NOTE: THE FOLLOWING DEMONSTRATIONS WILL INCLUDE AN EXPLANATION OF THE FUNCTION OF EACH PIECE OF BAKING MACHINE PLUS THE ACTUAL USE OF THE MACHINE IN BREAD PRODUCION FROM MIXING TO PACKAGING. AT THE END OF THE DEMONSTRATIONS, WILLIE PREJEAN WILL DISCUSS BREAD SCORING (EVALUATING QUALITY OF BREAD
EQUIPMENT USED IN THE DEMONSTRATIONS AND WHAT EACH MACHINE DOES.
The chilled water unit is used to cool ingredient water so thedough will be mixed at the proper temperature. Also, to circulatechilled water through the coils between the walls of the mixing bowl.
The automatic water tempering, measuring, and dispensing unitis used to deliver the correct pounds of water into the mixer.Desired water temperature is adjusted by blending a combinationof ice water with tap water or hot water with tap water throughthe by-pass valve which by-passes the scale. The scale is setfor the pounds of water called for by the formula and the valveis opened by the mixer operator allowing the correct amount ofwater to enter the mixer.
Flour is conveyed automatically to the flour hopper over the mixerby the bucket or screw conveyors where it is sifted and weighed as called for by the formula.
After the flour has been weighed in the hopper, it is dumped intothe mixer to be mixed into a dough. For the following demonstration,the Straight Dough Method of mixing will be used.
Mixer operator checking to determine when the gluten has beenfully developed during mixing. NOTE: Different types of flour differ greatly in their mixing requirements. A Mixatron which was developed several years ago can be attached to the mixer. It is useful in asisting the mixer operator in determining when the dough has been mixed to its optimum gluten development.
Stationary dough mixing machine are capable of mixing 500 to 3,000 pounds of dough at one time. The mixed dough will bedumped into the dough trough next to the mixer or the dough mixer can be located on the second floor. and the dough can be dumped from the mixer through a hole in the floor into the dough trough.
Using a dough thermometer the temperature of the mixeddough is checked and recorded. The trough is rolled into thefermentation room which is maintained at a temperature of80 degrees F. and a relative humidity of 75 percent. Thedough will remain in the fermentation room from 2 to 3 hours.
The hand is inserted into the dough. If the dough recedes slightlyit is ready to be punched. If it falls quickly, it has fermentedtoo long and must be made up immediately.
To punch the dough, use both hands and punch the dough throughthe center from one end to the other. Then fold the dough oneside and then the other. Punching equalizes the temperature ofthe dough. The dough is allowed to ferment a few more minutesbefore it is taken to the dough dividing machine.
When the dough has completed the fermentation stage, thedough can be cut in large pieces by hand and transfered from the dough trough to the dough dividing machine. Dough Trough Hoists have been designed to lift dough troughs filled with fermented doughs to be dumped into the divider hopper.
Other methods available are, Conveyor Transfer Systems, Dough Pumps, and Rotary Dough Feeders or Chunkers. Some doughs such as Frozen Doughs, and many Bread Doughs and Stiff Doughs are not suitable to be transferred by the Dough Pump. One reason why it is not suitable for some types of doughs is because it causes the dough to rise in temperature due to friction being created during the transfer process.
Once the dough has been transferred to the divider hopper, the divider divides the dough into individual size loaves. The pieces of dough travel on a short conveyor and are deposited into the doughrounding machine.
The dough rounding machine forms a smooth round ball which is thendeposited in cloth lined baskets of the dough intermediate proofer.
The dough pieces are conveyed through the intermediate proofer for a pre-determined time to allow them to rest and recover fromthe punishment they received during dividing and rounding. Theyare then discharged and enter the head rolls of the dough molding machine.
From the head rolls of the molder, the loaves pass through thesheeting rolls which forms an oblong shaped piece of dough. Theythen go through the curling rolls and drum where they are shapedand sealed into their final form.
Loaves molded by the conventional molder being panned and loadedonto proofing racks.
The cross grain molder sheets the dough in one direction. Then the dough is caused to change direction and travels under a curlingchain and pressure board to form a tight molded loaf. This molderproduces a closer grain with smoother texture than does theconventional molder.
Two pieces of dough are being twisted together.
The twisted loaves are placed into the baking pan, racked, and rolled into the dough proofing cabinet. The baked loaveshave excellent internal qualities with small, uniform cells and soft texture simular to that produced by the cross grain molder.
The temperature and humidity of the proofing cabinet are recorded.The cabinet is maintained at a temperature of 100 degrees F. and arelative humidity of 85 percent. The rack with the molded loavesis rolled into the proofing cabinet where they will remain forapproximately 60 minutes.
Rack of proofed loaves is rolled out of the proofing cabinet to beloaded into the oven.
Proofed loaves are loaded into 425 to 450 degree F. oven. Bakingtime is 25 to 30 minutes.
Baked loaves are unloaded onto cooling racks and rolled intocooling and storage room.
When the loaves are removed from the oven, it's internal temperatureis about 212 degrees F. The bread will be allowed to cool until theinternal temperature of loaves drops to 100 degrees F. before theyare sliced and packaged.
Cooled bread is sliced, bagged and the bag tied automatically by the slicing, bagging and tying machine. Bread is then ready tobe issued to the dinning facilities.
The perforated pan is used to bake French and Rye breads when theoven doesn't have a suitable hearth on which to bake the bread.
The pullman pan is used to bake sandwich bread. The cover is puton just before the loaves are loaded into the oven to form asquare loaf.
Just before the French loaves are loaded into the oven they are washed with corn starch wash or egg wash and cut or docked. Sesameseeds or Poppy seeds can be sprinkled on the loaves at this time. Lowpressure steam in injected into the oven and left on until the loavesbegin to color. This produces a shiny crust color.
NOTE: INFORMATION ON FORMULAS, MIXING, FERMENTATION, AND MAKE-UP OF VARIETY BREADS, INCLUDING FRENCH BREAD ARE INCLUDED IN PART FOUR-VARIETY BREADS. FOR MORE COMPLETE INFORMATION ON BREAD PRODUCTION IN GENERAL, SEE PART TWO-BREAD PRODUCTION PROCEDURES.
In evaluating quality of bread we do what is known in the Baking Industry as Scoring the Bread. Purpose of scoring is to detect faults and determine causes and remedies. Bread scoring is not an exact science. In fact, personal opinion plays a great part. A person who scores bread should have a scientific knowledge of bread baking and an ability to express an opinion.
A system of scoring has been developed for evaluating quality and appearance of a loaf of bread with a theoretically perfect loaf. The eleven factors listed on the Bread Scoring Form for evaluating appearance and quality are assigned numerical values accordance to their relative importance. For example, there are six factors used to evaluate the external characteristics. They are Volume ( size for a given weight of dough ) is worth 10 points, Color of crust 8 points, Symetry of form 3 points, Eveness of bake 3 point, Break and shred 3 points for a total of 30 points. There are five factors used to evaluate the internal characteristics. They are the Grain worth 10 points, Color of crumb 10 points, Texture 15 points, Flavor (Aroma) 15 points, and Taste 20 points for a total of 70 points. A perfect loaf would score 100 points, although that is practically impossible.
THIS COMPLETES THE SUBJECT ON BREAD BAKING DEMONSTRATIONS AND EVALUATING QUALITY OF BREAD.