Rusk Production Introduction: Rusk production involves a series of unit operations comprising dough mixing, molding, dividing and panning, proving, baking, cooling and wrapping. Measurements of final product quality are made, typically after baking, and few measurements are made at intermediate stages of processing (e.g., dough properties). The quality of the final product and the processing requirements of the dough are critically dependent on the flour properties. Principle of bread making Rusk is a double-baked product. At first, Bread is made from the first baking of dough, and the second baking transfer the bread into Rusk. Raw materials for bread making The raw materials which used for making bread are: Wheat flour: This is the composition of the wheat grain and flour. Among other things, one can determine the quality of flour using the following methods: Chopin, amylograph, falling number, moisture content, etc. Water: Water plays an important role in bread preparation. An essential element of any recipe is water, the importance of which is very often overlooked. A bread dough is roughly 40 % water. Yeast: Yeast is a microorganism cultivated in yeast factories. Its scientific name is Saccharomyces cerevisiae. The name stems from Latin: "saccharo" which means sugar and "myces" which means fungus. Baker's yeast is a single-celled mold which is capable of transforming sugars in alcohol, carbon dioxide and various aromatic compounds. We call the process of this transformation "the fermentation". Sourdough: Sourdough bread is made by the fermentation of dough using naturally occurring lactobacilli and yeast. The lactic acid produced by the lactobacilli gives it a sourer taste and improved keeping qualities. Enzymes: Enzymes are proteins that catalyze chemical reactions. This means that they help to initiate the chemical reaction. In this reaction, the enzymes are not converted or broken down, but they are deactivated by baking. One does not have to be afraid of enzymes. Our bodies are full of them and if they didn't exist there would be no life. Gums and hydrocolloids: Today, products in general, and bakery products in particular, need to be kept fresh for longer. This is mainly stimulated by the supermarket chains who have a total aversion to "unsold" products because they represent an outright loss. Gums and hydrocolloids can help extend the life of products in certain cases. Salt and salt product: Today's consumers are increasingly in need of healthy products, and are aware that too much salt is not good for health. It is sometimes claimed that bread is a "culprit" in that regard. But that is not the case at all. This does not alter the fact that the baker can intervene to reduce the salt content of his products and still make tasty products.

1. Production of Rusk
Presented by
Mrinal Kanti Debnath
ROLL No: 171712
Abdullah Al Numan
ROLL No: 171713
Department of Agro Product
Processing Technology.
Jashore University Of Science and
Technology.
Presented To
Farzana Yeasmin
Assistant Professor.
Department of Agro Product Processing
Technology.
Jashore University Of Science and
Technology.

2. Rusk
• A hard, dry biscuit, twice-baked bread is called a Rusk. Rusk is toast
bread where bread is toasted at a higher temperature which makes it
crisp and dry.

3. Principles of Rusk making.
Rusk is a double-baked product. At first, Bread is made from the first
baking of dough, and the second baking transfer the bread into Rusk.
Dough Bread Rusk
1st Bake 2nd Bake

4. Raw materials
Ingredient Quantity Percentages
Flour 100g 100%
Water 60g 60%
Butter 50g 50%
Granulated white
sugar
60g 60%
Baking powder 4g 4%
Milk powder 5-7g 5-7%
Salt 1.6g 1.6%
Vanilla extract 4 drops -
Egg 1 -
Yellow food color
(optional)
2-3 drop -

5. Flow Chart for Rusk making
Raw Materials Kneading (20 min.) Proofing (1Hr.
At 27ºC)
Knock Back
Proofing (30 min.
At 27ºC)
Filling in Pans
Proofing
Baking (220ºC,30-
35 min.
Cooling (< 15 min
at Ref. Temp.
15ºC)
Slicing
Re- Baking (220ºC,
30-40 min.
Cooling (1 Hr.)
Packing

6. Production process of Rusk making
The main production process are:
Weighting and Mixing Kneading Proofing Rising/Folding
Shaping
Baking
Cooling
Re Baking

7. Weighing and mixing
The production of rusk begins with mixing of the ingredients. For this
purpose, Accurate amounts of ingredients are combined.
Kneading: After mixing the ingredients, the dough is kneaded. By kneading
the dough the network of gluten is formed and air bubbles are created, where
the carbon dioxide (CO2), formed by fermentation, can accumulate.

8. Proofing: Proofing is the process of leaving the dough in the machine for 30
to 50 minutes at a steady temperature of 27°C.
Rising/ folding: After the first proofing, The pieces of dough are folded in the
folding machine and placed in nets in the proofer .

9. Shaping : After the folding, the dough is shaped for use in a baking tin. The
forming of the dough into a long roll is called shaping. During the shaping process
the dough ball is rolled into a slab.
Baking : After the final proofing the dough has risen sufficiently and
is ready to be baked. Baking the bread takes up 30 to 40 minutes at a
temperature of 200 to 220°C.

10. Cooling and Slicing : After the baking, The loaf will very hot. So it is necessary
to cool down. After cooling a slicer will slice the loaf.
Re-Baking : After the slicing the sliced bread is ready to be baked
again. Baking the bread takes up 30 to 40 minutes at a temperature of
200 to 220°C.

11. Some major problem for making Rusk
1. Dough is very soft & won’t held it’s shape. Too much liquid or fat or too bit little
flour
2. If butter content is very high ,rusks are fragile
3. Rusks stick to the baking tray. It occurs when baking sheet was not greased
unevenly.
4. Rusks are dry and too crisp on top. If the oven was too .
5. Sometimes rusks are broken during packing and transporting.

12. Equipment’s for Rusk production line
Dough Mixer: Dough mixer is a kind of food machine. Main function of it is to mix flour, water and
other materials evenly. There are vacuum dough mixer and spiral dough mixer.
Spiral mixer vacuum mixer

13. Dough divider machine : Dough divider machine can divide the dough into
specified dough block evenly. Block and weigh the dough according to the
requirements of specification.

14. Blade Cutting Machine : The cutting length can be adjusted by the machine, and the cutting blade
can also be replaced for different shapes of bread.

15. Safety precaution of Rusk making
•Use hot pads when handle something hot.
•Don't crowd the cooking area around the range with unnecessary
personnel or equipment.
•Never stand in front of the range cabinet or oven doors when you
open them. Always stand to the side.
•Close the range cabinet door the right way. Don't slam it.
•Do not fill your cooking utensils too fulfill only to a safe handling
level.
•Avoid "horseplay."

16. Composition
Table of Nutritional Information
Per 100g
Energy 1749 Kj
414 kcal
Fat 7.2 g
Carbohydrate 79.2 g
Fibre 2.1 g
Protein 7 g
Salt 0.03 g
Sodium 0.01 g
Table of Vitamins and Minerals Information
Per 100g
Vitamin A 450 µg
Vitamin D 10 µg
Thiamin (B1) 0.53 mg
Riboflavin (B2) 0.82 mg
Niacin 8.8 mg
Calcium 390 mg
Iron 7 mg

17. https://www.youtube.com/watch?v=f4NDy3pSzNs
Video

18. Thank YOU
Any Question?