This document provides information on the manufacturing processes for various fermented foods including bread, beer, and cheese. It discusses the roles of bacteria, yeast, and moulds in food fermentation and describes the fermentation of specific foods like bread, beer, cheese, and soy sauce. The document also outlines the benefits of fermented foods for consumers and provides details on industries involved in bread manufacturing.

1. BREAD, BEER AND
CHEESE
MANUFACTURING
SAKEENA ASMI
MAHATMA GANDHI UNIVERSITY

2. FERMENTED FOODS
• Fermented foods are an extremely important part of the human diet
and worldwide and may contribute to as much as one-third of
human food intake.
• The scope of food fermentation range from producing alcoholic
beverages, fermented milk and vegetable products to genetically
engineered superbugs to carry out efficient fermentation producing
nutritious and safe products with appealing quality.
• The consumer demand healthy natural foods produced by
compatible methods and it is the area where food fermentation
technology has far great role to play in the future.
• The application of biological and biotechnology principles results
in production or conversion of food stuff into more palatable,
nutritious or stable food. 2

3. CONCEPT OF FERMENTED
FOODS• Fermented foods are those foods produced by the modification of a
raw material of either animal or vegetable origin by the activities of
microorganisms.
• Bacteria, yeast and moulds can be used to produce a diverse range
of products that differ in flavour, texture and stability from the
original raw material.
BACTERIA
YEAST
MOULDS
Streptococcus, Lactobacillus, and
Bacillus produce lactic acid,
while Escherichia and
Salmonella produce ethanol,
lactic acid, succinic acid, acetic
acid, CO2.
Penicillium roquefortii and
Penicillium camemberti etc…
3

4. • The production of many fermented foods involves organisms that
are biochemically fermentative.
• Lactic acid bacteria that ferment carbohydrates to produce lactic
acid are particularly important, but yeasts also play a major role in
some food fermentations, fermenting carbohydrates to produce
ethanol and other organic chemicals.
• Mould fungi play an essential part in some food fermentations, for
example, the production of blue cheese and soy sauce.
BLUE CHEESE
Conti…
4

5. • Many hundreds of different types of fermented foods are found
world wide. Cheese, butter, yoghurt, bread, soy sauce and
fermented meat such as salami and pepperoni are very familiar to
all consumers.
Conti…
SALAMI PEPPARONI 5

6. BENEFITS OF FERMENTED
FOODS TO CONSUMER
1. Increase in variety
2. Use as ingredients
3. Improvements in nutritional quality
4. Preservation
5. Health benefits
6. Improve digestibility
7. Detoxification of
raw materials
6

7. BAKED FOODS -
BREAD• Baking technology transforms rather tasteless grains into most
appealing products for which there are no counterparts in nature.
• Flour is the ingredient which distinguishes ‘bakery products’ such
as bread and rolls from ‘baked confections’ such as macaroons or
meringues.
• Wheat flour can give unique texture and appearance, while other
cereal flour from rye, corn, oats, sorghum may also be used to
contribute special texture, flavour and appearance, economic and
nutritional qualities to bakery foods.
• Through the agency of heat, an unpalatable dough mass is
transformed into a light, porous, easily digestible and most
appetizing product.
7

8. • The biological activities that have been taking place in the dough
are stopped by baking, with the destruction of microorganisms and
enzymes present.
• The unstable colloidal system is stabilized.
• The basic characteristics of the native starch and proteins are
drastically changed, at the same time new flavouring substances are
formed including caramelized sugars, pyrodextrins and melanoidins
which give the baked products its desirable and distinctive
organoleptic properties.
Conti…
8

9. 9
• Bread is the product of baking a mixture of flour, water, salt, yeast
and other ingredients. The basic process involves mixing of
ingredients until the flour is converted into a stiff paste or dough,
followed by baking the dough into a loaf.
• The aim of bread making process is to produce dough that will rise
easily and have properties required to make good bread for the
consumer.
• To make good bread, dough made by any process must be
extensible enough for it to relax and to expand while it is rising. A
good dough is extensible if it will stretch out when pulled. It also
must be elastic, that is, have the strength to hold the gases produced
while rising, and stable enough to hold its shape and cell structure.
BREAD MANUFACTURING PROCES

