Manley’s technology of biscuits, crackers and cookies

611 Pages·2011·10.41 MB·English

by  Duncan Manley

Manley’s technology of biscuits,
crackers and cookies
© Woodhead Publishing Limited, 2011
Related titles:
Biscuit, cracker and cookie recipes for the food industry
(ISBN 978-1-85573-543-9)
This book provides a comprehensive collection of over 150 standard commercial
biscuit recipes and provides the ideal companion to the fourth edition of Duncan
Manley’s Technology of biscuits, crackers and cookies. It is designed for the biscuit
product developer as an aid in the task of creating and perfecting a biscuit product.
Biscuit, cookie and cracker manufacturing manuals (Volumes 1–6)
‘For anyone involved in the complex fi eld of biscuit technology, the name of Duncan
Manley will be well known ... These manuals take the reader through the entire
process from basic ingredients to packaging, wrapping and storage, looking at such
issues as quality, safety, maintenance and troubleshooting. All in all they are a useful
set of guides full of practical tips for both expert and novice alike.’ Biscuit World
Volume 1: Ingredients (ISBN 978-1-85573-292-6)
Volume 2: Biscuit doughs (ISBN 978-1-85573-293-3)
Volume 3: Biscuit dough piece forming (ISBN 978-1-85573-294-0)
Volume 4: Baking and cooling of biscuits (ISBN 978-1-85573-295-7)
Volume 5: Secondary processing in biscuit manufacturing (ISBN 978-1-85573-296-4)
Volume 6: Biscuit packaging and storage (ISBN 978-1-85573-297-1)
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© Woodhead Publishing Limited, 2011
Woodhead Publishing Series in Food Science, Technology and Nutrition:
Number 217
Manley’s technology of
biscuits, crackers and cookies
Fourth edition
Edited by
Duncan Manley
Consultant, Duncan Manley Limited, Stamford
Email: [email protected]
Oxford Cambridge Philadelphia New Delhi
© Woodhead Publishing Limited, 2011
Published by Woodhead Publishing Limited,
80 High Street, Sawston, Cambridge CB22 3HJ, UK
www.woodheadpublishing.com
Woodhead Publishing, 1518 Walnut Street, Suite 1100, Philadelphia, PA 19102-3406, USA
Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road, Daryaganj, New
Delhi – 110002, India
www.woodheadpublishingindia.com
First edition 1982, Ellis Horwood Limited
Second edition 1991, Ellis Horwood Limited
Third edition 2000, Woodhead Publishing Limited and CRC Press LLC
Fourth edition 2011, Woodhead Publishing Limited
© Duncan Manley, 2011 except: Chapter 5 © Duncan Manley and Malcolm Wilkes, 2011; Chapters 9
and 28 © Duncan Manley, Bram Pareyt and Jan Delcour, 2011; Chapters 7, 12, 20, 31 © Woodhead
Publishing Limited, 2011
The authors have asserted their moral rights.
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British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
Library of Congress Control Number: 2011935504
ISBN 978-1-84569-770-9 (print)
ISBN 978-0-85709-364-6 (online)
ISSN 2042-8049 Woodhead Publishing Series in Food Science, Technology and Nutrition (print)
ISSN 2042-8057 Woodhead Publishing Series in Food Science, Technology and Nutrition (online)
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© Woodhead Publishing Limited, 2011
Contents
Contributor contact details .................................................................................. xvii
Woodhead Publishing Series in Food Science, Technology
and Nutrition .......................................................................................................... xix
Preface to the fourth edition ................................................................................. xxvii
Preface to the third edition ................................................................................... xxix
Preface to the second edition ................................................................................ xxxi
Preface to the fi rst edition ..................................................................................... xxxiii
1 Setting the scene: A history and the position of biscuits ......................... 1
D. Manley, Consultant, Duncan Manley Ltd, UK
1.1 Introduction ....................................................................................... 1
1.2 The beginnings of biscuit manufacturing ....................................... 3
1.3 Ingredients and formulation development .................................... 6
1.4 Engineering ........................................................................................ 7
1.5 References and useful reading ........................................................ 9
Part I Management of technology in biscuit manufacture ........................... 11
2 The role of the technical department in biscuit manufacture ............... 13
D. Manley, Consultant, Duncan Manley Ltd, UK
2.1 Introduction ....................................................................................... 13
2.2 The requirements of the technical (or technology)
department ......................................................................................... 15
2.3 Selection of staff for the technical department ........................... 16
2.4 Facilities for the technical department ........................................... 18
2.5 Liaison with other technical establishments ................................ 19
2.6 Support for purchasing ..................................................................... 20
2.7 Support for training .......................................................................... 20
2.8 Management of technical developments ...................................... 21
2.9 Reference ........................................................................................... 22
2.10 Useful reading ................................................................................... 22
© Woodhead Publishing Limited, 2011
vi Contents
3 Quality management systems and hazard analysis critical control
point (HACCP) in biscuit manufacture ................................................... 23
D. Manley, Consultant, Duncan Manley Ltd, UK
3.1 Quality management ....................................................................... 23
3.2 Management of product safety ...................................................... 25
3.3 Useful reading ................................................................................... 28
4 Quality control and good manufacturing practice (GMP) in the
biscuit industry ............................................................................................... 29
D. Manley, Consultant, Duncan Manley Ltd, UK
4.1 Principles and management ............................................................. 29
4.2 Quality control tasks for fi nished product inspection .................. 31
