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Bio- and food technology –Bio- and food technology – BFBF
CHALLENGES IN DESIGNCHALLENGES IN DESIGN
TEA COOKIESTEA COOKIES
XXIII CONGRESS OF CHEMISTS AND TECHNOLOGISTS OF MACEDONIA
8-11 OCTOBER, 2014, OHRID
Skopje Design Week 2014
23 - 28 September Kursumli An
Julijana Savic-Dineva , eng.food biotech, food product design for Super Grup , e-
mail: savicdineva@yahoo.com
Super Grup, Boris Trajkovski 107, Skopje, +389 2 279 1 279,
info@supergroup.mk

CHALLENGES IN DESIGN TEA COOKIESCHALLENGES IN DESIGN TEA COOKIES
In this review we present 3 months trial production of tea cookies. We faced various challenges
in food product design, in making choices for raw material, processing time and
conditions. We achieved different forms and quantitative and qualitative desired
outcome, of new food product, tea cookies.
Standard process equipment was used, mixer, dosing and forming and tunnel owen. Small trial
dough of about 8 kg was baked 11 times. Each trial is different and is recorded as
recipe, process time, process conditions and sensory and quantitative basic
measurement of finished product, tea cookies. We also compare our products
with current tea cookies on the market as nutrient composition, form, color,
taste, and price per unit product. So far basic design of package for 200 g net
weight is chosen. Specification of process and product following GMP (Good
Manufacturing Practice) and GHP (Good Hygienic Practice) is being prepared for
optimal daily production.

Super Grup Company produces various products in healthy life style foods. Cold pressed oils as
sesame oil, flaxseed oil, pumpkin seed oil, black seed oil (Nigella Sativa), and sunflower oil is in
preparation. Also it produces defatted flour, as residue from oil extraction from the same type of
raw materials, mentioned before. One biotechnology product is packing solution of Super Maya,
enzyme from fungal origin (Rhizomucor miehei), and rennet for milk processing, for production
of hard and soft cheese.
Main products are sesame paste tahini and traditional sweet, sesame tahini halva. And also grain
energy bars cranberry and hazelnut. www.supergroup.mk
Most recent new raw material, that can be used for design of food product are natural sweeteners,
fig , grape and carob syrup which can be used as they are or in healthy food recipes and also
as mix with tahini paste.
Also production line for chocolate glaze is installed but so far this equipment is not being used .With
this trial production Super Grup Company is developing new production line of tea cookies
and broadening spectar of healthy life style food products.
Super Grup Company is also performing social role in employing people with special need.
Key words cookies, healthy, natural, design, food

Basic recipe for trial production kg %
Fats 1,4 17
Sugar 1,8 22
Flour 3,8 46
Milled (sesame, linen, oats, coconut, cocoa) 0,2 2
Milled dried fruit (resins, dates, strawberries, lemon, orange,
cranberry, fig)
0,2 2
Water 0,6 7
Baking powder, salt, lecithin, enzymes-freshey, aroma (vanilla,
cinnamon, strawberry, hazelnut, cranberry, orange, lemon)
0,2 2
Total 8,2 100

no. Process flow
1 Each ingredient is weight on the scales as in recipe formulation.
2 First fats are placed in mixer.
3 Water is added and then liquid compounds.
4 Sugar , aroma and fruit paste are added while mixing.
5 All ingredients are added while mixing.
6 Add rest of the water and active enzymes.
7 Salt and baking powder are added in flour.
8 Flour is added in small amounts while dough is mixing.
9 Each dough is mixed 20 minutes. And then transferred to dosing and forming machine.
10 You can choose form in which dough will be deposited on the trays (shape of cookies).
11 In the dosing and forming machine you can choose the amount of dough (weight of cookies).
12 Prepare 7 trays for 8.3 kg dough (dough shouldn’t stay long).
13 Tunnel owen is prepared in advance 60 minutes before.
14 Temperature of baking is chosen and speed of wire conveyor is chosen.
15 Trays with baked cookies are placed for cooling. Ready product is packed by hand.
16 Working areas and machines are cleaned after production batch is finished.

