EXECUTIVE SUMMARY

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EXECUTIVE SUMMARY

OBJECTIVE:-

To make a study of Bread Manufacturing & Processing of STAR FOOD PRODUCTS

UDAIPUR.

So, the objective of the study is to know about the manufacturing and processing of a

bread company and the process of supplying goods and products to retail stores then the

end users. The channel through which the whole process is completed and the various

intermediaries who plays important role to maintain the proper supply of goods and

products.

RESEARCH METHODOLOGY:-

The method of data collection used was survey method and the tool used for

survey was questionnaire. The sample population consists of the executives, purchase

manager, employees, salesmen, workers and outlets who keeps all the documents and

general information about manufacturing, processing, supply, distribution and warehousing.

Sampling Element : STAR FOOD PRODUCTS UDAIPUR.

Sampling Units : Executives, Purchase Manager, Employees,

Salesmen, Workers, Retail Outlets.

Extent : UDAIPUR(RAJ.) and the local area of it.

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INTRODUCTION

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"INTRODUCTION"

INTRODUCTION TO THE SUBJECT:

Bread Manufacturing & Processing is the combination of art and science that

goes into improving the way your company finds the raw components it needs to make a

product or service and deliver it to customers. The following are the five basic components

of Manufacturing & Processing:

PLAN

SOURCE

MAKE

DELIVER

RETURN

CLASSIFICATION OF LOGISTIC APPLICATION:

There are basically 6 applications of logistic management:

DECISION-WISE,

INBOUND & OUTBOUND LOGISTICS,

PRIVATE & PUBLIC SECTOR,

SINGLE & MULTIPLE PLANTS,

NATURE OF THE PRODUCT,

MADE TO STOCK & MADE TO ORDER.

TOTAL LOGISTIC COST:

The important elements of logistic cost are:

PRODUCT INVENTORY AT SOURCE,

PRODUCT INVENTORY AT WAREHOUSE & DEALERS,

TRANSIT LOSSES/INSURANCE,

STORAGE LOSSES/INSURANCE,

HANDLING & WAREHOUSE OPERATION,

PACKAGING,

TRANSPORTATION,

CUSTOMERS SHOPPING.

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RESEARCH OBJECTIVES

OBJECTIVES OF THE RESEARCH:

There are various objectives of the research, which are as follows:

CONDUCTING A STUDY OF MANUFACTURING & PROCESSING OF A BREAD

COMPANY.

IDENTIFYING KEYS FOR SUCCESS IN FOOD BUSINESS.

KNOWING THE PROBLEMS, CHALLENGES IN MANUFACTURING &

PROCESSING.

KNOWING THE PROBLEMS, CHALLENGES IN TRANSPORTATION.

EXPECTATIONS OF TRANSPORTERS (SALESMEN) FROM THE COMPANY.

EXPECTATIONS OF EMPLOYEES FROM THE COMPANY.

EXPECTATIONS OF CUSTOMERS FROM THE COMPANY.

TO FIND OUT THE COMPANY'S EFFORTS FOR A PROPER & SYSTEMATIC

DISTRIBUTION OF GOODS.

TO CREATE A VALUE BASED FLOW OF GOODS & INFORMATION.

TO INCREASE MARKET COVERAGE THROUGH BETTER SERVICES.

IDENTIFY SIGNIFICANCE OF BRAND BUILDING EFFORTS USED BY STAR

FOOD PRODUCTS UDAIPUR.

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COMPANY PROFILE OF

STAR FOOD PRODUCTS,

UDAIPUR

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BEGINNING

Seventy years ago, in the year 1940, Late Mr.Akbar Ali, started the production of Baked

goods. With his decent efforts and hardships, the demand for the product made a rapid

growth.

In the year 1980, in order to elevate the business started by Late Mr. Akbar Ali,

Mr.Ismail Ali (S/O Late Mr.Akbar Ali)started the company STAR FOOD PRODUCTS

UDAIPUR and began the production of Star Milk Bread. With God's grace and

active participation of the people of Udaipur, the product made its signified place in the

market.

Its been 30 years since then. The firm has achieved a milestone. In all these years,

Mr.Ismail Ali, at STAR FOOD PRODUCTS UDAIPUR, have always tried to be perfect in

quality matters of their food products. But in case, if the people are not fully satisfied with

the products, the company will always be ready to welcome all their grievances. The

company promises to the people of Udaipur that they will try their level best to enhance and

maintain the quality of food products.

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COMPETITIVE STRENGHTS:-

It is believed that its primary competitive strenghts are:

* Understanding of the 'Manufacturing & Processing' segment,

* Supply Chain Management,

* Logistics & Distribution network,

* Geographical spread,

* Identifying new locations,

* Private labels,

* Information Technology Systems, and

* Experienced & Skilled management team.

ITS STRATEGY:-

It intends to pursue the following strategies in order to consolidate its position as

an operator in the 'Manufacturing & Processing segment in Udaipur (Raj.):

* Increasing its penetration in the city by leveraging its supply chain,

* Distribution & Logistic network,

* Emphasis on backward integration,

* Expansion of quality food products,

* Procurement from low-cost production centres,

* Increasing customer satisfaction, and

* Its base of loyal customers.

SALES PROMOTION & CUSTOMER SERVICE:-

Its category management system is used to plan promotional schemes. It launches

promotional schemes weekly. Apart from general sales promotion, the category manager

formulates promotional plans for 'Slow Movers'. In addition, to promote sales, it focuses on

layout of the stores & positioning, presentation & display of merchandise, in order to

appeal to the customers.

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HUMAN RESOURCE:-

Its Human Resource policies are aimed towards creating a skilled & motivated

workforce. It has 50 employees both employed in its corporate office as well as in its

manufacturing unit & other facilities. Description is as below:

*According to age –

AGE NO. OF EMPLOYEES

18-24 10

25-35 25

35 & above 15

TOTAL 50

QUALITY CONTROL:-

Its dedicated professional quality control team ensures the quality of its products.

Its quality checks start the basic raw materials and end with its doing a full inspection on

the finished goods & products. It believes that Quality Control is the key to success. Basic

goal is to give the customer with the best quality and value for his money.

INFORMATION TECHNOLOGY SYSTEM:-

It focused on acquisition & implementation of advanced information technology

systems, processes and business applications in order to handle all stores operations

including inventory management & billing. Its office processes are also computerized which

support procurement, supply chain logistics, distribution centres management & inventory

control.

Based on its existing I.T. system, they are able to generate daily reports covering the

various aspects of its business such as Division & Area wise sales per store, inventory

movement & position at stores & distribution centres & generation of purchase and delivery

orders.

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COMPETITION:-

They face competition from other manufacturers of similar products & services.

These include manufacturers & processors in the organized and

unorganized sectors. They focus on offering their customers a vast variety of products

and services catering to their diverse requirements & needs.

INCENTIVE SCHEMES:-

Latest incentive scheme of STAR FOOD PRODUCTS UDAIPUR, is as follows:

90% to 99.99% Target achieved : 5% of Salary.

100% to 109.99% Target achieved : 10% of Salary.

110% to 119.99% Target achieved : 15% of Salary.

120% to 129.99% Target achieved : 20% of Salary.

130% to 139.99% Target achieved : 25% of Salary.

140% to 149.99% Target achieved : 30% of Salary.

150% and Above : 35% - 50% of Salary.

Products Range

Sr. No. Products

01 Star Bread

02 Star Milk Bread

03 Star Atta Bread

04 Star Toast and Biscuits

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BOARD OF DIRECTORS OF STAR FOOD PRODUCTS

UDAIPUR

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Mr. Ismail AliFounder Chairman & Managing Director

Star Food ProductsUdaipur (Raj.)

Mr. Yahya AliExecutive DirectorStar Food Products

Udaipur (Raj.)

Mr. Sabir AliExecutive DirectorStar Food Products

Udaipur (Raj.)

RESEARCH METHODOLOGY

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RESEARCH METHODOLOGY

A Systematic approach is essential in any project work each and every step must be

so planned that it leads to the next step. It is usually difficult to go back and correct the

mistakes of the previous steps. Sometimes it is impossible and if possible, it involves loss of

time and energy.

The project has been divided into number of steps. Planning and organization are

part of this systematic approach with a lot of emphasis given to their inter dependence of

the various steps. The plan of this project report is as under:

[1] TITLE OF THE PROJECT.

[2] DURATION OF THE PROJECT.

[3] METHODOLOGY.

[4] OBJECTIVES.

[5] TYPE OF RESEARCH (HYPOTHESES.)

[6] RESEARCH PLAN.

[7] SAMPLE DESIGN (SAMPLE SIZE AND METHOD OF SELECTING SAMPLE.)

[8] SCOPE OF THE STUDY.

[9] LIMITATIONS OF THE STUDY.

[1] TITLE OF THE PROJECT

Title : Bread Manufacturing and processing

[2] DURATION OF THE PROJECT

Date: 2nd August 2010 to 23th August 2010

Duration: 22 days

[3]. METHODOLOGY:-

In order to achieve the objectives different methods were adopted

regarding Bread Manufacturing & Processing by discussion with Companies Management

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and deliberations with Professionals Academicians etc. these exercises helped a lot in

collecting relevant information in time for the purpose of the present study and also to

interpret and analyze the result as also getting important clarifications

about various aspects of the study.

[4]. OBJECTIVES:-

To understand the Manufacturing & Processing of a food product i.e.

Bread followed by STAR FOOD PRODUCTS UDAIPUR, and to analyze them is the main

objective. Other objective is to find out satisfaction and dissatisfaction of employee.

[5]. HYPOTHESES:-

It could be assumed that Manufacturing & Processing of a food

product i.e. Bread followed in STAR FOOD PRODUCTS UDAIPUR, is based on the theory

given by the various Chefs & Culinary Institutes around the world. The objective is to be

tested and verified to prove any hypotheses.

[6]. RESEARCH PLAN:-

It is based on following tools such as:

[i]. SOURCES OF DATA COLLECTION:- It is of two types:

(A). PRIMARY SOURCE.

(B). SECONDARY SOURCE.

(A). PRIMARY SOURCE:- It is based on two types:

[1]. QUESTIONNAIRE:-

It is used to collect information about selected employees. There are two types of

questionnaire, Open ended (i.e. inviting free response) and Close ended (Le. Yes/No). The

questions, which are prepared, is to be easy and clear wording for the understanding of the

executives.