4.3 Quality control tasks for ingredient and packaging materials .... 32
4.4 Good manufacturing practice (GMP) ............................................ 34
4.5 Hygiene surveys ............................................................................... 39
4.6 References .......................................................................................... 40
4.7 Useful reading ................................................................................... 40
5 Process and effi ciency control in biscuit manufacture ............................. 41
D. Manley, Consultant, Duncan Manley Ltd, UK and M. Wilkes,
MW Associates, UK
5.1 Process control and effi ciency ......................................................... 41
5.2 Process audit ...................................................................................... 45
5.3 Process control checks and records for plants with no
continuous monitoring sensors ........................................................ 45
5.4 Making process control measurements .......................................... 50
5.5 Action procedures as a result of product measurements ............ 52
5.6 Instrumentation for monitoring ...................................................... 52
5.7 Effi ciency and integrated plant control ......................................... 52
5.8 Outline of the instrumentation that is available ........................... 54
5.9 Troubleshooting ................................................................................. 65
5.10 Energy effi ciency ............................................................................... 66
5.11 References .......................................................................................... 67
5.12 Useful reading and suppliers of instruments ................................. 67
6 Product development in the biscuit industry ........................................... 69
D. Manley, Consultant, Duncan Manley Ltd, UK
6.1 Introduction ....................................................................................... 69
6.2 Product development ........................................................................ 70
6.3 Facilities for process and product development ........................... 73
6.4 Assessing products ............................................................................ 77
6.5 Establishing the product specifi cation ........................................... 86
6.6 Management of product development ........................................... 87
6.7 References .......................................................................................... 92
6.8 Useful reading ................................................................................... 92
7 Sustainability in the biscuit industry ........................................................... 93
R. Brightwell, United Biscuits, UK
7.1 Introduction ....................................................................................... 93
7.2 Key drivers for sustainability in the biscuit industry ................... 94
© Woodhead Publishing Limited, 2011
Contents vii
7.3 Carbon emissions and energy use ................................................... 98
7.4 Reducing water use .......................................................................... 98
7.5 Reducing waste .................................................................................. 100
7.6 Packaging .......................................................................................... 101
7.7 Other options for improving sustainability ................................... 102
Part II Materials and ingredients for biscuit manufacture ........................... 105
8 Choosing materials for biscuit production ................................................. 107
D. Manley, Consultant, Duncan Manley Ltd, UK
8.1 Introduction ....................................................................................... 107
8.2 Important technical aspects ............................................................. 107
8.3 Important commercial aspects ........................................................ 107
8.4 Programme for the meeting with a supplier ................................. 108
9 Wheat fl our and vital wheat gluten as biscuit ingredients ..................... 109
D. Manley, Consultant, Duncan Manley Ltd, UK and B. Pareyt
and J. A. Delcour, Katholieke Universiteit Leuven, Belgium
9.1 Introduction ....................................................................................... 109
9.2 Flour from the viewpoint of the miller .......................................... 110
9.3 Flour from the viewpoint of the biscuit manufacturer ................ 127
9.4 Vital wheat gluten ............................................................................. 131
9.5 References .......................................................................................... 131
9.6 Useful reading ................................................................................... 133
10 Meals, grits, fl ours and starches (other than wheat) ................................. 134
D. Manley, Consultant, Duncan Manley Ltd, UK
10.1 Introduction ....................................................................................... 134
10.2 Cereal-based materials ..................................................................... 135
10.3 Non-cereal fl ours and starches ........................................................ 139
10.4 References .......................................................................................... 141
10.5 Useful reading and addresses .......................................................... 141
11 Sugars and syrups as biscuit ingredients .................................................... 143
D. Manley, Consultant, Duncan Manley Ltd, UK
11.1 Introduction ....................................................................................... 143
11.2 Common sugar, sucrose .................................................................... 145
11.3 Syrups .................................................................................................. 153
11.4 Sugars and syrups from starches – glucose .................................... 154
11.5 Non-diastatic malt extract ................................................................ 158
11.6 Maillard reaction ............................................................................... 158
11.7 Polyols ................................................................................................. 158
11.8 References .......................................................................................... 159
