope of diversity, by producing different varieties, keeping in view the palate
of the Indian consumer. This would help the industry to grow, on the right path.
Some of the varieties of breads that could be produced in the country are whole
wheat bread, brown bread, fruit bread, milk bread, composite flour bread, therapeutic
breads etc.
Whole wheat bread is produced using whole wheat flour (atta). The bread is not
only nutritious but also has typical wheat aroma. Whole wheat flour requires more
water to prepare the dough in view of higher water absorption capacity of bran. In
the preparation of whole wheat bread lesser fermentation time of 45-60 min and
additives like potassium bromate or ascorbic acid, sodium stearoyl-2-lactylate,fungal
alpha amylase and dry gluten are required.
Brown bread is normally made by mixing wheat flour (maida) and whole wheat flour
(atta) in the ratio of 50:50. The processing conditions and additives used are the
same as whole wheat bread. The volume of brown bread is generally better than
whole wheat bread. Incorporation of malt extract or brown sugar improves colour
and flavour of bread.
Fruit bread is made by sponge and dough method and about 20% of fruits are
added in the dough stage. The formulation is the same as sweet bread.

Milk bread is prepared using sweet bread formulation and should contain atleast
6.0 milk solids. Generally 6.0% skimmed milk powder is added. Addition of milk
improves the nutritional quality ofbread.

Objective
After studying and performing this experiment, you should be able to
• know the formulation and processing conditions for the preparation of whole
wheat bread, brown bread, fruit bread and milk bread. 15
Practical Manual
5.2 EXPERIMENT
5.2.1 Principle
Preparation of four varieties of bread namely whole wheat bread, brown bread,
fruit bread and milk bread and evaluation for crust and crumb characteristics.

5.2.2 Requirements

• Mixer having capacity for j-4kg dough.

• Cabinet for fermentation and proofing dough capable of maintaining constant

of30oC and 75-85% relative humidity.

• Sheeter and moulder.

• Baking pans - test baking pans and pans to bake 400g bread.

• Baking oven capable of maintaining temperature of 220°C .

• Thermometer: dough testing: - capable of reading to 50°C with graduations to

0.1 QC, oven testing:- capable from lOO-260°C

• Tuner.

• Loaf volume measuring device.

• Balances: coarse and fine (0.1 and 0.001 g respectively), scoops, spatulas,
pipets, graduated cylinders, bowls etc.

• Chemicals: Ascorbic acid, calcium propionate, glacial acetic acid, sodium

stearoyl-z-Iactylate, fungal alpha amylase.

• Ingredients: Wheat flour, whole wheat flour, salt, sugar, compressed yeast, fat
(dalda), dry gluten powder, tuity fruity, skimmed milk powder.

5.2.3 Formulation
A. Whole wheat bread
Ingredients (%) (g)
Whole wheat flour 100 1000

):east(compressed) 3 30

Salt 1.5 15

Sugar 5.0 50

Fat 3.0 30

Sodium stearoyl-2-laytate (SSL) 0.5 (2.0gpaste) 5 (20g paste)

Dry gluten powder 3.0 30

Fungal alpha amylase 0.001 0.01

Ascorbic acid 0.02 0.2

Calciurn propionate 0.3 3.0

Glacial acetic acid 0.1 1.0

Water 73-75 730-750

16
 Preparation of Bread
5.2.4 Procedure and Its Evauation

• Weigh the ingredients accurately.

• Dissolve yeast, salt, calcium propionate separately in part of total water and
add to mixing bowl.

• Place whole wheat flour, fat, SSL paste, dry gluten powder, fungal alpha
amylase, ascorbic acid chemical and acetic acid into mixing bowl. Use the
dough hook and mix the dough at speed I for 2-3min and at speed II for 4-5
min. If necessary stop mixer before optimum development to scrape down
sides of the bowl. Remove dough from the bowl and round it to smoothen
the surface.

• Place the dough into a greased bowl, cover a wet cloth and let it ferment in
the fermentation cabinet maintained at 30oC, 75% RH for 60 min.

• . Remix or knock back the fermented dough, divide the dough into 165g (2
Nos.), 450g (2 Nos.), round the dough and relax for 10-15 min.

• Sheet the dough and mould into a cylindrical shape.

• Place 165g and 450g moulded dough pieces into well greased test baking
pans and bread pans with lid respectively.

• Proof the 165g dough for 55 min and 450g for about 40-50 min (till the
dough surface touches the rim)

• Bake 165g dough open type and 450g dough with closed lid for 25 min at
220°C.

• Remove breads from the pan and cool on the rack.

• Pack the breads in polypropylene bags for evaluation, the next day.

B. Brown bread

Ingredients (%) (g)

Wheat flour 50 500

Whole wheat flour 50 500

Yeast, compressed 3 30

Salt 1.5 15

Sugar 5.0 50

Fat 3.0 30
/
/ Sodium stearoyl-2-lactylate (SSL) 0.5 (2.0g paste) 5.0 (20g paste)

Dry gluten powder 2.0 20

Fungal alpha amylase 0.001 0.01

Ascorbic acid 0.01 0.1

Calcium propionate 0.3 3.0

Glacial acetic acid 0.1 1.0

Water 70-72 700-720

17
 Practical Manual
Procedure

• Weigh the ingredients accurately.

• Dissolve yeast, salt, sugar, calcium propionate separately in part of total water.

• Place whole wheat flour, wheat flour, fat, SSL paste, dry gluten powder, fungal
alpha amylase, ascorbic acid, chemical and acetic acid into mixing bowl. Mix
the dough using the dough hook and at speed I for 2-3 min and at speed 11for
4- 5 min. If necessary stop mixer before optimum development to scrape down
sides of the bowl. Remove dough from the bowl and round it to smoothen the
surface.

• Place the dough into a greased bowl, cover with a wet cloth and let it ferment in
the fermentation cabinet maintained at 30°C, 75% RH for 60 min.

• Remix or knock back the fermented dough, divide the dough into 165g (2
Nos.) 450g (2 Nos.), round the dough and relax for 10-15 min .
•
• Sheet the dough and mould into a cylindrical shape.

• Place 165g and 450g moulded dough pieces into well greased test baking pans
and normal bread pans with lid respectively.

• Bake 165g dough open type and 450g dough with closed type for 25 min at
220°C.

• Remove the breads from the pan and cool on the rack.

• Packthe breads in polypropylene bags for evaluation, the next day.

C. Fruit bread

Ingredients (%) (g)

Wheat flour 100 ieoo

)'east(compressed) 2.25 22.5

Salt 1.5 15

Sugar 20 200

Fat 3.0 30

Glycerol monosterate (GMS) 0.5 (2.0g paste) 5 .(25g paste)

Calcium propionate 0.3 3~0

Glacial acetic acid 0.1 1.0

Water 58-60 580-600

Tuity fruity 20-25

Procedure

• Weigh the ingredients accurately.

• Dissolve yeast, salt, sugar, calcium propionate separately in part of total water.

• Place wheat flour, fat, GMS paste, acetic acid into mixing bowl. Mix the dough
18 using the dough hook at speed I for 2-3 min and at speed 11for 4-5 min. If
 Preparation of Bread
necessary stop mixer before optimum development to scrape down sides of the
and Its Evauation
bowl. Remove the dough from the bowl and round it to smoothen the surface.

• Place the dough into a greased bowl, cover with a wet cloth and let it ferment in
the fermentation cabinet maintained at 30DC, 75% RH for 90 min.

• Mix the fermented dough and fruits in a mixer for about 3 min or till the fruits are
uniformly distributed, divide the dough into 165g (2 Nos.), 450g (2 Nos.), round
the dough and relax for 10-15 min.

• Sheet the dough and mould into a cylindrical shape.

• Place 165g and 450g moulded dough pieces into a well greased test baking pans
and normal bread pans with cover respectively.

• Proof the 165g dough for 55 min and 450g dough for about 45-50 min (till the
dough surface touches the rim).

• Bake 165g dough open type and 450g dough with lid for 25 min at 220DC.

• Remove breads from the pan and cool on the rack.

• Pack the breads in polyprolyene bags for evaluation, the next day.

D. Milk bread

Ingredients (%) (g)

Wheat flour 100 1000
Yeast (compressed) 2.25 22.5
Salt 1.5 15
Sugar 20 200

Fat 3.0 30

Glycerol monosterate (GMS) 0.5 (2.5g paste) 5 (25gpaste)

Skimmed milk powder 6.0 60

Calcium propionate 0.3 3.0
Glacial acetic acid 0.1 1.0

Water 60-62 600-620

Procedure

• Weigh the ingredients accurately.

• Dissolve yeast, salt, sugar, calciwn propionate, skimmed milk powder separately
in part of total water.