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[2]. OBSERVATION METHOD:-

It is another tool that has been used in soliciting primary data about the subject of

study.

(B). SECONDARY SOURCE:- It includes:

[i]. Annual report of STAR FOOD PRODUCTS UDAIPUR.

[ii]. Quarterly reports and financial statements of the organization.

[iii]. A co-operate profile of STAR FOOD PRODUCTS UDAIPUR- The Past, the

Present and the Future.

[iv]. Text Books.

[v]. Study materials- in form of pamphlets and manuals.

[7]. SAMPLE DESIGN (Sample size & methods of selecting sample):-

The Plant & Corporate Office of STAR FOOD PRODUCTS UDAIPUR, have been

considered for this study.

(A). SAMPLING UNIT:- Executives working at corporate office are surveyed.

(B). SAMPLING SIZE:- A sample of 10 salesmen 40 employees was selected.

(C). SAMPLING PROCEDURE:- Non-probability sampling and that too

convenience samplings have been considered for the study.

[8]. SCOPE OF THE STUDY:-

The scope of the study is confined to the STAR FOOD

PRODUCTS UDAIPUR. Its Plant & corporate office is situated at Udaipur City. It is dealing

in manufacturing and processing of various types of food products like Milk Bread, Atta

Bread and different varieties of Toasts & Biscuits.

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[9]. LIMITATIONS OF THE STUDY:-

In the study both primary and secondary source of

information have been used. The researcher being a new person in the field, of research

has encountered a number of limitations in the completion of this report.

[1]. TIME PRESSURE:-

Not only the researcher had to attend to the dissertation work,

but also he had to give equal consideration to other papers of the course. So, the time

factor was a very big constraints as the exercise was the time consuming and tiresome.

[2]. INSUFFICIENT INTERACTION AND COOPERATION FROM THE RESPONDENTS:-

From the viewpoint of the respondents, research work was out

of their concern. On many occasion the researcher had to interrupt their routine work.

Under such circumstances he had to comply incase he was requested to come another

time or to wait until he was attend to. In this regard patience was his big asset.

[3]. MISUNDERSTANDING AND MISINTERPRETATION OF QUESTIONNAIRES:-

Some respondents could not provide the required information

in the questionnaires as they left some questions unattended or gave information that was

not at all relevant to particular question.

This can be attributed to misunderstanding of the questions or

due to the sensitivity they attached to some of the questions.

[4]. LACK OF SCIENTIFIC TRAINING IN THE METHODOLOGY OF RESEARCH

The researcher jacked scientific training in the methodology of

research but with proper guidance and supervision from the esteemed supervisor be as in

position to overcome this problem. Despite this constraints, the findings presented here are

well polished and could be said up-to-date and suffice for application.

After having described the methodology employed in this study,

an attempt is made to discuss the profile of the sample unit.

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FACTS AND FINDINGS & LITERATURE REVIEW

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BREAD

Bread is a staple food prepared by cooking a dough of flour and water and frequently

additional ingredients. Doughs are usually baked, but in some cuisines breads are

steamed, fried, or baked on an unoiled skillet. It may be leavened or unleavened. Salt, fat

and leavening agents such as yeast and baking soda are common ingredients, though

bread may contain other ingredients, such as milk, egg, sugar, spice, fruit (such as raisins),

vegetables (such as onion), nuts (such as walnuts) or seeds (such as poppy seeds). Bread

is one of the oldest prepared foods, dating back to the Neolithic era, and is referred to

colloquially as the "Staff of life". The development of leavened bread can probably also be

traced to prehistoric times.

Fresh bread is prized for its taste, aroma, quality, appearance and texture. Retaining its

freshness is important to keep it appetizing. Bread that has stiffened or dried past its prime

is said to be stale. Modern bread is sometimes wrapped in paper or plastic film, or stored in

a container such as a breadbox to reduce drying. Bread that is kept in warm, moist

environments is prone to the growth of mold. Bread kept at low temperatures, in a

refrigerator for example, will develop mold growth more slowly than bread kept at room

temperature, but will turn stale quickly due to retrogradation.

The soft, inner part of bread is known to bakers and other culinary professionals as the

crumb, which is not to be confused with small bits of bread that often fall off, called crumbs.

The outer hard portion of bread is called the crust.

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ETYMOLOGY

The word itself, Old English bread, is common in various forms to many Germanic

languages; such as Frisian brea, Dutch brood, German Brot, Swedish bröd, Norwegian and

Danish brød; it has been claimed to be derived from the root of brew. However, it may be

connected with the root of break, for its early uses are confined to broken pieces, or bits of

bread, the Latin crustum, and it was not until the 12th century that it took the place—as the

generic name for bread—of hlaf ([hlaifs] in Gothic: modern English loaf), which appears to

be the oldest Teutonic name; Old High German hleib and modern German Laib, or Finnish

leipä, Estonian leib, and Russian(khleb) are similar (all are derived from the Indo-European

word for "loaf").

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HISTORY

History of Bread

Grown in Mesopotamia and Egypt, wheat was likely first merely chewed. Later it was

discovered that it could be pulverized and made into a paste. Set over a fire, the paste

hardened into a flat bread that kept for several days. It did not take much of a leap to

discover leavened (raised) bread when yeast was accidentally introduced to the paste.

Instead of waiting for fortuitous circumstances to leaven their bread, people found that they

could save a piece of dough from a batch of bread to put into the next day's dough. This

was the origin of sour-dough, a process still used today.

In Egypt, around 1000 BC, inquiring minds isolated yeast and were able to introduce the

culture directly to their breads. Also a new strain of wheat was developed that allowed for

refined white bread. This was the first truly modern bread. Up to thirty varieties of bread

may have been popular in ancient Egypt.

It was also during this time that bread beer was developed. The bread was soaked in water

and sweetened and the foamy liquor run off. Beer was as popular in ancient Egypt as it is in

America today.

The Greeks picked up the technology for making bread from the Egyptians; from Greece

the practice spread over the rest of Europe. Bread and wheat were especially important in

Rome where it was thought more vital than meat. Soldiers felt slighted if they were not

given their allotment. The Roman welfare state was based on the distribution of grain to

people living in Rome. Later the government even baked the bread.

Through much of history, a person's social station could be discerned by the color of bread

they consumed. The darker the bread, the lower the social station. This was because whiter

flours were more expensive and harder for millers to adulterate with other products. Today,

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we have seen a reversal of this trend when darker breads are more expensive and highly

prized for their taste as well as their nutritional value.

In the middle ages bread was commonly baked in the ovens of the lord of the manor for a

price. It was one of the few foods that sustained the poor through the dark age.

Bread continued to be important through history as bread riots during the French Revolution

attest. The famous quotation attributed to Marie Antoinette that if the poor could not get

bread for their table then "let them eat cake," became a famous illustration of how royalty

had become ignorant of the plight of the lower classes. Actually, Marie Antoinette never

said this and was merely being slandered by her detractors.

Still thought of as the "staff of life", for centuries bread has been used in religious

ceremonies. Even the lord's prayer requests of God to "Give us this day our daily bread" -

meaning not merely loaves, but moral sustenance.

Today, even with the competition of a growing variety of foods, bread remains important to

our diet and our psyche. It has a prominent place in at the local market, in our cupboards,

and even in our language. The word "bread" is commonly used as a slang term for money.

It connotes importance as when we say that some aspect of our work is "our bread and

butter". In many households bread is still served with every meal.

Bread has a long history for a reason. It is a healthy and nutritious food that fills the

stomach as well as the soul.

Bread is one of the oldest prepared foods, dating back to the Neolithic era. The first bread

produced was probably a cooked version of a grain-paste, made from ground cereal grains

and water, and may have been developed by accidental cooking or deliberate

experimentation with water and grain flour. Yeast spores are ubiquitous, including the

surface of cereal grains, so any dough left to rest will become naturally leavened.There

were multiple sources of leavening available for early bread. Airborne yeasts could be

harnessed by leaving uncooked dough exposed to air for some time before cooking. Pliny

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the Elder reported that the Gauls and Iberians used the foam skimmed from beer to

produce "a lighter kind of bread than other peoples." Parts of the ancient world that drank

wine instead of beer used a paste composed of grape juice and flour that was allowed to

begin fermenting, or wheat bran steeped in wine, as a source for yeast. The most common

source of leavening, however, was to retain a piece of dough from the previous day to use

as a form of sourdough starter.

A major advance happened in 1961 with the development of the Chorleywood Bread

Process, which used the intense mechanical working of dough to dramatically reduce the

fermentation period and the time taken to produce a loaf. The process, whose high-energy

mixing allows for the use of inferior grain, is now widely used around the world in large

factories.

Recently, domestic breadmakers that automate the process of making bread have become

popular in the home.

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CULTURAL AND POLITICAL IMPORTANCE OF BREAD

As a foodstuff of great historical and contemporary importance, in many cultures in the

West and Near and Middle East bread has a significance beyond mere nutrition. The Lord's

Prayer, for example, contains the line "Give us this day our daily bread"; here, "bread" is

commonly understood to mean necessities in general. Bread is also significant in

Christianity as one of the elements (alongside wine) of the Eucharist; see sacramental

bread. The word companion comes from Latin com- "with" panis "bread". The Roman poet

Juvenal satirised superficial politicians and the public as caring only for "panem et

circenses" (bread and circuses). In Israel the most usual phrase in work related

demonstrations is "lekhem, avoda" [bread, work], and during the 1950s, the beatnik

community used the term bread as a euphemism for money. In Cockney Rhyming Slang,

bread means money and is derived from the phrase bread and honey. The word bread is

now commonly used around the world in English speaking countries as a synonym for

money (as also is the case with the word dough.)

The cultural importance of "bread" goes beyond slang, however, to serve as a metaphor for

basic necessities and living conditions in general. A "bread-winner" is a household's main

economic contributor and has little to do with actual bread-provision, for example. This also

goes along with the phrase "putting bread on the table". A remarkable or revolutionary

innovation is often referred to as "the greatest thing since sliced bread". In the USSR in

1917, Lenin and his fellow Bolsheviks promised "Peace, Land, and Bread." The term

"breadbasket" is often used to denote an agriculturally productive region. In Slavic cultures

bread and salt is offered as a welcome to all guests. In Egyptian Arabic, the word for life,

'ayish, is also the colloquial word for bread (the formal is 'khoubz'). In India, life's basic

necessities are often referred to as "roti, kapra aur makan" [bread, cloth and house.

