Discussions about the bakery products like cakes pastry biscuits talking about the manufacturing processes

1. Introduction
A bakery is an establishment which produces or/and sells bread, pastries, biscuits,
cookies etc
 Baking is the technique of prolonged cooking of food by dry heat
 Acting by convections, not by radiations, normally in an oven, also in hot ashes, or on
hot stones
 It is primarly used for the preparation of breads, tarts, quiches, cakes, pastries, pies, and
cookies
 Such items are sometimes referred to as baking goods and are sold at a bakery
 A person who prepare baked goods as a profession is called a Baker

2. Bakery
Products
The term “baked products”
encompasses a wide range
of products all of which are
based on the use of wheat
flour.
The two major bakery products,
i.e. breads and biscuits hold for
about 82% of the market share
 Product coverage
 Wafers
 Cakes
 Biscuits

3. Baking Tools:
Measuring cups
Spoons (wooden, steel)
Rubber spatula
Pastry brush
Kitchen scissors
Rolling pans
Whisk
Fine mesh sieve
Baking pans

4. Bakery fails and its causes:
1. Cake
Falling: Too much shortening or sugar
Too low an oven temperature
Insufficient baking
Too much batter in the pan
2. Moist,
Sticky
Crust:
Too much sugar
Insufficient baking

5. 3. Thick,
Heavy Crust: Over baking
Too hot oven
Not enough shortening or sugar
Too much flour
4. Soggy
Layer or
Streak at
Bottom:
Insufficient mixing
Too much sugar or baking
powder
5. Uneven
Shape: Uneven heat of oven
Cake not level
Pan warped

6. Wafers:
Wafers are a crisp, thin, aerated baked
good with characteristic surface reeds
 They are commonly filled with a cream
paste of vanilla, chocolate, hazelnut or
other inclusions
 Wafers can also be made gluten-free
Commercially, wafers come in two main
varieties:
1. No or low sugar wafers
2. Sugar wafers

7. Ingredients
NAME TYPE FUNCTION
water _  Aids in starch gelatinization
 Enhance leavening
flour Low protein flour ( All purpose wheat flour)  Provide structure
 Imparts brown color (by
millards reaction )
fat Butter (margarine )  Provides tenderness,
lubrication, mouthful feeling
 Provides a rich buttery
flavor

8. Sugar Granulated white  Add sweetness and brown color
 Enhance texture and
crunchiness
leavening Sodium bicarbonate or
Ammonium bicarbonate
 Provides leavening and aerated
structure
salt granulated  Enhance flavor and aroma
emulsifier lecithin  Aids in emulsification of batter
 Improves release of steam

9. Steps involves in wafer preparation
1. Mixing:
Water, flour, fats, lecithin and other minor ingredients are mixed in a stainless steel vessel to form a batter
2. Depositing:
Batter is deposited in large baking plates with top and bottom layer
3. Baking:
Wafer sheets are baked at 180 C (356 F) for 2 minutes or until moisture drops to below 2%
4. Cooling:
Wafer sheets are demolded and cooled at ambient temperature.
5. Cream application:
Cream is deposited and spread on cooled wafer sheets.

10. 6. Sandwich building:
A top wafer sheet is placed on top of the cream, and the wafer sandwich passes through a cooling
tunnel to solidify the cream.
7. Cutting:
Wafer sheets may be cut into smaller wafer fingers.
8. Packaging:
Wafers are immediately wrapped in moisture-tight packaging material

11. Cakes:
 Cakes are bakery products that are rich in
sugar, fat and eggs, and can be
accompanied with a wide variety of
inclusions like fruits and flavors such as
vanilla extracts.
 They are typically made from soft wheat
flour characterized by low protein content
and high purity (mostly endosperm and
starch from center of wheat kernels).
 They come in many varieties and are very
versatile in terms of flavors, textures,
shapes and colors, perfect as snack or as
servings.

12. Origin:
The first kinds were
produced by mixing
white flour, eggs, fresh
butter, and table sugar.
These were called
pound cakes, the first
known type of batter
cakes.
The next generation
was developed when
bakers found that a
lighter, fluffier product
could be made by
whipping the eggs, and
then folding in sugar
and flour. This became
known as the foam
type.
In 19th century layer
cake was created ,
when baking powders
were put on the
market, allowing a
greater variety of batter
types.
In the mid-20th
Century, an entirely
new type of cake that
combined the qualities
of two basic types—
foam and layer—were
created, resulting in
the chiffon type.