• Place wheat flour, fat, GMS paste, acetic acid into mixing bowl. Mix the dough
using the dough hook at speed I for 2-3 min and at speed II fo(.4-5 min. If
necessary stop mixer before optimum development to scrape down sides of the
bowl. Remove the dough from the bowl and round it to srrtoothen the surface.

• Place the dough into a greased bowl, cover a wet cloth and let it ferment in the
fermentation cabinet maintained at 30DC, 75% RH for 90 min.

19
Practical Manual • Remix or knock back the fermented dough divide the dough into 165g (2 Nos.),
450g (2 Nos.), round the dough and relax for 10-15 min.
• Sheet the dough and mould into a cylindrical shape.
• Place 165g and 450g moulded dough pieces into a well greased test baking pans
and normal bread pans with lid respectively.
• Proof the 165g dough for 55 min and 450g dough for about 45-50 min (till the
dough surface touches the rim).
• Bake 165g dough open type and 450g dough with closed lid for 25 min at 220°C.
• Remove breads from the pan and cool on the rack.

• Pack the breads in polyprolyene bags for scoring next day.

5.2.5 Bread evaluation

PROFORMA FOR EVALUATION OF BREAD
Name: Date:
Sample No.
Parameters
1 2 3 4 5
Crust
Colour
Shape
Symmetry
Crumb
Colour
Grain
Texture
Eating quality
Overall quality

Quality description Desirable Undesirable

Crust
Colour Golden brown Dark brown, Pale brown
Shape Normal Uneven, flat
Symmetry Symmetrical Low end, protruding, flat,
uneven
Crumb
Colour Whitish, creamish white Brownish white, brown, dull
Grain Fine, Uniform, thin cells Thick cells
Texture Soft Hard, dry, crumbly
Taste Typical Foreign
Mouthfeel No residue Gummy, doughy
Rating Excellent Satisfactory
Very good Fair
Good Poor
Very poor
20
 Preparation of Bread
5.2.6 Results and Its Evauation

(i) Weigh whole wheat breads, brown breads, fruit breads and milk breads
s~parately.

(ii) Measure volume (ml) and calculate specific volume (mllg).

(ill) Evaluate breads for crust and crumb characteristics.

5.3 PRECAUTIONS
• Weigh the additives accurately using electronic balance.

• U se finely ground, good quality whole wheat flour for preparation of whole
wheat bread.

The following are the characteristics of

Whole wheat bread

Slightly dark brown crust colour, brownish crumb colour and typical wheaty aroma.

Brown bread

Slightly dark brown crust colour, light brown crumb colour, mild wheaty aroma.

• U se fresh tuity fruity for preparation of fruit bread.

• Use calcium propionate and glacial acetic acid in bread making only when you
want to keep the breads for a week.

2}
 EXPERIMENT 6 DETERMINATION OF
EFFECT OF
INGREDIENTS - YEAST,
FATAND SUGAR-
Structure
6.1 Introduction
Objective

6.2 Experiment
Principle
Equipments
Procedure
Evaluation
Results

6.3 Precautions

6.1 INTRODUCTION
Yeast is one of the essential ingredients in a bread formulation. Yeast performs three
important functions in a bread formulation. These are leavening, dough ripening and
flavour development. Yeast utilizes sugar to produce carbon dioxide and ethyl alcohcl.
Along with ethyl alcohol yeast also produces several other organic compounds such
as organic acids, aldehydes, ketones etc. that impart typical flavour to bread.

Fat is an optional ingredient in a bread formulation and used at the level of 1 to 3 % in

bread making. It is thought that fat lubricates the gluten fibrils and make the dough
more extensible there by improving the gas retention capacity ofthe dough during
mixing. Addition of fat facilitates dough handling and processing, improves loaf volume,
crumb grain uniformity, tenderness, slicing properties and shelflife.

Sugar's main function is to provide food for the yeast. Even though adequate carbon
dioxide gas production can be maintained with 2-3% sugar, higher levels are normally
used in bread formulations. Sugars that are unfermented by yeast appear as residual
sugars in the finished bread. Residual sugars contribute to the development of crust
colour and flavour formation by taking part in caramelization and Maillard reactions.
Sugar provide sweet taste in bread if used above 6%.

Objective

After studying and performing this experiment, you should be able to

• understand the role of ingredients, optimum level of ingredients in bread making,

the effect of adding either low or excess amount of ingredients on the quality of
bread.

6.2 EXPERIMENT
6.2.1 Principle - Preparation of breads by varying yeast fat
and sugar
In bread making, use of optimum amount of ingredients is essential for producing
22
good quality bread. Use of either low or high amount has an adverse effect on the
quality of bread. In this experiment, the control bread is prepared using 2% yeast, Determination of
Effect of Ingredients-
1% fat and 2.S% sugar. The variations are yeast (O.S and S%), fat (0 and 4%) and Yeast, Fat and Sugar
sugar (0 and 12%). The processing conditions are as per test baking method.

6.2.2 Requirements
• Mixer having capacity for SOOg dough

• Cabinet for fermentation and proofing doughs capable of maintaining temperature

onoDc and 7S-8S% relative humidity.

" Sheeter and molder

• Baking pans

o Baking oven capable of maintaining temperature of 220°C

o Thermometers: dough testing:- capable of reading to SOoC with graduations to

O.I°C, oven testing'- capable from lOO-260°C

•• Timer

• Loaf volume measuring device

• Balances: coarse and fine (0.1 and 0.001 g respective) scoops, spatulas, pipets,
graduated cylinders, bowls etc.

• Ingredients: wheat flour, yeast (compressed), salt, sugar, fat (dalda)

6.2.3 Formulation

Experiment
1 2
I 3 4 I 5 6 7

Yeast(%) Fat (%) Sugar(%)

Ingredients Control 0.5 5.0 0 4 0 12

Flour 100 100 100 100 100 100 100

Yeast 2 0.5 5.0 2 2 2 2

Salt 1.0 l.0 1.0 1.0 1.0 1.0 1.0

Sugar 2.5 2.5 2.S 2.S 2.5 0 12

Fat 1 1 1 0 4 1 1

Water .Variable

Processing conditions Ingredients

Control Variations
Mixing 4min Yeast(%) 2 0.5 and 5.0
Fermentation 90min Fat (%) 1 Oand4
Remixing l min Sugar(%) 2.S o and 12

Fermentation 2Smin

Sheet & Mould

Proof 55min

Bake 25 min.at 2200C 23

Practical Manual 6.2.3 Procedure

• Weigh the ingredients accurately in duplicate given in the formulation.

• Dissolve yeast, salt and sugar separately in part of total water and add into
mixing bowl.

• Place flour, fat, yeast suspension, salt and sugar solution into mixing bowl.
Use the flat blade and mix until the dough is developed (3-4 min). ifnecessary,
stop mixer before optimum development to scrape down sides of bowl.
Remove dough from the bowl and round it to smoothen the surface.

• Place the dough into a greased bowl and let it ferment in the fermentation
cabinet maintained at 30°C, 75% RH for 90 min.

• Remix or knock back the fermented dough for 1 min.

• Allow second fermentation of25 min.

• Sheet the dough and mould into a cylindrical shape.

• Place moulded dough piece into well greased pan.

e Proof the dough for 55 min at 30°C and 85% RH.

• Bake at 220°C for 25 min.

• Remove from the pans and cool on the rack.

• Pack the bread in polypropylene bag for evaluation, the next day.

6.2.5 Evaluation

PROFORMA FOR EVALUATION OF BREAD

Name: Date:

Parameters Sample No.

1 2 3 4 5

Crust

Colour

Shape

Symmetry

Crumb

Colour

Grain

Texture

Eating quality

Overall quality

24
 Determination of
Quality description Desirable Undesirable
Effect of Ingredients-
Yeast, Fat and Sugar
Crust
Colour Golden brown Dark brown, Pale brown
Shape Normal Uneven, flat
Symmetry Symmetrical Low end, protruding, flat, uneven
Crumb
Colour Whitish, creamish white Brownish white, brown, dull
Grain Fine, Uniform, thin cells Thick cells
Texture Soft Hard, dry, crumbly
Taste Typical Foreign
Mouthfeel No residue Gummy, doughy
Rating Excellent Satisfactory
Very good Fair
Good Poor
Very poor
6.2.6 Results
• Weigh bread loaf (g)
• Measure volume (ml) by rapeseed displacement method
• Calculate specific volume
• Evaluate bread for crust and crumb characteristics by following the proforma.

• The following will be the characteristics of bread due to addition of

Low amount of yeast - very low vol ume , closed crumb grain and hard texture.

High amount of yeast-high volume, pale crust and coarse crumb grain.