The political significance of bread is considerable. In Britain in the nineteenth century the

inflated price of bread due to the Corn Laws caused major political and social divisions, and

was central to debates over free trade and protectionism. The Assize of Bread and Ale in

the thirteenth century demonstrated the importance of bread in medieval times by setting

heavy punishments for short-changing bakers, and bread appeared in the Magna Carta a

half-century earlier.

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Types

Bread is the staple food in Europe, European-derived cultures such as the Americas, and

the Middle East/North Africa, as opposed to East Asia whose staple is rice. Bread is usually

made from a wheat-flour dough that is cultured with yeast, allowed to rise, and finally baked

in an oven. Owing to its high levels of gluten (which give the dough sponginess and

elasticity), common wheat (also known as bread wheat) is the most common grain used for

the preparation of bread, but bread is also made from the flour of other wheat species

(including durum, spelt and emmer), rye, barley, maize (or corn), and oats, usually, but not

always, in combination with wheat flour. Although common wheat is best suited for making

highly risen white bread, other wheat species are capable of giving good black bread. Spelt

bread (Dinkelbrot) continues to be widely consumed in Germany, and emmer bread was a

staple food in ancient Egypt. Canadian bread is known for its heartier consistency due to

high protein levels in Canadian flour.

White bread is made from flour containing only the central core of the grain (endosperm).

Brown bread is made with endosperm and 10% bran. It can also refer to white bread with

added colouring (often caramel colouring) to make it 'brown'; commonly labeled in America

as "Wheat" bread (as opposed to "Whole Wheat" bread.)

Wholemeal bread contains the whole of the wheat grain (endosperm and bran). It is also

referred to as 'whole grain' or 'whole wheat' bread, especially in North America.

Wheat germ bread has added wheat germ for flavoring.

Whole grain bread can refer to the same as 'wholemeal bread', or to white bread with

added whole grains to increase its fibre content (i.e. as in "60% whole grain bread").

Roti is a whole wheat based bread eaten in South Asia. Chapatti is a larger variant of Roti.

Naan is a leavened equivalent to these.

Granary bread is bread made using flaked malted wheat grains malt. Trademarked to

Hovis, it is made from white or brown flour and flaked malted wheat grains. The standard

malting process is modified to maximise maltose / sugar content but minimise residual

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alpha amylase content. Other flavour components are imparted from partial fermentation

due to the particular malting process used and to Maillard reactions on flaking / toasting.

Rye bread is made with flour from rye grain of variable levels. It is higher in fiber than many

common types of bread and is often darker in color and stronger in flavor. In Scandinavia,

Germany, Finland, the Baltic States, and Russia, rye is a popular type of bread.

Unleavened Bread or Matzah used for the Jewish feast of Passover, does not include

yeast, thus it does not rise.

Sourdough bread is made with a starter.

Researchers at the Agricultural Research Service are inventing new whole-grain oat and

barley breads that offer more antioxidants and fibers than traditional whole-grain breads.

Quick breads

Quick breads usually refer to breads chemically leavened, usually with both baking powder

and baking soda, and a balance of acidic ingredients, and alkaline ingredients. Examples

include: pancakes and waffles, muffins and carrot cake, Boston brown bread, and zucchini

and banana bread.

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Composition and chemistry

Formulation

The amount of flour is the most significant measurement in a bread recipe, as it affects

texture and crumb the most. Professional bakers use a system of percentages known as

Bakers' Percentage in their recipe formulations, and measure ingredients by weight instead

of by volume. Measurement by weight is much more accurate and consistent than

measurement by volume, especially for the dry ingredients.

Flour is always stated as 100%, and the rest of the ingredients are a percent of that amount

by weight. Common table bread in the U.S. uses approximately 50% water, resulting in a

finely textured, light, bread. Most artisan bread formulas contain anywhere from 60 to 75%

water. In yeast breads, the higher water percentages result in more CO2 bubbles, and a

coarser bread crumb. One pound (~ 450 g) of flour will yield a standard loaf of bread, or two

French loaves.

Calcium propionate is commonly added by commercial bakeries to retard the growth of

molds.

Flour

Flour is a product made from grain that has been ground into a powdery consistency. It is

flour that provides the primary structure to the final baked bread. Commonly available flours

are made from rye, barley, maize, and other grains, but it is wheat flour that is most

commonly used for breads. Each of these grains provides the starch and protein necessary

for the production of bread.

The quantity of the proteins contained in the flour serve as the best indicator of the quality

of the bread dough and the finished bread. While bread can be made from all-purpose

wheat flour, for quality bread a specialty bread flour, containing more protein, is

recommended. If one uses a flour with a lower (9-11%) protein content to produce bread, a

longer mixing time will be required to develop gluten strength properly. This extended

mixing time leads to oxidization of the dough,[citation needed] which gives the finished

product a whiter crumb, instead of the cream color preferred by most artisan bakers.

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Wheat flour in addition to its starch contains three water-soluble protein groups, albumin,

globulin, proteoses, and two non-water soluble protein groups, glutenin and gliadin. When

flour is mixed with water the water-soluble proteins dissolve, leaving the glutenin and gliadin

to form the structure of the resulting dough. When worked by kneading, the glutenin forms

strands of long thin chainlike molecules while the shorter gliadin forms bridges between the

strands of glutenin. The resulting networks of strands produced by these two proteins are

known as gluten. Gluten development improves if the dough is allowed to autolyse.

Liquids

Water, or some other liquid, is used to form the flour into a paste or dough. The volume of

liquid required varies between recipes, but a ratio of 1 part liquid to 3 parts flour is common

for yeast breads, while recipes that use steam as the primary leavening method may have a

liquid content in excess of one part liquid to one part flour by volume. In addition to water,

other types of liquids that may be used include dairy products, fruit juices, or beer. In

addition to the water in each of these, they also contribute additional sweeteners, fats,

and/or leavening components.

Leavening

Leavening is the process of adding gas to a dough before or during baking to produce a

lighter, more easily chewed bread. Most bread consumed in the West is leavened.

However, unleavened breads have symbolic importance in Judaism and Christianity. Jews

consume unleavened bread called matzo during Passover. They are also used in the

Roman Catholic Christian liturgy when they celebrate the Eucharist, a rite derived from the

narrative of the Last Supper when Jesus broke bread with his disciples, perhaps during a

Passover Seder. On the other hand, the Orthodox Church always uses leavened bread.

Chemical leavening

A simple technique for leavening bread is the use of gas-producing chemicals. There are

two common methods. The first is to use baking powder or a self-rising flour that includes

baking powder. The second is to have an acidic ingredient such as buttermilk and add

baking soda. The reaction of the acid with the soda produces gas.

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Chemically leavened breads are called quick breads and soda breads. This technique is

commonly used to make muffins, pancakes, American-style biscuits, and sweet breads

such as banana bread.

Yeast leavening

Yeast

Many breads are leavened by yeast. The yeast used for leavening bread is Saccharomyces

cerevisiae, the same species used for brewing alcoholic beverages. This yeast ferments

carbohydrates in the flour, including any sugar, producing carbon dioxide. Most bakers in

the U.S. leaven their dough with commercially produced baker's yeast. Baker's yeast has

the advantage of producing uniform, quick, and reliable results, because it is obtained from

a pure culture. Many artisan bakers produce their own yeast by preparing a 'growth culture'

which they then use in the making of bread. This culture kept in the right conditions will

continue to grow and provide leavening for many years.

Both the baker's yeast and the sourdough method of baking bread follow the same pattern.

Water is mixed with flour, salt and the leavening agent (baker's yeast or sourdough starter).

Other additions (spices, herbs, fats, seeds, fruit, etc.) are not necessary to bake bread, but

are often used. The mixed dough is then allowed to rise one or more times (a longer rising

time results in more flavor, so bakers often punch down the dough and let it rise again),

then loaves are formed, and (after an optional final rising time) the bread is baked in an

oven.

Many breads are made from a straight dough, which means that all of the ingredients are

combined in one step, and the dough is baked after the rising time. Alternatively, dough can

be made using a pre-ferment, when some of the flour, water, and the leavening are

combined a day or so ahead of baking, and allowed to ferment overnight. On the day of the

baking, the rest of the ingredients are added, and the rest of the process is the same as

that for straight dough. This produces a more flavorful bread with better texture. Many

bakers see the starter method as a compromise between the highly reliable results of

baker's yeast, and the flavor/complexity of a longer fermentation. It also allows the baker to

use only a minimal amount of baker's yeast, which was scarce and expensive when it first

became available. Most yeasted pre-ferments fall into one of three categories: poolish or 28

pouliche, a loose-textured mixture composed of roughly equal amounts of flour and water

(by weight); biga, a stiff mixture with a higher proportion of flour; and pâte fermentée, which

is simply a portion of dough reserved from a previous batch. Sourdough (also known as

levain or "natural leaven") takes it a step further, creating a pre-ferment with flour and water

that propagates naturally occurring yeast and bacteria (usually Saccharomyces exiguus,

which is more acid-tolerant than S. cerevisiae, and various species of Lactobacillus.)

Sourdough

The sour taste of sourdoughs actually comes not from the yeast, but from a lactobacillus,

with which the yeast lives in symbiosis. The lactobacillus feeds on the byproducts of the

yeast fermentation, and in turn makes the culture go sour by excreting lactic acid, which

protects it from spoiling (since most microbes are unable to survive in an acid environment).

All yeast-leavened breads used to be sourdoughs, and the leavening process was not

understood until the 19th century, when with the advance of microscopes, scientists were

able to discover the microbes that make the dough rise. Since then, strains of yeast have

been selected and cultured mainly for reliability and quickness of fermentation. Billions of

cells of these strains are then packaged and marketed as "Baker's Yeast". Bread made with

baker's yeast is not sour because of the absence of the lactobacillus. Bakers around the

world quickly embraced baker's yeast for it made baking simple and so allowed for more

flexibility in the bakery's operations. It made baking quick as well, allowing bakeries to make

fresh bread from scratch as often as three times a day. While European bakeries kept

producing sourdough breads, in the U.S., sourdough baking was widely replaced by baker's

yeast, and only recently has that country (or parts of it, at least) seen the rebirth of

sourdough in artisan bakeries. According to Alton Brown, host of Food Network's Good

Eats television show, each region of the world has different strains of lactobacillus, hence

the flavor of the bread made from home starters is unique. The San Francisco Bay Area is

especially famous for its sourdough breads.

