TRAINING MANUAL FOR PRINTING, JUNE,2021.pptx

Creating value is our business
Olam International Ltd
The objective of the school is to train the participants on the basics of milling,
quality and baking process. The course will make the participants to:
Understand wheat.
Understand milling process.
Know GMP, Hygiene and Sanitation.
Know Quality control in milling.
Flour as a living thing! – A session breakout discussion.
Improve baking knowledge and how to use Bakewell and APF
Product packaging, transporting and delivery – from bakery to consumption.
Sales practice in baking business.
Account practice in baking business.
This course will highlight from baking to consumption, understanding the need
for bakery goods to be delivered in perfect conditions

3
1.0 - WHEAT INFORMATION
Morning session
Wheat - a cereal which is the most important kind grown
in temperate countries, the grain of which is ground to
make flour for bread, pasta, pastry, etc.Three species of
wheat:
(i) T.aestivum -90%
(ii) T. durum – 7%
(iii) T.dicoccum- 3%
are being cultivated mainly worldwide.
Internal parts of wheat
Endosperm - Flour is made from endosperm
which makes up about 83% of the wheat kernel
and is composed of starch and protein.
Bran - About 14% of the kernel weight
Germ - About 2.5% of the kernel weight

1.1 - WHEAT CLASSES
4
Classified based on the protein content
Hard Red Winter (HRW)- High protein
Soft Red Winter (SRW)- Low protein
Hard Red Spring (HRS)- Very high protein
Hard White – High protein
Soft White –Low protein, weak gluten
Durum – High protein, strong gluten, pasta
Morning session

5
Morning session
1.2 - UTILIZATION OF MAJOR VARIETIES OF WHEAT
Class Subclass Vitreous Content
Hard Red Spring (HRS) DNS - Dark Northern Spring ≥ 75 % DHV *
NS - Northern Spring 25-74 % DHV
RS - Red Spring < 25 % DHV
* Dark Hard and Vitreous
Hard Red Winter (HRW) No Subclasses None
Hard White (HW) No Subclasses None
Soft White (SW) SW - Soft White None
WC - White Club None
WW - Western White None
Soft Red Winter (SRW) No Subclasses None
Durum (DU) HAD - Hard Amber Durum ≥ 75 % HVAC *
AD - Amber Durum 60 – 74 % HVAC
DU - Durum < 60 % HVAC
* Hard and Vitreous of Amber
Color

6
Morning session
1.3 - MAJOR VARIETIES OF WHEAT GROW IN U.S
U.S. Wheat Quality
One of the major strengths of the U.S. grain production and marketing system is the variety of grades, classes,
and prices that it can offer customers around the world. Dramatic differences in topography, soils, and climate
from one region to another make this variety possible. By building on these natural advantages, seed breeders,
researchers, farmers, grain handlers, and merchandisers are continually seeking to expand both the type and
quality of wheat the United States can make available to its customers.

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2.0 - Milling Process
Morning session
Milling: the process of grinding grain or other materials in a mill
Flour milling process is basically the separation of the endosperm from the germ
and the bran layers of the wheat grain. Using the gradual reduction process
ensures that the endosperm (flour and semolina) is carefully separated through
several sub-processes of repeated grinding, scalping, sifting, grading and
purification. This is achieved only after a thorough dry cleaning and conditioning
of the wheat grains

Pre-Cleaning
Wheat Reception
Wheat Storage (silos)
Milling stage (see detail below)
Flour storage
Packing
Dispatch
Bran storage
Packing
Dispatch
From Ship or
truck
Water addition
Water addition
Light
grains
stones
Other
grains
First Cleaning
Second Tempering
First Tempering
Second Cleaning
Semolina storage
Dispatch
Packing
2.1 - MILLING PROCESS

Air channel separator
Tempering stage: 18-24hrs
Combi-cleaner (destonner,
separator)
Gravity table
B1 magnet
Wheat scourer
To
B1
Wheat Transfer (Conveying
and Elevating system)
2.2.1 - Wheat Cleaning Stage
Morning session

Detailed Flow diagrams
2.2.2 - Wheat Milling Stage
First Break (B1)
Sieving
Breaking Stage
Sieving
Reduction
stage
Flour collection from all the rolls (coll.
conveyor)
Bran Finisher
Sieving
Purification
stage:
Production
Blow line
Sterilator
Flour final sieving
By-product:
Bran produced
Flour Fortification (Vitamins, Premix,
Cassava)
To Semolina Bins
Morning session

Procedure for determining test weight (source US wheat)
Dockage tester (source US wheat)
2.2.4 - Flour Packing Stage

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2.2.7 - Milling Equipment Used For Analysis
Purifier Plain sifter Turbo sifter
Break Rolls
Bran
Finisher
Reduction
Rolls
Morning session

Quality Process
Afternoon session
At the end of the session, participants should be able to understand;
 Quality
 Lab equipment
 Test type
 Flour composition
 Session break out

3.1.1 - QUALITY DEFINITION
 Quality is defined by customer requirements
 Consistency is critical
 The role of the Quality Assurance department is to
deliver what the customer wants and needs also to
produce the type and quality of product they choose.

3.1.2 – Quality Dimension
Dimension
of QUALITY
Performance
Aesthetics
Durability
Conformance
to
specification
Serviceability
Features
Perception
Reliability
Putting quality in practice in your daily baking….