10. 10
• Two proteins present in flour (gliadin and glutenin) form gluten
when mixed with water. It is gluten that gives dough these special
properties. Gluten is essential for bread making and influences the
mixing, kneading, and baking properties of dough.
• When we first start to bake bread, learning to mix the ingredients is
very important.
Conti…
DOUGH

11. 11
CHARACTERISTICS OF
GOOD BREAD
EXTERNAL INTERNAL
Volume
Symmetry of shape
Bloom
Eveness of bake
Cleanliness
Cleanliness
Moistness
Colour
Crust colour
Sheen,
texture
Flavour and
aroma
Crumb clarity and
elasticity

12. 12
TYPES OF BREAD

13. 13
WHITE
BREAD
White bread
typically
refers to
breads made
from wheat
flour.
BROWN
BREAD
Brown bread is
a designation
often given to
breads made
with significant
amounts of
whole grain
flour, usually
rye or wheat
WHOLEMEAL
BREAD
It contains whole
of the wheat grain,
also referred to as
whole grain or
whole wheat
bread.
RYE
BREAD
It is a type
of bread
made with
various
proportions
of flour from
rye grain.
TYPES OF BREAD

14. 14
Sourdough bread Pumpernickel
Kibbled bread

15. 15
INGREDIENTS
• FLOUR – Main ingredient in bread production. It is
primarily responsible for bread structure and bite
characteristics.
• WATER – Transforms flour into a visco elastic dough
that retains gas produced during fermentation and it also
provides medium of all chemical reaction to occur.
• YEAST – It ferment sugars and produces CO2 gas and
ethanol. It thus, give us porous and leavened bread.
• SUGAR – Source of fermentable carbohydrate for yeast
and it also provides sweet taste.

16. 16
• SALT – It enhances flavour of all other ingredients and
adds taste to the bread. It also strengthens the gluten
network in the dough.
• FAT – Makes the bread texture softer and improves its
freshness and shelf life.
• The oxidising agents such as ascorbic acid, potassium
bromate, potassium iodate and azodicarbonamide are
used at parts per million levels to enhance dough
strength, loaf volume and softness.
• Surfactants – Antistaling agents.

17. 17
STARTER CULTURE
• Baker’s yeast is the common name for the strains of yeast
commonly used as a leavening agent in baking bread and bakery
products.
C6H12O6 → 2C2H5OH + 2 CO2
• Bakers yeast is of the species Saccharomyces cerevisiae, which is
the same species, but a different strain used in alcoholic
fermentation called brewer’s yeast.

18. 18
BREAD MAKING PROCESS
Packaged

19. 19
LARGE SCALE
MANUFACTURING OF
BREAD

20. 20
MIXING AND KNEADING THE DOUGH
FERMENTATION

21. 21
DIVISION AND GAS PRODUCTION
MOLDING AND BAKING

22. 22
SLICING
PACKING

23. 23
KNEADING

24. 24

25. 25

26. 26

27. 27
MICROBIAL SPOILAGE
• Molds are the primary spoilage organisms in baked goods, with
Aspergillus, Penicillium and Eurotium being most common.
• Penicillium tends to be more important in sourdough breads and in
breads stored at cooler temperatures.
• Freshly baked breads do not contain viable molds but soon become
contaminated upon exposure to air and surfaces.
• Bacillus spores are very heat resistant and can survive baking
process and start growing as the bread cools.
• Some strains cause a defect called ropiness, a soft sticky texture
caused by starch degradation and slimy exopolysaccharides often
accompanied by a fruity odor.
• Yeasts may also be involved in spoilage of some breads and
fruitcakes, causing chalky appearance on surface and offodors.