Sourdough breads are most often made with a sourdough starter (not to be confused with

the starter method discussed above). A sourdough starter is a culture of yeast and

lactobacillus. It is essentially a dough-like or pancake-like flour/water mixture in which the

yeast and lactobacilli live. A starter can be maintained indefinitely by periodically discarding

a part of it and refreshing it by adding fresh flour and water. (When refrigerated, a starter

29

can go weeks without needing to be fed.) There are starters owned by bakeries and

families that are several human generations old, much revered for creating a special taste

or texture. Starters can be obtained by taking a piece of another starter and growing it, or

they can be made from scratch. There are hobbyist groups on the web who will send their

starter for a stamped, self-addressed envelope, and there are even mailorder companies

that sell different starters from all over the world. An acquired starter has the advantage of

being more proven and established (stable and reliable, resisting spoiling and behaving

predictably) than from-scratch starters.

There are other ways of sourdough baking and culture maintenance. A more traditional one

is the process that was followed by peasant families throughout Europe in past centuries.

The family (usually the woman was in charge of breadmaking) would bake on a fixed

schedule, perhaps once a week. The starter was saved from the previous week's dough.

The starter was mixed with the new ingredients, the dough was left to rise, then a piece of it

was saved (to be the starter for next week's bread). The rest was formed into loaves which

were marked with the family sign (this is where today's decorative slashing of bread loaves

originates from), and taken to the communal oven to bake. These communal ovens over

time evolved into what are known today as bakeries, when certain people specialized in

bread baking, and with time enhanced the process so far as to be able to mass produce

cheap bread for everyone in the world.

Steam leavening

The rapid expansion of steam produced during baking leavens the bread, which is as

simple as it is unpredictable. The best known steam-leavened bread is the popover. Steam-

leavening is unpredictable since the steam is not produced until the bread is baked.

Steam leavening happens regardless of the rising agents (baking soda, yeast, baking

powder, sour dough, beaten egg whites, etc.)

The leavening agent either contains air bubbles or generates carbon dioxide.

The heat vapourizes the water from the inner surface of the bubbles within the dough.

30

The steam expands and makes the bread rise.

It is actually the main factor in the rise of bread once it has been put in the oven. CO2

generation, on its own, is too small to account for the rise. Heat kills bacteria or yeast at an

early stage, so the CO2 generation is stopped.

Bacterial leavening

Salt rising bread employs a form of bacterial leavening that does not require yeast.

Although the leavening action is not always consistent, and requires close attention to the

incubating conditions, this bread is making a comeback due to its unique cheese-like flavor

and fine texture.

Aeration

Aerated bread is leavened by carbon dioxide being forced into dough under pressure. The

technique is no longer in common use, but from the mid 19th to 20th centuries bread made

this way was somewhat popular in the United Kingdom, made by the Aerated Bread

Company and sold in its high-street tearooms.

Fats or shortenings

Fats such as butter, vegetable oils, lard, or that contained in eggs affects the development

of gluten in breads by coating and lubricating the individual strands of protein and also

helping hold the structure together. If too much fat is included in a bread dough, the

lubrication effect will cause the protein structures to divide. A fat content of approximately

3% by weight is the concentration that will produce the greatest leavening action[citation

needed]. In addition to their effects on leavening, fats also serve to tenderize the breads

they are used in and also help to keep the bread fresh longer after baking.

Bread improvers

31

Bread improvers are frequently used in the production of commercial breads to reduce the

time that the bread takes to rise, and to improve the texture and volume of bread. Chemical

substances commonly used as bread improvers include ascorbic acid, hydrochloride,

sodium metabisulfate, ammonium chloride, various phosphates, amylase, and protease.

Sodium/salt is one of the most common additives used in production. In addition to

enhancing flavor and restricting yeast activity, salt affects the crumb and the overall texture

by stabilizing and strengthening the gluten. Some artisan bakers are foregoing early

addition of salt to the dough, and are waiting until after a 20 minute "rest." This is known as

an autolyse,and is done with both refined and with whole grain flours.

The principles of bread making

The basic ingredients of leavened bread are flour (usually wheat flour), salt, yeast and

water. Other ingredients can be added to alter the flavour, appearance and keeping

qualities of the bread.

Fat or oil can be added to improve the flavour and help to keep the bread fresh for longer.

Milk can be used instead of or in combination with water to make a bread with a softer

texture. Savoury ingredients such as onion, tomato, cheese or herbs and sweet ingredients

such as sugar, cinnamon and dried fruits can all be added to the basic dough to make a

range of products.

A combination of different flours, such as rye, cassava, sorghum, millet or maize can be

mixed with the wheat flour in different proportions to produce a range of different breads.

At least 70% wheat flour must be used in leavened breads to allow the bread to rise.

Unleavened breads are made from many different types of flour, depending upon what is

locally available. Salt and water are added to the flour, but no yeast is used. The flour and

water are mixed and kneaded to give a smooth dough that is baked into a crisp flat bread.

Examples of unleavened bread include chapattis, rotis, matzos and tortillas.

The serving of bread

32

Bread can be served at any temperature. Once baked, it can subsequently be toasted. It is

most commonly eaten with the hands, or sometimes with a knife and fork. It can be eaten

by itself or as a carrier for another, usually less compact food. Bread may be dipped into a

liquid (such as gravy, olive oil, or sardine pâté), topped with various spreads, both sweet

and savory, or serve as the enclosure for the ubiquitous sandwich with any number of

varieties of meat, cheese, vegetables or condiments inside.

Bread crust

The bread crust is formed from exposed dough during the cooking process. It is hardened

and browned through the Maillard reaction using the sugars and amino acids and the

intense heat at the bread surface. The nature of a bread's crust differs depending on the

type of bread and the way it is baked. Commercial bread is baked using jets that direct

steam towards the bread to help produce a desirable crust. Bread crusts are sometimes

considered unpalatable, especially and notoriously by young children, who commonly

remove and throw away the crusts. Some manufacturers, such as Sara Lee, have begun to

market special crust-less breads. But for many, crusts are part of the allure of a delicious

loaf of bread.

Breads across different cultures

Being the simplest, cheapest and most basic type of food, bread is often referred as a

synecdoche for "food" in general, in some languages and dialects, such as Greek and

Punjabi. There are many variations on the basic recipe of bread worldwide, including pizza,

chapatis, tortillas, baguettes, brioche, pitas, lavash, biscuits, pretzels, naan, bagels, puris,

and many others.

In Mexico bread is called pan (Spanish for bread). Although corn tortillas are the staple

bread in most of Mexico, breadrolls in many varieties are an important daily food for city

dwellers. Popular breads in Mexico include the bolillo roll and pan dulce. There are many

varieties, about 1,000. Pan dulce, which is Spanish for "sweet bread", is primarily eaten at

breakfast.

33

In Peru, pan has many variations due to the diversity of Peruvian cuisine. People usually

eat Pan de piso, and Pan serrano. There are also some kind of bread made of potatoes,

currently popular in the Andes. Bizcochos are sweet bread usually eaten with some butter

and hot chocolate. A dough made with cooked pumpkin or squash, often shaped and fried

into doughnuts and served with a sweet fruity dipping sauce, is a traditional favorite.

In Spain bread is called pan. There is a region called Tierra del Pan (literally translated as

"Land of the Bread"), located in the province of Zamora, where economy was in the past

joined to this activity.

In South Asia ( India, Pakistan, Middle East, etc.), roti or chapati, types of unleavened flat

breads usually made from wholewheat flour and baked on a hot iron griddle called a tava,

form the mainstay of the peoples' diet. Rotis and naans are usually served with curry

throughout the region. A variant called makki di roti uses maize flour rather than white flour.

Another variant is puri, a thin flat bread which is fried rather than baked and puffs up while

cooked. Paratha is another variation on roti. Naan (leavened wholewheat bread), however,

is baked in a tandoor or clay oven and is rarely prepared at home. White and brown breads

are also very common, but not as much as roti.

In the Philippines, pandesal (or pan de sal; literally, bread of salt or salt bread) is a rounded

bread usually eaten by Filipinos during breakfast.

Germany prides itself on having the largest variety of breads worldwide. More than 300-500

basic kinds of bread come together with more than 1,000 types of small bread-rolls and

pastries. It has been estimated that the basic kinds of bread are so widely varied by more

than 16,000 local bakeries that more than 1,000 different breads have been presented at a

2005 Cologne bread show.Germans are worldwide the biggest consumers (per capita) of

bread followed by Chile.

In Scandinavian and Nordic countries, four grain types dominated in the prehistoric era

(prior to 1000 AD). Barley and rye are the oldest; wheat and oats are more recent. During

the Iron Age (500 AD–1050 AD), rye became the most commonly used grain, followed by

34

barley and oats. Scandinavian soldiers apparently learned baking techniques while working

as mercenaries in the Roman army (200–400 AD). They subsequently took the technique

home with them as a way to show that they had been employed in high-status work on the

continent. Early Christian traditions promoted an interest in bread. Rye was also the most

commonly used grain for bread up until the beginning of the 20th century. Today, older

grain types such as emmer and spelt are once again being cultivated and new bread types

are being developed from these grains. Culturally, Germany has influenced most of the

bread types in the Nordic countries. However, in the eastern part of Finland, there is a

cultural link to Russia and Slavic bread traditions.

In the late 19th century, Danish bakers in the larger towns baked fresh bread in the

morning. This bread, called morgenbrød, primarily made from wheat and intended for the

rising bourgeoisie, was baked into various shapes and with a variety of seasonings. Since

then, this freshly-baked bread has been produced in every Danish baker's shop, along with

a variety of other breads. This decentralised form of baking bread alongside the more

modern industrialised production of bread seems to be characteristic of the Danish bread

sector. Consumption, to a great extent, has switched from rye bread to wheat bread.

