Internship Report Outline

Introduction to industry

Functions of departments

Vision and mission

Objective and quality statement

Swot analysis of dawn bread

Baking ingredients and their functions

Cake Hal

Burger hall

Bread section

Friction factor

Bread baking problems

Suggestions

5 Products Of Dawn Bread

6 Introduction Dawn bread establishment of plant City Year Karachi 1981

Islamabad

1985

Hyderabad

1987

Lahore

Multan

1989

Faisalabad

1992

7 Vision and Mission Statement

Dawn Bread with a vision to exceed the expectations of consumers

With great taste products that delivers convenience, quality, safety and value
Dawn bread is undoubtedly market leader in fresh baked bakery products

“To provide quality products to customer and explore new markets to expand sales of the company
through good Governance and dynamic team

So as to achieve Optimum price of products of the company for sustainable and equitable Growth and
prosperity of the company”

8 Objectives and Quality Policy

Dawn Bread’s longstanding commitment toward consumer satisfaction is evident and initiation of
bringing Pakistan the world’s most technologically advanced baking units and processes

Quality Policy

We work together as a team for implementation and continual improvement of total quality system in
order to achieve satisfaction of our internal and external customers

9 Continue… ISO 9001: 1994 certified in 2000

Established yeast plant at Lahore

Halal certified

Supplier of McDonald’s hamburger

KFC (Kentaccy fried chickens)

Hardees

Avari Lahore

Subway

Dunkin donuts

Pearl continental

Hot dog

10 Continue… Comprises of Group of private limited companies

Group members based on food products

Bread and beyond

Dawn mayo

Dawn foods
Dawn bread

Dawn maizban

11 Nature of Organization Continue…

Dawn bread

Breads

Burgers

Buns

Rusks

Cakes

Biscuits

Dawn foods

Ready to eat

Zinger

Koofta

Aloo Paratha

Wings

Chicken Patties

Chicken rolls

12 Nature of Organization Continue…

Dawn mayo

Chili and soya sauce

Chicken spread

Mayonnaise

Tomato ketchup

Chili garlic

Sauce vinegar

Tomato sauce
Ginger & garlic paste

Dawn maizban

Chicken chapli kebabs

Chicken mallei boti

Chicken samosa

Chicken spring roll

Chicken seekh kabab

Chicken shami kabab

Vegetable spring roll

13 Bread and Beyond Dawn foods has various brands

Bread and beyond one of them

Daughter company of dawn bread

Have more than 200 products

Acutely aware of the needs for appealing products (confectionery and bakery products)

Satisfying customer

Backbone of dawn bread

14 Continue… Competitors Gourmet Bunny’s Cakes and bakes Bake parlors

City bread

Mary gold

Morgan bread

Wonder bread

15 Swot Analysis of Dawn Bread

Strength

Holding 35% shares of bread in Pakistan

Largest distribution network

Advance production units

Vast range of quality

Vast range of products with variety of flavors

Stability of production

16 Swot Analysis (Continue…)

Weakness

No quality control labs

No proper medical facilities

Hygiene and sanitation issues

No proper research laboratories

Over work burdens on employers

Large product range lacking proper planning

17 Swot Analysis (Continue…)

Opportunities

Innovation in product

Product quality

Growing varieties in RTE food

To create the awareness among customers about new products

To increase the skilled labor

Use motivational techniques regarding employees

18 Swot Analysis (Continue…)

Threats

More manual work

Trade discounts offered by competitors

Lack of implementation of quality standards

Lacking bench marking and re-engineering

Some products loose focus, due to new brands

19 Baking ingredients and their functions

Flour

Largest single component of bread

Reduced form of endosperm (particle size 140 mµ)

Powdery substance produced by finely grinding grain through milling

Patent (white) flour is used

Gelatinizing capacity

Contain essential amino acids except lysine

20 Flour continue…. Classification based on amount of protein

Protein determines gluten strength of flour

Gluten gives the dough its shape and form

Bread flour (9-13% gluten content, used for bread making)

Cake flour or soft flour (< 7 % gluten content )

