Biscuit baking technology : processing and engineering manual

349 Pages·2016·30.76 MB·English

by  Davidson

BISCUIT BAKING
TECHNOLOGY
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BISCUIT BAKING
TECHNOLOGY
Processing and
Engineering Manual
SECOND EDITION
IAIN DAVIDSON
Director, Baker Pacific Ltd.
Amsterdam • Boston • Heidelberg • London
New York • Oxford • Paris • San Diego
San Francisco • Singapore • Sydney • Tokyo
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First published 2013
Copyright © 2013 Baker Pacific Ltd
Second edition 2016
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Notices
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broaden our understanding, changes in research methods, professional practices, or medical
treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in
evaluating and using any information, methods, compounds, or experiments described herein.
In using such information or methods they should be mindful of their own safety and the safety
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To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors,
assume any liability for any injury and/or damage to persons or property as a matter of products
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instructions, or ideas contained in the material herein.
ISBN: 978-0-12-804211-3
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Printed and bound in the United States
Publisher: Nikki Levy
Acquisitions Editor: Nina D. Bandeira
Editorial Project Manager: Ana Claudia Garcia
Production Project Manager: Lisa Jones
Designer: Victoria Pearson
CONTENTS
Biography ix
Acknowledgements xi
Introduction xiii
1. The Biscuits 1
1.1 Crackers 4
1.2 Process for Snack Crackers 6
1.3 Process for Soda Crackers 8
1.4 Hard Sweet Biscuits 14
1.5 Process for Hard Sweet Biscuits 15
1.6 Short Doughs: Rotary Moulded Biscuits 19
1.7 Short Doughs (Moulded Biscuits) 20
1.8 Process for a Moulded Short Dough Biscuit 21
1.9 Cookies 24
1.10 Process for a Chocolate Chip Cookie 27
1.11 Long Shelf Life Cakes, Snack Cakes 31
1.12 Summary 33
Bibliography 33
2. Baking Process 35
2.1 From the Dough Piece to the Biscuit 35
2.2 Ingredients 37
2.3 Baking: The Development of the Biscuit Structure and Texture 42
2.4 Summary 46
Bibliography 48
3. Biscuit Design and Output 49
3.1 Cutter and Moulding Roll Layouts 49
3.2 Scrap and Scrap-Less Designs 50
3.3 Docker Pins 53
3.4 Oven Band Loadings 55
3.5 Oven Size and Output 55
3.6 Output Calculation 56
3.7 Summary 56
Bibliography 57
v
vi Contents
4. Heat Transfer 59
4.1 Radiation 59
4.2 Conduction 63
4.3 Convection 67
4.4 Summary 69
Bibliography 71
5. Oven Designs 73
5.1 Heat Transfer Methods 73
5.2 Hybrid Ovens 89
Bibliography 91
6. Oven Specifications: Hybrid Ovens 93
6.1 Specifications for Ovens: Crackers 93
6.2 Recommended Oven Specification for Light Carrier Products
(eg, Crispbreads, Rusks and Biscottes) 99
6.3 Recommended Oven Specification for Hard Sweet Biscuits (eg, Marie) 101
6.4 Recommended Oven Specification for Short Dough (Rotary Moulded)
Biscuits 102
6.5 Specifications for Ovens: Soft Dough Cookies 104
6.6 Modular Oven Design 106
6.7 Calculation of Oven Zone Lengths 106
6.8 Example 1: DGF Oven for Baking Crackers (1.5 m × 100 m Long) 107
6.9 Example 2: Indirect Radiant Oven for Baking a Short Dough Biscuit,
‘Glucose’ (1.25 m × 100 m Long) 110
Bibliography 112
7. Oven Construction: Direct Gas-Fired Ovens 113
7.1 Direct Gas-Fired Baking Chamber 113
7.2 Baking Chamber Construction 114
7.3 DGF Oven: Gas Burner System 125
7.4 Flynn Burners 127
7.5 Eratec MFB (Multifibre) Burners 130
7.6 Control Panel Fascia Designs 133
7.7 Control Panel Construction 135
