Tasks completed

1. Internship Project
Project Title- Standardization of product
formulation and processing
parameters for manufacturing
Gluten Free Protein Bread
Carried out at – Dr. G Wellness Pvt.Ltd.
Project Guide – Dr. Sateesh Kumar, V.P. (R&D)
Presented by –
Nilesh Kr. Kajaria
113090, 8th sem
B.Tech (FTM),
NIFTEM

2. IAbout the Company
Dr.G Wellness Pvt. Ltd. is widely recognized as India’s pioneer lifestyle and
wellness health-care company. The company is led by Dr. Gaurav Sharma, a
world-renowned diabetologist and visionary. Regarded as the forerunner in
manufacturing and promoting nutritional food supplement for lifestyle-
related disorders, Dr.G Wellness has a robust presence across the entire
wellness spectrum.
Dr.G Wellness started operating in the year 2011 with the mission to extend
helping hands to the patients suffering from the lifestyle-related disorders
and to provide them a ray of hope to live their life with dignity.

3. Company’s Product Porfolio

4. Work Carried out
 Overview of the R&D Lab
 Prepared the completed document of major and minor
ingredients available at workplace
 Making formulation of Quinoa Pasta, Wheat free aata
 Protein Enriched Pasta Formulation
 Trials of PE Pasta at Rohini pasta manufacturing facility
 Trials at IARI, Pusa
 Study on Additives, leavening agents
 Bread making trials at NIFTEM and lab
 Data Compilation

5. Product Developments
 Quinoa Pasta
 Protein Enriched Pasta
 Gluten Free Protein Bread
 Khakra
 Wheat free Atta

6. Quinoa Pasta
 Batch QP1 (10 Kgs) prepared at Rohini Pasta
manufacturing facility
S. No. Ingredients
1. Quinoa (less)
2. Modified Tapioca Starch
3. Arrowroot Powder
4. Whey Protein
5. Xanthan Gum
6. HPMC
7. Nisin
Result:- Since we didnt had any control on food
plant hygiene of the pasta manufacturing facility at,
the product had post processing and drying
contamination.

7. Quinoa Pasta
 Batch QP2 (8 Kgs) prepared at Rohini Pasta
manufacturing facility
S. No. Ingredients
1. Quinoa (more)
2. Modified Tapioca Starch
3. Arrowroot Powder
4. Whey Protein
5. Xanthan Gum
6. HPMC
7. Nisin
Result:- The product is fit for consumption
and after using almost 1Kg for various in house
cooking and tasting trials is lying at Food Lab,
Pitampura

8. Protein Enriched Pasta
 Batch PEP1 (10 Kgs) prepared at Rohini Pasta
manufacturing facility
Result:- Since we didnt had any control on food
plant hygiene of the pasta manufacturing facility at,
the product had post processing and drying
contamination.
S. No. Ingredients
1. Kodu Millet
2. Modified Tapioca Starch
3. Arrowroot Powder
4. Whey Protein
5. Xanthan Gum
6. HPMC

9. Protein Enriched Pasta
 Batch PEP2 (7 Kgs) prepared at Rohini Pasta
manufacturing facility
Result:- Since we didnt had any control on food
plant hygiene of the pasta manufacturing facility at,
the product had post processing and drying
contamination.
S. No. Ingredients
1. Bajra
2. Kodu Millet
2. Modified Tapioca Starch
3. Arrowroot Powder
4. Whey Protein
5. Guar Gum
6. CMC
7. Nisin

10. Result of Pasta formulations
 Shape and texture of both varieties were acceptable.
 PEP pasta with Bajra showed fragility and was easily
broken
 QP pasta with higher percentage of Quinoa had
colour distinguished from the lower.
 Cooking time for QP- 15 minutes
 Cooking time for PEP – 12 minutes