Does Our Product or Service Meet the Customer’s Expectations?
Performance
Consistency
Safety (Physical, Chemical, Microbiological)
What Can We Specify, Design and Maintain?
Working Environment
Processes
Systems
People?
Behaviour
Training
3.2 – Quality: Process in review

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3.3 - Lab Equipment Used For Analysis
Farinograph
• Measures flour water absorption and
dough strength
• Gluten washer
• Measures wet gluten, dry gluten and
gluten index contents of flour and
wheat
Source: US wheat

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3.3.1 - Lab Equipment Used For Analysis
Alveograph
• Measures dough elasticity
• Measures dough strength
• Measures dough extensibility and
resistance to extension
Source: US wheat
Extensograph

19
Falling Number Sieving Machine Farinograph
• Measures amylase activities in wheat
and flour
• Measures the effects of sprout
damage
Source: US wheat
Thousand Kernel Weight
• Measures the mass of the
wheat kernel

20
• High temperature incineration
• Measures ash content
• High temperature combustion protein analyser
• Measures protein content
Source: US wheat
Ash Content
Protein Content

21
• Low temperature heating
• Measures moisture content
• Laboratory scale flour mill
• Determines flour yield and makes
flour for other tests
Source: US wheat
Moisture Content
Laboratory Wheat
Milling

3.5 - COMPOSITION OF FLOUR
Paramater. Percentage (of flour)
Moisture (%) 11 - 14
Protein (%) 7 - 15
Starch (%) 63 - 72
Lipids (Fat) - (%) 1-2
Ash (%) 0.5-0.7

DAY 1: GOOD MANUFACTURING PRACTICE
The objective of the course is to train the participants on good manufacturing
practices (GMPs) and hygiene within the work area and environs:
Understand GMPs, Hygiene and Sanitation
GMP Regulations
Steps in GMPs
Food Safety

4.1 - Good Manufacturing Practice
Good Manufacturing Practice (GMP) is that part of quality assurance which
ensures that regulated products are consistently produced and controlled to the quality
standards appropriate to their intended use and as required by their marketing and legal
regulations

GOOD MANUFACTURING PRACTICE
(GMP)
• These are the basic Operational and Environmental conditions
required to produce SAFE FOOD.
• They ensure that INGREDIENTS, PRODUCTS and PACKAGING are
handled safely and that the food products are Processed in a suitable
Environment.

GOOD MANUFACTURING PRACTICE
• Good manufacturing practices (GMP) are the practices required in
order to conform to the guidelines recommended by agencies that
control the authorization and licensing of the manufacture and sale of
food and beverages,[ cosmetics, pharmaceutical products, dietary
supplements, and medical devices.

IMPORTANCE OF GMP.
To ensure that Businesses produce Safe and Wholesome food to the
Public.
Business in the Food Industry have a Legal and Moral Responsibility to
produce food that is Safe to the Consumers.
By not implementing GMP, a food Business face severe Legal action.
GMP also aid Manufacturers in Improving their production of Goods
within safe Environment, hence ,it prevent Contamination, Recall and
loss of PROFIT.

GMP CONTD…
• These guidelines provide minimum requirements that a manufacturer
must meet to assure that their products are consistently high in
quality, from batch to batch, for their intended use.
• The rules that govern each industry may differ significantly; however,
the main purpose of GMP is always to prevent harm from occurring to
the end user

GMP CONTD…
• Additional tenets include ensuring the end product is
free from contamination, that it is consistent in its
manufacture, that its manufacture has been well
documented, that personnel are well trained, and the
product has been checked for quality more than just
at the end phase.[2] GMP is typically ensured through
the effective use of a quality management system
(QMS)., which is a formalized set of Business
Processes , a Company uses to ensure the Continual
quality of the products or Services it Provides. The
core function of QMS is to document the
PROCESS,PROCEDURES & RESPONSIBILITIES for
achieving Quality Objectives.

GENERAL GUIDELINES
• Manufacturing facilities must maintain a clean and hygienic
manufacturing area.
• Manufacturing facilities must maintain controlled environmental
conditions in order to prevent cross-contamination from adulterants
and allergens that may render the product unsafe for human
consumption or use.
• Manufacturing processes must be clearly defined and controlled. All
critical processes are validated to ensure consistency and compliance
with specifications.

GENERAL GUIDELINES CONTD…
• Manufacturing processes must be controlled, and any changes to the
process must be evaluated. Changes that affect the quality of the
drug/Food are validated as necessary.
• Instructions and procedures must be written in clear and
unambiguous language using good documentation practices.
• Operators must be trained to carry out and document procedures.

• Records must be made, manually or electronically, during
manufacture that demonstrate that all the steps required by the
defined procedures and instructions were in fact taken and that the
quantity and quality of the food or drug was as expected. Deviations
must be investigated and documented.
• Records of manufacture (including distribution) that enable the
complete history of a batch to be traced must be retained in a
comprehensible and accessible form.

• Any distribution of products must minimize any risk to their quality.
• A system must be in place for recalling any batch from sale or supply.
• Complaints about marketed products must be examined, the causes
of quality defects must be investigated, and appropriate measures
must be taken with respect to the defective products and to prevent
recurrence.

…SAFEGUARDING THE HEALTH
• Good manufacturing practices are recommended with the goal of
safeguarding the health of consumers and patients as well as
producing quality products. In Nigeria, a food or drug may be deemed
"adulterated" by NAFDAC if it has passed all of the specifications tests
but is found to be manufactured in a facility or condition which
violates or does not comply with current good manufacturing
guideline.

NOT A MANUFACTURING
PROCEDURE
• GMP guidelines are not prescriptive instructions on how to
manufacture products. They are a series of general principles that
must be observed during manufacturing. When a company is setting
up its quality program and manufacturing process, there may be
many ways it can fulfill GMP requirements. It is the company's
responsibility to determine the most effective and efficient quality
process that both meets business and regulatory needs

ENFORCEMENTS
• GMPs are enforced in Nigeria National Food and Drug
Administration (NAFDAC). The regulations use the
phrase "current good manufacturing practices"
(cGMP) to describe these guidelines.
• Current Good Manufacturing Practice refers to the
Regulations provided by the US Food and Drug
Administration (FDA ) that guides the DESIGN,
MONITORING,& MAINTAINANCE of Manufacturing
Facilities.

