BREAD TECHONOLY PRELUCRATION

INTRODUCTION
Bread baking transforms an ordinary kitchen into a laboratory of earthy
sights, smells, and tastes. A recipe, after all, reads like a scientific
experiment. The baker combines flour, yeast, liquid, and salt in a bowl,
shapes it all into a dough, lets the dough rise, and bakes it in a hot oven.
Flour, which gives bread its structure, is made by milling cereal grains
such as wheat, barley, or rye. In this process, the grain seeds are crushed,
releasing starch and proteins. Starch molecules are long, gangly polymers
of simple sugars linked head to tail by chemical bonds. Proteins are more
complex--a single protein may contain hundreds of amino acids strung
together like beads on a necklace. What gives bread its light, fluffy
texture? The answer is gliadin and glutenin, two proteins found in flour.
When flour is added to water and kneaded, these proteins swell up like
sponges and form a tough elastic substance called gluten. Gluten can
stretch and trap the bubbles of gas that make dough rise. That gas comes
from the leavening action of tiny one-celled fungi called yeast. When you
combine yeast with flour and water, you'll end up with a sticky white
dough. Inside the dough, fermentation is occurring and molecules are on
the move. Enzymes from the yeast cells attack starch, breaking it down
into glucose. Other enzymes transform glucose molecules into carbon
dioxide and ethanol. The carbon dioxide (CO2) gas then bubbles up
through the mixture, causing the dough to rise. Breads which are leavened
by baking powder instead of yeast lack the tasty molecules of fermented
bread. That's because when baking powder gets wet, a chemical reaction
occurs that releases only carbon dioxide, salt, and water. In breads
leavened with yeast, however, the yeast cells grow under anaerobic
conditions and cannot convert glucose molecules completely to gas. Some
sugar molecules get sidetracked and are converted into alcohols, acids,
and esters--substances which add to bread's flavor. Salt strengthens
gluten by slowing down the enzymes which catalyze the breakdown of
proteins. If you add too little salt, the dough is tough and sticky. If you add
too much, water flows out of yeast cells by osmosis. Then nutrients are
lost and production of carbon dioxide slows down. After dough rises a
couple of hours in a warm place, it's ready to go into the oven. There, heat
causes pockets of gas in the dough to expand. Eventually the crust
becomes toasty brown--and soon you're enjoying a slice of warm, homebaked bread.
Bread is a staple food prepared from a dough of flour and water , ussualy
by baking . It s a product of daily rations and it is necessary for vital
activity. Bread manufacturing process is a set of operations , after which
raw materials are converted into finished product auxiliaries. Unitary

operations sequence diagram represents the technological operations as

they occur in the preparation of bread.
They can be grouped as follows : a qualitative and quantitative control
operations , storge , preparation and dosing .

METHOD OF PREPARIG THE DOUGH

The preparation of the dough two methods : the direct method and
indirect method.
Direct method consits of dough using all raw and auxiliary materials . Is
the simpliest and quickest method of dough preparation . It is
characterized by high consumption of yeast . There are two methods of
preparing the dough by direct method : the classic and the rapid process.
In the classical procedure , the dough is kneaded by conventional mixing
for 10-15 minutes , then it is fermented for 2-3 hours at a temperature of
30-32 Celsius degrees. During the fermentation process must be
completed the dough fermentation and complete the process of increasing
the volume when it is fretting. Enzymatic hydrolysis occurs
macromolecular components of flour . An important process is the
enzymatic hydrolysis of the starch dependent on the amount of
fermentation gas , color of skin and the formation of aroma substances.
In the quick process , kneading dough at 25-26 celsius degrees in high
speed mixers with kneading arm , then fermented 10 to 20 . Oxidising
substances are used : the most often used ascorbic acid , increases the
proportion of yeast by 3-4 %.
FLOUR SALT-WATER-YEAST : are auxiliar materials.

Qualitative and quantitative reception

Storage of raw and auxiliaryPreparation of raw and auxiliary
materialsDosage raw and auxiliary materialskneading doughdough
fermentationRekneadingDough ProcessingCookingCooling