11.9 Useful reading ................................................................................... 159
12 Fats and oils as biscuit ingredients .............................................................. 160
G. Atkinson, AarhusKarlshamn UK Ltd, UK
12.1 Introduction ....................................................................................... 160
12.2 The role of fat in biscuits ................................................................. 161
© Woodhead Publishing Limited, 2011
viii Contents
12.3 The chemistry and physical properties of fats ............................. 164
12.4 Quality and handling issues of fats ................................................. 171
12.5 Key characteristics of fats for biscuits ............................................ 172
12.6 Quality control of fats ...................................................................... 175
12.7 General specifi cation requirements for oils and fats ................... 178
12.8 Challenges for the biscuit manufacturer ........................................ 178
12.9 References .......................................................................................... 179
12.10 Useful reading ................................................................................... 180
13 Emulsifi ers (surfactants) and antioxidants as biscuit ingredients ........... 181
D. Manley, Consultant, Duncan Manley Ltd, UK
13.1 Introduction ....................................................................................... 181
13.2 Function of emulsifi ers in biscuits ................................................. 182
13.3 Types of food emulsifi ers ................................................................ 182
13.4 Reduced fat biscuits .......................................................................... 186
13.5 General use of emulsifi ers in biscuit doughs ................................. 187
13.6 Application help ................................................................................ 188
13.7 Antioxidants ....................................................................................... 189
13.8 References .......................................................................................... 190
13.9 Useful reading ................................................................................... 190
14 Milk products and egg as biscuit ingredients ............................................ 191
D. Manley, Consultant, Duncan Manley Ltd, UK
14.1 Introduction ....................................................................................... 191
14.2 Milk and milk products .................................................................... 192
14.3 Egg ...................................................................................................... 198
14.4 References .......................................................................................... 198
14.5 Useful reading ................................................................................... 198
15 Dried fruits and nuts as biscuit ingredients ............................................... 200
D. Manley, Consultant, Duncan Manley Ltd, UK
15.1 Introduction ....................................................................................... 200
15.2 Dried grapes ..................................................................................... 201
15.3 Other dried fruits used in biscuits .................................................. 204
15.4 Fruit pastes and syrups ..................................................................... 205
15.5 Tree nuts ............................................................................................. 205
15.6 Peanuts, arachis or ground nut ........................................................ 207
15.7 Health problems associated with nuts ............................................ 207
15.8 References .......................................................................................... 208
15.9 Useful reading ................................................................................... 208
16 Yeast and enzymes as biscuit ingredients .................................................. 209
D. Manley, Consultant, Duncan Manley Ltd, UK
16.1 Introduction ....................................................................................... 209
16.2 Yeast ................................................................................................... 209
16.3 Enzymes ............................................................................................ 212
16.4 References ......................................................................................... 214
16.5 Useful reading ................................................................................... 215
© Woodhead Publishing Limited, 2011
Contents ix
17 Flavours, spices and fl avour enhancers as biscuit ingredients ................. 216
D. Manley, Consultant, Duncan Manley Ltd, UK
17.1 Introduction ....................................................................................... 216
17.2 Sources and types of fl avours .......................................................... 217
17.3 Suitability of a fl avour material ..................................................... 219
17.4 Flavouring of biscuits ........................................................................ 219
17.5 Flavour enhancers ............................................................................. 220
17.6 Storage of fl avours and quality control .......................................... 221
17.7 References .......................................................................................... 221
17.8 Useful reading ................................................................................... 222
18 Additives as biscuit ingredients ................................................................... 223
D. Manley, Consultant, Duncan Manley Ltd, UK
18.1 Introduction ....................................................................................... 223
18.2 Common salt (sodium chloride, NaCl) ........................................... 224
18.3 Leavening agents ............................................................................... 226
18.4 Processing aids ................................................................................... 228
18.5 Food acids ........................................................................................... 231
18.6 Colours ................................................................................................ 232
18.7 Artifi cial sweeteners ......................................................................... 233