All purpose flour (medium gluten strength, suitable for any baking purpose)

21 Quantitative Analysis Of Flour

Component

%age

Protein

11-12%

Fat

0.3%

Fiber

0.6%

Minerals
0.5%

Sugar

2.5%

Starch

70%

22 Characteristics Of Flour

Water absorption

pH ( )

Color ( creamy white )

Uniformity ( uniform particle size )

Flour strength ( according to product)

23 Constituents of Flour Starch Important carbohydrate in flour

About 70% in bread making flour

Dilute gluten

Provide strong union with gluten

Become flexible by gelatinization

Moisture 14-16%

24 Flour constituents (Continue… )

Protein

8-10% in soft wheat flour

12-14% in hard wheat flour

>16% in extra hard wheat flour

4 types of protein in flour

Albumin

Globulin

Gliadin
Glutenin

25 Baking Ingredients (Continue…)

Others are

Water

Eggs

Leavening agent

Sugar

Fat

Shortening agents and emulsifiers

26 Baking Ingredients (Continue…)

Water

Basic ingredient

Solvent for the dispersion of salt, sugar and other ingredients

Hydration of protein to form gluten

Controls the consistency of dough

Controls the dough temperature

Make enzymes activities possible

Amount varies according to the product

27 Baking Ingredients (Continue…)

Sugar

Table sugar or sucrose

Major ingredient in baking

Amount varies according to the product

Serves as nutrient for yeast in fermentation

Retains moisture and prolong freshness

Improves flavor
Improves grain and texture of bread

28 Baking Ingredients (Continue…)

Shortening Agents and Emulsifiers

Type of solid fat, made from vegetable oils, such as soybean and cotton seed oil

It shortens gluten strands in wheat by adding fat

To obtain improved slicing properties as well as extra softness, tenderness

Example are butter and margarine

Increases the nutritive value

Assists in gas retention, thus giving better volume and crust.

29 Baking Ingredients (Continue…)

Leavening agents

Yeast and baking powder

Leavening dough by CO2 production

Types of yeast

Flavoring and fermentation purpose.

Give structure to the product

Acetic acid and lactic acid produced, give flavor to the product

The ideal temperature is 26-30°C

Living Yeast

Baker’s Yeast

Dead Yeast

30 Baking Ingredients (Continue…)

Salt

Used for taste and toughens the gluten

Effect on color and keeping quality

Controls the activity of yeast (fermentation)

Salt should have the following characteristics.

Completely soluble in water.

Pure, give a clear solution.

Free from bitter/ bad taste and lumps

31 Baking Ingredients (Continue…)

Eggs

Binders, holding ingredients together

Whole eggs and yolks contain emulsifiers that distribute fat in the batter

Provide coagulated structure, color, flavor

Egg whites contribute aeration and leavening when beaten due to the presence of air cells that are filled
with CO2

Egg proteins contribute to the structure

Play an important part in nutrition

32 Internship Areas Following areas: Cake hall Production hall

Burger section

Bread section

33 Cake Hall Products of Cake Hall Fruity buns Rusk Baqar khani Bread

Shawarma bread

Sheer mal

Muffins

Rusk

Bread

Biscuits

Fruit cake

Simple bun
34 Images of Cake Hall

35 Cake Hall (Continue…) Ingredients used in cake hall Salt Murabba Flour

Sugar

Improver

Calcium propionate

Exotic essence

Potassium sorbate

Murabba

Eggs

Oil

Ice and water

Leavening agents

Color

Flavor

36 Dividing, molding, Panning

Cake Hall (Continue…)

Fruit Bun

Mixing

Slow 3-4 min

Fast min

Dividing, molding, Panning

Proofing

35-37°C

min

Baking

°C

14-16 min
Depanning

Cooling

Packaging

Figure 1. Process Flow Diagram of Fruit Bun Making

37 Cake Hall (Continue…) Shawarma bread

Mixing (slow 2 min, fast min)

