Bakery Product Manufacturing | Explore the most profitable food processing business opportunity.

Are you looking for a clear and understandable description of bakery product manufacturing? Here, we explore the step-by-step description of the bakery industry manufacturing process.

Bakery Products Manufacturing

Bakery products are a huge consumption item due to their high nutrient value and affordability. Due to the rapid population rise, the rising influence, the emergence of a female working population, and people’s fluctuating eating habits, they have gained popularity, contributing significantly to the growth trajectory of the bakery industry. Several healthy products have been launched in the bakery segment and are gaining popularity at a high rate.

Introduction

Product Range:

Bakery products contain high nutritive value and are manufactured from wheat flour, sugar, baking powder, condensed milk, fat, salt, jelly, dry fruits, various essences and flavouring, etc.

Different types of bakery products can be classified as:

1. Dry Bakery Products:

• Biscuits: Soft biscuits, cookies, crackers, fancy biscuits, cream wafer biscuits.

2. Moist Bakery Products:

• Bread: Sweet bread, Milk bread, Masala bread, Garlic bread, Fruit bread, etc.
• Buns: Fruit buns, hamburger buns, dinner rolls, crisp bread, pizza.
• Others: cakes, pastries, doughnuts, muffins, etc.

Other popular bakery products are Bagels, Waffles, Tortillas, Pretzels, Pies, Cupcakes, Swiss Rolls, Puffs, and Rusk. Popular among these and which are now highly automated for mass production are biscuits, cookies, bread, cakes and wafer biscuits. We can buy all these bakery products. Across the globe, with variants as per local taste.

Growing popularity of these products had made investor, entrepreneurs and business owners putting huge investments in bakery plants. This report would help people interested in bakery business to understand the basic manufacturing pprinciplesof bakery products.

In this article, we describe the whole production process, from the storage and dosing of the raw material to the packaging step and the shipment of the products.

Production steps included in bakery products:

Storage and dosing of ingredients

This is the first step of the manufacturing process. The goal is to store the ingredients, i.e. flour, salt, improvers, yeast, seeds, sourdough, et,c. Inside the factory. Dry or liquid, raw materials may be stored with different methods. Palettised bags or small liquid containers stored on pallets arrive in trucks.

When quantities start to be important, the best practice is to deal with bulk deliveries. That is to say that major dey raw materials and liquids i.e. yeast or sourdough, are delivered by taners and then stored in silos or tanks. The raw materials are transferred to the mixing area to be precisely dosed according to the recipe. Yjis transfer and dosing stage may be automatic tanks to pneumatic conveying solutions, or automatic weighing hoppers.

Kneading

The kneading stage in bread making plays a crucial technological role in the texture of the dough and the development of flavours and aromas. Installations are often automated and of substantial size, but the functional principle remains very similar to traditional kneading. In a target of quality, a step of dough resting time may be added be upgrade quality, taste and dough texture.

Make-up Line

The dough is then conveyed to an industrial production line whose goal is to transform a mass of dough into a nice and almost finished product with the desired size, weight, and shape. The make-up line may include, at its end, filling and toppings units to fill and decorate the products.

These long lines are used to fill and decorate the products. These long lines composed of conveyor belts include specialised tools to transform a mass of dough into rows of baguettes, tools, pizza pieces, buns and loaves falling into models in case of sandwich bread or brioche.

There are two main methods to produce bread in industry:

1. Either divide the mass of dough into loaves at the right final target weight, and then carry out the final operations.
2. To produce a continuous flow of dough and then carry out the final operations in a lamination process.

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Proofing

The proofing stage allows wheat flour bakery products to gain volume and flavour. Yeast and, optionally, sourdough added that are retained by the gluten network in the dough, allowing it to rise.

The industrial proofing cabinet is a continuous tunnel through which the loaves rest, and the duration and conditions of temperature and humidity are precisely controlled to ensure the regularity and quality of the finished products.

Scoring

A portion of the surface of the loaves is incised to allow the product to expand harmoniously and aesthetically during baking. This industrial step is the automated machines or robots replication the barer’s blade stroke. Different technologies may be used today in industry, as well as mechanical, water jet or ultrasonic solutions.

Baking

At the beginning, thermal effects and fermentative processes give the product its final volume. Industrial ovens are tunnel ovens or rotary ovens. Once again, parameters such as time, temperature, humidity, and heat transfer methods are precisely controlled quality and perfect consistency of production.

Cooling

This cooling step allows the baked bread to cool. The products must cool down before freezing or packaging, otherwise, the risk of degrading the final products’ quality would be very high.

The products are stored, or even better, conveyed in an environment where temperature and humidity are under control to absorb the heat from the products.

Freezing

For some preservation solutions, finished products are frozen at temperatures close to -25°C in the heart of the loaf. The products go in a refrigerated chamber. The time is judiciously calculated to freeze them while preserving their taste and organoleptic qualities.

Products can be either conveyed on a belt in a continuous spiral or stored inside a static rack. In both cases, frozen air is in blown to reach the target of cold temperature.

Packaging

The Packaging stage aims to place one or many finished products in a bag, box or pack. All solutions are possible. Several products in cardboard boxes, a single product packaged in a plastic film bag and consequently, many technical solutions are available based also on the temperature of the product.

Different stages exist in packaging:

1. The preliminary packaging will be in contact with the loaf
2. The secondary packaging is composed of the carton box, which contains the plastic bags.
3. The third packaging consists of palletising the carton boxes.

Many options may be used during this stage. Automated or robotic form and fill installations, automatic packaging machines, and the use of MAP (Modified Atmosphere Packaging).

Storage and shipping

The majority of packaged products are stored on pallets in racks in ambient, cold or frozen warehouses. This stage is a key step in terms of parcel traceability and logistical data: labelling and product flow management are crucial to perfectly control this aspect of the supply chain.

Depending on supply requirements, products may be stored for a variable duration. The shipping dock marks the end of the industrial manufacturing process for the product.

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Machinery required for Bakery Product Manufacturing

1. Mixers

• Spiral Mixers: Used for mixing bread dough. Often with a stationary agitator and a rotating bowl.
• Planetary Mixers: Versatile for various tasks, including mixing dough, batters, and creams, with interchangeable attachments.

2. Ovens

• Convection Ovens: Efficient for baking a variety of items, using fans to circulate heated air.
• Rotary Rack Ovens: Ideal for baking large quantities of bread and pastries, with a revolving rack.
• Dec Ovens: Used for baking items that benefit from direct heat, like pizza and bread.

3. Provers

• Used to control the temperature and humidity while the dough rises, ensuring proper leavening.

4. Other Machinery

• Bread Slicers: For slicing bread evenly and efficiently.
• Dough Dividers/Rounders: For dividing dough into consistent portions and shaping them.
• Sheeters: For flattening dough evenly for pastries and pizza.
• Cream Rolling Machines: For rolling dough into desired shapes for pastries and pizza.
• Pacaging Machines: For sealing and packaging based goods.

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