0% fat - low volume, slightly coarse crumb grain and slightly

5% - High volume, medium fine cnunb grain, and very soft texture

0% sugar - Very low volume, pale crust, closed grain and hard texture

12% sugar - High volume, medium fine crumb grain, soft texture and sweettaste+

6.3 PRECAUTIONS
• Sift the flour to remove any foreign particles

• Weigh the ingredients accurately

• Salt and yeast should not come in direct contact

• Preheat fermentation cabinet and baking oven

• Check to ens~e that the bread samples are correctly labelled

The ratio of weight of compressed: dry: instant yeast is 1:0.6:0.3, add 2.0g of
compressed yeast or 1.2g of dry yeast or 0.6g of instant yeast.

25
 EXPERIMENT 7 EFFECT OF ADDITIVES,
POTASSIUM BROMATF,
ASCORBIC ACID, CEREAL
Ml-\LT AND FUNGAL
a-AMYLASE; GLUTEN;
GLYCEROL MONO
ST~EARATE(GMS);
SODIUM STEAROYL-2-
LACTYLATE (SSL);
DIACETYL TARTARIC
ACID ESTERS OF
MONO GLYCERIDES
(DATE.M) AND GUAR GUM.
Structure
7. 1 Introduction
Objective

7.2 Experiment
Principle
Equipments
Procedure
Evaluation
Resu 1ts

7.3 Precautions

7.1 INTRODUCTION
Additives are substances that are intentionally added to food in smaller quantities,
with a view to improve the functional performance of the raw materials, the processing
characteristics, the appeal, palatability, quality of baked products and the .torage
stability. The various additives that are commonly used in bread making are oxidizing
agents (potassium bromate or ascorbic acid); enzyme (fungal a-amylase); Surfactants /
emulsifiers (glycerol monostearate--GMS, sodium stearoyl-2-lactylate-SSL, diacetyl
tartaric acid esters of mono glycerides-DATE M) and gums (gaur gum).

Oxidizing agents are used by the baker to improver dough strength. Due to the
oxidizing action SH-groups in the gluten network will be transformed into -S-S bonds
between the protein chains rendering a stronger gluten network. They will improve
dough handling for better machining and contribute to improved gas retention, giving
better volume and a more regular grain of the crumb. As per PFA standard potassium
bromate up to 20 ppmand ascorbic acid upto 200 ppm are used in flour meant for
bread.

Wheat flour contain two enzymes namely alpha amylase and beta amylase. Alpha
amylase enzyme converts damaged or gelatinized starch granules to dextrins. Beta
amylases converts dextrins to maltose. The action of alpha and beta arnylases provide
a continuous source of maltose sugar during the fermentation process. This maltose
26
 Effect of Additives. Potassium
supplements the sugar that is utilized by the yeast for the production of carbon dioxide Bromate, Ascorbic Acid,
and also adds to the residual sugar in the finished product for the production of good Cereal Malt and Fungal
CL-amylase; Gluten; Glycerol
crust colour. Generally, Indian wheat flours are deficienf in alpha-amylase. It has to Mono Stearate (GMS);
be added during bread making to improve the gassing power of the flour. The Sodium Stearoyl-2-Lactylate
(SSL); Diacetyl Tartaric Acid
sources of alpha amylase are malted barley flour, fungal or bacterial sources. PFA Esters of Monoglycerides
pelmits use of malt flour but no limit is fixed while PFA permits use of fungal alpha (DATEM) and Guar Gum

amylase at 0.01 % (Max.) level.

Emulsifiers or surfactants are widely used in bread, biscuit, cake and other bakery
products. They are thought to complex with the protein and starch portions of the
viscoelastic wheat flour dough and to strengthen the extensible gluten starch film.
They also reduce the rate of crumb firming during storage. The advantages of using
surfactants are increased volume, more tender crust and crumb, brighter crumb colour,
finer crumb grain, increased softness and ease of slicing.

Gums are characterized by their ability to give high viscous solutions at low
concentration. Gums find use in bread and other bakery products. The gums are
reported to increase about 3-4% ofthe water required for dough making and hence
give increased yields, greater resilience and drier dough. The final baked product
are said to have softer texture as well as longer shelflife. PFA permits guar gum at
not more than 0.5% of the flour weight and hydroxy propyl methyl cellulose in bread.

Objective

After studying and performing this experiment, you should be able to

• understand the role of additives in bread making, level at which additives are
used, improvement in bread brought about by additives.

7.2 EXPERIMENT
7.2.1 Principle
Preparation of breads using different additives like oxidizing agents, alpha amylase
enzyme, surfactants and gum and evaluation for weight, volume, crust and crumb
characteristics.

7.2.2 Requirements
• Mixer having capacity for 500g dough
• Cabinet for fermentation and proofing doughs capable of maintaining temperature
onooc and 75-85% relative humidity.
• Sheeter and molder
• Baking pans
• Baking oven capable of maintaining temperature of 220°C
• e
Thermometers: dough testing: - capable of reading to 500 with graduations to
O.l°C, oven testing:- capable from lOO-260°C

• Tuner
• Loafvolume measuring device
• Balances: coarse and fine (0.1 and 0.001 g respective) scoops, spatulas, pipets,
graduated cylinders, bowls etc.
• Ingredients: wheat flour, yeast (compressed), salt, sugar, fat (dalda)
27
N
OQ .,,.,.,
"C

-
....
::.
.,
s:

7.2.3 Formulation
.,=
c

Control Oxidizing agents Alpha amylase enzyme Surfactaots Gum

Ingredients
and Potassium Ascorbic Cereal Fungal GMS SSL DATE M Guar
additives bromate acid malt alpha amylase (0.5%) (0.5%) (0.5%) gum
(15PPM) (lOOPPM) (0.5%) (lOOppm) (0.5%)
Experiment 1 2 3 4 5 6 7 8 9

Wheat flour 100 100 100 100 100 100 100 100 100

Yeast 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Salt 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

Sugar 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

Fat 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

Water 64 62.5 62.0 64.0 64.0 62 62.5 62.5 58

Potassium bromate - 1.5 - - - - - - -

Ascorbic acid - - 2.0 - - - - - -

Cereal malt - - - 0.5 - - - - -

Fungal alpha amylase - - - - 0.01 - - - -

GMSgel - - - - - 2.5 - - -

SSLgel - - - - - - 2.0 - -

::>ATEMgel - - - - - - - 2.0 -
Guar gum gel - - - - - - - - 10.5
Processing conditions Effect of Additives, Potassium
Bromate, Ascorbic Acid,
4min Cereal Malt and Fungal
Mixing: a-amylase; Gluten; Glycerol
Monn.Stearate (GMS);
Fermentation: 90 min (30oC, 75% RH) Sodium Stearoyl-2-Lactylate
(SSL); Diacetyl Tartaric Acid
Remixing: l min Esters of Monoglycerides
(DATEM) and Guar Gum
Fermentation: 25min

Sheet and mould

Proof: 55 min (30°C, 85% RH)
Bake: 25 min (220°C)

Additives

Oxidising agents

Potassium bromate

Dissolve 1OOmgof potassium bromate in water and make up to IOOml. Add I.5ml
of potassium bromate solution ip experiment 2.

Ascorbic acid

Dissolve 500mg of ascorbic acid in water and make upto 100 m1. Add 2ml of
ascorbic acid solution in experiment 3.

Surfactants

Preparation of Glycerol monostearate (GMS) gel

The ratio ofGMS :water is 1:4. Boil water, add GMS and stir nicely until you get a
smooth gel without any lumps. Add 2.5g of this gel in experiment 6. 2.5g of added
gel contains 0.5g ofGMS and 2.0 ml water. Subtract 2.0 ml of water from total
water in experiment 6.

Preparation of sodium stearoyl -2-lactylate (SSL) gel or diacetyl tartaric

acid esters of monoglyceride (DATEM) gel

The ratio ofSSLor DATEM:wateris 1:3. Boil water, add SSLIDATEM and stir to
a gel consistency. Add 2.0g of this gel in experiment 7. 2.0g of added gel contains
0.5g of SS LID ATE M and l.5ml water. Subtract I.5ml of water from total water in
experiment 7.

Hydration of guar gum

Mix together O.Sg of guar gum and 1Oml water. Hydrate it for 1 hr. Add the entire
amount (1 0.5g) in experiment 9. Subtract 1Oml water from total water (68ml) in
experiment 9. The total water (Extra 4% water due to addition of gum) in this
experiment is 68%. Addition of 0.5% guar gum results in an increase in water
absorption by 4%.

7.2.4 Procedure

• Weigh the ingredients accurately in duplicate given in the formulation.

• Dissolve yeast, salt and sugar separately in part of total water and add into
mixing bowl.