GMP INSPECTIONS
• Regulatory agencies (including the States Ministries of
Health and Local Government Health Departments)
and NAFDAC are authorized to conduct unannounced
inspections, though some are scheduled. NAFDAC
routine domestic inspections are usually
unannounced, but must be conducted within the
appropriate legal frame, which requires that they are
performed at a "reasonable time". Courts have held
that any time the firm is open for business is a
reasonable time for an inspection.

6 MAIN COMPONENTS OF GMP
6 Ps OF GMP.
• PEOPLE
• PREMISE
• PROCEDURE
• PROCESS
• PRODUCT
• PROFIT.

DAY 1: FOOD SAFETY

WHAT IS FOOD SAFETY?
• Food safety is a scientific discipline describing handling, preparation,
and storage of food in ways that prevent food-borne illness. The
occurrence of two or more cases of a similar illnesses resulting from
the ingestion of a common food is known as a Food-borne disease
outbreak.
• The Micro Organisms responsible for these illness are Salmonella,
Norovirus, Clostridium,Campylobacter and Staphylococcus.

WHAT IS FOOD SAFETY? CONTD..
• This includes a number of routines that should be followed to avoid
potential health hazards. In this way food safety often overlaps with
food defense to prevent harm to consumers. The tracks within this
line of thought are safety between industry and the market and then
between the market and the consumer.

WHAT IS FOOD SAFETY? CONTD..
• In considering market to consumer practices, the usual thought is that
food ought to be safe in the market and the concern is safe delivery
and preparation of the food for the consumer.

WHY FOOD SAFETY?
• Food can transmit pathogens which can result in the illness or death
of the person or other animals. The main mediums are bacteria,
viruses, mold, and fungus (which is Latin for mushroom). It can also
serve as a growth and reproductive medium for pathogens. Another
main issue is simply the availability of adequate safe water, which is
usually a critical item in the spreading of diseases.[2]

WHY FOOD SAFETY?
• In theory, food poisoning is 100% preventable. However this cannot
be achieved due to the number of persons involved in the supply
chain, as well as the fact that pathogens can be introduced into foods
no matter how many precautions are taken.

5 keys to safer food
. Keep Clean
.Seperate Raw and cooked food
.Cook food Thoroughly
.Keep Food at Safe Temperature.
.Use Safe Water and Raw Materials.

Source: Tin Can 2016 Quality Data Records
Source: From IGQMS Manual M-101
4.2 - FOOD SAFETY HAZARDS
Definition: Physical, chemical, Biological {microbiological) property that may cause a food to be
unsafe for consumption
PHYSICAL HAZARDS (size and injury related)
 Metal, sources (equipment, personnel and prevention (pre-operational
inspections,)
 Glass, ceramics, wood, stones and Brittle plastics
CHEMICAL HAZARD
 Chemical hazards naturally occurring: (mycotoxins like aflatoxin (20ppm), vomitoxin (2 to
4 ppm), ochratoxin A (3.0 to 10 μg/kg), heavy metals (selenium, mercury)
 Chemical hazards intentionnally added: (additives, packaging materials, food allergens)
 Chemical hazards non-intentional: (agricultural ingredients, facility chemicals, lubricants,
paint…)
BIOLOGICAL HAZARDS
 Coliforms (80% prevalence) <10~2 and mould (90%), yeast < 10~3
 Salmonella (most active at lower water activity and most persistent at low
temperature and low pH,
 E coli (fecal contamination) & Bacillus cereus (contamination) <10

HYGIENE Practice

PRINCIPLES OF FOOD HYGIENE
• The five key principles of food hygiene, according to WHO, are:
• Prevent contaminating food with pathogens spreading from people,
pets, and pests.
• Separate raw and cooked foods to prevent contaminating the cooked
foods.
• Cook foods for the appropriate length of time and at the appropriate
temperature to kill pathogens.
• Store food at the proper temperature.
• Do use safe water and safe raw materials.

WHAT IS HYGEINE?
Hygiene are conditions or practices conducive to maintaining
health and preventing disease, especially through cleanliness.
TYPES OF CONTAMINATION
There are basically three types of contamination :
 Chemical contamination
 Biological contamination
 Physical contamination
4.4 – Hygiene: An Approach

All foods are at risk of becoming contaminated, which increases the chance of
the food making someone sick. It’s important to know how food can become
contaminated, so that you can protect against it.
• Chemical contamination refers to food that has been contaminated by
some type of chemical substance. Because chemicals can be very useful
when cleaning in the kitchen, they can easily contaminate food. Chemicals
must be properly labelled, and stored separately to food stuff to minimize
the risk of contamination.
• Biological contamination refers to food that’s contaminated by substances
produced by living creatures – such as humans, rodents, pests or
microorganisms.
• Physical contamination refers to food that has been contaminated by a
foreign object at some stage of the production process. These objects have
the ability to injure someone and can also potentially carry harmful
biological contaminants, which then cause illness.
4.4.1 – Hygiene: An Approach

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4.5 - Hygiene significance in baking environment
A. Proper Display
 Only pack the bakery products after proper cooling (and use qualified food packaging materials);
 Perishable bakery products (e.g. cream cakes) should be stored at below 5⁰C. Do not sell bakery
products which have expired or deteriorated;
 Finished bakery products should be rotated to ensure that the distribution and sale of products is
carried out on a “first-in, first-out” basis;
 Use proper dust-proof and insect-proof equipment such as showcases to protect bakery products
that are in display or ready for sale;
 For self-serve bakery shops, cleaned and disinfected tongs and trays should be provided to
customers.
B. Environmental Hygiene
 All work surfaces should be impervious and stay away from the ground. The materials used should
be easy to clean;
 Use covered rubbish bins, and empty and disinfect them regularly;
 Containers that are used for transporting bakery products such as bread boxes and plastic trays
should be cleaned and disinfected before use;
 Set up effective pest control equipment;
 Do not keep pets at food premises.