Finland and Russia both have dark, sourdough breads made of rye. Traditional Finnish rye

bread is disc-shaped, with a hole in the center for easier storing. These breads have a

rougher composition and a stronger taste than wheat bread, and can thus be stored for

longer periods of time. Some families may still have leaven, handed down from one

generation to the next, that they use for baking these breads. . Bread is made from all four

of the cereals grown in Finland: wheat, rye, barley and oats; these are usually ground into

various grades. Rye bread can be either light or dark in colour, depending on the type of

flour mixture used. A few wheat breads are still made in Finland, although most are simple

buns or loaves of sliced or unsliced bread. Vesirinkeli (water rings), are small, almost

tasteless rings of yeast-leavened wheat bread, which resemble bagels. The potato,

although a late introduction to Finland in the early 19th Century, features heavily in food

culture and has found its way into many kinds of bread.

With the settlement Iceland circa 800–900 AD, grain, in the form of barley was brought,

cultivated and used for bread and porridge. Grain cultivation is thought to have been

35

abandoned before 1600 due to harsher climatic conditions, and subsequently most grains

such as barley and rye were imported. The scarcity of grain was overcome in different ways

in different parts of the country. In some areas, grain was made to go further using dulse

(Palmaria palmata; Icelandic söl), Iceland Moss (Cetraria islandica; Icelandic fjallagrös) or

Irish Moss (Chondrus crispus; Icelandic fjörugrös) in compotes and breads. It was not until

the 18th century that it became common practice to make leavened rye breads; sourdough

was mostly used. Rye breads baked in hot springs are a popular item today, and are served

for local consumption as well as for tourists. In general, stock fish (harðfiskur) was served

as a bread substitute, eaten with butter on the side with almost every meal. Today, it is a

popular snack which has found a new target group within the sports food market due to its

high protein and favourable amino acid content. Most types of breads available in other

Western countries are now also available in Iceland, either baked in Iceland or imported.

Everyday bread is mostly made by industrial bakeries or at the local bakery. Of the bread

types currently available, flatbrauð (flatbread) and laufabrauð (leaf bread) have the longest

history.

Many new types of bread have reached the markets in Norway in recent years. A high

percentage of people reported regularly eating bread types such as spelt, specialty,

gourmet, and fibre/bran bread, as well as ciabattas and baguettes, although very few

reported doing so on a daily basis. Norwegian bakers now have competition from abroad.

The wholegrain bread from local bakers must give way to huge lorry loads of baguettes and

frozen dough offering cheaper products. Flatbread is still a very popular bread type.

In Sweden, during the transion to a modern urban and industrialised society (19th century

AD), bread types changed when large industrial bakeries introduced new soft bread. From

from the early 1920s, these were often sweetened. From then on, bread was bought from

stores and bakeries, rather than baked at home, as had previously been the case. Regional

variation decreased due to the transportation and marketing of bread as a national product.

The consumption of bread products of various kinds has increased since the 1990s, and

wholegrain bread and wheat bread are the most popular. Many older bread types still exist

alongside the newer varieties.

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In Britain there is a wide variety of traditional breads, often baked in a rectangular tin. One

such type of traditional bread is known as a stottie cake. This is a thick, flat, round loaf that

is common in North East England.

In Scotland, another form of bread called plain bread is also consumed. Plain bread loaves

are noticeably taller and thinner, with burned crusts at only the top and bottom of the loaf.

Plain bread has a much firmer texture than English and American pan bread. Plain bread is

becoming less common as the bread consumed elsewhere in Britain is becoming more

popular with consumers.

In Ireland, it is traditionally held that the end of a loaf of bread (the 'heel' or 'hilt' of the loaf)

is the best part of the loaf. Other stories and myths surround this piece of the bread in Irish

Mythology. Irish soda bread, developed to make the most of the soft wheat grown in

Ireland, is unusual for a European bread in that it is a quick bread, using the reaction of

buttermilk and baking soda rather than yeast to rise.

In France, pan bread is known as pain de mie and is used only for toast or for making

stuffing; standard bread (in the form of baguettes or thicker breads) has a thick crust and

often has large bubbles of air inside. It is often baked three times daily and is sold totally

unwrapped for a crisp crust. Some fancy breads contain walnuts or are encrusted with

poppy seeds.

Due to its long history of regional political division, Italy specializes in many different kinds

of bread, reflecting its great regional variation and widely different breadmaking recipes and

traditions. As a rule of thumb, rolls are typical of the northern regions, while large loaves are

typical of the southern regions. Bread often has a small quantity of olive oil, butter, or

rendered lard mixed into the dough to make it softer and more palatable. Traditional rustic

breads include sfilatino imbottito (a stuffed bread roll) and pizza bianca (a flat white

bread).Focaccia is quite popular in Italy and southern France. In Provence, it is known as

fougasse or fouace, with the former becoming increasingly common. Fougasse can now be

bought all over France. It is usually seasoned with olive oil and herbs, and often either

topped with cheese or stuffed with meat or vegetables. Focaccia doughs are similar in style

and texture to pizza doughs.

37

In the United States, traditional breads include cornbreads and various quick breads, such

as biscuits. Cornbread is made from cornmeal and can differ significantly in taste and

texture from region to region. The South generally prefers white cornmeal with little to no

wheat flour or sweeteners added. It is traditionally baked in a cast-iron skillet and ideally

has a crunchy outside and moist inside. The North, however, usually prefers yellow

cornmeal with sometimes as much as half wheat flour in its composition, as well as sugar,

honey, or maple syrup. This results in a bread that is softer and sweeter than its southern

counterpart. Homemade wheat breads are made in a rectangular tin similar to those in the

United Kingdom. Rolls, made from wheat flour and yeast, are another popular and

traditional bread, eaten with the dinner meal. Sourdough biscuits are traditional "cowboy

food" in the West. The San Francisco Bay Area is known for its crusty sourdough. Spoon

bread, also called batter bread or egg bread, is made of cornmeal with or without added

rice and hominy, and is mixed with milk, eggs, shortening and leavening to such a

consistency that it must be served from the baking dish with a spoon. This is chiefly popular

in the South. Up until the 20th century (and even later in certain regions), any flour other

than cornmeal was considered a luxury; this would explain the greater variety in cornbread

types compared to that of wheat breads. Commercially, the most popular bread has been a

soft-textured type with a thin crust that is usually made with milk and is slightly sweet; this is

the type that is generally sold ready-sliced in packages. It is usually eaten with the crust,

but some eaters or preparers may remove the crust due to a personal preference or style of

serving, as with finger sandwiches served with afternoon tea. Some of the softest bread,

including Wonder Bread, is referred to as "balloon bread". Though white "sandwich bread"

is the most popular, Americans are trending towards more artisanal breads. Different

regions of the country feature certain ethnic bread varieties including the French baguette,

the Ashkenazi Jewish bagel, scali (an Italian-style bread made in New England), Native

American frybread (a product of hardship, developed during the Indian resettlements of the

19th century), and Jewish rye, a bread commonly associated with delicatessen cuisine.

Christian traditional societies (usually in poor communities), used to respect bread since

Jesus symbolised his body with it. The sign of the cross was performed with the knife on

the bread's surface, before the loaf was cut. Sometimes it was considered a sin to

desecrate bread (e.g., throw it away).

38

Jews have traditionally baked challah, a type of egg bread with a thin, hard crust and a soft,

well-leavened center. It is made by wrapping plaits of dough and then lightly baking them in

an oven. Challah is sometimes sweetened using honey and sometimes includes raisins.

During Passover, unleavened bread, in the form of various types of matzo, is required due

to the Biblical injunction to avoid any form of leaven during this time of year. There is some

debate within the Jewish community as to whether dairy products are allowed in kosher

bread; some authorities maintain that bread must be strictly pareve to avoid combining

meat and dairy in the same meal, while others feel it is acceptable as long as a sign of

some sort (usually a different loaf shape, but others are known) is baked into the loaf to

distinguish it from pareve bread.

In Morocco and West North Africa, a round bread which is roughly four inches tall is used to

eat most of the Mediterranean's watery cuisine. They also have a thick and chewy fried

bread which is smothered in oil beforehand. The rghifa bread is a staple in Morocco's food

and consists of several layers of lightly cooked bread.

In China, the traditional bread is Mantou. It is made by steaming or deep frying dough made

from either wheat flour or rice. In Northern China, Mantou is often eaten as an alternative

staple to rice. Steamed Mantou is similar to western white bread, but since it is not baked, it

does not have a brown outer crust. Mantou that have a filling such as meat or vegetables

(Char Siu Bao, for example) are called "baozi".

There are different types of traditional 'cheese breads' in many countries, including Brazil,

Colombia, Italy and Russia.

39

BREAD MANUFACTURING

AND PROCESSING

METHODS & MATERIALS

40

AUTOMATED   BREAD     PLANT   LAYOUT

Bread  plants  layout  consists of  mixers  , dough elevators ,  divider ,hander up ,

inter prover , moulding , final prover , oven , depanner and cooling tunnel .

Point s  to keep in mind while planning for bread plant layout

 Mixer with  dough elevators or  gravity tipping

 Final prover  loading manual or  automatic

 Oven  to be either  tunnel type  or  swingtray  as per requirement

  Oven  Loading to be  manual  or automatic

 Cooling tunnel to have  atleast  2- 3 hours  cooling time  hence check the

length .

 Ventilation of the baking hall

41

BREAD  MANUFACTURINGFlow  Diagram  for bread manufacturing

42

BREAD RECIPE

Added ingredients:

- Yeast -

Bakers yeast is a living micro-organism that is used to make the dough rise. When yeast

has optimal conditions to grow (warmth, moist and food) it becomes active and starts to

ferment. Yeast fermentation is the conversion of sugars to carbon dioxide, water and

alcohol.

Bakers yeast can be obtained as compressed fresh yeast, but is mainly available as dried

yeast. Dried yeast is easy to transport and store and has a longer shelf life than

compressed yeast. It needs to be reconstituted in five times its own weight of warm water

before it is used in a bakery. The amount of yeast added depends on the time and

temperature of fermentation but is usually between 0.3 and 1.0% of the flour weight.

Salt

Salt is obtained from two sources - rock salt and seawater. Powdered rock salt is

recommended for baking as it is purer than seawater salt. The salt should be clean, free

from large lumps and easy to dissolve. Salt is used during fermentation for the following

reasons:

It emphasises flavour

It improves colouring

It reduces staling

It helps to strengthen the gluten of the dough

It helps to control the rate of fermentation.