29
. Practical Manual • Place flour, fat yeast, suspension, salt and sugar solution and additives (l.5ml
potassium bromate solution in experiment 2, 2.0ml ascorbic acid solution in
experiment 3, O.5gof cereal malt inexperiment-l, O.Olg offungal alpha amylase
in experiment 5, 2.5g ofGMS paste in experiment 6, 2.0g ofSSL paste in
experiment 7, 2.0g of DATE M paste in experiment 8, 1O.5g of hydrated guar
gum in experiment 9) into mixing bowl. Use the flat blade and mix until the
dough is developed (3-4 min). If necessary stop mixer before optimum
development to scrape down sides of the bowl. Remove dough from the bowl
and round it to smoothen the surface.

• Place the dough into a greased bowl and let it ferment in the fermentation
cabinet maintained at 30°C, 75% RH for 90 min.

• Remix or knock back the fermented dough for 1 min.

• Allow second fermentation of25 min.

• Sheet the dough and mould into a cylindrical shape.

• Place moulded dough piece into well greased pan.

• Proof the dough for 55 min at 30°C and 85% RH.

• Bake at 220°C for 25 min.

• Remove from the pans and cool on the rack.

• Pack the bread in polypropylene bag for evaluation, the next day.

7.2.5 Bread evaluation

PROFORMA FOR EVALUATION OF BREAD

Name: Date:

Sample No.
Parameters
1 2· 3 4 5

Crust

Colour

Shape

Symmetry

Crumb

Colour

Grain

Texture

Eating quality

Overall quality
30
 Effect of Additives, Potassium
Quality Desirable Undesirable Bromate, Ascorbic Acid,
Cereal Malt and Fungal
description a-amylase; Gluten; Glycerol
Mono Stearate (GMS);
Crust Sodium Stearoyl-2-Lactylate
(SSL); Diacetyl Tartaric Acid
Colour Golden brown Dark brown, Pale brown Esters of Monoglycerides
(DATEM) and Guar Gum
Shape Normal Uneven, flat
Symmetry Symmetrical Low end, protruding, flat, uneven
Crumb

Colour Whitish, creamish white Brownish white, brown, dull

Grain Fine, Uniform, thin cells Duck cells
Texture Soft Hard, dry, crumbly
Taste Typical Foreign
Mouthfeel No residue Gummy, doughy
Rating Excellent Satisfactory
Very good Fair
Good Poor

Very poor

7.2.6 Results
i) Weigh bread loaf (g)

ii) Measure volume (ml) by rape seed displacement method. Calculate specific
volume (mlIg)

iii) Evaluate bread for crust and crumb characteristics by following the proforma.

7.3 PRECAUTIONS
• Weigh the additives accurately using electronic balance.

31
 EXPERIMENT 8 DIFFERENT BREAD
MAKING METHODS-
STRAIGHT DOUGH,
SPONGE AND DOUGH,
ACTIVATED DOUGH
DEVELOPMENT
Structure
8.1 Introduction
Objective

8.2 Experiment
Principle
Equipments
Procedure
Evaluation
Results

8.3 Precautions

8.1 INTRODUCTION
There are several methods of making bread of which the straight dough and the
sponge and dough methods are the main conventional methods. These methods are
commonly practiced in may commercial bakeries. During the past few decades a
number of alternatives for the traditional bread making methods have been intro-
duced. The no time dough mrhods, such as mechanical dough development and
chemical dough development methods are popular and were developed to make
the bread production continuous, produce good quality bread from soft flours and
reduce the processing time.

The straight dough method is a single step process in which all the dough ingredients
are mixed into a single batch.

In sponge and dough method total fermentation is divided into two stages. The
major fermentation takes place in a preferment called the sponge. The sponge
normally consists of 50 to 70% of the total flour, total yeast, yeast food and part of
the total water. The sponge is subsequently combined with the rest of the dough
ingredients to receive its final physical development during the dough mixing.

Activated dough development method is a no-time dough method of bread making.

The dough is developed using-chemicals during the mixing stage. In this method
cleavage of disulphide bonds is achieved by using reducing agents such as cysteine
hydrochloride. Formation of.new disulphide bonds is accelerated by the use of
oxidants like potassium bromate and ascorbic acid. After mixing the dough is given
a flour time of30-40 min. and.other operations are the same as followed for con-
ventional methods.

Objective

After studying and performing. this experiment, you should be able to

• prepare breads based on straight dough, sponge and dough and activated dough
32
development methods.
 Different Bread Making
8.2 EXPERIMENT Methods-Straight
Dough, Sponge and
Dough, Activated Dough
Development
8.2.1 Principle
Breads are prepared based on straight dough, sponge and dough and activated
dough development methods and evaluated separately for weight, volume, crust and
crumb characteristics.

8.2.2 Requirements

• Mixer having capacity for SOOgdough.

• Cabinet for fermentation and proofing dough capable of maintaining constant

temperature onoDc and 7S-80% relative humidity.

• Sheeter and moulder.

• Baking pans.
• Baking oven capable of maintaining temperature of 220°C.

• Thermometers: dough testing- capable of reading to SOoCwith graduations to

O.l°C, oven testing:- capable from lOO-260°C.

• Timer
• Loaf volume measuring device.

• Balances: coarse and fine (0.1 and O.OOlg respectively scoops, spatulas, pi-
pets, graduated cylinders, bowls etc.)

• Chemicals: Potassium bromate, ascorbic acid, cysteine hydrochloride.

• Ingredients: Wheat flour, salt, sugar, compressed yeast, fat, (dalda).

8.2.3 Formulation

A. Straight dough method

Ingredients (%)

Wheat flour 100

Yeast, compressed 2

Salt 1.S

Sugar S

Fat 3

Water variable

8.2.4 Procedure

• Weigh the ingredients accurately in duplicate given in the formulationA.

• Dissolve yeast, salt and sugar separately in part of total water.

• Place flour, fat, yeast suspension, salt and sugar solution into mixing bowl. Use
the flat blade and mix until the dough is developed (3-4 min). If necessary stop
mixer before optimum development to scrape down sides of bowl. Remove
dough from the bowl and round it to smoothen the surface. 33
Practical Manual • Place the dough into a greased bowl, cover a wet cloth and let it ferment in
the fermentation cabinet maintained at 30oC, 75% RH for 90 min.

• Remix or knock back the fermented dough for 1 min.

• Allow second fermentation of25 min.

• Sheet the dough and mould into a cylindrical shape.

• Place moulded dough piece into well greased pan.

• Proof the dough for 55 min at 30°C and 85% RH.

• Bake at 220°C for 25 min.

• Remove bread from the pan and cool on the rack.

• Place the bread in polypropylene bag for evaluation, the next day.

8.2.5 Bread evaluation

PROFORMA FOR EVALUATION OF BREAD

Name: Date:

Parameters Sample No.

1 2 3 4 5

Crust

Colour

Shape

Symmetry

Crumb

Colour
Grain

Texture

Eating quality

Overall quality

Quality description Desirable Undesirable

Crust
Colour Golden brown Dark brown, Pale
brown
Shape Normal Uneven, flat
Symmetry Symmetrical Low end, protrud- -
ing, flat, uneven

34
 Different Bread Making
Crumb Methods-Straight
Dough, Sponge and
Colour Whitish, creamish white Brownish white, brown, dull Dough, Activated Dough
Development
Grain Fine, Uniform, thin cells Thick cells
Texture Soft Ifard, dry, crumbly

Taste Typical Foreign

Mouthfeel No residue Gummy, doughy
Rating Excellent Satisfactory
Very good Fair

Good Poor

Very poor

8.2.6 Results
i) Weigh breads prepared using formulation A, B and C separately.

ii) Measure volume (ml) by rape seed displacement method. Calculate specific
volume (ml/g)

iii) Evaluate breads for crust and crumb characteristics by following the proforma.

8.3 PRECAUTION
• Weigh the additives accurately using electronic balance.
Sponge and dough method
Ingredients

Sponge Dough
Flour 60 Flour 40

Yeast 1.5 Salt 1.5

Yeast food 0.1 Sugar 5.0

(diammonium hydrogen phosphate) Fat 3.0

Water 36 Water 24
Procedure

.:. Sponge

o Weigh the ingredients accurately in duplicate given in the formulation B.

o Dissolve yeast in part of total sponge water.

6) Place flour, yeast food and yeast suspension into mixing bowl. Use the flat
blade and mix until smooth (2.0 min).
o Place sponge in a bowl, cover it with wet cloth and ferment it for 4 hr .

•:. Dough

o Dissolve salt and sugar in part oftotal dough water.

o Place flour, fat, salt and sugar solution, sponge and mix to optimum develop-
ment(3-4 min).
35
Practical Manual • Round up dough lightly, place in lightly greased bowl. Place bowl in fermentation
cabinet and leave for 30 min.

• After 30 min rest in fermentation cabinet, mould the dough and place in greased
baking pan, seam down.

• Proof the dough for 55 min in fermentation cabinet at 30°C and 85% RH.

