Tài liệu Manley’s technology of biscuits, crackers and cookies

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 field 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 Volume Volume Volume Volume Volume 1: Ingredients (ISBN 978-1-85573-292-6) 2: Biscuit doughs (ISBN 978-1-85573-293-3) 3: Biscuit dough piece forming (ISBN 978-1-85573-294-0) 4: Baking and cooling of biscuits (ISBN 978-1-85573-295-7) 5: Secondary processing in biscuit manufacturing (ISBN 978-1-85573-296-4) 6: Biscuit packaging and storage (ISBN 978-1-85573-297-1) Details of these books and a complete list of Woodhead’s titles can be obtained by: • visiting our web site at www.woodheadpublishing.com • contacting Customer Services (e-mail: [email protected]; fax: +44 (0) 1223 832819; tel.: +44 (0) 1223 499140 ext. 130; address: Woodhead Publishing Limited, 80 High Street, Sawston, Cambridge CB22 3HJ, UK) • contacting our US office (e-mail: [email protected]; tel.: (215) 928 9112; address: Woodhead Publishing, 1518 Walnut Street, Suite 1100, Philadelphia, PA 19102-3406, USA) If you would like to receive information on forthcoming titles, please send your address details to: Francis Dodds (address, tel. and fax as above; e-mail: francis. [email protected]). Please confirm which subject areas you are interested in. © 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. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the authors and the publisher cannot assume responsibility for the validity of all materials. 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. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming and recording, or by any information storage or retrieval system, without permission in writing from Woodhead Publishing Limited. The consent of Woodhead Publishing Limited does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from Woodhead Publishing Limited for such copying. Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. 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) The publisher’s policy is to use permanent paper from mills that operate a sustainable forestry policy, and which has been manufactured from pulp which is processed using acid-free and elemental chlorine-free practices. Furthermore, the publisher ensures that the text paper and cover board used have met acceptable environmental accreditation standards. Typeset by Toppan Best-set Premedia Limited Printed by TJI Digital, Padstow, Cornwall, UK © Woodhead Publishing Limited, 2011 Contents Contributor contact details .................................................................................. Woodhead Publishing Series in Food Science, Technology and Nutrition .......................................................................................................... Preface to the fourth edition ................................................................................. Preface to the third edition ................................................................................... Preface to the second edition ................................................................................ Preface to the first edition ..................................................................................... 1 xvii xix xxvii xxix xxxi xxxiii Setting the scene: A history and the position of biscuits ......................... D. Manley, Consultant, Duncan Manley Ltd, UK 1.1 Introduction ....................................................................................... 1.2 The beginnings of biscuit manufacturing ....................................... 1.3 Ingredients and formulation development .................................... 1.4 Engineering ........................................................................................ 1.5 References and useful reading ........................................................ 1 3 6 7 9 Part I Management of technology in biscuit manufacture ........................... 11 2 The role of the technical department in biscuit manufacture ............... D. Manley, Consultant, Duncan Manley Ltd, UK 2.1 Introduction ....................................................................................... 2.2 The requirements of the technical (or technology) department ......................................................................................... 2.3 Selection of staff for the technical department ........................... 2.4 Facilities for the technical department ........................................... 2.5 Liaison with other technical establishments ................................ 2.6 Support for purchasing ..................................................................... 2.7 Support for training .......................................................................... 2.8 Management of technical developments ...................................... 2.9 Reference ........................................................................................... 2.10 Useful reading ................................................................................... © Woodhead Publishing Limited, 2011 1 13 13 15 16 18 19 20 20 21 22 22 vi 3 4 5 6 7 Contents Quality management systems and hazard analysis critical control point (HACCP) in biscuit manufacture ................................................... D. Manley, Consultant, Duncan Manley Ltd, UK 3.1 Quality management ....................................................................... 3.2 Management of product safety ...................................................... 3.3 Useful reading ................................................................................... Quality control and good manufacturing practice (GMP) in the biscuit industry ............................................................................................... D. Manley, Consultant, Duncan Manley Ltd, UK 4.1 Principles and management ............................................................. 4.2 Quality control tasks for finished product inspection .................. 4.3 Quality control tasks for ingredient and packaging materials .... 4.4 Good manufacturing practice (GMP) ............................................ 4.5 Hygiene surveys ............................................................................... 4.6 References .......................................................................................... 4.7 Useful reading ................................................................................... Process and efficiency control in biscuit manufacture ............................. D. Manley, Consultant, Duncan Manley Ltd, UK and M. Wilkes, MW Associates, UK 5.1 Process control and efficiency ......................................................... 