13. Types of cakes
1. Batter type:
 Rely on eggs, flour, and milk for structure
 Contain high amounts of fat and water which creates an aerated and chemically-leavened oil-in-
water emulsion.
 Much of the volume of the finished product is created by baking powder.
 Batter types are classified into:
a. Pound cakes :
Which rely on eggs and fat for leavening, e.g. butter, pound and snack cake)
b. Layer cakes :
That rely more on chemical leaveners, e.g. white layer, yellow layer and chocolate layer cake)

14. 2. Foam type:
 rely mainly on the extension and denaturation of egg protein for the bulk of the final volume.
 They can be regarded as “cakes without shortening” given the absence of the oil-in-water emulsion.
 Depending on the egg fraction used, foam type cakes are divided into two classes:
a) Angel food cake (makes use of egg white proteins to trap air during mixing)
b) Sponge cake (makes use of either whole eggs or yolks, or a combination of both)
3. Chiffon type:
made with a combination of batter and foam to form a modified “foam-type” grain and texture

15. Ingredients:
Chlorinated soft wheat flour
Table sugar (refined, granulated sucrose)
Shortening (cake or all purpose)
Water
Whole eggs (liquid)
Natural cocoa or chocolate
Non-fat dry milk
Salt
Baking powder
Vanilla or lemon flavor
Emulsifier
Baking soda

16. Commercial production:
The manufacture of batter, foam and chiffon cakes follows in
general the same steps; each type of baked goods has its particular
processing conditions and dedicated equipment.
The basic steps are:
• Ingredient scaling/metering
• Mixing (target specific gravity or degree of air incorporation depends on the type of
product)
• Depositing or panning
• Baking
• Cooling
• Finishing (decoration can be optional)
• Packaging

17. Mixing methods:
• Single stage (all-in method)
• Creaming method
• Blending method
• Multi-stage method
• Continuous mixing (automated and controlled aeration)

18. Biscuits:
 Biscuits are small quick bread rounds that
can be either cakey and dense, or flaky and
light. Traditionally, biscuits have been
chemically leavened with baking soda or
baking powder.
Biscuit doughs are described as:
Short
Undeveloped
 Many types of biscuits are known such as
buttermilk biscuits, cream biscuits, etc.
 They are best served warm and topped
with a variety of options such as honey,
butter, or jam, and eaten as a breakfast or
brunch treat.
This Photo by Unknown author is licensed under CC BY-SA-NC.

19. Origin:
Biscuits date back to
Ancient roman times. The
term ‘biscuit’ originated from
the French word which
means “twice-cooked.”
The American biscuit was
introduced by European
colonists during the latter
part of the 18th century, and
was referred to as a “soda”
or “baking powder” biscuit.
Biscuits were quickly
adopted by home-bakers in
the Southern region of the
U.S. due to the availability
of buttermilk, lard and soft
wheat flour.
First refrigerated
(buttermilk) biscuits were
made and patented by
Ballard and Ballard in 1931
which later became
Pillsbury biscuits.

20. Ingredient:
Pastry flour / all-
purpose flour
Regular shortening /
all-purpose
Pasteurized skimmed
milk (>90% water)
Baking powder
Table sugar (sucrose)
Salt

21. Production:
1. Ingredient scaling/metering.
2. Mixing: The multi-stage mixing method is preferred for its ability
to produce consistent doughs which are not fully developed.
• Blending all dry ingredients , Mixing time could range from 2 to 3 min,
• Adding liquid ingredients (milk, water or other forms) until a homogeneous dough
is obtained. Mixing time could range from 1 to 2 min
• Target dough temperature ranges from 13–16°C (55–60°F). This prevents fat
from melting, slows down chemical leavening reactions, enhances flakiness and
reduces toughness in the baked good.

22. 3. Resting or bench time of dough for 10–15 minutes.
4. Extruding, folding and sheeting of dough to a predetermined thickness.
5. Rotary cutting of dough pieces.
6. Baking at 232°C (450°F) for 10–12 minutes.
7. Removal from oven and cooling for 20 minutes on racks.
8. Packaging or displaying on shelf for retail sale.

23. Pastry :
Pastry is a type of dough made
with flour, water and shortening.
Baked pastry dough can be sweet or savory,
and consumed alone or with fillings.
Pastry is characterized by its flaky and
crumbly texture, and rich buttery flavour.
Shelf life of filled pastry is dependent on
free water availability and susceptibility to
moisture migration.
Typical pastry shelf life ranges from a
couple of days for meat-containing pastries,
to a few weeks for high sugar fillings.