• Bake at 220°C for 25 min.

• Remove bread from the pan and cool on the rack.

• Pack the bread in polypropylene bag for evaluation, the next day.

C. Activated dough development method

Ingredients
Flour 100
Yeast 3
Salt 1.5
Sugar 5.0
Fat 3.0
Cysteine hydrochloride 35 ppm (3.5 ml)
Potassium bromate 15 ppm (1. 5 ml)
Ascorbic acid 100 ppm (2ml)
Water

Preparation of reducing agent solution

Cysteine hydrochloride solution

Dissolve 1OOmgof cysteine hydrochloride in water and make up to I OOml.Add 3.5ml

of cysteine hydrochloride solution which corresponds to 35 ppm in the mixing stage of
the dough of fermentation.

Preparation of oxidising agent solution

Potassium bromate solution

Dissolve I OOmgof potassium bromate in water and make up to IOOml. Add I.5ml of
potassium bromate solution which corresponds to I5ppm of potassium bromate in
the mixing stage ofthe dough ofFonnula C.

Ascorbic acid solution

Dissolve 500mg of ascorbic acid in water and make up to IOOml. Add 2ml of ascor-
bic acid solution which corresponds to I OOppm of ascorbic acid in the mixing stage of
the dough ofFonnula C.

Procedure

• Weigh the ingredients accurately in duplicate given in the F ormulation C.

• Dissolve yeast, salt and 'Sugar separately in part of total water.

36
 Different Bread Making
• Place flour, fat, yeast suspension, salt and sugar solution, 3 .5ml of cysteine Methods-Straight
hydrocholoride solution, 1.5rnl potassium bromate solution and 2ml ascorbic Dough, Sponge and
Dough, Activated Dough
acid solution into mixing bowl. Use the flat blade and mix until the dough is Development
developed (3-4 min). If necessary stop mixer before optimum development to
scrape down sides of bowl. Remove dough from the bowl and round it to
smoothen the surface.

• Place the dough into a greased bowl, cover with a wet cloth and allow the
dough to relax for 10-15min (Floor time). Sheet the dough and mould into a
cylindrical shape.

• Place moulded dough piece into well greased pan.

• Proof the dough for 55 min at 300 e and 85% RH.

• Bake at 2200C for 25 min.

• Remove bread from the pan and cool on the rack.

• Pack the bread in polypropylene bag for evaluation, the next day.

37
 -------------------------------------------------.----
EXPERIMENT 9 PREPARATIONS OF
VARIETY BAKERY
PRODUCTS-BUNS, RUSK,
ROLLS, DOUGHNUTS,
PIZZA, PUFF PASTRY
Structure
9.1 Introduction
Objective

9.2 Experiment
Principle
Equipments
Procedure
Evaluation
Results

9.3 Precautions

9.1 INTRODUCTION
Buns
Buns are yeast leavened bakery products possessing soft, spongy, tender texture
with an attractive and appealing golden brown crust colour. The ingredients used for
the preparation of buns are flour, fat, yeast, sugar, salt, skimmed milk powder and
water. The higher percentage offat and sugar used in the recipe imparts greater
softness to the product. The skimmed milk powder gives a good flavour and brown
colour to the buns. A variety of buns can be prepared like fruit buns, potato buns,
cheese buns, burgers, etc.
The steps involved in the preparation of buns are mixing the ingredients to form a well
developed dough, fermentation, remixing, scaling, rounding, proofing and baking.

Rolls
Rolls are of two types either soft or crusty. They should be unsweetened and not
heavily enriched so that they may be eaten with savoury as well as sweet
accompaniments.

Rusks
Rusk is a yeast leavened crisp product, which has been baked twice. It is prepared
by sponge and dough method wherein sponge is made which consists of part of flour,
yeast and water. Then the other dough ingredients like remaining flour, yeast, sugar,
fat, milk powder, water etc. are mixed with sponge to get well developed dough. A
good rusk should have golden brown colour, light crisp textures with fine cells in the
crumb.

Doughnuts
Doughnuts are deep fat fried product. Combination doughnuts are leavened by
baking powder and yeast. The dough is made with the basic ingredients present in
most sweet yeast doughs.
Pizza
Pizza is a flat bread with various toppings. The ratio of pizza crust to its toppings
38 usually is in range of55:45 respectively. The basic formula of pizza includes flour,
 Preparations of Variety
salt, shortening, yeast and water. There are two types of pizza namely thin crust or
Bakery Products-Buns,
cracker type and thick crust or deep dish style. The thickness of approximately 0.3 Rusk, Rolls, Doughnuts,
to 0.6cm is needed for thin and 0.6 to 1 cm for thick crust. The dough for pizza must Pizza, Puff Pastry

have extensibility to be rolled thin and it must also be ale to support the sauce and
toppings placed on the dough before baking.

Puff pastry

These are delicate, flaky products characterized by golden brown colour, light crispy
texture made of several layers. The flour used in puff pastry should be of bread flour
variety with good gluten quality as it is necessary to support the large percentage of
fat used for lamination and also to withstand repeated rolling to form layers of dough
and fat. The fat used is a special type, which should be firm and plastic. In tropical
climates, use of chilled water for the preparation of dough is very important so that
the dough temperature is lower and fat applied over it does not melt. In between the
roll-in-procedure, the dough has to be kept in refrigerator to help the fat remain
intact. The steam released by the moisture in layers of dough and fat begins to push
up as soon as the dough is kept in the oven. Hundreds oflayers of fat and dough pull
off producing laminated flakiness in the product.

Objective

After studying and performing this experiment, you should be able to

• know the formulation and processing conditions for the preparation of buns,
rusk, rolls, doughnuts, pizza and puff pastry.

9.2 EXPERIMENT
9.2.1 Principle
Preparation of buns, rusk, rolls, doughnuts, pizza, puff pastry and evaluation for
crust and crumb characteristics.

9.2.2 Requirements
• Mixer having capacity for 3-4kg dough.
• Cabinet for fermentation and proofmg dough capable of maintaining temperature
of30oC and 75-85% relative humidity.

• Sheeter and moulder.

• Baking trays.
• Baking oven capable of maintaining temperature of200-240°C.
• Thermomter: dough testing:- capable of reading to 50°C with graduations to
0.1 QC,oven testing:- capable from lOO-260°C.

• Timer
• Loaf volume measuring device.
• Balances: Coarse and fine (0.1 and 0.001 g respectively), scoops, spatulas,
pipets, graduated cylinders, bowls etc.
• Chemicals: calcium propionate, glacial acetic acid.
• Ingredients: Wheat flour, salt, sugar, compressed yeast, fat (dalda), puff pastry
fat (lily fat)
39
Practical Manual 9.2.3 Formulation
A. Buns
Ingredients (%) (g)

Flour 100 1000

Fat 10 100

lreast(cornpressed) 3 30
Sugar 20 200

Salt 1.5 15

Skimmed milk powder (SMP) 3 30

Water 60-62 600-620

Procedure

• Weigh the ingredients accurately based on one kg flour.

• Disperse yeast, salt, sugar and SMP separately in part of total water and add
to mixing bowl.

• Place wheat flour, fat and mix the dough using the dough hook and at speed I
for 2-3 min and at speed II for 4-5 min. If necessary stop mixer before
optimum development to scrape down sides of the bowl. Remove the dough
from the bowl and round it to smoothen the surface.

• Place the dough into a greased bowl, cover a wet cloth and let it ferment in
the fermentation cabinet maintained at 30°C, 75% RH for 60 min.

• Remix the dough, divide the dough into 65g each, round it and place them en
baking trays leaving sufficient space in between.

• Proof the dough balls for 60-80 min.

• Bake at 220°C for 20 min.

• Cool and pack.

B. Rolls

Ingredients (%) (g)

Flour 100 1000

l'east(compressed) 3.0 30

Sugar 5.0 50

Salt 2.0 20

Refined oil 5.0 50

Eggs (optional) 5.0 50 (lNo.)

Water 55-60 550-600

40
 Preparations of Vari. :y
9.2.4 Procedure Bakery Products-Buns
Rusk, Rolls, D(;.ighnut
~ Weigh the ingredients accurately based on one kg flour. Pizza, Puff Past

o Dissolve yeast, salt, and sugar separately in part of total water and add to
mixing bowl.

o Place wheat flour and fat, refined oil and egg into mixing bowl. Use the dough
hook and mix the dough at speed I for 2-3 min and at speed Il for 4-5 min.
Remove the dough from the bowl and round it to smooth en the surface.

• Place the dough into a greased bowl, cover a wet cloth and let it ferment in the
fermentation cabinet maintained at 30°C, 75% RH for 60 min.

G Remix the fermented dough and divide the dough into 65g pieces.

et Mould into different shape.