11. Wheat free Atta
 Of various formulations, the given below product has been liked
by majority in house tasting panel. The formulation is as
follows.:
A) Flour Mix
1. Jowar atta = X+50%
2. Bajra Atta = X%
Total = 100%
B.) Minor Ingredients (% of flour mix)
1. Chia Flour = 4%
2. Modified Tapioca Starch = 5%
3. Guar Gum = 1%
Total (A+B) = 110 gms
Result- Roti is prepared using above formulation were liked by the in house
tasting panel. As on date the above formulation has been considered to be
satisfactory.
Fig: Dough
Fig: Prepared roti

12. Khakra preparation
Batch AAA
A.) Flour Mix
1. Wheat Free Atta = X%
2. Whole wheat Flour = X+25%
Total = 100%
B.) Minor Ingredients (% of flour mix)
1. Turmeric Powder = 0.89%
2. Red Chilli powder = 0.94%
3. Kasuri Methi = 2.25%
4. Whole cumin seeds = 1.5%
5. Oil = 3%
Total (A+B) = 108.8 gms
C.) Water = 60-65% of (A+B)
Batch BBB
A.) Flour Mix
1. Wheat Free Atta = X+25%
2. Whole wheat Flour = X%
Total = 100%
B.) Minor Ingredients (% of flour mix)
1. Turmeric Powder = 0.89%
2. Red Chilli powder = 0.94%
3. Kasuri Methi = 2.25%
4. Whole cumin seeds = 1.5%
5. Oil = 3%
Total (A+B) = 108.8 gms
C.) Water = 60-65% of (A+B)
Result- The dough was prepared. Dough balls of 20-22 gms were rolled
into 115 mm dia khakhras and toasted on hot tava on slow flame. The
unit weight of khakras varied from 9.5 - 10.5 gms.

13. Gluten Free Protein Bread
 Objective-
The aim of the project is to develop a formulation of gluten-free
high protein loaf and standardize the processing parameters of
the bread with similar quality characteristics to that of standard
white bread that can be produced on commercial scale by setting
up processing lines by Dr. G Wellness Pvt. Ltd. with the
constraint that no egg ingredients to be added. With this healthy
product, the company caters to the needs of customers having
gluten insensitivity, diabetes and weight management problems.

14. Starting Point of Project
 A literature search revealed a large number of references for bread
texture
 a.) Crust and crumb characteristics of gluten free breads’ (Gallagher,
Gormley, & Arendt, 2003)
 b.) Functionality of rice flour modified with a microbial
transglutaminase’ (Gujral & Rosell, 2004a);
 c.) Improvement of the breadmaking quality of rice flour by glucose
oxidase’ (Gujral & Rosell, 2004b);
 d.) Effects of hydrocolloids on dough rheology and bread quality
parameters in gluten-free formulations’ (Lazaridou, Duta,
Papageorgiou, Belc, & Biliaderis, 2006).

15. Findings of Project
 Finding economical ingredients
 Modifying and finding best combination of different
gluten free flours
 Addition of supplementary protein, starch,
hydrocolloids and enzymes for dough formation
 A dough having ability to trap CO2 during proofing
and baking
 Get a bread of high specific volume and texture as of
white bread

16. Ingredients for bread making
S. No Ingredients
1. Wheat Flour
2. Rice Flour
3. Jowar Flour
4. Soya Flour
5. Corn Flour
6. Whey Protein
7. Potato Starch
8. Guar Gum
9. CMC
10. Yeast
11. Salt
12. Sugar
13. Bread Improver
14. Enzyme A
15. Enzyme B
16. Oil
17. Water

17. Equipments used
Table 2 Equipments used for bread making
Ph meter
Baking Oven
Water Activity meter
Moisture analyzer
Measuring scale

18. Bread prepared

19. Bread prepared

20. Bread prepared

21. Methodology for bread making
In total 15 formulations were prepared and 23 bread trials
were done.
 All the ingredients were weighed as per the formulation
and mixed.
 Water was maintained at 37`c for the yeast activity.
 Sugar was dissolved in 50 ml water maintained at 37`c.
 Yeast was added in the sugar solution and allowed to
ferment for 5 min.
 All the dry mix, sugar and yeast dissolved water was
mixed with hand and made into a dough consistency.
 Loaf pan was greased with oil on all sides and the dough
was kept in the pan for proofing.