Salt is hygroscopic therefore helps to retain moisture in the baked loaf.

Salt should be added at around 2.5-3% of the total weight of water. Care must be taken not

to add too much salt as this can prevent the yeast from working properly. Salt should be

stored in a dry place away from stored liquids, high humidity or damp.

Salt and yeast should not be allowed to come into direct contact with each other in the raw

state as the salt will damage the yeast cell walls and reduce or prevent fermentation.

43

Baking powder

Baking powder is a combination of two main ingredients - one alkaline (bicarbonate of

soda) and one acidic (cream of tartar). When the two ingredients are mixed together

thoroughly, then moistened and heated, they give off carbon dioxide gas. For the formula to

be successful, the ratio needs to be two parts of cream tartar to one part bicarbonate of

soda.

Sugar

Flour normally contains sufficient natural sugar (about 2.5-3%) for the fermentation, but

sometimes a little extra sugar is added to the yeast to help activate it.

In some countries sweetened bread is popular, but in general non-sweet breads are

preferred. Between 1 and 1.5% sugar is added to the flour.

Panela is unrefined dark sugar made from sugar cane juice. It can be used instead of

refined sugar.

Sugar for bread making should be fine and granulated. It gives breads their sweetness and

a good golden colour. Sugar also improves the eating and keeping quality of breads.

Fats

Fats used in baking include butter, margarine, bakers fats, vegetable oil.

When making bread, it is not necessary to add fat, although the inclusion of a small amount

of fat (up to 1% of the flour weight) can improve the keeping quality and softness of the loaf.

Some bakers like to add up to 3% fat as it improves the nutritional value of the bread.

Excessive use of fat is not recommended as it can inhibit the fermentation process.

Milk

Milk is used in several types of Breads. Fresh skimmed milk or reconstituted dried skimmed

milk are both suitable to use. Sour milk and buttermilk are also used in some products,

particularly for lactic fermented scones and buns.

Water

In breadmaking, water is mixed with the flour to make a strong, stretchy dough. The amount

of water added depends on the type of flour but is usually half the weight of flour used. The

water should be slightly warm (body temperature (36°C) is ideal) to encourage fermentation

by the yeast. It should not be hot as this reduces the yeast activity.44

The water should be clean and potable.

The pH of water varies from acid to alkaline. The length of time needed to mix the dough

depends partly on the pH of the dough. Alkaline doughs take longer to mix than acidic

doughs.

Fermenting dough has a pH between 5 and 6.

Raw materials: Flour

The quality of raw materials has an influence over the quality of the products. High quality

raw materials should be used.

Small-scale bakers do not normally have facilities for flour analysis and rely on information

supplied by the miller or wholesaler. There are a few simple tests that they can carry out

which give useful information about the flour quality.

Flour

Flour can be milled from a variety of cereals. The type available in each country or region

may depend upon the types of cereal grown, although wheat flour tends to be available in

most places.

Wheat flour

Wheat flour contains proteins known as glutens. These are capable of forming a strong

elastic network within the dough, which is very useful when making leavened bread.

The protein network traps the gas that is given off by the yeast during fermentation. This

causes the dough to increase in volume and produces a bread with a light texture.

If flours that are low in gluten are used to make leavened bread, the gas escapes and the

bread is flat and heavy.

Wheat flour is available in different grades according to the degree it is extracted from the

whole wheat grain. Flours of different extraction rates include the following:

- Wholemeal flour - 100% extraction

- Wheatmeal flour - 90-95% extraction

- Straight run flour - 70-72% extraction

- Patents - 20-40% extraction

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Non-wheat flours

There are a variety of non-wheat flours available that can be mixed with wheat flour to

make bread.

Cassava flour is a fine white powdery flour that has a shelf life of up to one year. It is widely

used as a staple food and for the production of a range of fried and baked goods including

bread, cakes and biscuits.

Cereal flours, especially from maize and sorghum, which are both staple crops, are used to

make breads and snackfoods.Sorghum is mainly used to make bread or porridge. Maize is

used to make tortillas, snacks and for the production of cornflour and thickeners.

Soy/composite flour is a fine creamy flour that is combined with maize flour or other cereal

flours to increase the protein content and balance the amino acid composition of the

composite flours. In this form it is used as a breakfast porridge and as a weaning food.

- Different types of wheat flour -

Different types of wheat flour are available in each country. Wholemeal flour is used for the

production of brown bread, rolls and other high fibre products.

Atta is a wheat flour that is suitable for making chappatis. It is also available as a

wheatmeal flour.

Special bakers flour (bread making flour) is a strong flour that is used for bread, rolls and

pastry. Bakers flour should contain a good quality gluten so that it can produce a light

bread.

Biscuit flour. This is a special blend of flour that is made for mechanical biscuit plants.

Self raising flour. This flour is a soft flour that is fortified with a chemical aerating additive

similar to baking powder. It is used for making chemically aerated breads such as soda

bread. Soft flour is used for cake making.

46

BREAD  RECIPE NORMAL BREAD

INGREDIENTS PERCENTAGE ON WT. BASIS OF  FLOUR

WATER 60%

SALT 1%

SUGAR 2%

SHORTENING 2%

YEAST 1.5-2%

BREAD RECIPE MILK BREAD

INGREDIENTS PERCENTAGE ON WT. BASIS OF  FLOUR

YEAST 3.8%-4%

 SUGAR 3%

MILK 18-20%

WATER 36%

                              Perservatives , flavours , essences ,  emulsifiers , dough conditioners

and other additives can be added as per requirement . Other varieties could  be  whole

meal wheat bread  or multi grain bread .

47

CALCULATION OF BREAD YIELD

During the production of bread, there are several stages where weight is lost. During

fermentation there is about 1% weight loss of air through the knock-back procedure.

Moisture loss through evaporation during baking, depanning and cooling can account for

about 9-11% weight loss. The baker must allow for about 10% loss of weight.

To obtain a 500g baked loaf, a piece of dough of 560g must be used. For an 800g loaf, a

dough piece of 880g should be used.

48

PROCESS OF BREAD MAKING

49

The sponge and dough process

The sponge and dough process is suitable for small bakeries where there is no mechanical

dough mixer available. The whole process is completed by hand.

The advantages of this process are better flavoured bread, better keeping quality and,

often, better appearance.

The sponge and dough process can be broken down into two parts:

First, a 'sponge' is formed. This is a fairly stiff batter that is made from part of the flour, the

yeast, some sugar and part of the water. These ingredients are thoroughly mixed together,

covered and left to ferment at a set temperature for a certain time. The length of time is

determined by the quantity of yeast used and can be as long as 14-16 hours.

Second is the 'dough' stage. The remainder of the flour, sugar and water, the fat or

margarine, salt and, sometimes, a small amount of yeast, are added to the sponge and

thoroughly mixed together to make a smooth, fairly stiff dough.

The final dough mixing by hand is strenuous, but properly made bread using this process

has an excellent flavour and an enhanced keeping quality.

The lengthier fermentation times for the sponge are more suitable to the single-handed

baker who can set the sponge in the afternoon (eg between 4.00 and 6.00pm) and then

continue with the dough at 6.00am the following morning. This allows the baker adequate

time for rest. It also makes a substantial saving in yeast.

50

The straight dough process

The straight dough process is really only suitable for mechanical mixing, although it can be

used when very small quantities of dough are made by hand.

All the ingredients are mixed together at the same time. Before mixing starts, the yeast is

activated in a little of the dough water. The temperature of the dough water is adjusted to

produce a pre-determined dough temperature which, together with the quantity of yeast

used, determines the length of the bulk fermentation. This can either be 'no-time' dough,

which is processed into loaves as soon as the dough has been mixed. Or it can be a dough

that is mixed and allowed to ferment in bulk for 1 hour or up to 10-12 hours.

About three quarters of the way through the estimated bulk fermentation time (BFT), the

dough will have swollen to its fullest extension. At this stage it is necessary to expel all the

gas from the dough. This is known as knock-back and can be done by hand or using a

machine.

The temperature is even throughout the dough so the yeast starts to function again and

generates more gas.

With a sponge that has a lower viscosity than a dough, no knock-back is required ans the

sponge collapses by itself then rises up again.

51

BREAD   MAKING PROCESS   FLOW IN AUTOMATED

BREAD PLANT

Mixing

Mixing  starts  with sifting flour  with help  of vibratory  sifter .Flour is then collected in

bowl and then weighed .All ingredient  are then added in  bowl .Ingerients are  flour ,

sugar ,fat, salt, yeast, gms powder, sodium stearoyl lactilate, smp solution ,bio-bake ,

Improvers, ammonium cholride , ascorbic acid , cystiene, pot.bromate, calcium propianate

and acetic acid  . These are added in std proportion as per requirement .

After addition of all ingredients bowl is moved to spiral mixer  where is done .Water

is added  in different quantities .Mixing time depends on  quality of flour in general mixing

time can vary from 6- 12 min . under mixing and over mixing can have  direct impact on

dough consistency . Dough quality can be checked with stretching the dough .dough

temperature is maintained between 80 deg f - 82 deg f .Role  of  Ingredients

FORMING

On completion of mixing dough bowl is lifted through  tilting hoist and from the hoist

bowl is tilted so as dough goes into hopper of Divider Hopper.

DIVIDER

Dough is  cut into  two equal  dough piece .Its  a mechanical device  which uses a

common crank  to cut , push and drop dough piece  through divider to conveyor .Volume of

the dough piece can be adjusted at divider . Divider is defined  as no of dough piece  per

min

HANDER UP

From divider  the dough piece moves to hander up which is mechanical device

conical in shape  on which dough piece takes curvelinear  path .It has got  blower  attached

to it  which continuously provides  air  on the path .Basic function of hander up  is to  give

dough piece  spherical shape and remove  moisture from surface from dough piece .

INTERPROOVER

52

Dough pieces are then transfered to  buckets of  interproover .Here dough piece are

allowed to travel for 5- 6 min .This helps in relaxation of dough as it would have  stress due

to mechanical  action  on it at divider.

MOULDER

It has  three set of roller . The dough piece is allowed to pass through these  rollers .

Now dough piece are  slighty flattened .