• Apply egg or milk wash. Spinkle sesame seeds (optional).

o Proof the dough for 20-25 min, and bake at 220DC for 15 min.

e. Rusk

The formulation for the preparation of rusk is

Sponge ingredients
Ingredients 0/0 (g)
Flour 20 200

'{east (compressed) 0.5 5

Water 10-12 ml 100-120

Dough ingredients
Ingredients 0/0 (g)

Flour SO SOO

'(east (compressed) 1.5 15

Sugar 20 200

Fat 10 100

Salt 1.5 15

Skimmed Milk Powder (SMP) 2 20

Water 4S 460-4S0

Procedure

• Weigh the ingredients accurately based on one kg flour.

• Mix the sponge ingredients and ferment for 1 hr.

• Dissolve yeast, salt, sugar, SMP of dough ingredients in part of total "dough"
water and mix along with SO% of the flour, fat, water, sponge, using dough
hook at speed I for 2-3 min and at speed Ilfor 4-5 min. Remove the dough
from the bowl and round it to smoothen the surface.
41
Practical Manual • Ferment the dough for 30 min.

• Remix and divide into 200g pieces, relax the dough for 10-15 min.

• Mould the dough into cylindrical shape and place it on a rusk tray or baking tray
leaving space in between.

• Proof for 80-90 min.

• Bake for 25 min at 220°C.

• Cool and pack in polypropylene bags for slicing next day

• Slice the rusks using bread slicer, place the pieces in a baking tray and rebake at
150°C for 20-25 min.
D. Doughnuts
Dough ingredients
Ingredients % (g)
Flour 100 1000
Baking powder 1.5 15
Compressed yeast 5 50
Skimmed milk powder 5 50
Sugar 10 100
Shortening 15 150
Salt 10 100
Eggs 5 50 (1 No.)
Vanilla essence As required As required
Lemon essence As required As required

Water 55-60 550-600

Procedure
• Weigh the ingredients based on one kg flour.
• Sift the flour and baking powder twice.
• Dissolve yeast, salt, sugar, in part of total water and mix with rest of the ingredients
to a well developed stage.
• Remove the dough from the bowl and round it to smoothen the surface.
• Place the dough into a greased bowl, cover a wet cloth and let itferment in the
fermentation chamber maintained at 30°C, 75% RH for 60-90 min.
• Remix the fermented dough, relax for 10-15 min and sheet the dough to about
1Omm thickness.
• Cut the sheeted dough with doughnut curter, place the pieces in the baking tray
lightly dustc. I with flour.
• Proof it for 30-40 min and deep fry in fat (dalda) orrefined oil at 185°C 1 min
on each side or until golden brown.
• When doughnuts are cooled, roll in powdered sugar or coat the doughnuts with
fondant icing. The icing should be in warm condition for quick and even drying.
42
 Preparations of Variety
Plain fondant Cocoa fondant
Bakery Products-Buns,
Rusk, Rolls, Doughnuts,
Sugar powder 500 Sugar 500 Pizza, fuff Pastry

Melted fat 15 Cocoa powder 25

Hot water 25-30ml Hot water 50

Melted fat 15

E. Pizza

Ingredients (%) (g)

Flour 100 1000

)(east(compressed) 1 10

Salt 2 20

Sugar 5 50

Fat 3 30

Skimmed milk powder (SMP) 3 30

Eggs (optional) 5 50 (1 No.)

Water 55-60 550-600

Preparation of pizza sause

Chopped onion 750g

Green chillies 4-5 Nos.

Garlic IOg

Ginger 20g

Tomato puree 1700g (2 tins)

Salt 50g

Sugar 50g

Garam masala powder 20g

Black pepper IOg

Cheese (grated) 50g

Comflour 50g

Procedure
• Fry ginger and garlic in oil until light brown.

• Add chopped onion and roast till transparent.

• Add tomato puree and spices, cook for 2-3 min.

• Add corn flour dispersed in water.

• Stir until slightly thick and add salt, pepper and sugar.

• Finally, add grated cheese. 43

Practical Manual Toppings

Onion 75g
Capsicum 300g
Chopped Tomato 500g
Procedure
1. FlY onion and capsicum in little oil and remove from fire.

2. Add salt and pepper for taste.

3. Add a pinch of ajinomoto.
4. Add tomato pieces.
Procedure
• Weigh the ingredients accurately based on one kg flour.

• Dissolve yeast, salt, sugar, SMP in part of total water and mix with rest of the
ingredients using dough hook to a well developed stage (2-3 min at Ispeed, 4-5
min at 11 speed)

• Round the dough, place it into a greased bowl, cover a wet cloth and let it rest for
20 min.

• Sheet the dough to about 4- 5 mm thick

• Cut the dough into desired size

• Place the dough on a greased tray.
• Dock the dough, spread the pizza sauce uniformly, place the chopped vegetables
and grated cheese on the top.

• Prooffor about 5-10 min.

• Bake at 230° C for 10-15 min.
F. Puff pastry
Ingredients % (g)
Wheat Flour 100 1000
Salt 2.5 25

Sugar 5.0 50
Egg(optional) 5.0 50 (1 No.)

Water chilled 55-58 550-580

Folding fat (lily) 50 500

Procedure
l. Mix all the ingredients except folding fat to get a well developed dough.

2. Cover the dough with wet cloth and rest for 20 min.

3. Sheet the dough to 5 mm thickness.

4. Apply 50% offat and book fold.

5. Rest for 20 min

6. Sheet, apply remaining fat and book fold.

7. Rest for 20 min.

44
8. Sheet the dough and give double book fold. Preparations of Variety
Bakery Products-Buns,
Rusk, Rolls, Doughnuts,
9. Rest for 20 min. Pizza, Puff Pastry
10. Sheet to approximately 4 mm thickness.
11. Cut 7 x 9 ern? pieces, put filling, fold and place it on wet tray.
12. Give water spray.
13. Rest for 10 min.
14. Bake at 220°C for 20 min.
9.2.5 Evaluation
Buns: Take weight (g) and volume (ml) calculate specific volume (ml/g). Evaluate
for crust and crumb characteristics.
Rolls: Evaluate for crust colour, shape, crumb colour, grain, texture and eating quality.
Rusk: Evaluate for crust colour, shape, crumb colour, grain, texture and eating quality.
Doughnuts: Evaluate for crust colour, crumb colour, grain, texture and eating quality.
Pizza: Evaluate for appearance, toping, textures and eating quality.
Puff pastry: Evaluate for colour, layers, texture and eating quality.
9.2.6 Results
The desirable characteristics for different products are
Buns: Good volume, golden brown crust colour, creamish white crumb, fme, uniform
grain, soft texture and typical taste.
Rolls: Good volume, attractive shape, creamish white crumb colour, fine uniform
grain, soft texture and typical taste.
Rusk: Slightly dark brown crust colour, brownish crumb colour, fine grain, crisp
texture and typical taste.
Doughnuts: Good volume, golden brown crust colour, creamish white crumb colour,
very fine grain, very soft texture and typical taste.
Pizza: Attractive, liberal toppings cheese flavour and soft bite.
Puff pastry: Golden brown crust colour, light, thin flaky layers and crisp texture.

9.3 PRECAUTIONS
• Bun dough consistency should be slightly loose.
• Puff pastry dough should be slightly tight.
• U se fresh oil or fat for frying doughnuts.
• Do not prove the pizza for more than 10 min.
• Pizza sauce consistency should be thick.
• Wrap the puff pastry sheeted dough with plastic films while keeping in the
refii.gerator.
• U se best quality cheese - Mozerulla cheese, Amul pizza cheese for pizza.

45
 EXPERIMENT 10 BAKING OF BISCUITS
Structure
10.1 Introduction
Objective

10.2 Experiment
Principle
Requirements
Procedure
Observations
Results

10.3 Precautions

10.1 INTRODUCTION
Baking is an important process but is very complex. The baking test is the most
important and the ultimate parameter to predict the flour quality and its suitability for
biscuit preparation. Flour performance may be evaluated by a standard test baking
procedure which is done under controlled conditions. By carrying out test baking,
the process can be optimized and also the effect of different treatments on the quality
characteristics of biscuits can be known.
The unit operations involved in the preparation ofbiscuits are mixing, sheeting, shaping,
baking, cooling and wrapping. After cooling, biscuits are evaluated.
Objective

After performing this experiment, you should be able to:

• Carry out the test baking of biscuits and assess the quality of biscuits.

10.2 EXPERIMENT
10.2.1 Principle
Four major changes associated with baking are

a) Development of open, porous or flaky texture in biscuits because of reduction

in product density.

b) Change of shape - Shrinkage or spread and increase in thickness of biscuits.

c) A reduction in moisture level of biscuits.

d) Surface colouration - development of golden brown colour in biscuits.

