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Biscuit, cookie and cracker manufacturing manuals Manual 1 Ingredients Types Handling Uses DUNCAN MANLEY W O O D H E A D PUBLISHING LIMITED Cambridge England Published by Woodhead Publishing Limited, Abington Hall, Abington, Cambridge CB1 6AH, England First published 1998 0 1998, Woodhead Publishing Ltd The author has asserted his moral rights. Conditions of sale All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage and retrieval system, without permission in writing from the publisher. While a great deal of care has been taken to provide accurate and current information, neither the authors, nor the publisher, nor anyone else associated with this publication, shall be liable for any loss, damage or liability directly or indirectly caused, or alleged to be caused, by this book. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. ISBN 1 85573 292 0 . Designed by Geoff Green Typeset by BookEns Ltd, Royston, Hem. Printed by St Edmundsbury Press, Suffolk, England Biscuit, cookie and cracker manufacturlng manuals Manual 1 Ingredients Please personalise your copy with your name below ............................................................................................ ............................................................................................ Biscuit, cookle and cracker manufacturing manuals The other titles in this series are: Manual 2 Biscuit doughs Types Mixing Conditioning Handling Troubleshooting tips Manual 3 Biscuit dough piece forming Sheeting Gauging Cutting Laminating Rotary moulding Extruding Wire cutting Depositing Troubleshooting tips Manual 4 Baking and cooling of biscuits What happens in a baking oven Types of oven Post-oven processing Cooling Handling Troubleshooting tips Manual 5 Secondary processing in biscuit manufacturing Chocolate enrobing Moulding Sandwich creaming Icing Application of jam Marshmallow Caramel Troubleshooting tips Manual 6 Biscuit packaging and storage Packaging materials Wrapping operations Biscuit storage Troubleshooting tips Preface My text Technology of Biscuits, Crackers and Cookies, which was first published in 1983, with an enlarged new edition in 1991,has proved very successful and been welcomed by biscuit manufacturers worldwide. Why, then, consider producing separate manuals in the same field? The idea started, I suppose, when my partner, Pam Chance, pointed out that, as a standard reference work, my book was both too detailed and expensive for the average plant operative to use in the course of his or her work. Over the years, I have worked as a consultant in very many factories in many countries. Not all the operatives speak English, but those that do have explained that they often do not know the biscuit technology with which they are involved nor have a convenient source of information. They and their managers have particularly expressed the need for aids to troubleshooting. Thus this manual was born. It is one of a sequence that covers the various parts of the biscuit-making and packaging process. It builds on Technology of Biscuits, Crackers and Cookies, but includes much new material. I have tried to give particular emphasis to process mechanisms and fault solving. I am sure that managers, trainers and operatives will find it useful both in training and as a reference source. I hope that all who read and use it will find it as useful as I would like it to be. If you have any comments or contributions, I should be pleased to hear from you. Duncan J R Manley 1998 Contents 1 Preface ix Introduction 1 2 1.1 2 Background to the biscuit industry 2.1 2.2 2.3 2.4 2.5 2.6 3 What are biscuits? How are biscuits made? How a factory is arranged What your company requires from the factory Ingredient storage areas Your contribution when working with ingredients Hygiene and safety aspects 3.1 3.2 3.3 4 Vocational qualifications Safety of food products Sources of contamination 3.2.1 People 3.2.2 Emptying containers 3.2.3 Small items of equipment 3.2.4 Plant machinery 3.2.5 Buildings and general factory areas Safety of people 3.3.1 Floors 3.3.2 Machine guards 3.3.3 Electrical connections 3.3.4 Strain injuries 3.3.5 Dust 3.3.6 Building maintenance Wheat flour and other cereals 4.1 4.2 Introduction Wheat flour 8 8 8 8 10 10 11 12 13 13 13 13 14 14 14 15 15 16 vi Biscuit, cookie and cracker manufacturingmanuals 4.3 4.4 4.5 4.6 5 6 4.2.1 Types of wheat flour 4.2.2 Uses and functions of wheat flours for biscuits 4.2.3 Common dough and baking problems related to flour quality 4.2.4 Delivery and quality testing of flour 4.2.5 Storage of flour 4.2.6 Handling of flour