cereal processing (2)

8/11/2019 Cereal Processing (2)

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CEREALS TECHNOLOGY

Wheat Processing


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Major Cereal Crops in India


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World three major crops


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Consumption/Uses of Wheat

Grinding wheat for (Atta), Maida, Suji, Bran Different products from Atta and Suji

Maida (Flour) for Bread, Bun and other bakery

products like, Biscuit, Cakes, Pastries Roasted, flaked and Puffed Wheat Product

For Breakfast foods and Energy Food

Pasta and other Extruded foods


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Wheat Grain Composition


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Wheat varieties

Wheat varieties are called "soft" or "weak"if gluten content is low, and are called "hard" or"strong" if they have high gluten content. Hardflour, or bread flour, is high in gluten, with 12% to

14% gluten content, and has elastic toughnessthat holds its shape well once baked. Soft flour iscomparatively low in gluten and thus results in afiner or crumbly texture. Soft flour is usually

divided into cake flour, which is the lowest ingluten, and pastry flour, which has slightly moregluten than cake flour.


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Turbo Milling and air classification

Processing of flour to separate higher protein andhigher starch fractions

The particle size of flour from conventional milling isfurther reduced by high speed turbo grinders andseparated in cyclone separator

Slightly lighter particles of protein rise and starchparticle settle in stream of air

Two fractions of flour differing in protein and starchcontent are recovered

Turbo milling can make tailor made flour for breadmaking and cake making from low protein wheat


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Types of Flour Graham floursis a special type of whole wheat flour The endosperm is finely

ground, as in white flour, while the bran and germ are coarsely ground.

Instant flouris pregelatinized (precooked) for easier incorporation in gravies

and sauces.

Pastry flouror cookie flouror cracker flourhas slightly higher protein

content than cake flour but lower than all-purpose flour. Its protein content

ranges between 9% and 10%.

Self-risingor self-raising flouris white flour that is sold premixed withchemical leavening agents. Baking powder and a pinch of salt

Atta Flour is a type of flour used in Asia to make chapatis and other flat

breads

Non wheat flour, also known as composite flours, are made from grains,

beans or seeds, corn, soybeans, rice, oats, buckwheat, potatoes and otheritems. These composite flours are ideal for those with a sensitivity to gluten

or celiacs who are unable to eat flour.

High-gluten flouris milled from hard wheat and has an especially high

protein content, making it high in gluten


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Types of Flour contd.. All-purposeor plain flouris a blended wheat flour with a protein content

lower than bread flour, ranging between 9% and 12%.

Bleached flouror maida flouris a white flour treated with flour bleaching

agents to whiten it. Oxidizing agents are peroxides like peroxide or benzoyl

peroxide, nitrogen dioxide, or chlorine. ("natural aging") for approx 10

days;

Bread flouror strong flouris always made from hard wheat. It has a veryhigh protein content, between 10% and 13%, making it excellent for yeast

bread baking. It can be white or whole wheat or in between

Bromated flourhas a maturing agent added. The agent's role is to help

with developing gluten, Bromate is usually used. Other choices

are phosphates ascorbic acid, and malted barley. Bromated flour has beenbanned


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Full Definition of ENTOLETER

used for a machine for disinfestations in flour

processing in which insect eggs remaining in

sifted flour are destroyed on impact as the

flour is thrown against the lugs and case of arotor revolving at a high rate of speed


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Cleaning Machine (Destoner)


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Wheat Grinding Machines

Conventional stone grinderHammer Machine

Break Rolls Reduction rolls


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Milling of Wheat


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MILLING OF WHEAT


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Roller Flour Milling Unit


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Bread Making Steps

Raw Materials weighing

Mixing

Fermentation

Remixing/Knock Back

Dividing

Rounding

Moulding and Panning

Final Prooving

Baking

Depanning Cooling

Slicing and Packing


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Mixing

One of the most important step in making a

good bread. Different methods and equipments

are available to suit the requirements

Straight Dough Method

Sponge Dough

Delayed Salt

Chorleywood Method Mechanical Dough Development


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Mixing Machines

Slow speed (single or double arm)

High speed (Horizontal or vertical)

Chorleywood Mixer MDD Mixer

The mixers are used to suit the specific

requirements regarding the quality of flourspace requirement etc.