Operating unit in Scheme biphasic method of preparing a dough

The method comprises two phases biphasic technology : Maia dough

Maia is preparations of flour water and yeast. The amount of yeast used is
0.6-1.5 % and 20-25% compressed yeast liquid yeast . For initial
acidification in yeast can be added an amount of mature fermented yeast
called bass , its proportion is varying quality and extraction flour . When
processing poor quality flours can add yeast and salt in a proportion of 0.5
%.
Maia can be consistent, semi-fluid and fluid . Maia has consistently 41-44
% humidity . This moisture ensure hydration of proteins and the formation
of gluten . Maial size is given by the quantity of flour used in its
preparation . This represents 30-60 % of processed flour , depending on
the quality of flour .
For poor quality flour to yeast proportion is 30 % for good quality flour is
50 % and for strong flours of 60 % .
The purpose of changing the proportion of flour in yeast is changing the
amount of gluten that is subject to a long process of proteolysis during
fermentation Maial , aiming to protect gluten of lower quality and strong
gluten softening .
Consistency Maial is given by the amount of water used , it is varying
quality flour . For poor quality flour cook maiale great consistency by
reducing the amount of water used to getting Maial for strong flours
prepared maiale little consistency by increasing the amount of water
used .
Consistency Maial influence the activity of enzymes, including proteolytic
enzymes , they activate the easier the more consistent environment where
acting is less .
If lower quality flours where you want to limit the activity of proteolytic
enzymes pentruprotejarea gluten maiale working with great consistency ,
while in the case of strong flours where you want some degree of
proteolysis using maiale with less consistency .
Temperature Maial for poor quality flour is 25-26 C , for good quality flour
is 28 C and for strong flour is 28-29 C. Temperature influences the rate
processes in dough, including the process of proteolysis . For this process
to proceed at slower speeds where lower quality flours working with the
Maial lower temperature , thus ensuring its better stability and for strong
flours working with higher temperature 28-29 C , in order to facilitate the
proteolysis .
Fermentation time is 90-180 min depending on the quality of flour . The
lower limit ( 90 min) is used in case of poor quality flours and high

extraction , the upper limit ( 180 min) is used where strong flours and the
small extraction .
Maial processing parameter changes depending on the quality of the flour
is made in order to obtain a yeast with the best possible rheological
properties .
The dough is made from fermented yeast bubble which add remaining
flour , water and salt. Parameters of dough : consistency , temperature
and duration of fermentation is determined by the quality of the flour , the
same principles as in the case Maial .
If poor quality flours prepared dough consistency higher, lower
temperature and undergoes a shorter fermentation time in order to protect
the rheological properties of dough .
In case of strong gluten flours very durable and less extensible dough
consistency working with smaller with higher temperatures and durations
fermantare higher.
Dough temperature is 25-26 C for flour of poor quality , 30 C for good
quality flour and 32 C for strong flours .
Duration of fermentation of poor quality flour is 0-20 minutes for good
quality flour is 25-35 minutes and 35-45 minutes is strong flours

Franzela bread formula

Raw and auxiliary materials U.M. Dough stages
and technological

Maia

Total

Dough

Flour type 480

Kg

50

50

79,36

Water

30

22

41,26

Compressed yeast

Kg

0,79

Salt

Kg

1,5

1,19

Malt extract

Kg

0,7

0,55

Mature Maia (bass)

Kg

15

11,90

Temperature Blanks

28-31

29-31

Kneading duration

min

8-10

10-12

Fermentation duration

min

120-

20-30

3-3,5

2,5-3

180
Final acidity

grad
e

Durata dospirii finale

min

20-50

The final piece of dough

31-32

grad

3-3,5

temperature
Final piece of dough acidity

e
Baking time

min

20-25

Baking temperature

250-

260

Technology intensive and fast fretting

The method is characterized by a more vigorous kneading dough than

classical kneading , kneading run at higher speeds kneading arms and
generally less time than conventional kneading .
At the end of intensive kneading dough quickly get mature in terms of
colloidal condition in classical kneading operation is achieved at the end of
fermentation .
During the quick and intensive kneading same processes occur as in
kneading slow , but they arise with different speed and intensity .
Because more vigorous agitation during kneading , blood protein
undergoes advanced unpacking which is why their surface reaches a
higher number of reactive groups able to interact with neighboring
molecules . Consequently it forms a larger number of intermolecular bonds
, resulting in more complete form gluten . Due to intense stirring flour
particles hydrate faster, gluten formation occurs faster.

Scientifically kneading PROCESS

Kneading is a fundamental operation in baking technology. Her role is to
obtain a dough tied, sticky, tenacious, resilient and extensible. These
characteristics depend on the quality of flour dough, the amount of water
added, included air kneading conditions.
Kneading process consists of mixing the components in order to obtain
homogeneous mixture dough and kneading process itself, which aims to
achieve specific rheological attributes of wheat flour dough.
During mixing, due to the relative movement of the components under the
action of external forces, flour particles come in contact with water and it
quickly moisten the outer surface of the particles of flour, which forms
small moist clumps.