Oats Rye flour Starches Soyaflour Sugars and syrups 5.1 Types of crystalline sugars 5.1.1 Sucrose, ‘sugar’ 5.1.2 Lower sugars 5.2 Relative sweetness 5.3 Types of Syrup 5.3.1 Syrups based on sucrose 5.3.2 Syrups derived from starch 5.3.3 Other syrups 5.4 Uses and functions of sugars and syrups 5.4.1 Uses in biscuit doughs 5.4.2 Uses in biscuit filling creams 5.4.3 Uses in jams and jellies 5.4.4 Use in marshmallow 5.4.5 Uses in chocolate 5.4.6 Function of sugars in biscuits Importance of sucrose particle size 5.5 5.6 Delivery and quality testing of sugars and syrups 5.6.1 Crystal sugars 5.6.2 Syrups 5.7 Storage and handling of sugars and syrups 5.7.1 Crystal sugars in bulk 5.7.2 Crystal sugars in bags 5.7.3 syrups Other sweeteners 5.8 Fats, oils and butter 6.1 Fats and oils 16 20 20 22 23 24 26 27 27 28 29 29 29 29 30 30 30 30 31 31 31 32 32 32 32 32 33 34 34 35 35 35 36 36 37 30 38 Contents 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 7 Dairy products 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 8 Milk Full cream milk powder, FCMF' Skimmed milk powder, S M P Evaporated milks W h e y powder Cheese and cheese powder Butter and butter oil Use of milk products in biscuits Eggs Dried fruit and nuts 8.1 8.2 8.3 9 Butter and butter oil Margarine Rancidity Bulk handling of fats Plasticised and boxed fat Sandwich cream fats Spray oil fats Use of emulsifiers and antioxidants Yeast Dried 8.1.1 8.1.2 Other 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 Nuts 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.3.7 grapes Currants Thompson seedless raisins and sultanas dried fruits used in biscuits Dates Glack cherries Crystallised or candied ginger Crystallised or candied peel Fruit pastes and syrups Almonda Brazils Cashews Coconut Hazelnuts Peanuts Walnuts and pecans vii 38 39 40 41 42 43 44 44 46 46 46 47 48 48 48 49 49 50 52 53 53 54 55 55 55 55 56 57 57 57 57 57 58 58 58 59 60 viii Biscuit, cookie and cracker manufacturing manuals 10 Enzymes 10.1 Safety aspects of handling proteinase enzymes 62 63 11 Flavours and spices 11.1 Introduction 11.2 Sources and types of flavour Spices and herbs 11.3 11.4 Essential oils 11.5 Oleo resins 11.6 Synthetic flavours-GRAS 11.7 Other flavouring substances 11.8 Form of the flavouring material 11.9 Flavouring of biscuits 11.10 Flavours applied after baking 11.11 Flavours in creams and jams 11.12 Flavour enhancers 11.13 Storage and critical quality points 64 64 64 65 65 65 65 66 66 66 67 67. 68 69 12 Chemicals 12.1 Salt, sodium chloride 12.2 Baking soda, sodium bicarbonate, ‘soda’ 12.3 Acid salts used as baking powders 12.4 Acid salts 12.5 Ammonium bicarbonate, ‘Vol’ 12.6 Fruit acids 12.7 Sodium metabisulphite, ‘Natron’ 12.8 Emulsifiers 70 70 71 71 71 72 73 73 74 13 Chocolate and cocoa 13.1 Types of chocolate Supply and storage of chocolate 13.2 13.3 Chocolate drops, chips and chunks 13.4 Chocolate flavoured coatings 13.5 Cocoa 75 75 75 76 77 77 Useful reading and additional study Index 79 80 1 Introduction This manual is one of a series dealing with materials and manufacturing procedures for biscuits. It describes, in general terms the most important ingredients used to make biscuits by type, function, handling and storage. Most of the ingredients are used to make biscuit dough. The techniques for mixing doughs are dealt with in Manual 2, Biscuit doughs and other aspects of biscuit manufacturing technology are described in later manuals. If you are a member of a manufacturing team you should know how to do your tasks and the reasons for doing things in a specified way. You should also understand the possible implications of not doing a task correctly or not communicating difficulties promptly. The nature, uses and functions of the ingredients are described so that you will know about these materials and the sort of problems that may arise if the qualities or quantities are not correct. If you work in a food factory you must accept some responsibilities. These to a greater or lesser extent will include: 1 Responsibility for the quality of the company’s products if you are a member of a production team. Depending on your job you may not be asked to do quality control checks on the ingredients used but if you observe critically and know what to look for and expect, a fault could be prevented from occurring in manufacturing. 2 Responsibility for the safety of consumers who will eat the products you help to make and pack. The procedures and precautions you should observe are described. 3 Responsibility for the machines and equipment with which you are required to work. The procedures and precautions you should observe are described. 1