5.2 Process audit ...................................................................................... 5.3 Process control checks and records for plants with no continuous monitoring sensors ........................................................ 5.4 Making process control measurements .......................................... 5.5 Action procedures as a result of product measurements ............ 5.6 Instrumentation for monitoring ...................................................... 5.7 Efficiency and integrated plant control ......................................... 5.8 Outline of the instrumentation that is available ........................... 5.9 Troubleshooting ................................................................................. 5.10 Energy efficiency ............................................................................... 5.11 References .......................................................................................... 5.12 Useful reading and suppliers of instruments................................. 23 23 25 28 29 29 31 32 34 39 40 40 41 41 45 45 50 52 52 52 54 65 66 67 67 Product development in the biscuit industry ........................................... D. Manley, Consultant, Duncan Manley Ltd, UK 6.1 Introduction ....................................................................................... 6.2 Product development ........................................................................ 6.3 Facilities for process and product development ........................... 6.4 Assessing products ............................................................................ 6.5 Establishing the product specification ........................................... 6.6 Management of product development ........................................... 6.7 References .......................................................................................... 6.8 Useful reading ................................................................................... 69 Sustainability in the biscuit industry ........................................................... R. Brightwell, United Biscuits, UK 7.1 Introduction ....................................................................................... 7.2 Key drivers for sustainability in the biscuit industry ................... 93 © Woodhead Publishing Limited, 2011 69 70 73 77 86 87 92 92 93 94 Contents 7.3 7.4 7.5 7.6 7.7 vii Carbon emissions and energy use ................................................... Reducing water use .......................................................................... Reducing waste .................................................................................. Packaging .......................................................................................... Other options for improving sustainability ................................... 98 98 100 101 102 Part II Materials and ingredients for biscuit manufacture ........................... 105 8 9 10 11 12 Choosing materials for biscuit production ................................................. D. Manley, Consultant, Duncan Manley Ltd, UK 8.1 Introduction ....................................................................................... 8.2 Important technical aspects ............................................................. 8.3 Important commercial aspects ........................................................ 8.4 Programme for the meeting with a supplier ................................. 107 107 107 107 108 Wheat flour and vital wheat gluten as biscuit ingredients ..................... D. Manley, Consultant, Duncan Manley Ltd, UK and B. Pareyt and J. A. Delcour, Katholieke Universiteit Leuven, Belgium 9.1 Introduction ....................................................................................... 9.2 Flour from the viewpoint of the miller .......................................... 9.3 Flour from the viewpoint of the biscuit manufacturer ................ 9.4 Vital wheat gluten ............................................................................. 9.5 References .......................................................................................... 9.6 Useful reading ................................................................................... 109 Meals, grits, flours and starches (other than wheat) ................................. D. Manley, Consultant, Duncan Manley Ltd, UK 10.1 Introduction ....................................................................................... 10.2 Cereal-based materials ..................................................................... 10.3 Non-cereal flours and starches ........................................................ 10.4 References .......................................................................................... 10.5 Useful reading and addresses .......................................................... 134 Sugars and syrups as biscuit ingredients .................................................... D. Manley, Consultant, Duncan Manley Ltd, UK 11.1 Introduction ....................................................................................... 11.2 Common sugar, sucrose .................................................................... 11.3 Syrups.................................................................................................. 11.4 Sugars and syrups from starches – glucose .................................... 11.5 Non-diastatic malt extract ................................................................ 11.6 Maillard reaction ............................................................................... 11.7 Polyols ................................................................................................. 11.8 References .......................................................................................... 11.9 Useful reading ................................................................................... 143 Fats and oils as biscuit ingredients .............................................................. G. Atkinson, AarhusKarlshamn UK Ltd, UK 12.1 Introduction ....................................................................................... 12.2 The role of fat in biscuits ................................................................. 