28. 28
INDUSTRIES AND
COMPANIES
INVOLVED IN BREAD
MANUFACTURING

29. 29
• One of the world’s biggest bakery companies, Grupo Bimbo has a
strong presence in the US, European, and Asian markets. From
freshly sliced breads and buns to pre-packaged foods, salted
snacks, and confectionery products, this company has
covered all the major bakery products.
• Its large distribution network has further helped the group to expand
its operations in Asian and European markets. Grupo Bimbo
already operates 5 plants in Africa and 14 in Asia. Additionally, the
company is in talks with regional players in these countries to work
on further expansion plans.
Grupo Bimbo | Mexico

30. 30
• It is a leading speciality bakery manufacturer.
• With a meaningful presence in the continental European markets,
Finsbury Food Group is working on building a strong presence in
the Middle Eastern market as well. The company is also focusing
on replicating its UK success pattern in other European countries as
well.
• Recently, in a bid to cut down manufacturing costs, the company
has invested in process automation. Forward facing, innovative and
expansion minded. Finsbury is truly a heavy hitter for the global
bakery market.
Finsbury Food Group | United Kingdom

31. 31
• Monginis is a premier provider of breads,cakes, chocolates,
pastries, and cookies, with a commanding and distinguished
presence in twelve cities around India and two in Egypt.
• Monginis sells ready-made and order-made cakes for catering or
carry-out and sells both Indian and Western savories as well as
snack foods and breads.
Monginis | India

32. 32
• Modern is an iconic brand that pioneered the concept of bread, and
literally created the bread category in India. Launched in 1965
as Modern Bakeries (India) Limited, the company was
rechristened Modern Foods India Ltd in 1982.
• For generations of Indians Modern Bread’s iconic Blue & Orange
Waxed Paper Bread pack was virtually synonymous with bread.
Modern Foods was the first company to be privatised by the
Government of India in 2000, and it was sold to Hindustan Unilever
Ltd. (HUL).
Modern Bread

33. 33
FERMENTED ALCOHOLIC
BEVERAGES - BEER
• Beer is defined as a fermented alcoholic beverage made from
barley, wheat, rice etc and flavoured with hops.
• Beer is the world’s oldest & most widely consumed alcoholic
beverage.
• It is 3rd most popular drink after water & tea.
• The process of making beer is known as brewing.
• The alcoholic strength of beer is usually around 4% to 6%
alcohol by volume (ABV).

34. 34
INGREDIENTS
• Water
Water constitutes 90% of the volume of beer.
Must proved to be clean and pure.
• Malt
Mainly used is barley (Hordium Vulgare).
Provides extractive substance that could
ferment.
• Hop (Humulus lupulus)
Increases taste.
Has anti – bacterial properties.
• Yeast
Single – celled organism.
Responsible for converting the sugar to alcohol
and carbon dioxide in the fermentation stage.

35. 35
BEER PROCESSING

36. 36

37. 37
1. MILLING AND MASHING
• Malt is crushed for easier absorption of water.
• Then malt is mixed with water during the
Mashing process.
• The starch Malt is converted to sugar by natural
enzymes.
• The Mash is then filtered to remove residual
husk, leaving behind a sweet solution called
wort.
MALTED BARLEY

38. 38
2. BOILING
• Wort is boiled with hops and sometime other
ingredient.
• This stage is what decide flavour, colour and
aroma of the beer are made.

39. 39
3. WHIRLPOOL
• The wort now contains sugar, amino acids, vitamins.
• Wort is then transferred to a whirlpool to further clarify the
wort.

40. 40
4. COOLING
• After whirlpool, the wort is cooled to about 10OC, ready for
fermentation.

41. 41
5. FERMENTING
• Based upon beer style, the appropriate strain of brewers yeast
is added to the wort inside fermentation tanks.
• Yeast breaks down the sugar in wort to produce alcohol and
carbon dioxide.
• Once fermentation is complete, the yeast also settles, leaving
the beer clear and then is stored for reuse.

