Introduction to Bakery Processes: From Concept Through Construction
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The webinar introduces bakery processes from concept through construction. It discusses bread processing steps from receiving ingredients to shipping finished product. Key aspects of mixing, fermentation, proofing, baking and cooling are explained. Safety considerations for bakeries and construction sites are reviewed. Standard layouts for bakery buildings and sites are presented. The schedule for a typical construction project is outlined. Sanitation details are important design considerations. The presentation provides a comprehensive overview of bakery operations and construction.
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Introduction to Bakery Processes: From Concept Through Construction
- 1. Presents: Webinar Series #1: Introduction to Bakery Processes From Concept Through Construction In Partnership with: November 14, 2013
- 2. Introduction to Bakery Processes 2 Introduction Charles Albertone − Project Manager for Construction Projects − Industrial Engineer for Master Planning Efforts − BSIE, EMBA, PMP, AIB, ASB, IBIE, OSHA The Austin Company − − − − − − − Founded in Cleveland, OH in 1878 ABA, ASB, AIB, B&CMA, BEMA Site Location and Incentive Negotiation Master Planning Engineering Construction Registered Trademark Design-Build Process: The Austin Method ®
- 3. 3 Introduction to Bakery Processes Introduction
- 4. Introduction to Bakery Processes 4 Agenda Bakery Introduction − Bread Processing − Dough Systems − Ingredients Construction − Building − Site − Schedule − Sanitation Details
- 5. Introduction to Bakery Processes 5 Safety in Bakeries Types of Risk Managing the Risk Slips, Trips, Falls • Wet floors • Dough • Equipment platforms • • • Slip resistant flooring with epoxy or diamond grinding Cleaning Provide safety ladders Manual Handling • Bulk ingredients • Trays and racks • • Utilize mechanical aids (trolleys, lifts) Proper lifting techniques Machinery • Conveyors • Blades • • • Maintain safe clearances Preventative maintenance Safety guarding/interlocks Hazardous Substances • Cleaning chemicals • • Store in proper location Wear proper protection (gloves) Burns and Scalds • Ovens and trays • Syrups and liquids • • Wear oven gloves Design systems to handle hot liquids Flour Dust Inhalation • • Ventilation PPE (face mask)
- 6. 6 Introduction to Bakery Processes Safety on Construction Sites
- 7. Introduction to Bakery Processes 7 Good Manufacturing Practices Bakeries − Hair nets, including beards − No loose jewelry or rings with settings − All items in pockets below waist − Smocks Construction − Typically wouldn’t apply, however, in renovation projects, construction areas must be properly barricaded to avoid product contamination
- 8. 8 Introduction to Bakery Processes Bread Processing Steps
- 9. 9 Introduction to Bakery Processes Bread Dough Systems
- 10. 10 Introduction to Bakery Processes Bread Dough Systems
- 11. Introduction to Bakery Processes 11 Fermentation Floor Time − Dough is more viscous (flowable) immediately after mixing. Resting allows the dough to become more elastic. Retarding − A step that elongates fermentation by refrigerating the dough. −PROS: Flavor development and ability to mix larger batches and store until needed. −CON: Dries out dough.
- 12. Introduction to Bakery Processes 12 Fermentation and Proofing Fermentation Room (after mixing) Step Proofer (after makeup)
- 13. Introduction to Bakery Processes 13 Mixing Stages Pick Up Dough is sticky, cold, lumpy
- 14. Introduction to Bakery Processes 14 Mixing Stages Initial Development Dough is getting warmer, smoother, and drier
- 15. Introduction to Bakery Processes 15 Mixing Stages Clean Up Dough is at maximum stiffness. It will slap around mixer and come together as one mass
- 16. Introduction to Bakery Processes 16 Mixing Stages Final Development Dough is at correct temperature and handling quality
- 17. Introduction to Bakery Processes 17 Mixing Stages Letdown (1-3 mins) Dough is too warm and sticky – can be recovered with floor time
- 18. Introduction to Bakery Processes 18 Mixing Stages Breakdown Dough beginning to liquefy
- 19. Introduction to Bakery Processes 19 Typical Mixers and Ovens Horizontal Mixer Tunnel Oven Vertical Mixer Rack Oven
- 20. Introduction to Bakery Processes 20 Bread Processing Steps General relationship in Baking times and temperatures:
- 21. Introduction to Bakery Processes 21 Cooling & Packaging Equipment Spiral Cooler Tray Former Blast Cooler Palletizer
- 22. Introduction to Bakery Processes 22 Ingredients 4 REQUIRED Ingredients: − − − − Flour = Structure Salt = Flavor Water = Hydration Yeast = Levening (air pockets) 6 OPTIONAL Ingredients: 6 Types of ADDITIVES: − Gluten = Strength − Enrichments = Nutrition − Mineral Yeast Food = Conditioning − Enzymes = Breaks down dough = of dough Elasticity − Fats/Oils = Tenderness and − Oxidizer = Strengthen lubricant − Reducers = Weaken − Sugars = Food for yeast − Emulsifiers = Soften − Milk = Nutrition − Emulsifiers = Strengthen − Mold Inhibitors = Slows molding
- 23. Introduction to Bakery Processes 23 Bread Labels Bakers Percent – instead of a typical recipe, everything is calculated based on flour being 100%. 2% Line – On a nutritional label, everything below “Yeast” usually contains less than 2% of the formula.
- 24. Introduction to Bakery Processes 24 Bread Quality Baker control measures: − Look, temperature, pH, feel, specific gravity, proof temp & time, oven temp & time, cooling temp & time, mix temp & time − Cost (ingredients, labor, utilities) Consumer judging characteristics: − External – color, shape, volume, softness, toppings, mold, lack of foreign material − Internal – taste, texture, crumb color, crumb structure/cell size − Price
- 25. Introduction to Bakery Processes 25 Trends in Baking Reuse of mixed dough into recipe − Has been a standard procedure – improves volume, minimizes waste, improves consistency between batches NOW BEING CONSIDERED A BAD PRACTICE −Traceability – what if there was a defect? Where would you start and stop product recall since dough was used from previous mixes? −Allergens
- 26. Introduction to Bakery Processes 26 “Standard Bakery” Building Receiving Scaling Mixing Makeup Proofing Baking Cooling Packaging Shipping
- 27. 27 Introduction to Bakery Processes “Standard Bakery” Site
- 28. 28 Introduction to Bakery Processes “Standard Bakery” Site
- 29. Introduction to Bakery Processes 29 Schedule February February 2013 March 2013 April 2013 December 2013
- 30. Introduction to Bakery Processes 30 Schedule February February 2013 March 2013 April 2013 December 2013
- 31. Introduction to Bakery Processes 31 Schedule February February 2013 March 2013 April 2013 December 2013
- 32. Introduction to Bakery Processes 32 Schedule February February 2013 March 2013 April 2013 December 2013
- 33. Introduction to Bakery Processes 33 Structural Steel & Roof Design Rendering
- 34. Introduction to Bakery Processes 34 Structural Steel & Roof Design Actual Construction Photograph
- 35. Introduction to Bakery Processes 35 Sanitation Detail Considerations Pipe Hanger & Aisle Vertical Storing Dock Leveler Sanitation Room Standoff Detail
- 36. Introduction to Bakery Processes 36 Thank You! Next Seminar Topic, Early 2014: A Young Professional’s Guide to Baking Tech Baking Tech 2014, Chicago, March 2-4 YPC Social Event Sunday Night Questions?