Bibliography 137
8. Oven Construction: Indirect Radiant Ovens 139
8.1 Indirect Radiant Baking Chamber 139
8.2 Indirect Fired Ovens: Burners 150
Bibliography 156
Contents vii
9. Heat Recovery System 157
9.1 Calculations of Hot Air Flow to the HRS Zone 161
Bibliography 161
10. Oven Conveyor Bands 163
10.1 Open Wire-Mesh Bands 163
10.2 Heavy Mesh Bands 173
10.3 Steel Bands 179
Bibliography 183
11. Oven Conveyor Design 185
11.1 Feed End 186
11.2 Delivery End 191
11.3 Oven End Hood Design 199
11.4 Calculation of Oven Band Tension 200
11.5 Calculation of Torque Required for the Conveyor Drive 200
11.6 Calculation of Electric Motor Power 201
Bibliography 202
12. Process Control Systems 203
12.1 Temperature Control 203
12.2 Temperature Monitoring and Control 204
12.3 Temperature Controllers 205
12.4 PID Control 205
12.5 Top and Bottom Temperature Control and Heat Ratio Control 208
12.6 Baking Time 210
12.7 Humidity 211
12.8 Colour Control 214
12.9 Colour Measurement 217
12.10 PLC Control 217
Bibliography 219
13. Oven Safety Monitoring and Alarm 221
13.1 Oven Band Safety Systems 222
13.2 Oven Burners and Gas System 227
13.3 Extraction, Combustion Air and Circulation Fans 232
13.4 Oven: General Safety Equipment and Instructions 233
Bibliography 236
viii Contents
14. Oven Operation: Direct Gas-Fired Oven 237
14.1 Starting the Direct Gas-Fired Oven 237
14.2 Heating Up/Start of Production 241
14.3 Shutting Down the Direct Gas-Fired Oven 242
Bibliography 242
15. Oven Operation: Indirect Radiant Oven 243
15.1 Operation of the Indirect Radiant Oven 243
Bibliography 251
16. Oven Efficiency 253
16.1 Energy Use 253
16.2 Example 255
16.3 Comparison of Oven Efficiency for Different Oven Types 261
16.4 Calculations for the Energy Required to Bake Biscuits 261
16.5 Comparing Fuel Costs 264
Bibliography 267
17. Oven Inspection and Audit 269
17.1 Oven Performance 269
17.2 Oven Operation and Maintenance 273
Bibliography 291
Appendix 1: Ingredients for Biscuits: An Introduction 293
Appendix 2: Oven Maintenance 301
Appendix 3: Combustion Data 317
Appendix 4: Oven Manufacturers 319
Appendix 5: Oven Band Manufacturers 325
Index 329
BIOGRAPHY
Iain graduated from the School of
Industrial Design (Engineering) at
Royal College of Art in London in
1965 and joined Baker Perkins Ltd. He
was Industrial Design Engineer, work-
ing in the Technical Department on the
design of new biscuit, bakery and candy
processing machines until 1975, gaining
a thorough technical knowledge of the
machines and processes.
In 1975 Iain was appointed Market Development Manager at
Baker Perkins, involved in developing the Baker Perkins forward
planning for new business, product development and acquisitions.
In 1979 Iain became International Sales Manager with responsi-
bility for the biscuit business in Asia and Africa.
In 1990 Iain was appointed Regional Manager Asia-Pacific
for Baker Perkins and relocated to Indonesia and later in 1997
to China. His appointments included Managing Director of
Baker Perkins (Hong Kong) Ltd and Director of Baker Perkins
Japan KK.
In 1990 Iain negotiated an agreement with the Liaoning
Foreign Trade Corporation in Dalian to establish a manufacturing
facility for biscuit ovens. This was subsequently successful in manu-
facturing ovens under the supervision of Baker Perkins Japan KK
engineers. In 2004 a manufacturing capability was established for
Baker Pacific Ltd in India and later in China and Indonesia.
BAKER PACIFIC COMPANIES
Iain established PT Baker Pacific Mandiri in Indonesia in 2000.
As the business outside Indonesia grew, Baker Pacific Ltd was
established in Hong Kong in 2004 and is now the principal
ix