The importance of this can not be over stressed. EVERYONE working in the bakery must respect
hygiene rules ;
 BAKERS HYGIENE
 Must wash their hands frequently
 Remove any ornament like watches, earrings etc.
 Cut his or her finger nails
 Protect self from any cut and avoid any cutting and sharp objects that can fall in the dough.
In order to protect the consumers, all these and more must be applied such as:
 RAW MATERIALS
 Choose good quality of incoming materials e.g. design incoming material records
 Verify sealing and integrity of material
 Verify expiry date
 Verify organismic functions : smell, taste.
 Verify and keep in good storage conditions
 WORKING ENVIRONMENT
 Clean area and dirty area must be clearly separated.
 The walls and the environment must be washed regularly.
 There should be adequate ventilation.
 There should be good water evacuation system.
 There should be no smoking and animals should not be allowed.
 Hand washing stations must be installed.
 There should be frequent fumigation and de-rating

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C. Personal Hygiene
 Wash hands thoroughly before handling food;
 Wear clean and light-coloured outer clothing or protective overalls;
 Do not wear rings, bracelets and watches, etc. Do not wear nail polish or false nails;
 Wear gloves or use utensils such as scoops, tongs, etc. when handling ready-to-eat
food;
 Use waterproof dressings to cover open wounds;
 Do not handle money while handling food;
 Do not use finger to taste food;
 Suspend from engaging in any food handling work when suffering from symptoms of
illness such as running nose, coughing, diarrhea, vomiting and fever, etc.
D Work Area Hygiene
It is also important to maintain the work area hygiene to protect food from
contamination.
 Regular cleaning of the work place. e.g sweeping and dusting
 Regular cleaning and maintenance of the equipment and utensils
 Proper garbage disposal on a regular basis
 Develop a pest control system. e.g fumigation and de-rating
 All the cracks and crevices should be sealed or fixed
 There should be wire mesh on windows to prevent flies.
Exercise
Q What do you understand by personal hygiene?
Q Mention any five ways of maintaining personal hygiene?

4.8 - BAKING WEAR
Baking / Lab Coat
Apron
Resistant and Anti-slip
work shoes
Cap to prevent hair loss
The
work
wear
must
be
cotton,
clean
and
clear

• How to lift bags
• Remember there are spare parts for machine but no
spare parts for you.
DO’s DON’Ts
Evaluate the weight of the bags
and verify space.
Don’t try to lift heavy bags alone.
Bend the knees and maintain a
straight back.
Don’t try to rotate while carrying
a heavy material.
Keep the arms close to the body
and lift with the back straight.
Don’t carry a heavy material via
long distances.
2.5 - HEALTH AND SAFETY

DAY 1: QUALITY CONTROL IN BAKING

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3.7 - BAKING PROCESS:
The objective is to train the participants on the basics of baking process in particular
OUR BRANDS Mama Gold Flour, Mix , Bake, Bakewell Flour &Dangote All Purpose
Flour, (APF)
Understand baking ingredients and their importance
Understand basic steps of baking process
Weighing and measurement
Yeast process and management
Mixing time management
Water addition
Proofing time
Room temperature effect
Control of oven temperature
Practical demonstration of baking process
Understand the significance of hygiene within the baking environment
Understand product handling and storage
Understand Bread: faults and control management
Interactive session / break out session – sharing of learning experience: BEFORE and NOW!
Legal and regulatory controls in the baking sector

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3.8 - BAKING PROCESS: Practice
BREAD PRODUCTION FLOW CHART
Wheat Flour
Sieving
Adding Of All Ingredients
Mixing To Optimum Gluten Development (Dough)
Cutting/Scaling/Moulding or Shaping
Panning
Proofing
Baking (To Form Bread)
De-panning
Cooling
Slicing
Packaging
Selling

DAY 1: BAKING INGREDIENTS AND THEIR FUNCTIONS

3.9.1 - Flour
 Major structure building ingredient
 Visco-elastic properties due to gliadin and glutenin.
 Retains carbon dioxide
 Strong flour - high percentage of gluten forming proteins
Flour Storage
Below are advice to help you store your flour correctly;
 Refresh your flour frequently ( try not to store up old flour).
 Store the flour in cool dry aerated places.
 Store the flour on pallets and free flow and easy access
around the pallets.
 Use “FIFO” RULE : First in, first out (FIFO) is an asset-
management and valuation method in which the assets
produced or acquired first are sold, used or disposed
of first and may be used by a individual or a corporation.
 Do not store flour against the wall or directly on the floor
 Do not store near items like soaps, oil, fuel, disinfectants etc.

3.9.2 - Yeast
Features:
 Unicellular micro-organism belonging to the fungi
group.
 Species name Saccharomyces cerevisiae
 Three main types:
I. Compressed yeast also called “fresh yeast” (CY)
II. Dried yeast (Instant dry yeast (IDY)
III. Active dry Yeast( ADY)
Instant Dry Yeast
 Rapid loss of activity on exposure to atmospheric
conditions
 Once the package is opened, IDY should be used within
3 – 5 days
 4 -6% moisture content ; 45% - 55% protein content
 Unlike ADY, IDY always contains some type of emulsifier

TYPES OF YEAST.
• 1.BAKERS YEAST
• a. Compressed Yeast
• B. Instant Dry Yeast.
• C. Active Dry Yeast.
• 2.Nutritional Yeast.(deactivated or killed)
• 3.Brewers Yeast (bitter taste)
• 4. Distiller and Wine Yeast.