160 © Woodhead Publishing Limited, 2011 109 110 127 131 131 133 134 135 139 141 141 143 145 153 154 158 158 158 159 159 160 161 viii Contents 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 13 14 15 16 The chemistry and physical properties of fats ............................. Quality and handling issues of fats ................................................. Key characteristics of fats for biscuits ............................................ Quality control of fats ...................................................................... General specification requirements for oils and fats ................... Challenges for the biscuit manufacturer ........................................ References .......................................................................................... Useful reading ................................................................................... 164 171 172 175 178 178 179 180 Emulsifiers (surfactants) and antioxidants as biscuit ingredients ........... D. Manley, Consultant, Duncan Manley Ltd, UK 13.1 Introduction ....................................................................................... 13.2 Function of emulsifiers in biscuits ................................................. 13.3 Types of food emulsifiers ................................................................ 13.4 Reduced fat biscuits .......................................................................... 13.5 General use of emulsifiers in biscuit doughs ................................. 13.6 Application help ................................................................................ 13.7 Antioxidants....................................................................................... 13.8 References .......................................................................................... 13.9 Useful reading ................................................................................... 181 181 182 182 186 187 188 189 190 190 Milk products and egg as biscuit ingredients ............................................ D. Manley, Consultant, Duncan Manley Ltd, UK 14.1 Introduction ....................................................................................... 14.2 Milk and milk products .................................................................... 14.3 Egg ...................................................................................................... 14.4 References .......................................................................................... 14.5 Useful reading ................................................................................... 191 Dried fruits and nuts as biscuit ingredients ............................................... D. Manley, Consultant, Duncan Manley Ltd, UK 15.1 Introduction ....................................................................................... 15.2 Dried grapes ..................................................................................... 15.3 Other dried fruits used in biscuits .................................................. 15.4 Fruit pastes and syrups ..................................................................... 15.5 Tree nuts ............................................................................................. 15.6 Peanuts, arachis or ground nut ........................................................ 15.7 Health problems associated with nuts............................................ 15.8 References .......................................................................................... 15.9 Useful reading ................................................................................... 200 Yeast and enzymes as biscuit ingredients .................................................. D. Manley, Consultant, Duncan Manley Ltd, UK 16.1 Introduction ....................................................................................... 16.2 Yeast ................................................................................................... 16.3 Enzymes ............................................................................................ 16.4 References ......................................................................................... 16.5 Useful reading ................................................................................... © Woodhead Publishing Limited, 2011 191 192 198 198 198 200 201 204 205 205 207 207 208 208 209 209 209 212 214 215 Contents 17 18 19 20 Flavours, spices and flavour enhancers as biscuit ingredients ................. D. Manley, Consultant, Duncan Manley Ltd, UK 17.1 Introduction ....................................................................................... 17.2 Sources and types of flavours .......................................................... 17.3 Suitability of a flavour material ..................................................... 17.4 Flavouring of biscuits........................................................................ 17.5 Flavour enhancers ............................................................................. 17.6 Storage of flavours and quality control .......................................... 17.7 References .......................................................................................... 17.8 Useful reading ................................................................................... ix 216 216 217 219 219 220 221 221 222 Additives as biscuit ingredients ................................................................... D. Manley, Consultant, Duncan Manley Ltd, UK 18.1 Introduction ....................................................................................... 18.2 Common salt (sodium chloride, NaCl)........................................... 18.3 Leavening agents ............................................................................... 18.4 Processing aids ................................................................................... 18.5 Food acids........................................................................................... 18.6 Colours................................................................................................ 18.7 Artificial sweeteners ......................................................................... 18.8 References .......................................................................................... 18.9 Useful reading ................................................................................... 223 Chocolate and cocoa as biscuit ingredients ............................................... D. Manley, Consultant, Duncan Manley Ltd, UK 19.1 Introduction ....................................................................................... 19.2 The flavour of chocolate................................................................... 