ANALYSIS OF TRIAL COOKIES WITH DIFFERENT DOSING 1, 1.5 , 2
ANALYSIS OF COOKIE 1 no. type value unit comments
1 7 DOTS FLOWER 7,1 g minimal
2 1 LINE 7,3 g
3 8 RAYS FLOWER 10,7 g
4 5 LINES SUN 11 g maximal
5 HALFMOON FORM 9,7 g
6 HEART FORM 9,9 g

TOTAL 55,7 g AVERAGE
9,28

ANALYSIS OF COOKIE 1.5 no. type value unit comments
1 7 DOTS FLOWER 8,3 g min
2 1 LINE 9,7 g
4 5 LINES SUN 14,7 g max
6 HEART FORM 13,3 g

12,25

ANALYSIS OF COOKIE 2 no. type value unit comments
1 7 DOTS FLOWER 10,6 g min
2 1 LINE 11,5 g
4 5 LINES SUN 17,1 g max
6 HEART FORM 15,7 g

14,3

FOOD PRODUCT DESIGN GOALS
1. FORMULATE NEW AND EXSISTING PRODUCTS TO MEET OBJECTIVES
SENSORY
NUTRITIONAL
QUALITY
COST
TIMELINE
MANUFACTURABILITY
2. DESIGN AND CONDUCT EXPPERIMENTS TO EVALUATE FORMULATION, PRODUCT
PARAMETERS AND PACKIGING PROCESS
3. MONITOR SENSORY CHANGES AND MICROBIOLOGY SHELFLIFE OF TEST PRODUCTS
4. MAINTAIN DETAILED, COMPREHENSIVE RECORDS OF FORMULATIONS, PROCESS
PARAMETERS , FINISHED PRODUCT RESULT AND SENSORY EVALUATION
5.TECHNICAL AND PRODUCTION CHALLENGES, DATA COLLECT PATTERN ANALYSIS
6.RECOMMEND, SET UP, CALIBRATE, BASIC EQUIPMENT AND LAB EQUIPMENT

Trial production Time Line
1 week 49 date 05-12-2013
2 date 06-12-2013
3 w50 date 11-12-2013
4 w2 date 08-01-2014
5 date 10-01-2014
6 w3 date 17-01-2014
7 w4 date 23-01-2014
8 w5 date 30-01-2014
9 w6 date 07-02-2014
10 w7 date 13-02-2014
11 w8 date 20-02-2014

Baking time and temperature (oC) for 13-02-2014
entrance of material part 1 part 2 part 3 part 4
1 2 3 4
upper heaters 190 260 250 210
190 260 250 210
lower heaters 170 210 190 165
170 210 190 165

type value unit
time for baking 12 min
speed of conveyor 27,1 rpm
max time START END
time for mixing dough 30 min 9.00 h 11.00 h
time for dosing ,forming 30 min
time for 1 trial 2 casa

dosing dough cookies 1,5 unit
shape of cookies S-shape

Basic Material Balans
type value unit
no. of tray 8 tray
no. of cookies on 1 tray 54 cookies
time of mixing 20 min
total dough 8300 g
dough in dosing machine 2000 g
no. of baked cookies 432 cookies
average baked cookie 12,3 g
total cookies 5313,6 g
total dough for cookies 6300 g
1 package cookies 200 g 16 cookies
1 batch 27 packages

ANALYSIS OF THE COOKIES ALREADY IN THE MARKET, SIZE, SHAPE ,COMPOSITION
ANALYSIS OF COOKIES
no. TYPE 1 COOKIE (g) 1 PACKAGE (g) NO. COOKIES
1 musli int 15 115 8
2 musli int cocoa 15 115 8
3 vita day 26 200 8
4 ocake 13 210 16
5 coko donia 12 300 25
6 tea cookie mako 11 180 16
7 my cookie butter 5 100 20
8 vitalix 10 200 20
9 nutri keksic 7 150 21
10 sunday biscoti 16 350 22
11 balans vincini 11 180 16
12 my cookie cocoa 12 300 25
13 medenka 50 50 1

