Biscuit Baking Technology

Biography

• Baker Pacific Companies
• Experience in the Biscuit Industry

Acknowledgements

Introduction

Chapter 1. The Biscuits

• Abstract
• 1.1 Crackers
• 1.2 Process for Snack Crackers
• 1.3 Process for Soda Crackers
• 1.4 Hard Sweet Biscuits
• 1.5 Process for Hard Sweet Biscuits
• 1.6 Short Doughs: Rotary Moulded Biscuits
• 1.7 Short Doughs (Moulded Biscuits)
• 1.8 Process for a Moulded Short Dough Biscuit
• 1.9 Cookies
• 1.10 Process for a Chocolate Chip Cookie
• 1.11 Long Shelf Life Cakes, Snack Cakes
• 1.12 Summary
• Bibliography

Chapter 2. Baking Process

• Abstract
• 2.1 From the Dough Piece to the Biscuit
• 2.2 Ingredients
• 2.3 Baking: The Development of the Biscuit Structure and Texture
• 2.4 Summary
• Bibliography

Chapter 3. Biscuit Design and Output

• Abstract
• 3.1 Cutter and Moulding Roll Layouts
• 3.2 Scrap and Scrap-Less Designs
• 3.3 Docker Pins
• 3.4 Oven Band Loadings
• 3.5 Oven Size and Output
• 3.6 Output Calculation
• 3.7 Summary
• Bibliography

Chapter 4. Heat Transfer

• Abstract
• 4.1 Radiation
• 4.2 Conduction
• 4.3 Convection
• 4.4 Summary
• Bibliography

Chapter 5. Oven Designs

• Abstract
• 5.1 Heat Transfer Methods
• Bibliography

Chapter 6. Oven Specifications: Hybrid Ovens

• Abstract
• 6.1 Specifications for Ovens: Crackers
• 6.2 Recommended Oven Specification for Light Carrier Products (eg, Crispbreads, Rusks and Biscottes)
• 6.3 Recommended Oven Specification for Hard Sweet Biscuits (eg, Marie)
• 6.4 Recommended Oven Specification for Short Dough (Rotary Moulded) Biscuits
• 6.5 Specifications for Ovens: Soft Dough Cookies
• 6.6 Modular Oven Design
• 6.7 Calculation of Oven Zone Lengths
• 6.8 Example 1: DGF Oven for Baking Crackers (1.5 m×100 m Long)
• 6.9 Example 2: Indirect Radiant Oven for Baking a Short Dough Biscuit, ‘Glucose’ (1.25 m×100 m Long)
• Bibliography

Chapter 7. Oven Construction: Direct Gas-Fired Ovens

• Abstract
• 7.1 Direct Gas-Fired Baking Chamber
• 7.2 Baking Chamber Construction
• 7.3 DGF Oven: Gas Burner System
• 7.4 Flynn Burners
• 7.5 Eratec MFB (Multifibre) Burners
• 7.6 Control Panel Fascia Designs
• 7.7 Control Panel Construction
• Bibliography

Chapter 8. Oven Construction: Indirect Radiant Ovens

• Abstract
• 8.1 Indirect Radiant Baking Chamber
• 8.2 Indirect Fired Ovens: Burners
• Bibliography

Chapter 9. Heat Recovery System

• Abstract
• 9.1 Calculations of Hot Air Flow to the HRS Zone
• Bibliography

Chapter 10. Oven Conveyor Bands

• Abstract
• 10.1 Open Wire-Mesh Bands
• 10.2 Heavy Mesh Bands
• 10.3 Steel Bands
• Bibliography

Chapter 11. Oven Conveyor Design

• Abstract
• 11.1 Feed End
• 11.2 Delivery End
• 11.3 Oven End Hood Design
• 11.4 Calculation of Oven Band Tension
• 11.5 Calculation of Torque Required for the Conveyor Drive
• 11.6 Calculation of Electric Motor Power
• Bibliography