Moulding

Dividing

Sheeting (Sheeter machine) and loading

Proofing

40-50 min

Baking

°C

7-8min

Depanning

Cooling

Packaging

Figure 2. Process Flow Diagram of Shawarma Bread Making

38 Cream filling(Apply Puff on The dough) Cutting , Rolling and pressing

Cake Hall (Continue…)

Baqar khaani

Mixing

10-12 min

Weighing

Dough wt. 3kg

Margarine puff wt. 1kg

Molding and Sheeting

Cream filling(Apply Puff on The dough)

Folding and pressing

Sheeting

Rolling and folding

(Pressing)

Cutting , Rolling and pressing

Baking

210°C

45min

Figure 3. Flow Diagram of Baqar Khaani Making

39 Cake Hall (Continue…) Sheer maal Mixing Slow 3min Fast 28 min

Molding and dividing

Proofing

Molding

(Manually)

Second proofing

Baking

180°C

16 min

DE panning

Cooling

Packaging

Figure 4. Process Flow Diagram of Sheer Mal

40 (pouring mixed fluid into cups)

Cake Hall (Continue…)

Muffins
Mixing

15 min

Filling

(pouring mixed fluid into cups)

Baking

220°C

13-17 min

Cooling

De panning

Packaging

Figure 5. Flow Diagram of Muffins Making

41 Burger Hall Followings are the type of burgers

Followings are the regular customer of dawn burger

KFC

OPTP

Hardees

Fri chicks

FAT restaurant

Johnny Rocket

Local market

Followings are the type of burgers

Burger bun

Junior bun

Minni hoggi

Hot dog bun

Hoggi roll

Bran bun

Macroil
42 Images of Burger Hall

43 Ingredients used in Burger hall

Flour

Yeast ( AB Maury )

Water / ice

SSL ( sodium sterol lactilate)

Sugar (powder form)

Improver (wheat flour, soy flour,

enzymes, flour treatment agent E-300)

Oil

Gluten

Till (sesame)

Ascorbic acid

Burger softener

Salt

Calcium propionate

44 Procedure For Manufacturing of Burger

Fist spongue is made (7min)

Stay time half hour

Mixing

( min

20-21°C )

dividing,

Molding, dusting

Initial proofing

(3-4 min)

Sheeting and loading

Final proofing (45 min, Humidity 95% 35◦C temp)

Seeding by seeding machine

Baking

10min, °C

Depaning and cooling

Slicing

Packaging

45 Bread Section Flour, water, yeast, sugar and salt are the

four basic ingredients of bread

Shortening, mineral, vinegar, soya flour, milk powder, preservatives and fruits are optional

The different types of breads are

White bread

Atta bread

46 Bread Section (Continue…)

Bran bread

Milky bread

Mini bread

Sandwich bread.

It is largest bread

Called as extra-large bread.

It is close top bread

47 Bread Section (Continue…)

Kinds of mixing

Straight dough method

Mixing of all the ingredients at a time to make dough

Less labor cost

Time saving

Less bread flavor and volume

2. Sponge and dough method

Take 1/3 of ingredients and mix them to make spongue

Leave the spongue for 2-3 hours

After that 2/3 of ingredients are added and mixed

Then fermentation time is given minutes

48 Purposes of Dough Mixing

Intimate and uniform mixture of the necessary ingredients

To properly form the smooth glutinous mass called dough

Complete wetting of the starch

Insure complete hydration of the gluten

Promoting its extensibility and palatability which is later perfected by yeast action

Completely and uniformly distribute the yeast cells throughout the dough mass

Bringing them into intimate contact with the rest of the dough from which the yeast secures its nutrition

49 Four Stages of Dough Mixing

Initial Stage:

Uniform Blending of the Ingredients

Dough Wet and Sticky

Pick up Stage:

Gluten Structure develop

Clean up stage:

Dough Become dry and Elastic

Cohesive Mass is produce which avoid stickiness from the wall

Development Stage:
Critical Stage

Smooth, Dry and Silky Appearance

Form Smooth and Long Structure

50 Friction factor

Temperature resulting from the action of kneading or mixing, is friction factor

Friction factor refers to the amount of energy or heat generated during the dough making process

Friction varies according to whether the action is manual or mechanical,

How much time the action takes,

And the firmness of the dough.