Bread is made from wheat flour, water, yeast and salt : with these four "simple"
raw materials we succeed in making many thousands of different types of bread.
Apart from the quality of the raw materials, the process itself has an enormous
influence on the final quality of the bread.
1. The raw materials
1.1. Wheat flour
In this chapter we talk about the wheat kernel and wheat flour. Which methods
are used to determine the quality of the flour: Chopin, amylograph, falling
number, moisture content etc. What are flour improvers? What kind of enzymes
are present in the flour and what is enzymatic activity in the flour? What is the
relationship between the quality of the flour and the quality of bread? What
other types of cereals are used in the bakery?
1.2. Water

Water plays an important role in the production of bread. However bakers

normally don't think about the water. It comes out of the tap and that's it. And
why is water the best bread improver (and the cheapest) you can get?
1.3. Yeast and sourdough
What is yeast and what is sourdough? General description of yeast and its
characteristics. What are lactic acid bacteria? How is sourdough made, what
different technologies are used in the different countries of Europe (France,
Germany, Italy etc.). What is the difference between a poolish and a sourdough?
Why has bread made with sourdough a longer shelf life and why does it tastes
better? What is the importance of the temperature, the pH, the quantity of
water used etc.? Which aromatic compounds are formed during the sourdough
fermentation and how can the ratio between acetic acid and lactic acid be
influenced?
1.4. Other raw materials: emulsifiers, sugar, salt, malt
Emulsifiers are important ingredients of bread improvers. Why do they improve
the bread and what does improvement mean? What role plays sugar and what is
the influence of salt? Everybody has heard about enzymes but what are they
and which enzymes play an important part in the production of bread?
1.5. Other raw materials: fruits, nuts, eggs etc.
Quite some different ingredients can be added to dough either to make a
savoury product or to obtain a luxury product with nuts and raisins for instance.
These ingredients also need to be of the highest quality and there are quite
some possible issues linked to their use.
1.6. Enzymes
Enzymes are naturally occurring components of many bakery ingredients. If an
enzyme is added, it often is destroyed by the heat of the baking process. In
both cases, product designers can obtain the functional benefits of the enzyme
while maintaining a "clean label" image for the finished product. Enzymes also
are specific to a particular function, eliminating concerns about undesired
effects.
1.7. Gums and hydrocolloids
Gums and hydrocolloids are used to create texture. These are substances that
are added to foods to emulsify and create interesting mouth feel and diversity

in texture. They can be used for shelf life extension of cakes and bread for
instance, to control batter consistency, as partial fat replacers etc. This
chapter gives an overview of the hydrocolloids used in the bakery industry. If
you read carefully the label of your bread improver or your cake's stabilising
system you might discover some gums and hydrocolloids in the ingredient
declaration.
2. The technology

We will limit us to the 3 most important phases of the production process.

Finally we will take a look at the freezing of dough and parbaked bread.
2.1. Mixing
It cannot be stressed enough that the mixing is the most important stage of the
entire process. If you do it wrong, there is no possibility to correct it later.
Mixing is the only discontinuous step in an otherwise continuous process.
Therefore discipline is required. I know it is not easy to repeat exactly every 12
or 15 minutes exactly the same process however it is necessary and of the
utmost importance. Someone who wants to be proud of quality of the product he
made, must also be proud of the fact that he is capable of repeating over and
over again the same process. And that really is a challenge.
2.2. Moulding, make-up and proofing
The early use of yeasts for bread making was dependent upon wild yeast cells
from the surrounding environment falling into a batch of dough. Such
fermentation was highly variable due to the unknown quantity, type of organisms
present and the conditions to which the dough was subjected. Eventually it was
seen that when a piece of this dough was saved for the next batch, the
subsequent dough was more consistent and fermented fasted. Hence, the birth
of the starter dough. To leaven bread became an "art" and remained as such for
thousands of years. Even today some sours are handled as in generations past.
2.3. Baking
The final step in bread making is the baking process in which the dough piece is
transformed into a light readily digestible and flavourful product under the
influence of heat. Within this baking process, the natural structures of the
major dough constituents are altered irreversibly by a series of physical,
chemical and biochemical interactions. In this chapter the concepts and
knowledge of baking processes are discussed.

2.4. Cooling & Freezing

The quality of fresh bread is often related to its crust (thickness, crispiness,
colour and taste) and to the structure of the crumb (flavour, softness, cell wall
thickness and cell size). Unfortunately fresh bread is a product with a short
shelf life and a number of chemical and physical changes, known as staling, take
place during storage. As a result of these changes the bread gradually loses its
freshness and crispiness while the crumb firmness and rigidity increase. The
pleasant aroma vanishes and off tastes can be detected. So the basic challenge
for the baker is to get is product as fresh as possible to the market. This can be
done by making sure that the moment of baking is as close as possible to the
moment of consumption. For this reason frozen dough and bake-and-serve
products were developed.
3. Quality, recipes and other interesting aspects of bread
3.1. What is quality ?
3.2. Recipes from all over the world
This topic is of course endless and it would be rather impossible to describe
here all types of bread. Suffice to say that, if there are in a town 5 bakers,
there will be 5 different kinds of bread, because the secret of bread does not
lie in the recipe but in the way the product is made. So by definition we had to
limit ourselves and we made a choice of a number of products which however are
distinct and well know all over the world. So, in this chapter, we describe a
number of products and their production methods from a selected number of
countries.
3.3. Staling of bread
The subject of bread staling is certainly not something new and studies on this
particular topic go back many years. Various definitions have been given to the
term "bread staling." Very broadly speaking, bread staling refers to all of the
changes which occur in bread after baking and has been defined as "a term
which indicates decreasing consumer acceptance of bakery products by changes
in the crumb other than those resulting from action of spoilage organisms."
3.4. The nutritional value of bread
Nutritious fibres are considered to be an important element in the prevention of
the typical prosperity diseases such as obesity, heart conditions and cancer of
the bowels. A fibre shortage is not the cause of these diseases, but fibres will