10.2.2 Requirements
• Balance (least count 0.01 g)
• Baking oven
• Hobart mixer (500g capacity)
• Sheeting platform
46
• Sheeting frame of thickness 3.5 mm Baking of Biscuits

• Rolling pin

• Circular cutter of diameter 45 mm

et Docking pin

• Plastic bowls

• Spatulas

• Glass Beakers (100 ml)

• Flat knife

• Baking trays

• Refined wheat flour (maida)

• Sugar powder

• Salt (sodium chloride)

• Fat (Marvo, bakery shortening)

• Skimmed milk powder

• Dextrose

• Ammonium Bicarbonate

• Sodium Bicarbonate

• Vanilla flavour

• Water
10.2.3 Procedure

• Sieve the flour before use

• Set the baking oven at 200°C
• Weigh all the ingredients separately and accurately.
The biscuits are prepared using two flour samples 1 & 2 with the following formulation
and method:
Quantity (g)
Flour 1* Flour2**
Flour 300 300
Sugar powder 90 90
Fat (Marvo) 60 60
Skimmed milk powder 6 6
Dextrose 6 6
Salt 3 3
Ammonium bicarbonate 3 3
Sodium bicarbonate 1.5 1.5
Vanilla flavour (ml) 0.6 0.6
Water (ml) 54 63

Flour I * Good quality flour

Flour 2** Poor quality flour 47
.;>. -e
ee .,
••
-
f'>

••
;:; .

::
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'"

10.2.4 Observations
Evaluate the biscuits using the following format:
Quality characteristics of biscuits

SI. No. Sample No. Colour Surface character Crum b colour Texture I• Taste Mouth feel Over all quality

1.

2.
3.
I
4.
i
5. I

6. I

Quality Description Colour Surface character Crumb colour Texture I Taste MouthfeeJ Over all quality

Desirable - Golden - Smooth -Creamy Crisp - Pleasant to Easy Break Very Good
brown white mouth don Good
- University - Yellowish -Normal Fair
in colour white Satisfactory

Undesirable - Brownish - Rough - Whitish -Hard - Off Flavour - Residual taste Poor
- Whitish -Dark - Brittle - Off taste - Formation of Very poor
- Non- brown - Grittiness Dislikeness dough iump in
I I , mouth
I
 Baking of Biscuits
Method
1. Cream sugar powder, fat, skimmed milk powder, dextrose and flavour at 1st
speed for 1 min, 2nd speed for 1 min and 3rd speed for 4 min using a flat blade.
2. Dissolve salt, ammonium. bicarbonate, sodium bicarbonate separately in part of
water and add to the cream and mix again at 1st speed for 1 min, 2nd speed for
1 min and 3ld speed 5 min.
3. Add flour and mix for 2 min in 1st speed.
4. Sheet the dough to 3.5 mm thickness and cut into round shape using the cutter
and transfer the dough pieces to baking tray leaving two inches gap in between
the dough pieces and dock the biscuits dough.
5. Bake at 200°C for 9-10 min.
6. Cool thoroughly and evaluate

10.2.4 Observations
Evaluate the biscuits using the following format

10.2.5 Results
Different flours can be evaluated for their suitability for making biscuits. Biscuits
with golden brown colour smooth surface, creamy white crumb colour, crisp texture
pleasant mouthfeel and taste are related as very good.

Quality characteristics of biscuits

Sample Colour Surface Crumb Texture Taste Mouth Over
No. character colour feel all
quality

Flour 1* Golden Smooth Creamy Crisp Pleasant Easy Very Good

brown white to mouth break
down

Flour 2** Brownish Rough Dark Hard Off taste Doughy Poor
brown lump in
mouth
1* - Good quality flour, ** 2 - Poor quality flour
We can see from the results above, that sample No. I is a good quality flour and is suitable for biscuit
making.

10.3 PRECAUTIONS
• Put on the oven well in advance so that when you place the baking tray, the
oven is already at 200°C.

• Weigh the ingredients accurately.

• Dissolve the salts completely to avoid brown specks on biscuits.

• Follow the mixing conditions (speed and duration) properly.

• Sheet the dough to a uniform thickness.
• Transfer the circular dough pieces by gently lifting without causing distortion of
shape.
• Cooling thoroughly is very important.
• Packing immediately after cooling to avoid loss of crispness. 49
 EXPERIMENT 11 DETERMINATION OF
EFFECT OF
INGREDIENTS - SUGAR,
FAT,GMS, STARCH,
LECITHIN
Structure
11.1 Introduction
Objective

11.2 Experiment
Principle
Requirements
Procedure
Observations
Results

11.3 Precautions

11.1 INTRODUCTION
Refmed wheat flour (maida) is the most important basic ingredient in biscuit making.
Flour gives structure to the biscuit, holds all the ingredients uniformly distributed in
the dough & retains gas during baking. This is because of the presence of unique
gluten proteins present in wheat. Weak flour having a gluten of7 -9% is suitable for
biscuits. Sugar imparts sweetness, softens gluten, contributes colour and hardens
. the biscuit texture. The action of fat in biscuit dough is to prevent the gluten formation.
Gluten does not form until the flour is in contact with water and it is mixed. The
inclusion of fat insulates the gluten - forming proteins from the water resulting in a
soft dough. Skimmed milk powder imparts wholesome flavour, taste and colour to
the products. Salt imparts taste. To increase the palatability and to improve texture
and bite it is necessary to achieve some form of aeration. Ammonium bicarbonate
and sodium bicarbonate are the aerating chemicals used. Aerating agents make the
biscuit porous, light and crisp by liberating carbon-di-oxide gas when heated. The
water hydrates the flour, dissolves salt and chemicals. Glycerol mono stearate (GMS)
and lecithin are additives used in biscuit making and they are called as emulsifiers.
Fats and water are not miscible. Emulsifiers, when used is small quantities improve
the dispersion of aqueous phase of the dough. Lecithin is the most commonly used
emulsifier in biscuits which is derived from soya beans. The emulsifiers are added in
the creaming stage of biscuit preparation.

11.2 EXPERIMENT
11.2.1 Principle
To study the role of different ingredients and additives on the quality characteristics
of biscuits.

11.2.2 Requirements
• Balance (least count 0.01 g)
50 • Baking oven (preheated to 2000C)
 Determination of
• Hobart mixer (500g capacity) Effect of Ingredients-
Sugar, Fat, GMS,
• Sheeting platform Starch, Lecithin

• Sheeting frame of thickness 3.5 mm

• Rolling pin

• Circular cutter of diameter 4.5 mm

• Docking pin

• Plastic bowls

• Spatulas

• Glass Beakers (100 ml)

• Flat knife

• Baking trays

• Refined wheat flour (maida)

• Sugar powder

• Salt (sodium chloride)

• Fat (Marvo, bakery shortening, Manufactured by: Hindustan Lever Ltd.)

• Skimmed milk powder

• Dextrose (D-Glucose, analytical reagent grade, molecular weight 180.16)

• Ammonium Bicarbonate (Analytical reagent grade, molecular weight 79.06)

• Sodium Bicarbonate (Analytical reagent grade, molecular weight 84.01)

•. Vanilla flavour (Liquid, Manufactured by: Bush Boake & Allen Ltd.)

• Water (potable)

• Glycerol mono stearate (GMS)

• Soya lecithin (liquid)

11.2.3 Procedure

• Sieve the flour before use

• Set the baking oven at 200°C

• Weigh all the ingredients separately and accurately

• Prepare glycerol mono stearate (GMS) gel by using emulsifer and waterratio of
1:4. Heat the water to boil, add the GMS and stir well to dissolve. Cool the
mixture to get a smooth paste.

We will be doing the following set of experiments to study the effect of ingredients:

a) With a good quality flour which will be the control biscuit for comparison.

b) With different levels of sugar - 20% and 40%

c) With different levels of fat - 15% and 25% 51

Practical Manual
d) Withemulsifier-GMS 0.5%

e) With lecithin emulsifier- 0.5%

f) Replacement of 10% wheat flour with corn flour

Prepare the biscuits as per the following formulation:

Table 1: Effect of ingredients and additives on the quality of biscuits

Control Sugar Sugar Fat Fat GMS Lecithin 10%

20% 40% 15% 25% 0.5% 0.5% corn
flour

Refined wheat flour, g (maida) 300 300 300 300 300 300 300 270
Sugar powder, g 90 60 120 90 90 90 90 90
Fat (Marvo), g 60 60 60 45 75 60 60 60
Skimmed milk powder, g 6 6 6 6 6 6 6 6
Dextrose, g 6 6 6 6 6 6 6 6
,..,
Salt,g 3 3 3 3 3 3 -' 3
,.., ,..,
Ammonium bicarbonate, g -' 3 3 3 3 3 -' 3
Sodium bicarbonate, g 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
Cornflour,g - - - - - - - 30
Glycerol mono stearate, g* - - - - - 7.5 - -
Lecithin,g - - - - - - 1.5 -
Vanilla flavour (ml) 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
Water (ml) 54 64 49 57 52 48 54 54

* GMS: Water 1:4 (Total 5)

0.5 x 5 = 2.5 g paste / IOOgflour

7.5 g paste for 300g flour

7 .5g contains 6 ml water, so deduct from total water (54-6=48 ml)

Method
• Add GMS and lecithin in the creaming stage (step 1)
• Sieve wheat flour and corn flour together before using.
• Cream sugar powder, fat, skimmed milk powder, glucose and flavour. 1st speed 1
min, 2nd speed I min and 3rd speed 4 niin.