24. Origin :
Pastry dough may have
originated in Egypt.
However, its use in
bakeries is attributed to
the Greeks and Romans.
In the 17th century, pastry
baking became extremely
popular and several
timeless creations such as
puff pastry were
developed then.
Today, pastries are
consumed worldwide and
new variations are
developed routinely.

25. Ingredients :
Ingredient Type Function
Flour
Pastry flour, low
protein flour
 Provides low gluten
network structure
 Imparts colour, a result
of Maillard’s browning
reaction
 Yields tender products
Fat
Solid fats
(butter or margarine)
 Improves mouthfeel and
moistness
 Increases tenderness by
coating starch and
protein particles
 Provides flakiness
 Prevents staling
 Imparts flavour

26. Sugar White granulated sugar
 Provides sweetness
 Tenderizer
 Retains moisture, and
improves shelf life
 Imparts colour, a result of Maillard’s
browning reaction
Salt Granulated  Enhances flavour
Water Ice cold
 Controls fat temperature
 Aids in flaky crust texture

27. Nutrition :
Component Grams
Carbohydrate 60.25
Water 19.00
Fat 12.50
Protein 8.25

28. Commercial production:
Pie crust made with pastry dough is manufactured through the following
process:
Weighing and scaling of the ingredients
Mixing: flour and fat are mixed in a stainless steel vessel.
Liquid addition: ice water is added , and gently mixed to avoid gluten
development.
Refrigeration: dough is cooled overnight.

29. Pressed crust (for small operations):
ØDividing and pressing: dough balls are formed and pressed into a
pie plate.
ØFilling: pie filling is deposited on the pie crust.
ØBaking: pies are baked at 230-260 C (450-500 F), baking time will
depend on the type of pie.
ØCooling: pies are cooled to room temperature for further processing.
ØPackaging

30. Faults in pastries:
Fault Reason
Blistered pastry  Ingredients too warm
 Oven temperature too cold
 Too much flour used for rolling out
 Too much water used for mixing
Hard tough pastry  Uneven addition of water
 Over temperature too hot
Pastry soggy in a pie  Steam not allowed to escape during cooking
Pastry fragile and
crumbly when cooked
 Too much fat used
 Over rubbing in of fat
 Too little water used
Pastry shrinks during
cooking
 Pastry over stretched during preparation and rolling
Oily, greasy pastry  Fat too soft
 Oven temperature too cool.

31. Referance:
• Kilcast, David, and Persis Subramaniam, eds. Food and beverage stability and shelf life. Elsevier, 2011.
• Figoni, P. I. How Baking Works: Exploring The Fundamentals Of Baking Science. 3rd ed., John Wiley &
Sons, 2011.
• U.S. Department of Agriculture, Agricultural Research Service. FoodData Central, 30 October
2020.https://fdc.nal.usda.gov/fdc-app.html#/food-details/1817049/nutrients . Accessed 01 November
2018.
• Labensky, S.R. “Quick Breads” On baking: A Textbook of Baking and Pastry Fundamentals, 2nd
edition, John Wiley & Sons, Inc., 2009, pp. 136–167.
• Figoni, P. I. How Baking Works: Exploring The Fundamentals Of Baking Science. 3rd ed., John Wiley
& Sons, 2011.
• Gisslen, W. “Quick Breads” Professional Baking, 7th edition, John Wiley & Sons, Inc., 2017, pp. 211–
227.

32. • The Culinary Institute of America (CIA) “Quick Breads and Cakes” Baking and Pastry: Mastering the Art
and Craft, 2nd edition, John Wiley & Sons, Inc., 2009, pp. 237–252.
• Tucker, D.R. and Willis, R.E. Refrigerated biscuit dough, U.S. Patent 3,879,563, The Pillsbury Company,
1975.
• Lallemand Inc,.”Pie Crust Production”. Lallemand Baking Update. Vol 3, no. 12, 2018, pp. 1-2., Accessed 27
June 2021.
• Food and Drug Administration (FDA). US Department of Health and Human Services. CFR Code of Federal
Regulations Title 21, Part 101 Food
Labeling, https://www.accessdata.fda.gov/scripts/cdrh/cfdocs/cfcfr/cfrsearch.cfm?fr=101.54 , Accessed
13 June 2021.
• Food Safety Authority of Ireland. Guidance Note On The EU Classification Of Food. Food Safety Authority
Of Ireland, Dublin, 2001, p. 11.