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Presents:
Webinar Series #1:

Introduction to Bakery Processes
From Concept Through Construction
In Partnership with:

Nov...
Introduction to Bakery Processes
2

Introduction
 Charles Albertone
− Project Manager for Construction Projects
− Industr...
3

Introduction to Bakery Processes

Introduction
Introduction to Bakery Processes
4

Agenda
 Bakery Introduction
− Bread Processing
− Dough Systems
− Ingredients

 Const...
Introduction to Bakery Processes
5

Safety in Bakeries
Types of Risk

Managing the Risk

Slips, Trips, Falls
• Wet floors
...
6

Introduction to Bakery Processes

Safety on Construction Sites
Introduction to Bakery Processes
7

Good Manufacturing Practices
 Bakeries
− Hair nets, including beards
− No loose jewel...
8

Introduction to Bakery Processes

Bread Processing Steps
9

Introduction to Bakery Processes

Bread Dough Systems
10

Introduction to Bakery Processes

Bread Dough Systems
Introduction to Bakery Processes
11

Fermentation
 Floor Time
− Dough is more viscous
(flowable) immediately after
mixing...
Introduction to Bakery Processes
12

Fermentation and Proofing
Fermentation Room
(after mixing)

Step Proofer
(after makeu...
Introduction to Bakery Processes
13

Mixing Stages

Pick Up

Dough is
sticky, cold, lumpy
Introduction to Bakery Processes
14

Mixing Stages

Initial Development
Dough is getting warmer,
smoother, and drier
Introduction to Bakery Processes
15

Mixing Stages

Clean Up

Dough is at maximum
stiffness. It will slap
around mixer and...
Introduction to Bakery Processes
16

Mixing Stages

Final Development

Dough is at correct
temperature and handling
qualit...
Introduction to Bakery Processes
17

Mixing Stages

Letdown (1-3 mins)

Dough is too warm and
sticky – can be recovered
wi...
Introduction to Bakery Processes
18

Mixing Stages

Breakdown

Dough beginning to
liquefy
Introduction to Bakery Processes
19

Typical Mixers and Ovens
Horizontal
Mixer

Tunnel Oven

Vertical
Mixer

Rack Oven
Introduction to Bakery Processes
20

Bread Processing Steps
 General relationship in Baking times and
temperatures:
Introduction to Bakery Processes
21

Cooling & Packaging Equipment
Spiral
Cooler

Tray Former

Blast Cooler

Palletizer
Introduction to Bakery Processes
22

Ingredients
4 REQUIRED Ingredients:
−
−
−
−

Flour = Structure
Salt = Flavor
Water = ...
Introduction to Bakery Processes
23

Bread Labels
 Bakers Percent – instead of a typical
recipe, everything is calculated...
Introduction to Bakery Processes
24

Bread Quality
 Baker control measures:
− Look, temperature, pH, feel, specific gravi...
Introduction to Bakery Processes
25

Trends in Baking
 Reuse of mixed dough into recipe
− Has been a standard procedure –...
Introduction to Bakery Processes
26

“Standard Bakery” Building

Receiving

Scaling

Mixing

Makeup

Proofing

Baking

Coo...
27

Introduction to Bakery Processes

“Standard Bakery” Site
28

Introduction to Bakery Processes

“Standard Bakery” Site
Introduction to Bakery Processes
29

Schedule
February
February
2013

March
2013

April
2013

December
2013
Introduction to Bakery Processes
30

Schedule
February
February
2013

March
2013

April
2013

December
2013
Introduction to Bakery Processes
31

Schedule
February
February
2013

March
2013

April
2013

December
2013
Introduction to Bakery Processes
32

Schedule
February
February
2013

March
2013

April
2013

December
2013
Introduction to Bakery Processes
33

Structural Steel & Roof Design

Rendering
Introduction to Bakery Processes
34

Structural Steel & Roof Design

Actual Construction Photograph
Introduction to Bakery Processes
35

Sanitation Detail Considerations

Pipe Hanger & Aisle

Vertical Storing
Dock Leveler
...
Introduction to Bakery Processes
36

Thank You!
 Next Seminar Topic, Early 2014:

A Young Professional’s Guide to Baking ...
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Introduction to Bakery Processes: From Concept Through Construction

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The American Society of Baking's (ASB) Young Professionals Committee partnered with The Austin Company to offer the first in a series of webinars focused on the baking industry. Charles Albertone, Industrial Engineer/Project Manager with The Austin Company, hosted this first webinar on "Introduction to Bakery Processes - From Concept to Construction."