composition vitaday
polski
balance ocake muesli
sweet plus
muesli
integ sweet
plus
no nutrition information 100g
product
100 g
product
100 g
product
100 g
product
100 g
product
1 energy 465 kcal,
1944 kJ
412 kcal,
1732 kJ
427 kcal.
1788 kJ
461 kcal,
1937 kJ
674 kcal,
1997 kJ
2 proteins (g) 5.4 g 8.5 g 8,1g 6.5 g 6.4 g
3 carbohydrates (g) 52.4 g 63 g 60,9 g 68 g 65.2 g
of which sugars 20.6 g 19,9 g 29 g 29 g
4 fats  (g) 25.7 g 15.8 g 18,5 g 17.5 g 20.5 g
of which  no
saturated fats
9.3 g 4,2 g 7 g 7 g
5 fiber (g) 6.36 g 7,9 g 2.9 g 2.6 g
6 salt, natrium (g) 0.4 g 0,37 g 0.171 g 0.252 g

cookie card oat -lemon type description
smell very slight fragrance from lemon aroma
color light, light brown from integral flour
taste sweet , from lemon comes freshness a citrusy flavor
length 50 mm
thickness 7 mm
wide 50 mm
average weight 12.7 g
texture soft enough, bottom and crust formed
other
description
these cookies have a lot of oats, but it isn't dominant
these are slim cookies, form and taste and time of baking are right
these type of cookie has natural style color and taste for healthy food
products

cookie card oat -coconut type description
smell very slight fragrance from coconut
color light, cream white from coconut and  integral flour
taste sweet , slight coconut flavor
length 55 mm
thickness 10 mm
wide 55 mm
average weight 11,7 g
texture soft and wet inside ,bottom and crust formed
other
description
cookies should be made with other fresh  coconut flour  aroma
these are slim cookies, form and taste and time of baking is not good cookie is
wet
these type of cookie has natural style color and taste for  healthy food products

cookie card oat -orange type description
smell very slight fragrance from orange
color light, cream white  and  integral flour
taste sweet , slight orange  flavor
length 50 mm
thickness 11 mm
wide 35 mm
average weight 12,33g
texture soft and wet inside ,bottom and crust formed
other description cookies are made with  fresh orange,  aroma, dates ,raisins
these are bigger cookies, super taste,  time of baking should be 2 min more

cookie card oat - fig type description
smell very slight fragrance from fig
color light, light brown
taste sweet , slight fig  flavor
length 40 mm
thickness 7  mm
wide 40 mm
texture soft but not  crumbly ,bottom and crust formed
other description cookies are made with  fig marmalade, vanilla aroma
these are small flat cookies,  time of baking  and form are correct

cookie oat-strawberry type description
smell neutral
color light  pink, light brown, aroma compound is intensive red
taste sweet only
length 40 mm
thickness 11  mm
wide 40 mm
texture soft but not crumbly ,bottom and crust formed
other
description
cookies are made with  dried strawberries, and aroma
taste is not achived in cookies,  time of baking  and form are correct
aroma compound should be colorless and  maby strawberry marmalade for taste

cookie card oat-flax-malt type description
smell neutral, slight malt aroma
color light, light brown, golden
taste not sweet , slight aroma malt
length 50 mm
thickness 7  mm
wide 50 mm
texture not soft but chewy ,bottom and crust formed
other
description
cookies are made with  specific aroma and taste of barley malt
taste is not achived in cookies,flat cookies,  time of baking  and form are correct

cookie oat-malt-cranberry type description
smell smell and aroma cranberry and malt
color light, light brown,
taste not sweet , malt aroma, slight bitter
length 50 mm
thickness 10 mm
wide 40 mm
average weight 11 g
texture soft and wet inside ,bottom burned and crust formed
other
description
cookies are made with malt, which is dominant taste and
aroma
taste is barley malt ,thick cookies, time of baking is not correct
these type cookie has malt taste for healthy food, slight bitter