22. Methodology for bread making
In total 15 formulations were prepared and 23 bread
trials were done.
 Proofing was done at 40`c , 80% R.H.,1 hour with
moist cloth covering the pan
 After proofing, the pan was kept inside the OTG
oven for baking for 30 minutes temperature 130-
150`c
 With a thermometer probe the core temperature
was noted to be 96`c.
 The bread was allowed to cool down and the final
weight was noted and yield was calculated.

23. Critical parameters
 Dough temp.- 27`c
 Proofing Time - 1 hr .
 Dough Weight - 372 gm
 Baking Temp. – 150`c
 Baked bread weight - 307 gm
 Core Temp. - 97`c
 Yield – 82.5%

24. Evaluation of bread quality
 In total 15 formulations were prepared and 23 bread
trials were done.
 Evaluated bread quality by following methods
- Water Activity –
- Oven Spring
- Moisture Loss –
- Crust and crumb color-
- Sensory evaluation

25. Results
 Protein content of bread - 19.76 %
 Oven Spring (cm) – 1.4
 Moisture Loss during baking – 13%
 Discussion-
- Presence of high initial moisture content as batter consistency.
- Hydrocolloids network acted as barrier to gas diffusion, decreasing
water vapor losses.
Dough weight (g) (A) = 200
Bread weight after baking (g) (B) = 174
Moisture loss (g) (A-B) = 26
Percent moisture lost = 13

26. Results
Moisture loss during storage–
Observation-
Increase in moisture content in crust.
Decrease in moisture content in crumb
Discussion-
This behaviour is due to the added hydrocolloids, that bound the
moisture in crumb and retarded its loss during storage
Days Bread Crust (%) Bread Crumb (%)
1 31.2 44.8
2 32.7 44.3
3 33.1 44.1
4 33.8 43.9
5 34.8 43.4

27. Results
Water activity of bread crumbs –
Observation-
Water activity in gluten-free bread was higher and more stable.
Discussion-
High water activity due to moisture retention by added hydrocolloids.
The migration of moisture from crumb to crust during storage.
Days Water Activity of Bread
1 0.986
2 0.985
3 0.985
4 0.984
5 0.983

28. Sensory evaluation
Sensory was done by panel of 5 members, company heads.
The attributes evaluated and the mean score are-
Discussion-
The apperance and textue could be improved by using dough mixers to
get standardized results.
The taste and softness were satisfactory.
Attributes Formulated Gluten free Protein Bread
Crumb Structure 7.6
Taste 8.5
Texture 6.5
Appearance 6.9
Softness 7.0

29. Results
Crust and Crumb color –
Observation-
Pale crust colour of Gluten free protein bread
Discussion-
Due to high moisture in flours diluting conc. of sugars and amino acids
thus retarding browning
Lightness Saturation Hue Angle ΔL*1 Δ a* Δ
b*
Crust 55.5 35.6 1.16 8.2 -1.41 3.20
Crumb 78.1 15.7 1.55 4.1 -0.31 -3.32

30. Bread Trials data compiled

31. Bread formulations data compiled

32. Bread Trials data compiled

33. Bread Trials data compiled

34. Future scope of study
 QUALITY CHECKS - Further quality checks that have
been missed due to lack of facility can be carried out to
enhance product characteristics.
 HEALTHY BAKERY PROUCTS - With the
development of gluten free protein bread, more new and
innovative bakery products can be formulated.
 COMMERCIAL PRODUCTION - The products
prepared can be commercially produced and made
available in market to create company image and brand
value.

35. Area of improvement
 The equipments and the R&D setup needs to be upgraded
to carry out product developments and their evaluations.
 The lab facility could be improved.
Area of Appreciation
• Support of guide and company in terms of procuring of
raw materials, finding facilities where the evaluations
could be carried out.

36. Key learnings
 Understanding of the importance of research and
technology in our day to day products of use.
 Ability to identify, formulate and come up with solutions
based on a systems approach
 Team building and working together.
 Importance of Authenticity of myself and my work.

37. Thank You