This webinar provided attendees with an overview of major baking processes, including mixing, make-up, proofing, baking, cooling and packaging; design considerations for each process from line layout to construction; sample construction details and photos; and a Q&A session.

Published in: Business, Self Improvement
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Introduction to Bakery Processes: From Concept Through Construction

  1. 1. Presents: Webinar Series #1: Introduction to Bakery Processes From Concept Through Construction In Partnership with: November 14, 2013
  2. 2. Introduction to Bakery Processes 2 Introduction  Charles Albertone − Project Manager for Construction Projects − Industrial Engineer for Master Planning Efforts − BSIE, EMBA, PMP, AIB, ASB, IBIE, OSHA  The Austin Company − − − − − − − Founded in Cleveland, OH in 1878 ABA, ASB, AIB, B&CMA, BEMA Site Location and Incentive Negotiation Master Planning Engineering Construction Registered Trademark Design-Build Process: The Austin Method ®
  3. 3. 3 Introduction to Bakery Processes Introduction
  4. 4. Introduction to Bakery Processes 4 Agenda  Bakery Introduction − Bread Processing − Dough Systems − Ingredients  Construction − Building − Site − Schedule − Sanitation Details
  5. 5. Introduction to Bakery Processes 5 Safety in Bakeries Types of Risk Managing the Risk Slips, Trips, Falls • Wet floors • Dough • Equipment platforms • • • Slip resistant flooring with epoxy or diamond grinding Cleaning Provide safety ladders Manual Handling • Bulk ingredients • Trays and racks • • Utilize mechanical aids (trolleys, lifts) Proper lifting techniques Machinery • Conveyors • Blades • • • Maintain safe clearances Preventative maintenance Safety guarding/interlocks Hazardous Substances • Cleaning chemicals • • Store in proper location Wear proper protection (gloves) Burns and Scalds • Ovens and trays • Syrups and liquids • • Wear oven gloves Design systems to handle hot liquids Flour Dust Inhalation • • Ventilation PPE (face mask)
  6. 6. 6 Introduction to Bakery Processes Safety on Construction Sites
  7. 7. Introduction to Bakery Processes 7 Good Manufacturing Practices  Bakeries − Hair nets, including beards − No loose jewelry or rings with settings − All items in pockets below waist − Smocks  Construction − Typically wouldn’t apply, however, in renovation projects, construction areas must be properly barricaded to avoid product contamination
  8. 8. 8 Introduction to Bakery Processes Bread Processing Steps
  9. 9. 9 Introduction to Bakery Processes Bread Dough Systems
  10. 10. 10 Introduction to Bakery Processes Bread Dough Systems
  11. 11. Introduction to Bakery Processes 11 Fermentation  Floor Time − Dough is more viscous (flowable) immediately after mixing. Resting allows the dough to become more elastic.  Retarding − A step that elongates fermentation by refrigerating the dough. −PROS: Flavor development and ability to mix larger batches and store until needed. −CON: Dries out dough.
  12. 12. Introduction to Bakery Processes 12 Fermentation and Proofing Fermentation Room (after mixing) Step Proofer (after makeup)
  13. 13. Introduction to Bakery Processes 13 Mixing Stages Pick Up Dough is sticky, cold, lumpy
  14. 14. Introduction to Bakery Processes 14 Mixing Stages Initial Development Dough is getting warmer, smoother, and drier
  15. 15. Introduction to Bakery Processes 15 Mixing Stages Clean Up Dough is at maximum stiffness. It will slap around mixer and come together as one mass
  16. 16. Introduction to Bakery Processes 16 Mixing Stages Final Development Dough is at correct temperature and handling quality