3.9.2.1 - Yeast
Functions:
 Three major functions are leavening, dough maturation, and flavour development.
 Gassing power depends on temperature, pH, alcohol concentration, nature of
carbohydrate supply, osmotic pressure and yeast concentration.
 Temperature – 38 °C
 pH - 4 to 6
 Decline of yeast activity towards the end of sponge fermentation - raising alcohol
content
 Yeast ferment different sugars at different rates.
 Exhibits a pronounced sensitivity toward osmotic pressure
 Fermentation rate decreases above 5% sugar level
 Salt at 2% normal level, also exerts inhibitory effect
 Inorganic salts are used to provide yeast with a source of readily available nitrogen and
minerals

3.9.2.2 - Roles of yeast in Baking Application
 Production of carbon dioxide:
Carbon dioxide is generated by the yeast as a result of the breakdown of fermentable sugars in the dough. The
evolution of carbon dioxide causes expansion of the dough as it is trapped within the protein matrix of the
dough.
 Causes dough maturation:
This is accomplished by the chemical reaction of yeast produced alcohols and acids on protein of the flour and
by the physical stretching of the protein by carbon dioxide gas. This results in the light, airy physical structure
associated with yeast leavened product
 Development of fermentation flavor:
Yeast imparts the characteristic flavor of bread and other yeast leavened
products. During dough fermentation, yeast produce many secondary
metabolites such as ketones, higher alcohols, organic acids, aldehydes and
esters. Some of these, alcohols for example, escape during baking. Others
react with each other and with other compounds found in the dough to
form new and more complex flavor compounds. These reactions occur
primarily in the crust and the resultant flavor diffuses into the crumb of the
baked bread.
C6H12O6 2(CH3CH2 OH) + 2(CO2 ) + Energy

3.9.3 - Salt
Performs three principal functions
 Improvement of flavour
 Bread without salt is insipid and flat in taste and
flavour
 Strengthening and tightening effect on the gluten
 Inhibitory effect on proteolytic enzymes (protease) –
aids in breaking down of protein molecules into
smaller fragments
 Delayed salt addition
 Reduction in water-holding capacity of the flour
proteins thereby increasing the dough’s “free water”
content
 Reduces yeast activity
 Controlling yeast fermentation

3.9.4 - Sugar
 Sucrose is the most commonly used sweetener
 Sucrose, when added to dough, is hydrolysed or inverted, almost
instantly into glucose and fructose by the yeast enzyme
invertase
 Yeast ferments glucose and fructose at essentially the same rate
when they are present separately. When both are available
simultaneously, however, yeast ferments glucose preferentially
 Maltose remains largely unfermented as long as either glucose
or fructose is available to the yeast
 Adequate carbon dioxide gas production can be maintained with
2-3% sugar
 Unfermented sugar appears as residual sugars in the finished
bread
 Crust colour - caramelization and Maillard
 Volatile acids and aldehydes - bread flavour and aroma
 Sugars improve the colour, texture, grain
 Sweet taste in bread if used above 6%
 Shelf life extended due to increased moisture retention

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It helps make it soft and tender by absorbing some of the water
and slowing down the formation of gluten strands.
 It feeds the yeast, resulting in a faster rise.
 Via caramelisation, it aids in the browning of the crust.
 It acts as a preservative, keeping the bread fresher for longer
 It does have some effect on the flavour.
 Sugar plays an important role in extending the shelf life of
bakery products. Sugar can bind to water molecules, slowing
moisture loss and preventing staleness in baked goods
3.9.4.1 - Roles of sugar in Baking Application

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3.9.5 - Water
 To form gluten proteins and also for the necessary swelling of starch.
 Acts as a solvent for some of the released carbon dioxide gas to form carbonic acid.
 Hardness in water is due to the presence of calcium and magnesium in the form of their bicarbonates, chlorides,
sulphates, phosphates etc.
 Very hard water - retards fermentation, tightening of gluten
 Soft water yields soft and sticky doughs.
 Excessive amounts of salts leads to high alkalinity.
 Alkaline waters tend to show abnormal fermentation behavior.
 Natural water has a pH value range between 6 and 8.
NOTE : The degree of hardness is an indication of the amount of calcium and magnesium ions in water, expressed in parts
per million (ppm). Soft water has less than 50 ppm, while hard water has over 200 ppm. Generally, water of medium
hardness, with about 100 to 150 ppm of minerals, is best suited to bread baking. The minerals in water provide food for
the yeast, and therefore can benefit fermentation. However, if the water is excessively hard, there will be a tightening
effect on the gluten, as well as a decrease in the fermentation rate (the minerals make water absorption more difficult for
the proteins in the flour). On the other hand, if water is excessively soft, the lack of minerals will result in a dough that is
sticky and slack.

70
3.9.6 - Shortenings (Fat)
 Bread formulation generally contains 2 – 5 % fat.
 Lubricates the gluten fibrils and make the dough more
extensible thereby improving the gas retention capacity.
 To facilitate dough handling and processing.
 To improve slicing properties.
 To prolong shelf life and enhance keeping qualities.
 To increase loaf volume, improve crumb grain and tenderness.
 Plastic fats (such as lard, shortening, butter, margarine) perform
more satisfactorily than oils.
 Fluid shortenings contain suspended fat solids and emulsifiers.

71
3.9.7 - Bread Improvers
Bread improvers: carefully dosed formulas
A bread improver is a coherent, balanced combination of baking ingredients chosen from among various
manufacturing aids and raw ingredients (both cereal-based and other), mixed together in an appropriate
formula.
Better baking performance
Bread improvers boost dough enhancer and reinforce tolerance during the different manufacturing(baking)
stages. They make the work safer and simplify production, enabling bakers to prepare quality, standardized end
products.
Bread improvers can also act on the following properties of dough:
Rheological properties: by increasing the dough’s handling, strength or extensibility, so as to better tolerate its
time in the machine;
Fermentation properties: by optimizing the yeast’s action through stabilized fermentation and increased gas
retention capacity.
Why add bread improvers?
Bread improvers simplify the work of bakers, allowing them to show off their full expertise. They can be used
with any technology, under the most widely varying production conditions.
Reasons for adding improvers:
 smooth out the dough more quickly;
 enhance machinability;
 boost tolerance in control proofing, especially for raw frozen and pre-cooked specialty breads;
 increase yields.
Afternoon session

72
3.9.7.1 - Bread improvers types

DAY 1: SCIENCE OF BREAD MAKING – PRACTICE
At the end of the session, the participants will understand:
 science of bread making
 comparison procedure
 opportunities