42. 42
6. MATURING AND FILTERING
• Beer undergoes maturation for a few days before it is ready
to filter.
• Residual yeast and protein are removed through the beer
filter to form clear bright beer.
• Filtration also help to stabilize the flavour of the beer.

43. 43
7. PACKAGING
• Packaging is a critical quality control point.
• Using advanced technology, the beer is keg, bottled or canned,
labelled and then packed.

44. 44
LIFE SPAN
• BOTTLE BEER – 6 MONTHS
• CANNED BEER – 1 YEAR
• DRAUGHT BEER –
48 HOURS AFTER BEING TAPED

45. 45
• Ferment at lower temperatures (2o-6oc), settle
in bottom of wort after fermentation.
• Characterized by a crisp-tasting, lighter body
and less-fruity aroma, smooth beer.
• Over last 150 years or so lagers have become
the predominate beers.
TYPES
BOTTOM FERMENTING BEER
TOP FERMENTING BEER
BOTTOM FERMENTING BEER – LAGER

46. 46
• Ferment at temperature 15° – 19°c, settle at top of wort after doing
the fermentation.
• Ferments less fully and less discriminately.
• Characterized by more-fruity flavors & aromas with a malty, full
bodied flavor.
• Prior to the 1800’s ales were almost universal.
TOP FERMENTING BEER - ALE

47. 47
Beer spoilage is caused due to following reasons:-
i. Spoilage caused by bacteria:- lactic acid bacteria, acetic acid
bacteria, Zymomonas anaerobia, Pediococcus cerevisiae causes
beer spoilage.
ii. Spoilage caused by wild yeast:- wild yeast causes spoilage at
any level of beer production, such yeasts are- Saccharomyces
diastaticus, Candida lambica, Dekkera intermedia. In
production of ales, Saccharomyces uvarum acts as a wild yeast
where as in production of lagers Saccharomyces cerevisiae acts
wild yeast.
SPOILAGE OF BEER

48. 48
INDUSTRIES AND
COMPANIES
INVOLVED IN BEER
MANUFACTURING

49. 49
• Kingfisher is an Indian beer brewed by United Breweries Group,
Bangalore.
•The brand was launched in 1978. With a market share of over 36%
in India, it is also available in 52 other countries.
• The Heineken Group holds 42.4% equity shares in United
Breweries Ltd.
Kingfisher

50. 50
• Heineken Lager Beer, or simply
Heineken is a pale lager beer with
5% alcohol by volume produced
by the Dutch brewing company
Heineken International.
• Heineken is well known for its
signature green bottle and red star.
Heineken

51. 51
• Tuborg is a Danish brewing
company founded in 1873 on a
harbour in Hellerup, an area North
of Copenhagen, Denmark.
• Since 1970 it has been part of
the Carlsberg Group.
• In Tuborg, pilsner was brewed for
the first time in 1880.
Tuborg

52. 52
• Carlsberg is a global brewer.
• Founded in 1847 by J. C. Jacobsen, the
company's headquarters is located in
Copenhagen, Denmark.
• Since Jacobsen's death in 1887, the
majority owner of the company has been
the Carlsberg Foundation. The company's
flagship brand is Carlsberg.
Carlsberg

53. 53
CHEESE
MANUFACTURING

54. 54
DEFENITION:
It is defined as “a product made from the curd obtained from
milk by coagulating the casein with the help of rennet or similar
enzymes in the presence of lactic acid produced by added or
adventitious micro-organisms, from which part of the moisture
has been removed by cutting, cooking and pressing, which has
been shaped in and then ripened by holding it for sometimes at
suitable temperatures and humidities.”
 The word CHEESE comes from the latin term caseus, which
means to ferment or to become sour, from which the modern
word casein is also derived.

