Biscuit Manufacture: fundamentals of in-line production

373 Pages·1995·13.396 MB·English

by  Peter R. Whiteley (auth.)

BISCUIT MANUFACTURE
BISCUIT
MANUFACT·URE
fundamentals of in-line production
by
PETER R. WHITELEY
DIP. F.E., F.lnst. B.B.
Head of the Department of Baking.
Rush Green Technical College.
Rmriford. Essex
APPLIED SCIENCE PUBLISHERS LTD
LONDON
APPLIED SCIENCE PUBLISHERS LTD
RIPPLE ROAD, BARKING, ESSEX, ENGLAND
ISBN: 0-444-20072-X
LIBRARY OF CONGRESS CATALOG CARD NUMBER 70-122961
WITH 121 ILLUSTRATIONS AND 5 TABLES
Cl 1971 ELSEVIER PUBLISHING COMPANY LTD
All rights reserved. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of the publishers, Applied
Science Publishers Ltd, Ripple Road, Barking, Essex, England
Author's preface
THE intention of this book is to provide a guide for
potential management and supervisors and for those
who wish to understand the fundamental principles of
biscuit manufacture. It does not set out to be a learned
treatise. The purpose of the book is to simplify and
explain processes and materials so that the 'mystique'is
replaced by logic. Once the mystique is removed the
biscuit maker is one step closer to anticipating and
solving problems.
In attempting to cover this subject within one concise
volume, it is difficult to avoid over-simplification or
generalisation, and apologies must be offered in advance
where these occur. To wallow in the fine details of
specialisation is to defeat the object of the book, and
less would be achieved if the issues were confused. The
reader's attention is drawn to the interpretation of
formulae (recipes). Raw materials, equipment, methods,
processes, and conditions vary considerably; the
formulae are intended as blue prints from which, with a
knowledge of the materials and aims of the processes,
and by trial and error, a biscuit can be produced bearing
some semblance to the original. All formulae should be
interpreted in conjunction with the 'Guide to using
formulae' at the beginning of Chapter 12.
As the biscuit industry advances towards complete
automation, plant and equipment become more
advanced and sophisticated. Training of a very high
standard is necessary to use sophisticated machinery
efficiently, and where skills of this exacting degree are
not available, then the simpler, less advanced equip
ment, should be used. It is with this in mind that
processes have been dealt with in such a way that they
can be carried out by hand or through varying degrees
of mechanisation.
Similarly, the legislation regarding foods becomes so
involved and changes so frequently that it is impossible
to review for inclusion in a book of this nature. It is
essential to be aware that there is legislation pertaining
v
vi AUTHOR'S PREFACE
to practically every aspect of biscuit making and
marketing, and as the legislation differs from country to
country, further confusion arises. All governments issue
pamphlets about their laws, and the appropriate
Ministry or information office (in the United Kingdom,
Her Majesty's Stationery Office) or legation should be
approached for the current regulations.
Upminster, 1970 PETER R. WHITELEY
Acknowledgements
AN expression of thanks and gratitude is due to all
those who helped with advice, information and
photographs to make this book possible, including:
Baker Perkins Ltd, Peterborough
British Cellophane Ltd, Twickenham
Co-operative Wholesale Society Ltd, Biscuit Factory,
Harlow
Walter Denis Contacts Co., Ltd, Blackpool
Flour Milling and Baking Research Association,
Chorleywood
J. Alan Goddard Ltd (Hecrona), Croydon
J. W. Greer Co., Ltd, Bromley
Kek Ltd., Macclesfield
A. M. Lock & Co. Ltd, Oldham
Machinery Continental Packaging Ltd (Aucouturier),
Rochester
Morton Machine Co. Ltd, Wi shaw
E. T. Oakes, Ltd, Macclesfield
Radyne Ltd, Wokingham
Rank Precision Industries Ltd, Brentford
Rose Forgrove Ltd, Leeds
SIG Wrapping Machines Ltd, Croydon
Simon-Vicars Ltd, Newton-Ie-Willows
.Spooner Food Machinery Engineering Co., Ltd, Ilkley
My greatest appreciation is due to my wife, whose
untiring efforts of encouragement and help spurred me
on at all times.
Upminster, 1970 PETER R. WHITELEY
vii.
Contents
AUTHOR'S PREFACE
v
ACKNOWLEDGEMENTS vii
LIST OF FIGURES IN THE TEXT xi
LIST OF TABLES xii
LI ST 0 F P L ATE S xiii
PART I RAW MATERIALS
1 Flour and cereal products 1
2 Fats and oils 22
3 Sweetening agents 34
4 Aerating agents 42
5 Dairy products 50
6 Fruits and nuts 59
7 Setting materials 69
8 Chocolate and cocoa products 73
9 Flavouring materials 81
10 Colouring materials 94
PAR T II CLASSIFICATION AND METHODS
11 Classification of biscuit types and methods of
production 103
PAR T III FORMULAE-QUALITY CONTROL AND
DEVELOPMENT
12 Basic ingredient proportions of biscuit doughs 1 27
13 Basic ingredient proportions of wafers, marsh-
mallows, creams, and fillings 148
ix
x CONTENTS
14 Quality control 161
15 Re-use and disposal of unsatisfactory products 189
16 Development 193
PART IV PLANT AND EQUIPMENT
17 Raw materials storage and handling 201
18 Mixing room equipment 209
19 Machine room equipment 219
20 Ovens and baking 230
21 Wafers and second process equipment 241
22 Ancillary equipment and automation 250
23 Packaging of biscuits 258
PART V GENERAL CONSIDERATIONS
24 Factory layout and hygiene 269
BIBLIOGRAPHY 289
INDEX 290
List of figures in the text
1. Longitudinal section of a wheat grain 4
2. The pH scale 47
3. Sketch of a yeast cell 106
4. Yeast reproducing by budding 107
5. Colony of yeast cells 1 08
6. Diagram showing enzymic activity during
fennentation 111
7. Structure of a farinogram 163
8a. Farinogram: Manitoba flour 163
8b. Farinogram: strong English flour 164
8e. Farinogram: soft English flour 164
9a. Extensogram: Manitoba flour 166
9b. Extensogram: strong English flour 167
ge. Extensogram: soft English flour 167
10. Typical alveograms: (a) Manitoba flour;
(b) strong English flour; (c) soft English
flour 168
11. Typical graphs ofe xtensom eter: (a) Manitoba
flour; (b) strong English flour; (e) soft
English flour 170
12. Line drawing of Simon-Vicars vertically
integrated dough feeding, gauging and
laminating unit 221
13. Examples of wire band patterns (Baker
Perkins) 231
14. Air blast gas burners for direct fired oven
(Baker Perkins) 235
15. Diagrams illustrating the principle of forced
air convection baking used in a Spooner
oven section 236
16. Line drawing of a Walden refrigerated air
blast cooling tunnel 248
17. Diagrams illustrating how metals affect the
electromagnetic field of an electronic metal
detector 254
xi
List of tables
1. Structural composition of wheat 3
2. Typical analyses of flour samples 9
3. Typical analyses of milk and milk products 53
4. Table converting ingredient percentages to
pounds when based on flour weight of 280 Ib
(i.e. one sack) and vice versa 128/129
5. Examples of texture meter readings obtained
on retail samples of various types of biscuits 181
xii