74
5.1 – Bread: Science of bread making
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.
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 making involves the following basic steps:
 Sieving
 Weighing
 Mixing
 Fermentation
 Gas Production
 Gas retention
 Dough makeup
 Moulding
 Final Proof
 Baking

• Before baking, it is important to measure the quantities of raw materials to be used. the
weighing of the ingredients allows the baker determine to a few grams his weight of paste.
Weighing of the flour
Weighing of the yeast
Weighing of the sugar
Weighing of oil/fat
5.2.a - Weighing

5.2.b - Weighing
• Before baking, it is important to measure the quantities of raw materials to be used. the
weighing of the ingredients allows the baker determine to a few grams his weight of paste.
Weighing of salt
Weighing of the water
Blending of the ingredients
Blended ingredients in the mixer
Dosage of water

77
5.2.c - Weighing
Weighing of Ingredients
Before baking, it is important to measure the
quantities of raw materials to be used. the weighing of
the ingredients allows the baker determine to a few
grams his weight of paste
Weighing of Flour Weighing of water
Weighing of yeast Blending of ingredients
Weighing of sugar
Flour + ingredients in the
mixer
Weighing of fat / oil Dosage of water
Weighing of salt

78
5.3 - Mixing and Dough Checking
What is Mixing?
As the mixing action continues, the particles are rubbed against each other, exposing
the next layer for hydration. Therefore, mixing is not only simply homogenizing the
ingredients, but hydrating the ingredients as well.
All the mixing machines available today are designed to incorporate both the mixing
and the kneading processes. Kneading is the development of the dough gluten
structure after the homogenized distribution of the ingredients.
Local kneading Machine Mixing machine
MIXING – initial, pickup, cleanup, development and let down stages
 Dough Development
 Time Depends
• Flour
• Mixer type and Speed
• Consistency of Dough
• Salt and Shortening
• Enzymes

79
5.4 - Fermentation
What is Fermentation?
Fermentation occurs when yeast converts the sugar, present in the flour and dough, into carbon
dioxide and alcohol. Yeast provides the enzyme zymase which catalyzes the fermentation of sugar into
alcohol and carbon dioxide.
Functions:
 Increase in Dough Volume
 Increase in Temperature
 Increase in Yeast Cells
 Loss of Moisture
 Change in Dough Consistency
 Drop in pH 5.3 – 5.5 to 4.6 – 4.5
 Dough development
 Production of Carbon di Oxide
 Mellowing of Gluten by Proteases
 Dough Weight Loss

80
5.5 - The baking
What is Baking?
Baking - Radiation - from heated internal surfaces of the oven, heats exposed loaf surface; convection
transfer of heat by either fluids or gases air, steam, gas and conduction – sides, bottom crusts – heat
transmitted by the walls of the pans.
temperature phenomena
30°C because of the rising temperature, gasses present in the dough expand
enzymatic production of sugars
solubility of CO2 decreases
45 - 50°C yeast dies
50 - 60°C intensive enzymatic activity
starch starts to gelatinise
60 - 80°C end of the gelatinisation of starch
enzymatic activity ceases because of the denaturation of the enzymes
crumb starts to form
interaction between gluten and starch
100°C water starts to boil
formation of water vapour
first signs of crust formation
110 - 120°C formation of pale yellow dextrins in the crust
130 - 140°C formation of brownish dextrins in the crust
140 - 150°C start of caramelisation process
150 - 200°C formation of the "crustiness" of the bread and aromatic compounds
> 200°C carbonisation of the crust
formation of a porous black mass

81
Weighing of all the Ingredients (1)
Before baking, it is important to weigh the quantities of raw materials to be used. The
weighing of the ingredients allows the baker determine to a few grams his weight of
paste/ dough.
Mixing with spiral mixer (2)
Removal of dough after mixing. (3) cutting of dough (4)
5.5.a - The baking

TO CALCULATE DESIRED WATER
TEMPERATURE IN A SPIRAL MIXER.
• FORMULA,
• WATER TEMPERATURE=
• 3(DESIRED DOUGH TEMP.) _ ( RT +FT +FF )
• RT = ROOM TEMPERATURE.
• FT= FLOUR TEMPERATURE
• FF = FRICTIONAL FACTOR.

83
Covering Pan (8)
Weighing Of Dough (5)
5.5.b - The baking
Moulding Of Dough (6)
Arranging Kneaded Dough In Pan (7)

84
Arranging To Rack For Proofing Preparation (9) Baking And Removing From The Oven (10)
Removing From Pans
(11)
Arranging The Bread For Cooling, Slicing And
Packaging On Bread Rack (12)
5.5.ci - The baking

DAY 2: RECIPE FORMULATION USING BAKERS
PERCENTAGE
At the end of the session, the participants will understand:
 science of bread making
 comparison procedure
 opportunities

In any manufacturing setting there 3 things that are important:
Your inputs Your processing method Becomes Your outputs
• The inputs are your raw materials
• The processing method is determine by the kind of equipment's you are using
and your baking procedures(SOP)
• The outputs is the final finished product.
Once you don’t get it right in the first two stages ,it is likely that you cannot get a
good final product, hence proper care or caution should be taken.
4.3 - BAKING INGREDIENTS CLASSIFICATION

Primary ingredients(major ingredients):
These are the major ingredients that must be used for bread to be produced;
• Wheat flour
• Water
• Salt
• Yeast
Secondary ingredients(optional ingredients):
These are ingredients that are not mandatory to be used in the production of bread. Bakers
use them depending on the type he/she want to produce.
• Sugar
• Butters
• Improvers
• Preservatives
• Flavors
• Colourings
• Sweeteners
4.4.a - CLASSIFICATION OF BAKING INGREDIENTS

Dry ingredients:
• Wheat flour
• Salt
• Yeast
• Sugar
• Preservatives
Some ingredients can be in liquid or solid form.
Wet ingredients:
• Water
• Butter (semi solid)
• Flavors
• Improvers
Functional ingredients:
These are ingredients that are mostly regarded as food additives, they are added to food in
small quantity to improves and maintains nutritional value, enhances quality, reduces
wastage, enhances acceptability by customers, improve keeping quality and makes food more
readily available. Example bread improvers, preservatives, colourants, sweeteners etc
4.4.b - CLASSIFICATION OF BAKING INGREDIENTS:
( IN GROUP )

IMPORTANT HINTS ON RECIPE CONSTRUCTION (1)
The amount of all ingredients is usually calculated as percentages of weight of the
flour.
The flour is 100% no matter the quantity to be used.
Small adjustment in the recipe will be necessary according to the type of yeast being
used.
Fast and very active yeast will require less quantity.
Slow and less active yeast may require to be slightly increased in standard recipe.