PRESSURE BOARD

Dough piece  are turned and fed into pressure board where it takes cylindrical shape

.Air is passed through the board .

FINAL PROOVER

These dough pieces are then carried to platform where these lobes

are twisted and kept in moulds ,two lobes are twisted in one mould box as per  wt  required

like 400 gms  or 800gms loaves . Mould box are greased prior to lobes  being put into.

Final proover has arrangement for steam which spreads uniformly  in entire

chamber.Temperatures at final proover is maintained between 36-38deg c.Humidity  and

temperature are maintained so as to get maximum of yeast activity .Precautions are taken

to see if there is over or under development  of dough . Speed can be varied at final

proover. Dough should rise 3/4 th of the mould .vol of mould is 1320cc for 400gm and

2700cc for 800 gm loaves . Travel of trays is longitudinal  in  swing tray type plant where as

in contray type it is vertical .Prooving time =75 min

Depending upon design  we can define capacity of final proover as

cap/cycle : no of loaves .no of racks x no of moulds box  per rack x no of mould in each box

.After dough has been developed these mould box are then transferred manually to baking

oven.

53

BREAD MANUFACTURING- BAKING

Mould  with dough  are placed in racks of oven . (They are developed from steam which

has been treated with at Final proover ) These are then allowed to  travel in baking zones

with temperature inside between - 250 - 280 deg c . Baking time : 26- 28 min Basic  ovens

are   CONTRAY OVENS  AND  SWING  TRAY TYPE.

CONTRAY OVEN : Compact and robust  , lidding  is done manualy and has fixed  racks

where mould box are placed .

SWING TRAY :  Large and spacious  takes large area in comparison with contray oven .  It

has hinged  tray  which swings  either way .lidding and unlidding  is done automatic .

Capacity of bread oven = no of racks  x no of mould box  x  no  of mould in each box

No of loaves /cycle . Baking consist of  two process  with regard  to starch .

Gelatinasation, Dexterisation

Gelantinasation :  This is  a process where  starch is heated  in presence of

water .gelantinasation occurs inside of  crumb  which is soft  and  molten  state during  the

baking period .

Dextrisation  : This is  a process  in which starch  is heated  in absence  of water .It results

into  a solid crust  formation at the top .Temperature required for dexterisation is  225 deg c

-and above .

Baking temperature also stops  yeast activity . Execessive Temperature  results  into

dark brown crust on loaves and   to avoid such instances  operator has to increase the

speed of oven . Hence by adjusting we can avoid under baking and over baking.

Baked loaves in mould box are then passed  through Depanner  where loaves are taken out

of mould box  and placed on racks . Which are then stationed in cooling tunnel  for loaves

to come to ambient temperature .

PACKING

Loaves   are  then  passed on to bread slicer . These slicers has  blades and no of blades

are as per no of slice required . normally 27 - 28 blades are  used for  normal bread .

Blades regularly regrinded  .Slices are then packed  in polybags   with codes and price .

54

Automated bagging machines are also available  where bagging is  automated . Most

popular method is to pack manually .

BREAD   PACKAGING

Bread packaging is evolving like any other bakery product packaging . Special

characteristic of bread which has to be considered while selecting packaging material are

Very short shelf life Softness Transportation Following materials are used by bakery

manufacturers for bread. Normal   weights   of bread packs available   are 250g , 400g , 800g

, 1000g Paper bags :Preferred by local   bakery manufacturers these are simple bags as per

size of the loaves. These are normally used for local population who prefers loaves rather

than slices of bread Wax paper : Still few of bakery manufacturers are   using   it . Automatic

sealing machines are used   for sealing Hdpe bags : Breads are packed   and   sealing is

done at one side   ,flow wrap machines are used   in automated bread manufacturing.

Ldpe bags : These a re vertical bags used for packing bread .and bag closure of ties are

used to seal the bag Poly bags : For products like   bun , pav   these sorts of packing

material are used.

These   are then placed in platic trays specifically made for handling of bread .These crates

are then transported   to retail shop and returned back to the manufacturers

FEW   OTHER ITEMS FOR BREAD PACKING Bag   closure - Different type of   bag closure

are available in market   these re usable and bit trendy in use Twist n Tie   or Wire tie : These

ties are used to tie knots in bread bags .Cost effective method to close bags Bread

Handling Plastic crates : These crates are used to handle bread bags during process,

packaging and transportation . Different   types of plastic trays   are available for   this

purpose .Bread bags are placed into these trays and are loaded in vans to be   unloaded at

reatil shops . Strength is important characteristics of these of trays.

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56

NUTRITIONAL

INFORMATION

Nutritional Information

Nutritional value per 100 g (3.5 oz)

Energy 1,113 kJ (266 kcal)

Carbohydrates 51 g

Dietary fiber 2.4 g

Fat 3 g

Protein 8 g

Vitamin A 0 IU

Thiamine (Vit. B1) 0.5 mg (38%)

Riboflavin (Vit. B2) 0.3 mg (20%)

Niacin (Vit. B3) 4 mg (27%)

Folate (Vit. B9) 111 μg (28%)

Vitamin B12 0 μg (0%)

Vitamin K 3.1 μg (3%)

Calcium 151 mg (15%)

Iron 3.74 mg (30%)

Magnesium 23 mg (6%)

Sodium 681 mg (30%)

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58

EQUIPMENTS FOR TESTING & QUALITY

CONTROL

EQUIPMENTS FOR TESTING & QUALITY CONTROL

Equipment category Scale Name of Equipment Technical Description

Temperature control S-Mthermometer general purpose

Made of stainless steel (0-150 C), this thermometer comprises a mercury-filled, toughened bulb, with an anti-roll cap. Seven versions are available, differing in temperature range and graduation. Length: 30.5cm.

Weight control

S-M add and wegh scale

This measures the weight of foods. The add-and-weigh facility allows the continuous weighing of ingredients to be carried out in the same bowl. Measurements are carried out in 25g increments. Capacity: 3kg.

S-M hanging scale These heavy duty, hanging scales have an adjustable tare. Capacity: 30kg x 100g.

M portable platform scale

These scales weigh bulky/large materials such as sacks of flour. The equipment includes a cast iron box, steel knife edges, and a platform-on-wheels. Weight of scales: 250kg. Dimensions: 40.6 x 63.7cm.

S-M electronic scale

These scales weigh in 1g increments. Any type of bowl or solid food can be placed onto the scales directly. There is also an add-and-weigh feature, and an automatic cut-off. Capacity: 4kg. Dimensions: 15 x 16 x 3cm.

Volume control

S-M mixer jugs

This jug can be used as either a measuring jug or a mixing bowl. It is fabricated from heat-resistant polypropylene and can withstand boiling water. The jug is graduated in pints, fluid ounces and millilitres with an overall capacity of 2 litres. Smaller jugs (0.57 and 1.1 litres (1 or 2 pints)) are also available.

S-Mpyrex measuring cylinders

This measuring cylinder has a capacity of 10-250ml.

pH control

S-Mbattery operated pH meter

This portable pH meter has a range of pH 2-12, with 0.1 pH accuracy.

S-M pH meter digital

This is a self-contained and portable instrument designed for accurate pH reading. The meter has an LED display for easy reading. Range: pH 0-14. Accuracy: pH +/- 0.01 unit, mV +/- 0.1% of full scale. Temperature compensation: 0-100°C. Power supply: 230V.

59

S-MWaterproof pocket pH meter

This easy to use, hand held pH meter is completely water proof and can be completely imersed in water. It has an easy-to read LCD and a positive push-button ON/OFF switch. The display indicates when a stable pH value has been reached, ensuring that only accurate readings are taken. Calibration is automatic and can be performed easily , even by non-technical operators. The meter has an auto-switch-off feature (after 10 minutes) that prolongs the life of the batteries and gives up to 300 hours of use.

S-MGroCheck Meter pH, EC and TDS

This combination model measures pH, EC (conductivity) and TDS (for measuring fertiliser application). It is an easy-to-use, hand held meter that is battery operated (total battery life is about 150 hours). It is supplied complete with probe, pH 7 buffer, 1.41 EC and 1500ppm calibration solutions, a 9V battery and instruction manual.

S-M

Combo Waterproof pH/EC/TDS tester

This battery-operated waterproof tester is designed for high accuracy pH, EC/TDS and temperature measurements. Calibration and temperature compensation is automatic.

S-MFisher Accumet (AP71) pH meters

A range of pH meters is available form Fisher Scientific. Easy to use, hand-held models come with a range of specifications and in various prices.

Brine control

S-M Brine meter This meter can be used to measure the percentage of salt in a solution.

S-M

Fisherbrand salt water/brine unit

This hand held equipment is a two scale unit that measures specific gravity and the concentration of salt in water (parts per thousand (ppt)). It has automatic temperature compensation. The meter measures salinity from 0-100ppt.

Testing equipment M samplers for milk

These are ladles which are dipped into milk to obtain a sample for testing.

Refractometers

S-M Fisherbrand Refractometers

These refractometers are handheld, easy to use and accurate, with a focusing eye piece. Nine models are available, that cover a range of applications and measurement scales. Some models have automatic temperature compensation (ATC) between 10 and 30C. The Brix scale is used to measure the sugar concentration in solutions such as fruit juice, wine and soft drinks. Different sizes are available as follows: 0-18 Brix; 0-32 Brix; 28-62 Brix; 45-82 Brix; 58-90 Brix.

S-M Pocket Refractometer Comes with leather carrying case.

S-M Sugar Refractometer

This measures sugar content. The following size ranges are available: 0-45% and 40-85%.

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Water treatment

S-M

sodastream filterstream on line water filter unit

This high specification water filter removes the chlorine taste, organic particles and herbicides from water. Easy installation, no plumbing skills are needed. Continuous supply of purer water from an extra tap fitted on the sink. Up to 2000 litres from one cartridge, recommended replacement interval is 6 months.

MUV water disinfection unit

This is used to treat water by destroying bacteria using ultra-violet light. It uses a single phase, 220V 50Hz power supply, or alternatively it can be battery-operated. Water flow is at 750 litres per hour.

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62

BREAD TYPES

DIFFERENT  TYPE OF BREADS

White bread

The most common variety of bread is white bread. It is made from wheat flour

(extraction rate of 77%) and is made into many different sizes, shapes and textures.

Ingredients such as other cereal or vegetable flours, seeds, herbs or a mixture of these can

be added.