cookie card oat-cranberry type description
smell intensive smell and aroma cranberry
taste very sweet , used 3 type of sweetners
length 50 mm
thickness 10 mm
wide 32 mm
average
weight
8.4 g
texture soft ,bottom and crust formed
other
description
cookies are made with specific aroma and taste of cranberry
taste is very very sweet,flat cookies, time of baking and form are correct
these type cookie has very intensive sweet and cranberry taste for healthy
food

cookie flax-hazelnut type description
smell smell and aroma hazelnut, not very intensive
color light, light brown, natural
taste sweet , hazelnut aroma, slight flax
length 60 mm
thickness 10 mm
wide 45 mm
texture firm shape ,bottom and crust formed , enough crumbly
other description taste is good but pieces of hazelnut stuck in dosing forms!
so only use powder or paste nuts and fruits, or else cookies will deform in shape
these type cookie has hazelnut taste, natural colour and is healthy food product
cookie flax-hazelnut type description
smell smell and aroma cinnamon
taste sweet , cinnamon aroma, slight flax
length 60 mm
thickness 10 mm
wide 45 mm
texture firm shape ,bottom and crust formed , slight crumbly
other description taste is good but pieces of hazelnut stuck in dosing forms!
so only use powder or paste nuts and fruits, or else cookies will deform in shape
these type cookie has hazelnut taste, natural colour and is healthy food product

cookie card flax-cocoa type description
smell smell and aroma of cocoa
color dark, dark brown,
taste enough sweet ,cocoa aroma, slight bitter, like chocolate
length 50 mm
thickness 12 mm
wide 30 mm
texture soft and slight wet inside ,bottom and crust formed
other description cookies are made with dominant taste and aroma of cocoa
time of baking is correct, taste is like chocolate, flax and cocoa make dark color
these type cookie has taste and colour for natural healthy food

cookie sesame-vanilla type description
smell smell and aroma of vanilla
color light, light brown, seeds of sesame are visible
taste enough sweet ,maby more fat taste , from sesame
length 60 mm
thickness 8 mm
wide 40 mm
average weight 10 g
texture soft inside ,bottom and crust formed
other
description
cookies are made with sesame deffated flour, and sesame seed
time of baking is correct, taste is more on fat, because of the sesame

cookie sesame-strawberry type description
smell smell and aroma of straberry
taste enough sweet ,strawberry
length 47 mm
thickness 9 mm
wide 42 mm
texture soft inside ,bottom and crust formed
other description cookies are made with dried strawberies,
time of baking is correct, taste is fresh

cookie flax-cinnamon type description
length 60 mm
thickness 5 mm
wide 60 mm
average weight 15 g
texture firm shape ,bottom and crust formed , enough crumbly,
thin
other description these cookies are with T-500 wheat flour and whey
so this combination makes cookie very hard for bite, but when broken is crumbly
these type cookie should be made with dosing speed 1, and whole wheat flour
cookie flax-cinnamon type description
length 60 mm
thickness 10 mm
wide 50 mm
other description these cookies are with T-500 wheat flour and whey
these type cookie should be made with dosing speed 1, and whole wheat flour

smell smell and aroma vanilla
color golden brown, natural
taste sweet , vanilla aroma, taste is very good
length 60 mm
thickness 7 mm
wide 60 mm
average weight 14 g
texture firm shape ,bottom and crust formed , enough crumbly,
thin
other description these cookies are with wholewheat flour and whey
these type cookie should be made with dosing speed 1, and do not use whey
smell smell and aroma vanilla
taste sweet , vanilla aroma, taste is very good
length 60 mm
thickness 10 mm
wide 45 mm
average weight 14 g
these type cookie should be made with dosing speed 1, inside the cookie is wet

cookie coconut-pumpkin type description
smell smell and aroma of fat compounds, slight coconut
taste sweet , coconut, taste is not good, too much fat compounds
length 60 mm
thickness 7 mm
wide 60 mm
average weight 13 g
texture firm shape ,bottom and crust formed , enough crumbly, thin
these type cookie should be made with dosing speed 1
cookie coconut-pumpkin type description
smell smell and aroma of fat compounds, slight coconut
taste sweet , coconut, taste is not good, too much fat compounds
length 60 mm
thickness 10 mm
wide 50 mm
average weight 14 g
these type cookie should be made with dosing speed 1, inside the cookie is wet