IMPORTANT HINTS ON RECIPE CONSTRUCTION (2)
Amount of water used for making bread depends on the
types of flour used and the type of bread produced.
• Strong flours will always take more water than soft flours
or those with high moisture content.
Adequate amount of water is necessary (even in long
process dough). This is necessary in order to ensure good
yields for satisfactory cash returns.
Whole wheat for brown bread will take more water than
plain white flour.
When too much water is used, bread produced is very loose
in the crumb, light and fluffy but go stale quickly. Too little
water produced bread with very tight and dry crumb.

4.5 - BAKER’S PERCENTAGE %
Baker's percentages % Flour total weights Actual ingredients weights
Flour 100 % 50kg (50000g) 50000
Yeast (0.5-1.0) % 250g
Sugar (10 - 12)% 5kg
Salt (1.5-2.0) %
Water (50-52) %
Butters (2.0-5.0) %
Flavours (0.1-1.0) %
Edc 0.1 %
Preservatives 0.4 %
Improvers;
• Beta baker (0.02)%
• Dynamii (0.2) %
• EDC 2000 (0.04) %

CONTINOUS ASSESSMENT
1) Calculate the value of the other ingredients using a known bakers
percentage, if the weight of the flour available is 50kg. Show all
workings.
• 2) Calculate the number of pan you will get if you cut 850g per pan
and calculate the residual dough.

From the above formula, with a known bakers percentage , bakers can easily develop any recipe
that can satisfy the needs of any customer without compromising quality.
EXERCISES:
Using bakers percentage, calculate the weight in grams of other ingredients given a 12.5 kg flour
weight.
SOLUTION: from the table, sugar is within the range of ( 10 - 12) %; so let us pick 12%
For sugar =12 %, Flour weight= 12.5 kg, Actual ingredients weight= ?
The first thing to do is to convert kilograms to grams. Flour weight 12.5 x 1000 = 12500g
THEN SUBSTITUTE THE KNOWN VALUES FROM THE FORMULA
Actual ingredients weight= 12 x 12500g = 150000 = 1500g
100 100
Sugar weight = 1500g or 1.5kg for 12.5kg flour
CLASS EXERCISES: STUDENT SHOULD CALCULATE THE VALUES OF THE REMAINING INGREDIENTS.
4.6 - RECIPE FORMULATION USING BAKER’S PERCENTAGE %
ACTUAL INGREDIENTS WEIGHT = BAKER’S PERCENTAGES % X TOTAL FLOUR WEIGHT

SOURCE: TCA & TCB CUSTOMER ALERT NOTIFICATION
BAKEWELL FLOUR
 Best Yield
 Always fresh and soft bread
 Exclusive and unique
 Available any time
 Good value for money
 Latest Premium flour in the market
 Always Technical + After sales service
 Overall 100% satisfaction guaranteed
MASTERS SECRET…
 25 Litres minimum!
 Best between150-350g yeast/bag
Improvers:
 50-100g Panok/bag + EDC
Or
 50-100g Dynamill + EDC
Or
 1 sachet of B baker + EDC
 Or any good improver
7.3.a - PRODUCT AND PACKAGING

MIX & BAKE FLOUR
7.3.b - PRODUCT AND PACKAGING
 Best Yield
 Latest Premium flour in the market
MASTERS SECRET…
 26Litres minimum!
 Best between 150-350g yeast/bag
Improvers:
Or
Or

 Best Yield
 Latest Premium flour in the
market
 Always Technical + After sales
service
 Overall 100% satisfaction
guaranteed
MASTERS SECRET…
 27 Litres minimum!
 Best between 150-350g yeast/bag
Improvers:
Or
Or
MAMAGOLD FLOUR

DANGOTE ALL PURPOSE FLOUR
 Very Good Yield
 Designed for special needs
MASTERS SECRET…
 25 litres minimum!
 Best between 150-300g yeast/
bag
Improvers:
Or
Or
 Or any other good improver
7.3.c - PRODUCT AND PACKAGING

BAKEWELL
FLOUR
ALL PURPOSE
FLOUR
MAMA GOLD
FLOUR
MIX AND BAKE FLOUR
SUPREME NOODLE
FLOUR
EXCELLENT YIELD
EXCELLENT VOLUME
BEST QUALITY
VERY GOOD YIELD
VERY GOOD VOLUME
BAKERS’ PREFERRED QUALITY
GOOD YIELD
GOOD VOLUME
GOOD QUALITY
VERY GOOD YIELD
VERY GOOD QUALITY
Our Brands
7.3.c - PRODUCT AND PACKAGING
EXCELLENT YIELD
EXCELLENT VOLUME
BEST QUALITY

SUPREME BISCUIT
FLOUR
SUPREME GURASA FLOUR
BUA PREMIUM FLOUR
WHOLE WHEAT
FLOUR
EXCELLENT YIELD
EXCELLENT VOLUME
BEST QUALITY
VERY GOOD YIELD
VERY GOOD VOLUME
VERY GOOD QUALITY
GOOD YIELD
GOOD VOLUME
PREFERRED QUALITY
VERY GOOD VOLUME
VERY GOOD QUALITY
Our Brands
7.3.d - PRODUCT AND PACKAGING