55. 55
TYPES OF CHEESE
1. Fresh cheese - Requires high acidity by bacterial action.
E.g., Cottage cheese, Cream cheese
2. Soft cheese - Requires slow acid development, washing
to control lactose and minimal cooking time.
E.g., Brie, Camembert, Mozzarella and Gouda
3. Hard cheese - Requires high acid development and high
temperature.
E.g., Cheddar, Parmesan, and Edam

56. 56
Conti…
Roquefort Cheese Camembert Cheese
Brie Swiss cheese

57. 57
Grana
Stilton
Gouda

58. 58
NGREDIENTS FOR CHEESEMAKING
1. MILK :
• The most important ingredient in cheese is milk.
• The milk of many mammals can be used but the
milk of ruminants is the best.
• This is because it contains high levels of the milk protein,
casein, which is required to provide an adequate coagulum.
2. STARTERS :
• There are two types which are the mesophilic and the
thermophilic cultures.
• Three characteristics of starter cultures of primary importance
in cheese making are:
 ability to produce lactic acid in the curd
 ability to break down the protein
 ability to produce CO2 when applicable.

59. 59
SOME MICROBES USED IN CHEESEMAKING
Conti…
BACTERIA
Penicillium camemberti Camembert and brie
Penicillium roqueforti Blue cheese MOLDS

60. 60
Conti…
3. COAGULANT :
• Rennet is the usual coagulating enzyme used.
• Rennet is an enzyme which acts on protein and causes it to
coagulate.
• Rennet is derived from one of four sources:
 the stomach lining of a young calf (the enzyme rennin is found
in the stomach lining of animals because it aids in the digestion
of their mother's milk)
 plants (typically thistle)
 microbes in fungus and yeast
 Genetically engineered rennet that imitates animal rennet.
4. SALT :
• Sodium chloride is added to most varieties of cheese to give it
flavour.
• The quantity and method of addition depends on the recipe.

61. 61
Conti…
• It may be added directly to the milk or curd pieces, rubbed into
the finished cheese or immersed in a brine solution.
5. COLOUR :
• The recipe determined if colouring matter must be used.
6. CHEMICALS :
• CaCl2 is frequently added to aid coagulation and reduce amount
of rennet required.
• Sodium or Potassium nitrate inhibits pathogenic microbes such
as the gas forming Clostridium tyrobutyricum.

62. 62
STEPS INVOLVED

63. 63
Milling
Salting
Pouring into moulds
Pressing
Ripening

64. 64
SPOILAGE OF CHEESE
• Cheese is extremely susceptible to microbiological spoilage.
• There are a number of limiting factors inherent in cheese
which can influence the microbiological quality of cheese.
• These factors include moisture content, residual lactose
content, oxygen level, salt concentration and pH of the
product.

65. 65
INDUSTRIES AND
COMPANIES
INVOLVED IN CHEESE
MANUFACTURING

66. 66
• It is the most renowned brand in India. It produces varieties of
cheese that can be categorised into five different categories.
 Processed cheese
 Gouda cheese
 Emmental cheese
 Cheese spread
 Pizza Mozzarella cheese
Amul – The Taste of India

67. 67
• It produces cheese under the brand name of Go and Govardhan.
• It manufactures two varieties of cheese- Mozzarella and Processed
cheese. It is available in 1 kg, 400 gm, 200gm and 2.5 kg packs.
• It offers Go cheese in various pack sizes like cheddar cheese,
cheese wedges, shredded cheese, cheese spread, pizza cheese,
cheese slices and much more.
Gowardhan

68. 68
• It was started as a biscuit company in 1892 in Kolkata. It offers a
wide range of products from biscuits to lifestyle cheese.
• It manufacturers cheese made from cow’s milk. It is available in
many sizes, pack size and flavours. They offer eight types of
cheese:
Cubes
Blocks
Britannia Cheezza
Cheese slices
Britannia Slimz
Britania natural Cheddar cheese
Britannia

69. 69
THANK
YOU