18.8 References .......................................................................................... 234
18.9 Useful reading ................................................................................... 234
19 Chocolate and cocoa as biscuit ingredients ............................................... 235
D. Manley, Consultant, Duncan Manley Ltd, UK
19.1 Introduction ....................................................................................... 235
19.2 The fl avour of chocolate ................................................................... 236
19.3 Chocolate viscosity ............................................................................ 237
19.4 Cocoa butter, cocoa butter equivalents and hard butters ........... 238
19.5 Defi nitions of cocoa and chocolate products ................................ 240
19.6 Types of chocolate ............................................................................. 240
19.7 Supply and storage of chocolate ..................................................... 241
19.8 Chocolate drops and chips ............................................................... 242
19.9 Cocoa .................................................................................................. 243
19.10 Handling of chocolate and chocolate chips ................................... 244
19.11 Compound chocolate ........................................................................ 244
19.12 Carob powder .................................................................................... 245
19.13 References .......................................................................................... 245
19.14 Useful reading ................................................................................... 245
20 Packaging materials for biscuits and their infl uence on shelf life .......... 247
G. L. Robertson, Food(cid:129)Packaging(cid:129)Environment and University
of Queensland, Australia
20.1 Introduction ....................................................................................... 247
20.2 Packaging materials .......................................................................... 248
20.3 Packaging and shelf life .................................................................... 255
20.4 Indices of failure (IoFs).................................................................... 260
20.5 Package requirements to address indices of failure (IoFs) ......... 260
20.6 References .......................................................................................... 267
© Woodhead Publishing Limited, 2011
x Contents
Part III Types of biscuits ................................................................................... 269
21 Classifi cation of biscuits .............................................................................. 271
D. Manley, Consultant, Duncan Manley Ltd, UK
21.1 Introduction ....................................................................................... 271
21.2 Classifi cation based on enrichment of the formulation ............... 272
21.3 Conversion of units ........................................................................... 278
21.4 Reference ........................................................................................... 278
21.5 Useful reading ................................................................................... 278
22 Cream crackers .............................................................................................. 279
D. Manley, Consultant, Duncan Manley Ltd, UK
22.1 History and introduction to cream crackers ................................ 279
22.2 Mixing and fermentation of cream cracker doughs ..................... 281
22.3 Dough piece forming ........................................................................ 286
22.4 Baking of cream crackers ................................................................. 289
22.5 Yields from fermented doughs ........................................................ 292
22.6 References .......................................................................................... 292
22.7 Useful reading ................................................................................... 292
23 Soda crackers ................................................................................................. 293
D. Manley, Consultant, Duncan Manley Ltd, UK
23.1 Introduction ....................................................................................... 293
23.2 Dough preparation ............................................................................ 294
23.3 Outline of typical soda cracker manufacturing
techniques ........................................................................................... 295
23.4 References .......................................................................................... 297
23.5 Useful reading ................................................................................... 297
24 Savoury or snack crackers ............................................................................ 298
D. Manley, Consultant, Duncan Manley Ltd, UK
24.1 General description ......................................................................... 298
24.2 Manufacturing technology ............................................................... 298
24.3 Post-oven oil spraying ..................................................................... 301
24.4 Useful reading ................................................................................... 302
25 Matzos and water biscuits ............................................................................ 303
D. Manley, Consultant, Duncan Manley Ltd, UK
25.1 Matzos ................................................................................................. 303
25.2 Water biscuits ..................................................................................... 303
25.3 Typical recipes ................................................................................... 305
25.4 Useful reading ................................................................................... 305
26 Puff biscuits .................................................................................................... 306
D. Manley, Consultant, Duncan Manley Ltd, UK
26.1 General description ......................................................................... 306
26.2 Puff dough preparation .................................................................... 308
26.3 Baking of puff biscuits ...................................................................... 310
26.4 Puff biscuit production techniques ................................................. 311
© Woodhead Publishing Limited, 2011