Wholemeal or wholewheat bread Made from wholemeal flour (contains all the

components of the grain -close to 100% extraction rate), it has become more popular with

increasing knowledge of the health benefits of bran and wheat germ. Mixed grain bread

May be made from any combination of flours (e.g. wholemeal or white flour, rye meal or

flour), grains (e.g. kibbled grains, wheat germ, whole grains or wheat and other cereals)

and seeds (e.g. sesame seeds). Kibbled wheat and cracked wheat bread

Contains or is rolled in kibbled (cracked) wheat grains. Fibre-increased white breads

Made with the addition of bran or other fibre-containing material. Rye bread

Made from a combination of rye flour and wheat flour. Dark rye bread contains a higher

proportion of rye flour and rye meal than light rye and is consequently more dense, heavy

and has a stronger flavour. Pumpernickel is a heavy, dark bread made from rye flour, rye

meal and kibbled or cracked rye grains.

Sourdough bread Sourdough bread has a slightly sour flavour and a denser texture

than regular bread. Sourdough describes the raising agent used to make this type of bread.

A starter, made from a mixture of flour and water, serves as a medium for growing either

commercial yeast that is added to the mixture or the ever-present wild yeast that is

captured by the mixture from the air we breathe. (Yoghurt is also sometimes added to

provide yeast.) This mixture is allowed to sour through a fermentation process that

produces a gas and an acid. It is then used as a starter to leaven other breads; the gas

produced by the fermentation is trapped in the elastic gluten structure of the dough, causing

it to rise, while the acid imparts the final product with a tart flavour.

Damper

Traditionally baked in the Australian bush, damper is a chemically leavened white, round

bread.

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Lavash bread

A thin, flat bread made from white wheat flour, yeast, salt and water which is oven-

baked on a heated metal plate.

Bagel

A Jewish bread where the dough (with yeast) is shaped into a ring and thrown into boiling

water before baking. This gives the crust a chewy texture. It may be coated with poppy or

sesame seeds and can be flavoured, e.g. raisin and cinnamon.

Middle Eastern flat, pocket or pita bread

Flat, oval or round wheat bread made from flour, water, yeast and salt. The "pocket"

in some breads is made by resting the flattened pieces of dough under dry conditions so

that both sides become slightly drier than the centre. During baking at high temperature, the

steam produced inside the dough is trapped by the baked, drier outside layers. The pocket

can also be stuffed with various fillings. The Turkish version of pita bread is pide.

Naan

Made in India, Pakistan and Afghanistan, naan is a wheat-flour bread leavened with

a starter of the sourdough kind and cooked in a clay Tandoor oven. The clay and the smoke

in the tandoor combine to produce a characteristic flavour. The bread is flattish and has a

crisp crust.

Chapatti (chappati)

Sometimes called roti, chapatti is served throughout India, Pakistan and also Iran.

They are made from finely milled wholewheat flour, called atta. The dough is rolled into thin

rounds which are cooked in an iron pan or on a griddle. They are made every day in North

India where they are used as a plate to hold other food, curved to scoop up food or used for

dipping in soups or sauces.

Paratha or parata

An Indian flaky bread prepared by smearing the unleavened dough with ghee or oil and

then folding the dough. This procedure is repeated three times. The dough is then rolled out

and fried in oil or dry cooked on a griddle.

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Chinese steamed bread

Eaten in most countries of east Asia, Chinese steamed breads are shaped like a ball and

have either no filling, a sweet bean paste or a meat filling. Lao bing is a Chinese-style flat

bread which is baked in a pan until both sides are golden brown.

Chinese buns and dumplings

Buns and dumplings are common in north and South-East Asia. Manju, the generic term for

steamed Japanese buns, are either lightly baked or steamed buns prepared by steaming

fermented dough with a pork, curry or sweet bean paste filling. In northern China, mantou is

a steamed leavened bread without a filling, eaten as a staple in place of rice. Yit bien or

moon cake is a baked bun filled with nuts and seeds popular amongst Chinese populations.

Mantou or mantu describes the food category of dumplings in Asia. They resemble

ravioli and are stuffed with meat and/or vegetables and beans.

Gluten-free bread

Gluten-free bread is usually based on cornflour to which flour from gluten-free grains (such

as rice and maize), potato or pulses is added. Gluten-free bread has a denser, more

crumbly texture than traditional bread, since the presence of gluten is essential for the

typical structure and texture

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Types of bread

[1] Anadama bread

[2] Beer bread

[3] Biscuit

[4] Bread roll

[5] brown bread

[6] Brioche

[7] Broa

[8] Bun

[9] Bush bread

[10] Canadian White

[11] Cardamom bread

[12] Challah

[13] Chapati

[14] Cornbread

[15] Cottage loaf

[16] Damper

[17] Flatbread

[18] Focaccia

[19] Indian bread

[20] Lavash

[21] Matzo

[22] Mantou

[23] Melonpan

[24] Monkey bread

[25] Naan

[26] Pandoro

[27] Paratha

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[28] Pita

[29] Portuguese sweet bread

[30] Potato bread

[31] Pumpernickel

[32] Puri

[33] Roti

[34] Irish soda bread

[35] Rye bread

[36] Seed cakes

[37] Texas toast

[38] Tiger bread

[39] Tortilla

[40] White bread

[41] Whole wheat bread

[42] Zopf

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68

SUMMARY & CONCLUSIONS

FOOD MANUFACTURING

A total sequence of food operations, including the growth and selection of raw materials,

harvesting, processing, preservation, and distribution. In general, the aim of all food

manufacturing operations is to extend the availability of seasonal crops to year-round use.

Food manufacturing is not solely involved with the preservation of food but is also

concerned with the production of high-quality, appealing, wholesome food. To fulfill these

goals, five broad categories of food additives are often used: flavors, coloring agents,

preservatives, texturizing agents, and miscellaneous. The last category includes a variety of

substances that may retain moisture, control acidity, act as leavening agents, or provide

nutrients such as vitamins and minerals.

The final operation in the manufacturing process is that of packaging, which is governed by

the physicochemical attributes of the food, the preservation process involved, the gaseous

permeability desired, the conditions under which the product is to be stored, the desirability

of viewing the product through a clear film or glass, and the expense.

Food Manufacture:-

Packaged household food itemsPackaged foods are manufactured

outside the home for purchase. This can be as simple as a butcher preparing meat, or as

complex as a modern international food industry. Early food processing techniques were

limited by available food preservation, packaging and transportation. This mainly involved

salting, curing, curdling, drying, pickling, fermentation and smoking. Food manufacturing

arose during the industrial revolution in the 19th century. This development took advantage

of new mass markets and emerging new technology, such as milling, preservation,

packaging and labeling and transportation. It brought the advantages of pre-prepared time

saving food to the bulk of ordinary people who did not employ domestic servants.

At the start of the 21st century, a two-tier structure has arisen, with a few international food

processing giants controlling a wide range of well-known food brands. There also exists a

wide array of small local or national food processing companies. Advanced technologies

have also come to change food manufacture. Computer-based control systems,

sophisticated processing and packaging methods, and logistics and distribution advances,

can enhance product quality, improve food safety, and reduce costs.

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FOOD PROCESSING

Food processing is the methods and techniques used to transform raw ingredients into food

for human consumption. Food processing takes clean, harvested or slaughtered and

butchered components and uses them to produce marketable food products. There are

several different ways in which food can be produced.

[A]. One Off Production

This method is used when customers make an order for something to be made to their own

specifications, for example a wedding cake. The making of One Off Products could take

days depending on how intricate the design is and also the ability of the chef making the

product.

[B]. Batch Production

This method is used when the size of the market for a product is not clear, and where there

is a range within a product line. A certain number of the same goods will be produced to

make up a batch or run, for example at XYZ Bakery they will bake a certain number of

Bread loaves. This method involves estimating the amount of customers that will want to

buy that product.

[C]. Mass production

This method is used when there is a mass market for a large number of identical products,

for example, chocolate bars, ready meals and canned food. The product passes from one

stage of production to another along a production line.

[D]. Just In Time

This method of production is mainly used in sandwich bars such as Subway. All the

components of the product are there and the customer chooses what they want in their

product and it is made for them fresh in front of them.

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71

RECOMMENDATIONS & SUGGESTIONS

RECOMMENDATIONS AND SUGGESTIONS

The Performance Appraisal report must reveal the type of training input that any

executives needs and then only he/she should be nominated.

The executives must make a presentation and must share experiences and

knowledge with colleagues.

Strict action should be taken against those who remain absent during the factory

training programmes.

There must be an increased number of factory training programmes to motivate the

executives and employees on a regular basis and a track record of the training

programme attended must be kept so as to see what effect does the training have on

an executives, which exists in STAR FOOD PRODUCTS UDAIPUR.

More jobs related trainings should be arranged for the executives and the employees

of STAR FOOD PRODUCTS UDAIPUR.

Equal opportunities must be given to all the executives, employees and workers of

STAR FOOD PRODUCTS UDAIPUR.

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73

APPENDIX

BIBLIOGRAPHY

[1]. COMPANY PROFILE OF STAR FOOD PRODUCTS UDAIPUR.

[2]. GUIDANCE FROM FOUNDER CHAIRMAN OF STAR FOOD PRODUCTS

UDAIPUR.

[3]. GUIDANCE FROM DIRECTORS & EXECUTIVES OF STAR FOOD PRODUCTS

UDAIPUR.

[4]. WEBSITES:

[A]. www.bakerybazar.com

[B]. http://www.fao.org/inpho/content/fpt/CEREALS/prbread.htm.

[C]. www.wikipedia.org

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QUESTIONNAIRE

[1]. Are you satisfied with the prevailing food manufacturing and processing of STAR

FOOD PRODUCTS UDAIPUR?

[A]. Yes. [B]. No.

[2]. Would you all like to make changes in prevailing food manufacturing and processing

of STAR FOOD PRODUCTS UDAIPUR?

[A]. Yes. [B]. No.

[3]. Are you providing quality products against the resources paid by the customer?

[A]. Yes. [B]. No.

[4]. Have you ever done a survey to know your feedback in the market?

[A]. Yes. [B]. No.

[5]. What type of feedback you have got?

[A]. Good. [B]. Fair. [C]. Average.

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THANK YOU

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