19.3 Chocolate viscosity ............................................................................ 19.4 Cocoa butter, cocoa butter equivalents and hard butters ........... 19.5 Definitions of cocoa and chocolate products ................................ 19.6 Types of chocolate ............................................................................. 19.7 Supply and storage of chocolate ..................................................... 19.8 Chocolate drops and chips ............................................................... 19.9 Cocoa .................................................................................................. 19.10 Handling of chocolate and chocolate chips ................................... 19.11 Compound chocolate ........................................................................ 19.12 Carob powder .................................................................................... 19.13 References .......................................................................................... 19.14 Useful reading ................................................................................... 235 Packaging materials for biscuits and their influence on shelf life .......... G. L. Robertson, Food•Packaging•Environment and University of Queensland, Australia 20.1 Introduction ....................................................................................... 20.2 Packaging materials .......................................................................... 20.3 Packaging and shelf life .................................................................... 20.4 Indices of failure (IoFs).................................................................... 20.5 Package requirements to address indices of failure (IoFs) ......... 20.6 References .......................................................................................... © Woodhead Publishing Limited, 2011 223 224 226 228 231 232 233 234 234 235 236 237 238 240 240 241 242 243 244 244 245 245 245 247 247 248 255 260 260 267 x Contents Part III 21 22 23 24 25 26 Types of biscuits ................................................................................... 269 Classification of biscuits .............................................................................. D. Manley, Consultant, Duncan Manley Ltd, UK 21.1 Introduction ....................................................................................... 21.2 Classification based on enrichment of the formulation ............... 21.3 Conversion of units ........................................................................... 21.4 Reference ........................................................................................... 21.5 Useful reading ................................................................................... 271 Cream crackers .............................................................................................. D. Manley, Consultant, Duncan Manley Ltd, UK 22.1 History and introduction to cream crackers ................................ 22.2 Mixing and fermentation of cream cracker doughs ..................... 22.3 Dough piece forming ........................................................................ 22.4 Baking of cream crackers................................................................. 22.5 Yields from fermented doughs ........................................................ 22.6 References .......................................................................................... 22.7 Useful reading ................................................................................... 279 Soda crackers ................................................................................................. D. Manley, Consultant, Duncan Manley Ltd, UK 23.1 Introduction ....................................................................................... 23.2 Dough preparation ............................................................................ 23.3 Outline of typical soda cracker manufacturing techniques ........................................................................................... 23.4 References .......................................................................................... 23.5 Useful reading ................................................................................... 271 272 278 278 278 279 281 286 289 292 292 292 293 293 294 295 297 297 Savoury or snack crackers ............................................................................ D. Manley, Consultant, Duncan Manley Ltd, UK 24.1 General description ......................................................................... 24.2 Manufacturing technology ............................................................... 24.3 Post-oven oil spraying ..................................................................... 24.4 Useful reading ................................................................................... 298 Matzos and water biscuits ............................................................................ D. Manley, Consultant, Duncan Manley Ltd, UK 25.1 Matzos ................................................................................................. 25.2 Water biscuits..................................................................................... 25.3 Typical recipes ................................................................................... 25.4 Useful reading ................................................................................... 303 Puff biscuits .................................................................................................... D. Manley, Consultant, Duncan Manley Ltd, UK 26.1 General description ......................................................................... 26.2 Puff dough preparation .................................................................... 26.3 Baking of puff biscuits ...................................................................... 26.4 Puff biscuit production techniques ................................................. 306 © Woodhead Publishing Limited, 2011 298 298 301 302 303 303 305 305 306 308 310 311 Contents 26.5 26.6 27 28 29 30 xi References .......................................................................................... Useful reading ................................................................................... 311 311 Hard sweet, semi-sweet and Garibaldi fruit sandwich biscuits ............... D. Manley, Consultant, Duncan Manley Ltd, UK 27.1 General description of this group of biscuits ................................ 