slow down the development of these diseases. Especially in the industrialized

and well-developed countries, these prosperity diseases appear. Exactly in these
places, the use of refined products such as white bread, white rice and white
sugar is high. The image of bread as "starchy" or "fattening" is, ironically,
contrary to the unique role of cereal grain foods in the history of man.
3.5. The microbiological shelf life of bread
The distribution of fresh bread is a particular problem. The consumer expects a
certain microbiological shelf life of bread. Bread that has been packed in a
hermetically sealed packet, will stay mould free for a couple of days. Next to
the phenomenon of staling, mould will develop. It is even possible that harmful
bacteria grow in the bread. This is possible because the crumb of bread has a
rather high moisture content. Methods (physical as well as chemical) to extend
the mould free shelf life of bread are discussed in this chapter.
3.6. The history of bread
Look at bread: it is the history of the humanity which you contemplate. Bread is
the very base of our food since millennia; it is the privileged witness of the
history of mankind and of its civilization. As a spiritual symbol, it has
accompanied religious festivals and rites. With the whims of nature and military
campaigns, the bread has been token of opulence or misery, of constraint or
freedom. Lack of bread caused famine in the Middle-Ages, protests because of
the bread price at the dawn of the French revolution, bread rationing during
World War II, the success of white bread in the post-war period and until
recently the rediscovery of tasty whole grain bread, made with sourdough.
3.7. Allergy and intolerance for bread
4. Specialties
4.1. Danish and puff pastry
The origin of puff pastry and Danish pastry is thought to be the Turkish
baklava. Baklava is a rich, sweet pastry made of layers of filo pastry filled with
chopped nuts and sweetened with syrup or honey. It is characteristic of the
cuisines of the former Ottoman Empire. We all think that a croissant originated
in France. While traditionally ascribed to the French painter and cook Claude
Gele, the origin of the croissant lies in Vienna.
It is important to understand all these types of products (puff pastry,
croissant, Danish pastry) are made by creating alternating layers of dough and

fat by folding and rolling the dough. There are basically 3 methods to make puff
pastry and Danish pastry: French method, Dutch method and the extruder
system.
4.2. Cakes and muffins
Cake is often the dessert of choice for meals at ceremonial occasions,
particularly weddings, anniversaries, and birthdays. There are countless cake
recipes; some are bread-like, some rich and elaborate and many are centuries
old. In this chapter we talk about the raw materials needed to make a good cake
and how to make it.
The definition of muffin here is the American muffin i.e. a small individual cakes
baked in paper cups. An English muffin, which predates by far the American
muffin, is a type of light bread leavened with yeast. The English muffin will be
discussed in another chapter.
4.3. Recipes from the Middle Ages
This chapter is not available in English. It also would be a rather difficult task
to translate as the original recipes are in Dutch of the 16 th and 17th century.
4.4. Donuts and other fried products
You might be surprised by the presence of leavening agents in a yeast raised
donut but they tenderise and benefit fermentation and the handling of the
dough at make-up. It is not uncommon to use for donuts a combination of baking
powder and yeast. I prefer to keep the yeast on the lower side for the better
sheeting and handling of doughs. Excessive uses of yeast to hurry the doughs
along only causes gassiness, less tolerance to proofing and sometimes collapse
when the donuts are removed from the fryer.
4.5. Tortilla production
Tortillas have been used for many centuries in Mexico, where they are consumed
year round. More recently other countries have begun producing them to serve
the Mexican market and the growing demand for Mexican food, particularly in
North America, Europe and Eastern Asia. Tortillas are most commonly prepared
with meat to make dishes such as tacos, burritos, and enchiladas, however, there
are many alternate versions without meat.
4.6. Gluten free products

The baking industry is paying increased attention to consumers seeking glutenfree products. In fact, sales of these products is on the rise. Coeliac disease is
a common digestive condition where a person has an adverse reaction to gluten.
Consumers with an intolerance to the wheat protein gliadin or suffer from
sensitivity to gluten, are estimated at up to 5 % of the EU population. Besides
the people who suffer from coeliac disease, an increasing number of consumers
choose gluten free products because they are perceived as more healthy.