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Divider

Single Pocket divider

Multi pocket (2 or 3 pocket) divider

Rounder: To give a round shape to the doughInterproover: Usually from 8-12 minutes


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WHITE BREAD v/s WHOLE GRAIN BREAD


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Bakery Technology

(Bread Production )


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History of Bread Production

The bread was first started in Egyptbysimply grinding the grains by stone(quern) manually kneading and baking infired brick oven in as back as 8000 B.C. Allbread was unleavened, there were no

raising agents and bread was made from amixed variety of grains. Today'sequivalents to Indian Chapattis (flat bread)and Mexican tortillas

A number of additions and

improvements were made in the rawmaterials and process of production toreach the bread being made in the

presently

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Ancient Process of bread making


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Ingredients in Bread Making

BASICINGREDIENTS:Flour, Yeast, Salt and Water

OPTIONALIngredients:

Sugar, Fat (bakery shortening) butter, milkemulsifiers, tuti fruity, raisin, multi grain flours,caramel, spices, improvers and preservatives

(Calcium Propionate, Acetic Acid) vitamins andMinerals

.

Mi i K di


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Mixing or Kneading

Kneading is the most important process which determines

the quality of final product Mixing of the dough uniformly incorporate all ingredients

Hydrate the flour and other dry ingredients

Develop the gluten by putting in energy and mixing

If the dough is under mixed or over mixed, it will have

poor handling properties of the dough and texture of the

grain of crumb

If the temperature of the dough isn't right (around 80F),the fermentation rate will be faster or slower and that

will influence the volume and other characteristics of

bread.


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Steps in bread making

Flour Sifting (passing through sieves 180 micron)

Weighing the ingredients required as per formulation Mixing/ Kneading

Bulk Fermentation of Dough

Remixing/ Knock back

Dividing in pieces of required size

Rounding of dough pieces

Intermediate Proving

Molding and Panning

Final Proofing to raise the dough in pan

Baking De-panning, Cooling

Packing


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Mixing Methods

Straight Dough Method:Mixing all ingredients at single step, knock back after bulk fermentationand process

Delayed salt Method:Mixing all ingredients except salt at first stage, bulk fermentation andremix the dough adding salt and process

Sponge Dough Method:Mix a part of flour (30-50%) yeast, sugar to form sponge, remix the doughby adding remaining flour and other ingredients and process

Chorleywood Process


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Chorleywood Process

Developed in 1961revolutionized bread baking process.

Now 80% production of the bread using this processFeatures:

The process uses intensive high speed mixers for short time

about 3 min. to make the dough reducing from 30-50 min.

Flour to a ready loaf time is reduced to about 3 hours asdough is mechanically developed. No Bulk Fermentation

required

Lower protein (soft) wheat can be used to produce bread

using this processLess space requirement as fermentation room not needed

Better process control and handling of dough during Break

Down

Rest of the process remains the same


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Mixer/ Dough Kneaders

Single arm mixer Spiral Mixer

Horizontal Mixer High Speed Mixer

MDD Mixer


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Dough Dividers

Bread Dough DividerBun Divider cum molder


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Bread Molding Machine

Sheeting, molding

Dough pieces are sheeted by

passing through a set of

rollers, moulded by passing

through a curling chainpressed by passing through a

pressure board. The moulded

pieces fall into the bread

baking pans the pans aretransferred


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Final Proofer

The machine is used forraising the dough in the pans.

To facilitate the fermentation

process, the temperature

around 90F and humidity

around 90-95% are

maintained. Normally the

bread is prooved in 60

minutes. However, the time

depends on the formulation

used, size of the bread dough

temperature

Tray Type Final Proover

Cabinet Type final proover


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Baking Ovens

For baking breads at

Temperature from

230-250C for around

30 minute depending

upon formulation and

size of the bread

Brick oven

Laboratory ovenTray oven

Wood fired oven

Rotary oven


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Depanner


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Slicing Machines

Manual slicer Commercial SlicerSlicer cum Twist & Tie Machine

Different Types of slicer and packing machinesare used based on the requirement


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Thank You

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