FINISHED PRODUCT COSTING
BREAD COSTING

8.1 CALCULATING SMALL BUSINESS EARNINGS
To determine how much the owner of a small bakery makes per month, subtract the
bakery's gross revenue or receipts from its monthly operating expenses, including labor,
ingredients, rent and advertising. For a sole proprietorship, partnership or limited
liability company the bakery's net income equals the income of the owner or owners.
8.2 BUSINESS MODEL AND SCALE
The monthly earnings of the owner of a small bakery depend on how effectively that
bakery is run. If the bakery owner is committed to using only high quality or specialty
ingredients, the price of the baked goods must cover the added cost of these
ingredients. Greater volume allows you to purchase ingredients at lower prices,
increasing your profit margin and owner earnings. Economies of scale also allow you to
produce more cost effectively, spending less and earning more for each unit produced.
To calculate your cost of production, the following data are required:
Your Recipe
Cost of material in bulk
Unit cost as per recipe
Dough weight value
Approximate cost of other expenses like diesel usage, electrcity etc
Staff Salary
Total Daily production

1. Make a full list of your recipe
INGREDIENTS QUANTITY
FLOUR 50,000
SUGAR 5,000
YEAST 300
SALT 800
BUTTER 1,000
MILK 500
WATER 25,000
EDC 50
PRESERVATIVE 200
IMPROVER 10
FLAVOUR 30
16.3

2. Write out the wholesale prices of the ingredients
INGREDIENTS QUANTITY (g) WHO LESALE PRICE
FLOUR 50,000 15000/50KG
SUGAR 5,000 20000/50KG
YEAST 300 800/250G
SALT 800 4300 /50KG
BUTTER 1,000 12500/15KG
MILK 500 55000/50KG
WATER 25,000 50/25LITRES
EDC 50 25000 /20 LTR
PRESERVATIVE 200 50000 /25KG
IMPROVER 100 500/500G
FLAVOUR 30 32000/4 LTR
16.4

3. Calculate the cost per quantity used by multiplying the quantity by the bulk
price over the bulk weight.
INGREDIENTS QUANTITY WHOLESALE PRICE COST
FLOUR 50,000 15000 15000
SUGAR 5,000 20000 2000
YEAST 300 800 480
SALT 800 4300 70
BUTTER 1,000 12500 670
MILK 500 55000 550
WATER 25,000 50 50
EDC 50 25000 63
PRESERVATIVE 200 50000 400
IMPROVER 100 500 100
FLAVOUR 30 32000 240
16.4

4. Add the weight of the recipe together. Also add the unit cost together.
Divide the total weight of recipe by the cut dough weight. Then divide the
answer by the total unit cost.
INGREDIENTS QUANTITY WHOLESALE PRICE COST
FLOUR 50,000 15000 15000
SUGAR 5,000 20000 2000
YEAST 300 800 480
SALT 800 4300 70
BUTTER 1,000 12500 670
MILK 500 55000 550
WATER 25000 50
EDC 50 25000 63
PRESERVATIVE 200 50000 400
IMPROVER 100 500 100
FLAVOUR 30 32000 240
TOTAL 82980 19623
DOUGH WEIGHT 230 360
EXPECTED DOUGH 360 COST OF ONE LOAF 54.50
16.5

5. Add the cost of other variables to the cost of loaf to get the total cost
of the product.
6. If you are distributing yourself or you hire a salesman to work for you , then you must remove
another N10 from the margin to cover for fuel, vehicle repairs and salary of the salesman.
DESCRIPTION AMOUNT
COST OF ONE LOAF 54.50
Nylon 6.00
Tighter 1
Oil/butter (5,000/month) 3.0
DIESEL/FUEL(5000/month) 4.0
PHCN (5000/month) 3.50
Firewood (20,000/month) 5.00
Salary ( 6 WORKERS)#250000 8.00
Total Other Cost 30.50
FINAL COST OF ONE LOAF 85.00
SELLING PRICE 90.00
MARGIN 5.00.
16.6

It is important to note that there are some costs that are not included in the
calculations because they do not occur daily. Examples are :
Local Government Health department charges
Local Government Commercial rates
Quarterly Fumigation Cost
State Government Commercial Rates
Other Vehicle Repairs
Equipment Repairs
Distribution Cost
Staff Lunch (If any) and
Unforeseen Expenses
All these must be put in mind as you decide on what type of bread you want to
produce and the material cost.
16.7 OTHER VARIABLES

INTRODUCTION
BREAD FAULTS

CAUSES OF FAULTS IN BREAD
• RAW MATERIALS
• PROCESSING
• FLOUR.

CAUSES OF FAULTS,
• Defective or inappropriate ingredients
• Unbalanced Formulation
• Poor Dough Development and Maturity
• Incorrectly adjusted or poorly maintained Equipment
• Undercutting dough weight
• Uneven Oven Temperature.
• Inconsistent Pan Sizes.

CLASS DISCUSSIONS.
• COMPLAINTS EXPERIENCED BY PARTICIPANTS ON OUR FLOUR
BRANDS IN RECENT TIMES .
• LIKE CAUSES
• SOLUTIONS.
•

CHARACTERISTICS OF GOOD LOAVES
• INTERNAL EXTERNAL
. Grain Loaf Volume
• Crumb colour Break and Shred
• Flavour Symmetry( shape)
• Aroma Crust Colour
• Tactile crumb Texture Crust Surface.
• Mouthfeel

CHARACTERISTICS OF GOOD LOAVE
• Unique Flavour and Aroma.
• Smooth thin crust with no Hole streaks/crack or
Wrinkle
• Uniform Golden Brown Crust
• Fine Crumb with uniform cell structure, thin cell wall
and Texture soft to Touch.

Source: Tin Can 2016 Quality Data Records

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