27.2 Ingredients and recipes .................................................................... 27.3 Dough mixing .................................................................................... 27.4 Mixer instrumentation ...................................................................... 27.5 Dough piece forming ........................................................................ 27.6 Instrumentation of the forming machine ....................................... 27.7 Baking ................................................................................................. 27.8 Flavouring of biscuits ...................................................................... 27.9 Cooling and handling of biscuits ..................................................... 27.10 Continental semi-sweet biscuits ...................................................... 27.11 Garibaldi or fruit sandwich biscuits................................................ 27.12 References .......................................................................................... 27.13 Useful reading ................................................................................... 312 312 315 317 320 321 324 325 325 326 326 327 329 330 Short dough biscuits ...................................................................................... D. Manley, Consultant, Duncan Manley Ltd, UK and B. Pareyt and J. A. Delcour, Katholieke Universiteit Leuven, Belgium 28.1 Description of the group .................................................................. 28.2 Recipes and ingredients ................................................................... 28.3 Dough mixing .................................................................................... 28.4 Dough piece forming ........................................................................ 28.5 Instrumentation of the forming machine ....................................... 28.6 Baking ................................................................................................. 28.7 Factors affecting dough piece spread during baking .................... 28.8 References .......................................................................................... 28.9 Useful reading ................................................................................... 331 Deposited soft dough and sponge drop biscuits ....................................... D. Manley, Consultant, Duncan Manley Ltd, UK 29.1 Description of deposited biscuits .................................................... 29.2 Description of sponge batter drops ................................................ 29.3 Typical recipes ................................................................................... 29.4 Useful reading ................................................................................... 347 Wafer biscuits ................................................................................................. D. Manley, Consultant, Duncan Manley Ltd, UK 30.1 Introduction ....................................................................................... 30.2 The wafer oven or wafer baker ....................................................... 30.3 Wafer sheet production .................................................................... 30.4 Batter mixing ..................................................................................... 30.5 Batter handling .................................................................................. 30.6 Batter deposition and baking .......................................................... 30.7 Sheet handling, creaming and cutting ............................................ 30.8 Process control of wafer production ............................................. 353 © Woodhead Publishing Limited, 2011 331 335 336 338 340 341 342 345 346 347 350 352 352 353 355 357 360 361 361 364 367 xii 31 32 Contents 30.9 Hollow rolled wafer sticks ............................................................... 30.10 References .......................................................................................... 30.11 Useful reading ................................................................................... 370 371 371 The position of biscuits in nutrition ........................................................... H.C. Smith, Cereal Partners United Kingdom (CPUK), UK 31.1 Introduction ....................................................................................... 31.2 Biscuits in our diets........................................................................... 31.3 The evolution of biscuit nutrition ................................................... 31.4 Different biscuits for different people ........................................... 31.5 Food labelling can help – when you understand it....................... 31.6 References .......................................................................................... 31.7 Useful reading ................................................................................... 372 Miscellaneous biscuit-like products ............................................................ D. Manley, Consultant, Duncan Manley Ltd, UK 32.1 Introduction ....................................................................................... 32.2 Products that are made on a type of biscuit plant ....................... 32.3 Products that are not made on conventional biscuit plant ......... 32.4 References .......................................................................................... 32.5 Useful reading ................................................................................... 385 Part IV 33 34 372 374 375 376 380 382 384 385 385 393 394 394 Biscuit production processes and equipment ................................... 395 Bulk handling and metering of biscuit ingredients ................................. D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 33.1 Introduction ....................................................................................... 33.2 Bulk handling..................................................................................... 33.3 Some technical aspects of bulk handling ....................................... 33.4 Process control in bulk storage ....................................................... 33.5 Metering of ingredients to mixers................................................... 33.6 References .......................................................................................... 33.7 Useful reading ................................................................................... 