• Dissolve salt, ammonium bicarbonate, sodium bicarbonate separately in part of

water and add to the cream. I st speed 1 min, 2nd speed 1 min and 3rd speed 5 min.

• Add flour and mix for 2 min in 1st speed.

• Sheet the dough to 3.5mm thickness and cut into round shape of 45 mm diameter.
Dock the biscuits ..

• Transfer these into baking trays. Leave 2 inches gap in between the dough pieces.

• Bake at 2000C for 9-10 min.

52 • Cool and evaluate.
 11.2.4 Observations: Evaluate the biscuits using the following format:
Evaluate the biscuits using the following format:
Quality characteristics of biscuits

SI. No. Sample No. Colour Surface character Crumb colour Texture Taste Mouth feel Over all quality

1.

2.

3.

4.

5.

6.

Quality Description Colour Surface character Crumb colour Texture Taste Mouthfeel Over all quality

Desirable . Golden - Smooth -Creamy Crisp - Pleasant to Easy Break Very Good
brown white mouth don Good
- University - Yellowish -Normal Fair
in colour white Satisfactory

Undesirable - Brownish - Rough - Whitish -Hard - Off Flavour - Residual taste Poor
- Whitish -Dark -Brittle - Off taste - Formation of Very poor
-Non- brown - Grittiness Dislikeness dough lump in
mouth

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Pr actical Manual 11.2.5 Results
Based on the results we can evaluate the effect of ingredients and additives on the
quality of biscuits.
Samples Colour Surface Crumb Texture Taste Mouth Over all
character colour quality
Control Golden Smooth Creamy Crisp Normal Easy break Good
brown white down,
no residue

Sugar- Pale Slightly Whitish Hard Normal No residue Poor

20% brown rough
Sugar Dark Smooth Slightly Brittle Normal No residue Poor
40% brown dark
brown
Fat-15% Pale Slightly Whitish Brittle Normal No residue Poor
brown rough
Fat-25% Dark Smooth Whitish Slightly Normal No residue Fair
brown soft
GMS-O.5o/! Golden Smooth Creamy Crisp Normal Easy break Very good
brown white
Lecithin- Golden Smooth Creamy Crisp Normal Easy break Very good
0.5% brown white
Corn Golden Smooth Creamy Crisp Normal Easy break Very good
flour 10% brown white

We can see from the results with less sugar (20%) and less fat (15%) the surface
character, texture and spread of the biscuits are affected whereas with more sugar
(40%) and more fat (25%), the spread of biscuit increased. The surface colour and
texture are also influenced. The emulsifiers GMS and lecithin improve the quality
characteristics resulting in very good quality biscuits. Replacement of 10% corn flour
also produced very good quality biscuits.

11.3 PRECAUTIONS
• Weigh ingredients accurately.
• Put on the baking oven well in advance so that when baking trays are placed the
oven is already at the specified temperature.
• Follow the mixing conditions as specified.
• Uniform sheeting is very important.
• Do not allow the biscuit dough to dry.
• Baking temperature and time are very critical. Follow it strictly.
• Slow cooling after baking is very important.

54
EXPERIMENT 12 BAKING OF CAKES -
SPONGE CAKE AND
DECORATION
Structure
12.1 Introduction
Objective

12.2 Experiment
Principle
Requirements
Procedure
Observations
Result

12.3 Precautions

12.1 INTRODUCTION
There are wide varieties of cakes and broad range offormulations. The cakes can
be leavened mainly by baking powder but occasionally by air incorporation as in
case of foam type cakes. The foam type cakes depend for their structure and
volume primarily on the foaming and aerating properties of eggs. The sponge cakes
do not contain fat, they depend on whipping of eggsfor their lightness and aeration.
Angle food cake and chiffon cakes are the examples of sponge cake. The sponge
cakes serve as the bases for birthday cakes and cakes that are made on other
occasions. They are decorated with icing of different types.

The icings are sweet coverings or coatings in which sugar is the predominant ingre-
dient. The materials used and manner in which they are mixed determine the type of
icing. The icing used and the finish of a baked product add to its sales appeal as it
attracts the customer.

The basic ingredients in an icing are sugar and water, but additions such as egg
white, gelatine, fat, milk etc. may be made to produce a variety of different icings.
The butter cream used for decoration of cakes is a mixture of butter / margarine and
icing sugar blended in a certain proportion to give a cream free oflumps. It is
spread on the base or it is piped. The royal icing is made by whipping egg white and
icing sugar to form a stiff paste and then it is piped on the sponge cake bases.
Fondant icing comprises of granulated sugar and water which is gently heated to
38°C and then it is used when warm so that it sets to a firm coating when cool.
Objective
After performing this experiment, you should be able to
• prepare a sponge cake.

12.2 EXPERIMENT
12.2.1 Principle
Sponge cakes are those which are primarily leavened with eggs - whole eggs, egg
yolks, egg whites or a combination of these. The aeration of the sponge cakes is
achieved by beating the egg into a foam which is constituted by trapping air in the 55
Practical Manual form of small cells. This property of egg is mainly due to the protein albumin of the
egg white which partially coagulates forming a semi-rigid membrane around each air
cell. The sugar added to egg when it is beaten helps to stabilize the foam. Sugar is
whisked with egg to a thick light foam and flour is carefully blended in to prevent the
structure from breaking down.

12.2.2 Requirements

• Baking oven

• Hobart mixer (500g capacity) and a cake whipper

• Balance (lest count 0.01 g)

• Plastic bowls, spoons and spatula

• Cake pans (previously greased / lined with butter paper)

• Softflour

• Castor sugar (crystal sugar)

• Fresh eggs of good quality

• Vanilla flavour (Liquid, Manufactured by: Bush Boake &Allen Ltd.)

• Fat (Marvo, bakery shortening, Manufactured by: Hindustan Lever Ltd.)

• Icing sugar / sugar power

• Food grade colours (permitted)

• Set the baking oven at specified temperature/

The fatless sponge (or sponge cake) is prepared as per the following formulation and
method.

Quantity (g)

Refined wheat flour (maida) 200

Eggs (without shell) 400

Sugar (crystal) 200

Vanilla essence (liquid, ml) 5

Method

• Beat eggs, essence and sugar in 1st speed for 1 min, 4 min at 3rd speed till a
stable foam is formed,

• Add flour at 1st speed little by little and mix for 2 min at 1st speed.

• Pour the batter to previously greased pans upto 3th / 4 ofthe pan.

• Bake at 200°C for 30 min.

• Take out the sponge cake from the pan carefully and cool it over a mesh.

56 • Cool thoroughly and pack.

 Baking of Cakes-
Preparation oflcing Cream Sponge Cake and
Decoration
Quantity (g)

Powder sugar or Icing sugar 200

Margarine 100

Vanilla (liquid, ml) 10

Method

• Cream fat, sugar and essence at 1st speed for 2 min, 3rd speed for 5 min till a
1ight fluffy cream is obtained.

Icing of sponge cake

• Use different food grade colours (a small pinch of powder or 3-4 drops of
liquid colour) and mix with little quantity of white cream (above mentioned)
and mix well with flat knife till the colour is uniformly distributed in the cream.

• Fill the piping cones with colour.

• Take the sponge and remove the crust.

• Apply the cream of desired colour to the base and spread evenly.

• Decorate on the top with coloured cream using piping bag.

12.2.3 Result
. The desirable quality characteristics for sponge cake are good volume, soft, moist
and tender texture, fine uniform crumb grain and a pleasant mouthfeel.

12.3 PRECAUTIONS
• Select fresh eggs of very good quality as egg is the most important ingredient
to get a good quality sponge.

• It eggs are refrigerated, bring the eggs to the room temperature before use.

• Whips the egg-sugar mixture to the right consistency.

• Add flour carefully to the whipped egg-sugar mixture.

• After pouring the batter to the pan, bake it immediately to prevent loss of air
cells.

• Do not move the pans in the oven before the cakes are set.

• Remove the cake gently from the pan after it is baked and cool it thoroughly
over a mesh.

57
Notes