cookie sesame-coconut type description
smell smell and aroma of fat compounds,sesame ,slight coconut
color white , slight yellow
taste coconut, taste is not good, too much fat compounds
length 90 mm
thickness 10 mm
wide 40 mm
average weight 18 g
texture firm shape ,bottom and crust formed , not baked
other description these cookies are with T-500 flour and whey
in the process of making , double amount of water is used, so cookie couldn’t form
later additional flour is used, but taste is not achived, cookie is not baked
cookie sesame-coconut type description
smell smell and aroma of fat compounds, sesame, slight coconut
length 78 mm
thickness 8 mm
wide 42 mm
average weight 14 g
texture firm shape ,bottom burned and crust formed , slight crumbly
in the process of making , double amount of water is used, so cookie couldn’t form
later additional flour is used, but taste is not achived, cookie is with burned bottom

cookie coconut-vanilla type description
smell smell and aroma of fat compounds,sesame ,slight coconut
color white , slight yellow
length 65 mm
thickness 4,5 mm
wide 65 mm
average weight 12 g
texture firm shape ,bottom and crust formed , not baked
other description these cookies are with T-500 flour and whey
in the process , double amount of water is used, so cookie couldn’t form
later additional flour is used, but taste is not achived, cookie is thin
cookie coconut-vanilla type description
smell smell and aroma of fat compounds, sesame, slight coconut
length 65 mm
thickness 4 mm
wide 65 mm
average weight 11 g
texture firm shape ,bottom burned and crust formed , slight crumbly
in the process , double amount of water is used, so cookie couldn’t form
later additional flour is used, but taste is not achived, cookie is thin

cookie card vanilla T-500 type description
smell smell and aroma of vanilla
color light , light brown
taste neutral
length 40-60 mm
thickness 5 mm
wide 40-55 mm
texture these are firm cookies, flat and thin
other description cookies are made with vanilla and flour T-500
time of baking is correct, but shapes are various and also weight
these type cookie has taste and colour for standard tea cookies

cookie card 06-12-2013 type description
smell sweet, fat, slight vanilla
color light brown
taste sweet, fat, slight vanilla
length 50 mm
thickness 10-15 mm
wide 60 mm
average weight 20-25-30 g
texture soft and crumbly
other description these are large cookies, dosing is 2,5 and dough is soft
time of baking is correct, taste is vanilla and sweet, but also fat compound
these type cookie is very big and dosing should be less

cookie card 05-12-2013 type description
smell sweet, fat, slight vanilla
color light brown
taste sweet, fat, slight vanilla
length 50 mm
thickness 10-15 mm
wide 60 mm
average weight 20-25g
texture soft and crumbly
other description soft and not baked
time of baking is not correct these are large cookies, not baked
these type cookie are standard tea cookies, T-500 flour and vanilla

BASIC MATERIAL BALANCE AND BASIC TIME LINE FOR 100 KG DOUGH
type value unit
START END
time for mixing dough 4*30 min min 8.00 h AM 10.00 h AM
time for dosing ,forming 4*30 min min 10.00 h AM 12.00 h PM
time for baking 4*30 min min
time for trial 4 hours
time for cooling cookies 4*30 min min 12.00 h PM 2.00 h PM
time for packing cookies 4*30 min min 2.00 h PM 4.00 h PM
dosing dough cookies 1-1,5 unit
shape of cookies Y -shape
average weight 10 g

speed of conveyor 27,1 rpm

Basic Material Balans
type value unit
total dough 100 kg
1 batch dough 25 kg
dough in dosing machine 2 kg

dough for cookies 98 kg
total baked cookies 82,44 kg 6,3 kg dough 5,3 kg cookies
1 cookie average weight 10 g baked
total number of cookies 8244 pieces
1 package 200 g
number of cookies 1pack 20 pieces
total number of packages 412 pieces

no. of cookies on 1 tray 54 cookies
no. of tray 153 tray

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