  17. 17. Introduction to Bakery Processes 17 Mixing Stages Letdown (1-3 mins) Dough is too warm and sticky – can be recovered with floor time
  18. 18. Introduction to Bakery Processes 18 Mixing Stages Breakdown Dough beginning to liquefy
  19. 19. Introduction to Bakery Processes 19 Typical Mixers and Ovens Horizontal Mixer Tunnel Oven Vertical Mixer Rack Oven
  20. 20. Introduction to Bakery Processes 20 Bread Processing Steps  General relationship in Baking times and temperatures:
  21. 21. Introduction to Bakery Processes 21 Cooling & Packaging Equipment Spiral Cooler Tray Former Blast Cooler Palletizer
  22. 22. Introduction to Bakery Processes 22 Ingredients 4 REQUIRED Ingredients: − − − − Flour = Structure Salt = Flavor Water = Hydration Yeast = Levening (air pockets) 6 OPTIONAL Ingredients: 6 Types of ADDITIVES: − Gluten = Strength − Enrichments = Nutrition − Mineral Yeast Food = Conditioning − Enzymes = Breaks down dough = of dough Elasticity − Fats/Oils = Tenderness and − Oxidizer = Strengthen lubricant − Reducers = Weaken − Sugars = Food for yeast − Emulsifiers = Soften − Milk = Nutrition − Emulsifiers = Strengthen − Mold Inhibitors = Slows molding
  23. 23. Introduction to Bakery Processes 23 Bread Labels  Bakers Percent – instead of a typical recipe, everything is calculated based on flour being 100%.  2% Line – On a nutritional label, everything below “Yeast” usually contains less than 2% of the formula.
  24. 24. Introduction to Bakery Processes 24 Bread Quality  Baker control measures: − Look, temperature, pH, feel, specific gravity, proof temp & time, oven temp & time, cooling temp & time, mix temp & time − Cost (ingredients, labor, utilities)  Consumer judging characteristics: − External – color, shape, volume, softness, toppings, mold, lack of foreign material − Internal – taste, texture, crumb color, crumb structure/cell size − Price
  25. 25. Introduction to Bakery Processes 25 Trends in Baking  Reuse of mixed dough into recipe − Has been a standard procedure – improves volume, minimizes waste, improves consistency between batches NOW BEING CONSIDERED A BAD PRACTICE −Traceability – what if there was a defect? Where would you start and stop product recall since dough was used from previous mixes? −Allergens
  26. 26. Introduction to Bakery Processes 26 “Standard Bakery” Building Receiving Scaling Mixing Makeup Proofing Baking Cooling Packaging Shipping
  27. 27. 27 Introduction to Bakery Processes “Standard Bakery” Site
  28. 28. 28 Introduction to Bakery Processes “Standard Bakery” Site
  29. 29. Introduction to Bakery Processes 29 Schedule February February 2013 March 2013 April 2013 December 2013
  30. 30. Introduction to Bakery Processes 30 Schedule February February 2013 March 2013 April 2013 December 2013
  31. 31. Introduction to Bakery Processes 31 Schedule February February 2013 March 2013 April 2013 December 2013
  32. 32. Introduction to Bakery Processes 32 Schedule February February 2013 March 2013 April 2013 December 2013
  33. 33. Introduction to Bakery Processes 33 Structural Steel & Roof Design Rendering
  34. 34. Introduction to Bakery Processes 34 Structural Steel & Roof Design Actual Construction Photograph
  35. 35. Introduction to Bakery Processes 35 Sanitation Detail Considerations Pipe Hanger & Aisle Vertical Storing Dock Leveler Sanitation Room Standoff Detail
  36. 36. Introduction to Bakery Processes 36 Thank You!  Next Seminar Topic, Early 2014: A Young Professional’s Guide to Baking Tech  Baking Tech 2014, Chicago, March 2-4  YPC Social Event Sunday Night Questions?

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