397 Mixing and premixes in biscuit manufacture............................................. D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 34.1 Introduction ....................................................................................... 34.2 General conditions for mixing ....................................................... 34.3 Process control and instrumentation of mixers ............................ 34.4 Considerations in the selection of a mixer .................................... 34.5 Types of mixer available for biscuit doughs .................................. 34.6 Integrated mixing schemes in the future ....................................... 34.7 Premixes ............................................................................................. 34.8 References .......................................................................................... 34.9 Useful reading ................................................................................... 410 © Woodhead Publishing Limited, 2011 397 397 399 403 403 409 409 410 411 415 417 418 422 423 425 426 Contents 35 36 37 38 Sheeting, gauging and cutting in biscuit manufacture ............................. D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 35.1 Principles ............................................................................................ 35.2 Sheeters .............................................................................................. 35.3 Gauge rolls ......................................................................................... 35.4 Multiple-roller gauging units ........................................................... 35.5 Dough relaxation units ..................................................................... 35.6 Cutting ................................................................................................ 35.7 Cutter scrap dough handling ........................................................... 35.8 Dough piece garnishing and panning ............................................. 35.9 Control of biscuit cutting machines ................................................ 35.10 Operator maintenance requirements ............................................. 35.11 Useful reading ................................................................................... Laminating in biscuit manufacture ............................................................. D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 36.1 Principles and techniques of laminating ........................................ 36.2 Types of automatic laminator .......................................................... 36.3 Is laminating really necessary? ........................................................ 36.4 Process control during laminating .................................................. 36.5 Useful reading ................................................................................... xiii 427 427 429 434 436 437 438 441 442 442 443 444 445 445 446 450 450 452 Rotary moulding in biscuit manufacture ................................................... D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 37.1 Introduction ....................................................................................... 37.2 General description of the rotary moulding machine .................. 37.3 The formation of the dough piece .................................................. 37.4 Dough piece weight control ........................................................... 37.5 Differential speeds of moulding roller and extraction roller ...... 37.6 Common difficulties that may be encountered with rotary moulders ............................................................................................. 37.7 Instrumentation of a rotary moulder ............................................. 37.8 Disadvantages of a rotary moulder ................................................ 37.9 The soft dough rotary moulder and Rotodepositor ..................... 37.10 Printing on dough pieces .................................................................. 37.11 Reference ........................................................................................... 37.12 Useful reading ................................................................................... 453 Extruding and depositing of biscuit dough ............................................... D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 38.1 Introduction ....................................................................................... 38.2 General description of extruding and depositing machines for doughs ......................................................................................... 38.3 Process control of extruded and deposited biscuits ..................... 38.4 Sponge batter drops and sponge finger biscuits ........................... 38.5 Useful reading ................................................................................... 467 © Woodhead Publishing Limited, 2011 453 454 457 460 461 462 463 463 464 465 466 466 467 467 473 475 476 xiv 39 40 41 42 Contents Biscuit baking ............................................................................................... D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 39.1 Introduction ....................................................................................... 39.2 Changes to the dough piece during baking ................................... 39.3 Oven conditions ............................................................................... 39.4 Typical baking profiles ...................................................................... 39.5 Types of oven ..................................................................................... 39.6 Preparation and care of oven bands............................................... 39.7 Measurement and control in baking ............................................. 39.8 Post oven oil spraying ....................................................................... 39.9 References .......................................................................................... 39.10 Useful reading ................................................................................... 477 477 479 485 487 489 495 497 499 499 500 Biscuit cooling and handling ...................................................................... D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 40.1 Introduction ....................................................................................... 40.2 Checking ............................................................................................. 