If the action is mechanical, friction also depends upon the type of mixer used

51 Friction factor Continue…

The general procedure for calculation of friction is given below

Prior to making the dough, note the exact temperature of the room, flour, and water.

After the dough is made, note the dough’s temperature

FF = (FDT×3) – (RT+FT+WT)

FF = friction factor

FDT = finished dough temperature

RT = room temperature

FT = flour temperature

WT= water temperature

52 Friction factor Continue…

I calculated friction factors for various batches. Some examples are given below.

For large bread

RT = 28.5ºC

FT = 26.5ºC

WT = 5.5ºC
FDT= 26.5ºC

FF = (26.5×3) – ( )=79.5 – 60.5 = 19ºC

53 Friction factor Continue…

For medium bread

RT = 28ºC

FT = 26.5ºC

WT = 6ºC

FDT= 27ºC

FF = (27×3) – ( )

= 81 – 60.5

= 20.5ºC

54 Friction factor Continue…

For standard bread

RT = 29ºC

FT = 27ºC

WT = 6ºC

FDT= 25ºC

FF = (25×3) – ( )

= 75 – 62

= 13ºC

55 Friction factor Continue…

For mini bread

RT = 28.5ºC

FT = 25ºC

WT = 5ºC

FDT= 26ºC
FF = (26×3) – ( )

= 78 – 58.5

= 19.5ºC

56 Study the Indication of Completion of Mixing

Proper mixing is very important to obtain good quality end product

Under or over mixing will result in poor quality bread.

Completion of mixing is checked by using window test.

Procedure of checking the mixing indication is given below.

Pinch off a piece of dough

Using both hands, grasp opposite sides of the piece of dough with your fingertips

Slowly pull your hands apart and stretch the dough by approx cm

Dough should look like a window with a thin membrane in the center

57 Continue… Stop kneading Keep kneading

If the dough forms a window-like membrane and stretches without breaking.

Keep kneading

If the dough doesn't stretch easily and tears, continue kneading

58 Manufacturing process of Bread

weighing of ingredients

Shifting

Mixing

Loading of dough into divider/hopper

weighing of dough balls

shifted to the rounder

Dusting

Initial proofing

28-30°C
10min

Sheeting and molding

Cutting by cutters

Panning

(greased pans)

Loading into trays

Final proofing

75-85min

35-37°C

Baking

°C

28-30min

Depaning and cooling

Packaging

59 Baking Report S.no Time (min) 36 225 200 40 203 202 34 204 196 195 198

Bread Type

RPM

Time (min)

Temperature

A-Zone B-Zone

Standard Milky

36

225

200

Simple Large

40
203

202

Simple O.T

34

204

Milky Small

196

Medium Bread

195

198

290

194

Bran Bread

380

25

206

211

60 Baking Report Continue…

S.#

Bread Type

RPM

Time (min)

Temperature
A-Zone B-Zone

Milky Standard

290

37

191

200

Simple Large

196

10

Sandwich Bread

203

201

11

Milky Large

38

202

207

13

Milky O.T

300

212

14 36

210

15

Small Rusk

450

25
208

16

198

216

61 Bread Baking Problems Too high and low oven temperature

Too low rise in loaf

Not enough yeast

Too much salt in the recipe

Too much sugar in dough

Under proofing or too short final rise of loaf

Over proofing or too long final rise time

Too high oven temperature

62 Bread Baking Problems Continue…

Too much expansion in dough

Loaves too large for pan

Under mixed or under developed dough

Over proofing

Too dark crust

Too pale crust

Not enough salt in the dough

Dough baked before it had finished proper proofing

Baking too long

Too much sugar in the recipe

63 Suggestions Hygiene of workers should be maintained

Sanitization of industry should be done

Industry should have its own ambulance and first aid facilities
Industry should develop research laboratories

Timely presence of workers and management persons

Appraisal must be done in different forms

Time wastage should be avoided

Keep an eye on every task and production line

Every one should be allowed to give innovative idea