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Controlling the Bread Making Process ©Copyright AIB International

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Bryan Gordon, Dr. Richard Dempster, Tom Lehman AIB International IBIE 2013

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Controlling the Bread Making Process ©Copyright AIB International

May not be reproduced without written permission.

Bryan Gordon AIB International IBIE 2013

BREAD CONTROL PROCESSES

• Why do we have them? • What are they? • Their importance in baking.

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Main Process Control Points • • • • •

Mixing Absorption Proofing Baking Cooling

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1. Mixing • “It all starts with the mix!” • The HUMAN ELEMENT • Use of senses

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2. Absorption Always an issue… Water and its effects on dough and bread  Mix time  Grain  Softness/eating quality  Mold issues ©Copyright AIB International

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3. Proofing • Time • Faults • Relative Humidity ― too dry ― too wet a) spots b) blisters c) crusted over d) capping ©Copyright AIB International

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4. Baking • One thing in common… • Fast as we can • Fast as slowest piece of equipment • Three measurable points ― Internal temperature ― Color ― Volume ©Copyright AIB International

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5. Cooling • We cool product for proper slicing and bagging. • Temperature a key factor …too cool leads to the “crumb shower” … too warm leads to “pilling” and possibly mold. ©Copyright AIB International

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Getting the Dough Right Dr. Richard Dempster AIB International IBIE 2013

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Background • Farm raised, Northeast Kansas • Ph.D. Engineering • Areas of emphasis – Remote sensoring – Data analysis

• Current Research – True flour quality – Dough quality

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Do you know your Bake Absorption • How do you determine bake absorption?

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Absorption in the Mixer R

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Development Time Stop Test

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Stop Screen

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A Final Check • Additionally, a mixer based NIR system can do a final check on your dough for certain missing or correct levels of ingredients. • NIR can “SEE” – Sugar – Shortening

• NIR can indirectly “SEE” – Salt

• NIR cannot “SEE” yeast.

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Possibilities • • • • • •

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The mixer may become smarter Consistency should increase Dough errors can be reduced Cripples should reduce Profits should increase Gateway to enhanced/automated processing

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Controlling the Bread Making Process ©Copyright AIB International

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Tom Lehmann AIB International IBIE 2013

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Controlling the Bread Making Process • Lack of technical training, especially with small to mid-size bakeries is a major issue today. • How do you achieve better correlation between flour COA and actual mixing time and absorption?

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Controlling the Bread Baking Process • How do you maintain consistent product quality when producing whole-grain and multi-grain products? • How do you improve the shelf life properties of breads and rolls made with an all natural label? ©Copyright AIB International

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Controlling the Bread Making Process Bryan Gordon Dr. Richard Dempster Tom Lehman [email protected], [email protected], [email protected] AIB International ©Copyright AIB International May not be reproduced without IBIE 2013 written permission.