Frontline Food Consultants and Engineers provides all round consultancy for intended manufacturing of well baked breads and buns. Through our Recipe Development and Process Optimization Services here is what you would be able to make from the best Industrial Bread Manufacturing: We provide support for any type or kind of bread and buns production, from Homemade Bread breads, to soft and fluffy Hamburger Buns and Gluten-Free Bread Solutions all with consistent quality, taste and quality. We give much emphasis in the modification of the dough handling, its fermentation and packaging of bread to attain the correct textual rhythms and optimal rate of staling.
We offer services for buying Ingredients and Quality control; all of us ensure to buy only the best quality flour, yeast and all kinds of bread ingredients – healthy whole grain, gluten-free, fortified and other bread types. Your business might need new products to be created; or old products to be modified in some way; this is where our R & D department stands ready to assist. In addition, through our Regulatory Compliance Consulting service you can fulfull requirements regarding the food safety related to bread and buns or with the labeling. Our packaging solutions services are developed with focus on the needs to have better quality of products beside elongating their shelf life, for convenience purposes to support affordable and or eco-friendly packaging products.
What are Breads and Buns?
Breads and Buns are sub-groups of baked product classifications that encompass soft dinner rolls or dust-coated buns and artisan breads. The most basic consist of flour, water, active yeast, and salt as the base, but there are options of adding sugar, butter, milk and similar products for desired results. For bread and buns to be standard, some ingredients proportions must be used, some period of time for proofing must be ensured and the technique of baking used should be accurate.
To meet the demands such as kneading of the dough by Industrial mixers, confirmation and distribution of ingredients evenly by Dough dividers and Rounders and cutting and shaping the dough uniformly by Rounders to get proper size breads and buns. In proofing chambers, the dough can be allowed to rise under restrictions of humidity and temperatures and once the products or breads are set they are baked using deck ovens or tunnel ovens. Cooling conveyors are employed to cool different kinds of breads and buns before packing them. In the current study, cutting and packing machines are used to place the product in blank packets as well as pack it in different air-tight bags for enhancing the freshness. Some of these are; the control of the dough rheological characteristic, bake time and the quality of final product.
Types of Breads and Buns
Sliced White Bread: It has a light texture and should be classified as a sandwich and toast bread.
Whole Wheat Bread: A very compact product with nutrients as it contains whole grain flour.
Buns: The thin, smaller and specific for hamburger, hot dog or slider bread.
Artisan Bread: Sourdough bread and ciabatta bread and baguettes, that is bread which has a soft crispy crust and thick large hole.
Bread & bun production processes.
- Dough Preparation
- Ingredient Mixing: In a concrete mixer, water, flour, yeast, sugar and salt etc are mixed, than dough mixer is used. For the breads and buns which are not very firm interstitial ingredients as butter, milk and eggs may be used to have tender or soft crumb.
- Kneading: The dough is mixed or other wise worked by hand or by dough mixing machines to the required gluten development for the type of bread manufactured. In other words, the dough is managed in a manner that see it take the right amount of firmness and malleability.
- Resting/Proofing: The dough stretches and clearly gains volume through bulk fermentation or usage of ferment proof containers at the desired temperature and humidity for fermentation time. This process of fermentation is crucial because the yeast requires fermenting gas which fills the dough or undergoes expansion and gains cooking flavor.
- Shaping and Proofing
- Shaping: After fermenting and the first proofing, the dough is divided into portions to conform to the form of the required product, bread or bun and the like. This step is additional for buns and can be done by the help of the special equipment called dough dividers and rounders, if the production is buns, while in case with bread mechanical loaf formers can be used.
- Final Proofing: After that stage of shaping, the cookies are expected to be put through second proofing before they are baked. It helps to ensure that the end product of dough is at the appropriate size it has to be before it can be baked.
- Baking
- Oven Selection: Tunnel or deck ovens are used in preparing bread and buns based on the degree of production and kind of bread. For mass production conveyorized tunnel ovens provide the same heat to all parts of the batch to be baked.
- Baking Conditions: Breads are baked at high temperature, which ranged between 190-250 ⁰C for 20-40min depending on the type of bread. In regards to buns they do not really take long to bake and will take a maximum of 10-15 minutes baking time. They are typically employed at the starting of the baking process to facilitate creation of a crust for artisan breads on the other hand steam is critical in baking.
- Cooling: Immediately after baking, bread and buns are slid off the baking trays and allowed to cool on wire racks or tunnels because to do so develops the crust and releases the steam. From sogginess and product quality perspectives, cooling is needed.
- Slicing and Packaging
- Slicing: They obtain their bread through slicer machines which are of high speed and slic it into equal thickness. When it comes to an industrial product such as buns, slicing is normally accomplished towards the final stages only if the bun is a pre-sliced type required in wrap products such as sandwiches and hamburgers.
- Packaging: As a rule, it is packed in hermetic bags or shrink-wraps to avoid any opportunity for bread to become stale. For purposes of increasing the shelf life of the products, Modified Atmosphere Packaging (MAP) is used to remove oxygen, which slows down the formation of mould.
Packaging Material for Breads & Buns
- Plastic Bags
- Objective: To retain the food quality and to meth the process of staling.
- Materials: Polyethylene bags that are both water proof and, eatable.
- Benefits: This product is relatively inexpensive, easily shaped and can be employed in packaging sliced breads and buns. They provide reasonable protection from the environment including air and moisture and calamities brew within the shortest time possible.
- Modified Atmosphere Packaging (MAP)
- Objective: Prolong shelf life of food by reducing the amount of dissolved oxygen in the packages.
- Materials: Plastic bags or trays that are typically washed with an environment of low oxygen and high nitrogen or carbon dioxide.
- Benefits: Delays the formation of mold and keeps the freshness of the product making MAP ideal for bakeries that deliver way from producers.
- Eco Friendly Packaging
- Objective: Thus, there is a need to reduce the impact of the environment to the quality of the products as much as possible.
- Materials: PAPER BAGS or BIPPY-Changing packaging solutions to environmentally friendly bags such as paper bags or biodegradable plastic containers.
- Benefits: Eco friendly packages are well receptiveness of the customer’s perspective of environmental concerns but the packaging itself must adequately protect the product during transit and storage.