Biscuit Baking Technology, Second Edition: Processing and Engineering Manual

327 Pages·2016·51.596 MB·English

by  Davidson, Iain

BISCUIT BAKING
TECHNOLOGY
BISCUIT BAKING
TECHNOLOGY
Processing and
Engineering Manual
SECOND EDITION
IAIN DAVIDSON
Director, Baker Pacific Ltd.
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First published 2013
Copyright © 2013 Baker Pacific Ltd
Second edition 2016
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ISBN: 978-0-12-804211-3
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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
x Biography
operating company, providing process technology and machinery
for the biscuit, chocolate and candy industries. A team of expe-
rienced engineers and food technologists now provide Baker
Pacific with a wide range of capabilities.
EXPERIENCE IN THE BISCUIT INDUSTRY
Engineering design of biscuit process machines including a
●
range of baking ovens
Biscuit baking oven manufacture in China, Indonesia and
●
India
Sales and marketing in Europe, Asia, North America, Africa
●
Project management and service.
●
Iain Davidson
ACKNOWLEDGEMENTS
I wish to record the contributions to our business from our team, John
Lilley, Steve Eldridge, David Young, Sunny Xu, Glyn Sykes and our col-
leagues in the baking industry, Jean Marc Simandoux, P.K. Nandy and
our colleagues over the years in the Baker Perkins Group worldwide.
Iain Davidson,
October 2015
xi
INTRODUCTION
Our book is way of sharing over 50 years of experience in the
biscuit baking industry worldwide. As engineers, we have worked
with first class food technologists, bakers and confectioners in
Europe, North and South America, Africa, Asia and Australasia.
Our customers have included the largest multinationals and many
local businesses.
You will find here a great deal of technical information and
recommendations regarding biscuit baking. These are offered to
share experience which has been valuable for us. It is not the
only way to bake and to build biscuit baking ovens, but it has
worked well for us and many of the bakeries we served.
Please note that the formulations and process information are
highly dependent on the specification and properties of the local
ingredients and the production equipment. All formulations and
process have to be developed at the commissioning stage to suit
local conditions.
My experience has taught me that it takes a small team to
build the ovens. At our company a team of five people has devel-
oped the ovens described in this book: a project manager, design
engineer, installation engineer, site supervisor and commission-
ing engineer, with a local manager to introduce and liaise with
the local contractors. All manufacture has been carried out under
contract by excellent engineering companies in China, India and
Indonesia.
We believe that this may increasingly become a feature of
future biscuit oven supply. Larger biscuit makers with substantial
production facilities, experience and investment in development
may lead the way to future improvements in product quality and
production efficiencies. Smaller local teams may manufacture and
install the ovens.
xiii
CHAPTER 1
The Biscuits
Contents
1.1 Crackers 4
1.2 Process for Snack Crackers 6
1.2.1 Description 6
1.2.2 Product Specification 6
1.2.3 Formulation 6
1.2.4 Critical Ingredients 7
1.2.5 Mixing 7
1.2.6 Standing Time 7
1.2.7 Forming 7
1.2.8 Baking 8
1.2.9 Baking Band 8
1.3 Process for Soda Crackers 8
1.3.1 Description 8
1.3.2 Product Specification 9
1.3.3 Formulation 9
1.3.4 Critical Ingredients 10
1.3.5 Mixing and Fermentation 10
1.3.6 Dough Forming 10
1.3.7 Baking 12
1.3.8 Alternative Oven Band 13
1.3.9 Oil Spray 13
1.3.10 Cracker Breaking 13
1.4 Hard Sweet Biscuits 14
1.5 Process for Hard Sweet Biscuits 15
1.5.1 Description 15
1.5.2 Product Specification 16
1.5.3 Formulation 16
1.5.4 Critical Ingredients 16
1.5.5 Mixing 17
1.5.6 Forming 17
1.5.7 Baking 18
1.5.8 Cooling 18
1.6 Short Doughs: Rotary Moulded Biscuits 19
1.7 Short Doughs (Moulded Biscuits) 20
Biscuit Baking Technology. © 22001164 Elsevier Inc.
DOI:http://dx.doi.org/10.1016/B978-0-12-804211-3.00001-7 All rights reserved. 1
2 Biscuit Baking Technology
1.8 Process for a Moulded Short Dough Biscuit 21
1.8.1 Description 21
1.8.2 Product Specification 22
1.8.3 Formulation 22
1.8.4 Critical Ingredients 22
1.8.5 Mixing 22
1.8.6 Standing Time 23
1.8.7 Rotary Moulding 23
1.8.8 Baking 23
1.8.9 Cooling 23
1.9 Cookies 24
1.10 Process for a Chocolate Chip Cookie 27
1.10.1 Description 27
1.10.2 Product Specification 27
1.10.3 Formulation 28
1.10.4 Mixing 28
1.10.5 Forming 29
1.10.6 Baking 29
1.10.7 Cooling 29
1.11 Long Shelf Life Cakes, Snack Cakes 31
1.12 Summary 33
Bibliography 33
This book is primarily about the design, manufacture and opera-
tion of biscuit baking ovens. It covers in detail many aspects of
the mechanical and electrical engineering of the ovens. However,
the starting point of our discussion must necessarily be the bis-
cuits and the baking process. The book is about how to bake bet-
ter biscuits and to bake economically to deliver the products that
consumers enjoy to eat and at an affordable cost.
Unfortunately oven builders have often given primary consid-
eration to engineering factors such as manufacturing cost, speed
of installation, ease of control and other hardware and software
issues. The industry has often made cost reduction a major aspect
of oven design over the last 40 years. Some of these developments
have been done at the expense of the baking process and the
The Biscuits 3
consequent quality of the biscuits, as we shall see in the following
sections of the book.
Our focus will be constantly on how to bake high-quality
biscuits and the optimum oven design features to achieve this.
Alongside this focus, we will also consider the design implica-
tions for efficiency of heat transfer, fuel cost, increased output and
other important production considerations, but the quality of the
product should remain foremost.
Let us first describe briefly the types of products our discussion
will cover. Biscuits are the first and the best snack food – they need
no preparation, are eaten straight from the pack, have a long shelf
life, are nutritious and available in many functional forms. Biscuits
are now a truly international food, consumed in large and increas-
ing quantities in the Americas, Asia, Australasia, Africa, Middle East,
as well as their original source in Europe.
Biscuits broadly fall into four categories, distinguished by their
recipes and process: crackers, hard sweet and semi-sweet biscuits,
short dough biscuits and cookies (including filled cookies). Each
category and each product type requires a particular mixing,
forming and baking process.
An example is given of the formulation and process for a
product in each main biscuit category. Note that all formula-
tions, recipes and process information given are only guides, and
their use depends on the local ingredients and production equip-
ment. In each case the recipes and process will require develop-
ment during commissioning to suit the particular ingredients and
equipment available.
In general the biscuit-making process follows the main steps
shown below. Mixing and fermentation or dough standing time,
is usually a batch process. The forming, baking, oil spraying and
cooling are continuous operations with a high degree of automa-
tion. Packing is generally offline, unless the line is dedicated to a
single product (Fig. 1.1).