Chapter 12. Process Control Systems

• Abstract
• 12.1 Temperature Control
• 12.2 Temperature Monitoring and Control
• 12.3 Temperature Controllers
• 12.4 PID Control
• 12.5 Top and Bottom Temperature Control and Heat Ratio Control
• 12.6 Baking Time
• 12.7 Humidity
• 12.8 Colour Control
• 12.9 Colour Measurement
• 12.10 PLC Control
• Bibliography

Chapter 13. Oven Safety Monitoring and Alarm

• Abstract
• 13.1 Oven Band Safety Systems
• 13.2 Oven Burners and Gas System
• 13.3 Extraction, Combustion Air and Circulation Fans
• 13.4 Oven: General Safety Equipment and Instructions
• Bibliography

Chapter 14. Oven Operation: Direct Gas-Fired Oven

• Abstract
• 14.1 Starting the Direct Gas-Fired Oven
• 14.2 Heating Up/Start of Production
• 14.3 Shutting Down the Direct Gas-Fired Oven
• Bibliography

Chapter 15. Oven Operation: Indirect Radiant Oven

• Abstract
• 15.1 Operation of the Indirect Radiant Oven
• Bibliography

Chapter 16. Oven Efficiency

• Abstract
• 16.1 Energy Use
• 16.2 Example
• 16.3 Comparison of Oven Efficiency for Different Oven Types
• 16.4 Calculations for the Energy Required to Bake Biscuits
• 16.5 Comparing Fuel Costs
• Bibliography

Chapter 17. Oven Inspection and Audit

• Abstract
• 17.1 Oven Performance
• 17.2 Oven Operation and Maintenance
• Bibliography

Appendix 1. Ingredients for Biscuits: An Introduction

• A.1 Wheat Flour
• A.2 Corn Flour
• A.3 Sugar
• A.4 Glucose Syrup
• A.5 Cane Syrup 80%
• A.6 Invert Syrup 70%
• A.7 Fructose Syrup 80%
• A.8 Malt Extract 80%
• A.9 Dough Fat
• A.10 Butter
• A.11 Palm Oil
• A.12 Coconut Oil
• A.13 Whole Egg Powder
• A.14 Lecithin
• A.15 Yeast (Fresh)
• A.16 Ammonium Bicarbonate (“Vol”) (NH₄)HCO₃
• A.17 Sodium Bicarbonate
• A.18 ACP – Acid Calcium Phosphate
• A.19 SAPP – Sodium Acid Pyrophosphate
• A.20 Salt
• A.21 SMS – Sodium Metabisulphite Na₂S₂O₅
• A.22 Proteolytic Enzyme
• Bibliography

Appendix 2. Oven Maintenance

• A2.1 New Equipment
• A2.2 Safety Devices
• A2.3 Routine Maintenance
• A2.4 Mechanical Components
• A2.5 Electrical Maintenance
• A2.6 Maintenance Schedule
• A2.7 Oven Cleaning
• A2.8 Standard Lubrication
• A2.9 General Lubrication Schedule
• A2.10 Maintenance Log or Record
• A2.11 Recommended Spare Parts
• Bibliography

Appendix 3. Combustion Data

• Bibliography

Appendix 4. Oven Manufacturers

• China
• Europe
• India
• Japan
• Korea
• USA

Appendix 5. Oven Band Manufacturers

• Agrati Group La Bridoire S.A.R.L.
• Ark Engineers
• Ashton Green & Company
• Ashworth Bros. Inc.
• Audubon
• Berndorf Band Gmbh
• Bharat Wire Mesh Company
• Cambridge Engineered Solutions
• Durgesh Industries
• Heights Wire Belt Factory
• AB Sandvik Process Systems
• Steinhaus Gmbh
• Yangzhou Jiangdu Huada Metal Mesh Belt Factory
• Yangzhou Jinrun Mesh Belt Manufacturing Co.

Index