40.3 Methods and speeds of cooling ....................................................... 40.4 Biscuit handling prior to packaging................................................ 40.5 References .......................................................................................... 40.6 Useful reading ................................................................................... 501 Secondary processing of biscuits ................................................................. D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 41.1 General considerations ..................................................................... 41.2 Sandwich creams ............................................................................... 41.3 Icing ..................................................................................................... 41.4 Jams, jellies, caramels and marshmallows ...................................... 41.5 Chocolate and chocolate flavoured coatings ................................. 41.6 References and useful reading ........................................................ 511 Biscuit packaging and storage ..................................................................... D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 42.1 Introduction ....................................................................................... 42.2 Functions of a pack ........................................................................... 42.3 Types of primary packages............................................................... 42.4 Collation and feeding to wrapping machines ................................ 42.5 Biscuit size variations ....................................................................... 42.6 Post-wrapping operations ................................................................. 42.7 Process and quality control .............................................................. 42.8 Storage ................................................................................................ 42.9 Robotics .............................................................................................. 42.10 Useful reading and address ............................................................ © Woodhead Publishing Limited, 2011 501 501 502 505 509 510 511 512 521 524 534 545 547 547 548 549 551 554 555 556 561 561 563 Contents 43 Recycling, handling and disposal of waste biscuit materials ................... D. Manley, Consultant, Duncan Manley Ltd, UK, reviewed by H. Clark, Baker Perkins Ltd, UK 43.1 Management of waste ....................................................................... 43.2 Sources of waste materials ............................................................... 43.3 Estimating the size of the problem ................................................. 43.4 Recycling ............................................................................................ 43.5 Disposal of waste materials that are not recycled ........................ Part V xv 564 564 565 566 566 568 Suppliers’ presentations ........................................................................ 569 Index ........................................................................................................................ 576 © Woodhead Publishing Limited, 2011 Contributor contact details (* = main contact) Chapter 7 Editor and chapters 1, 2, 3, 4, 6, 8, 10, 11, 13, 14, 15, 16, 17, 18, 19, 21, 22, 23, 24, 25, 26, 27, 29, 30 and 32 Duncan Manley The Old Well House Walcot Road Ufford Stamford PE9 3BP UK E-mail: [email protected] Chapter 5 Duncan Manley* The Old Well House Walcot Road Ufford Stamford PE9 3BP UK E-mail: [email protected] Malcolm Wilkes Clough House The Clough Bamford Hope Valley S33 0AN UK E-mail: malcolmwilkes@btopenworld. com Robert Brightwell United Biscuits Hayes Park Hayes End Road Hayes UB4 8EE UK E-mail: [email protected] Chapters 9 and 28 Duncan Manley* The Old Well House Walcot Road Ufford Stamford PE9 3BP UK E-mail: [email protected] Bram Pareyt and Jan A. Delcour Laboratory of Food Chemistry and Biochemistry and Leuven Food Science and Nutrition Research Centre (LFoRCe) Katholieke Universiteit Leuven Kasteelpark Arenberg 20, box 2463 B-3001 Heverlee Belgium E-mail: [email protected] [email protected] © Woodhead Publishing Limited, 2011 xviii Contributor contact details Chapter 12 Mr G Atkinson AarhusKarlshamn UK Ltd King George Dock Hull HU9 5PX UK E-mail: [email protected] Chapters 33, 34, 35, 36, 37, 38, 39, 40, 41, 42 and 43 Duncan Manley The Old Well House Walcot Road Ufford Stamford PE9 3BP UK E-mail: [email protected] Chapter 20 Gordon L. Robertson Food•Packaging•Environment and University of Queensland 6066 Lugano Drive Hope Island, QLD 4212 Australia E-mail: [email protected] www.gordonlrobertson.com Reviewed by Henry Clark Baker Perkins Ltd Manor Drive Paston Parkway Peterborough PE4 7AP UK E-mail: henry.clark@ bakerperkinsgroup.com Chapter 31 Hayley Smith Nestlé UK Ltd St Georges House Park Lane Croydon CR9 1NR UK E-mail: [email protected]. com [email protected] © Woodhead Publishing Limited, 2011 Woodhead Publishing Series in Food Science, Technology and Nutrition 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Chilled foods: a comprehensive guide Edited by C. Dennis and M. Stringer Yoghurt: science and technology A. Y. Tamime and R. K. Robinson Food processing technology: principles and practice P. J. Fellows Bender’s dictionary of nutrition and food technology Sixth edition D. A. Bender Determination of veterinary residues in food Edited by N. T. Crosby Food contaminants: sources and surveillance Edited by C. Creaser and R. Purchase Nitrates and nitrites in food and water Edited by M. J. Hill Pesticide chemistry and bioscience: the food-environment challenge Edited by G. T. Brooks and T. Roberts Pesticides: developments, impacts and controls Edited by G. A. Best and A. D. Ruthven Dietary fibre: chemical and biological aspects Edited by D. A. T. Southgate, K. W. Waldron, I. T. Johnson and G. R. Fenwick Vitamins and minerals in health and nutrition M. Tolonen Technology of biscuits, crackers and cookies Second edition D. Manley Instrumentation and sensors for the food industry Edited by E. Kress-Rogers Food and cancer prevention: chemical and biological aspects Edited by K. W. Waldron, I. T. Johnson and G. R. Fenwick Food colloids: proteins, lipids and polysaccharides Edited by E. Dickinson and B. Bergenstahl Food emulsions and foams Edited by E. Dickinson Maillard reactions in chemistry, food and health Edited by T. P. 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