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MANLEY’S TECHNOLOGY OF BISCUITS CRACKERS AND COOKIES Edited by Duncan Manley, Published by ELSEVIER LTD Contents Contributor contact details Preface to the fourth edition Preface to the third edition Preface to the second edition Preface to the first edition 1 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 Part I Management of technology in biscuit manufacture 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 3 Quality management systems and (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 4 Quality control and good manufacturing practice 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 5 Process and efficiency control in biscuit manufacture D. Manley, Consultant, Duncan Manley Ltd, UK and M. Wilkes, M.W.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 contacts 6 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 6.7 References 6.8 Useful reading 7 Sustainability in the biscuit industry R. Brightwell, United Biscuits, UK 7.1 Introduction 7.2 Key drivers for sustainability in the biscuit industry 7.3 Carbon emissions and energy use 7.4 Reducing water use 7.5 Reducing waste 7.6 Packaging 7.7 Other options for improving sustainability Part II Materials and ingredients for biscuit manufacture 8 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 9 Wheat flour and vital wheat gluten as biscuit ingredients D. Manley, Consultant, Duncan Manley Ltd, UK, 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 10 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 11 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 Useful reading 12 Fats and oils as biscuit ingredients G. Atkinson, AarhusKarlshamn UK Ltd, UK 11.1 Introduction 11.2 The role of fat in biscuits 11.3 The chemistry and physical properties of fats 11.4 Quality and handling issues of fats 11.5 Key characteristics of fats for biscuits 11.6 Quality control of fats 11.7 General specification requirements for oils and fats 11.8 Challenges for the biscuit manufacturer 11.9 References 11.10 Useful reading 13 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 Anti-oxidants 13.8 References 13.9 Useful reading 14 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 15 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 16 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 17 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 18 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 19 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 20 Packaging materials for biscuits 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 IoFs 20.6 References 20.7 Useful reading Part III Types of biscuits 21 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 22 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 23 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 24 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 25 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 26 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 26.5 References 26.6 Useful reading 27 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 28 Short dough biscuits D. Manley, Consultant, Duncan Manley Ltd, UK, 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 29 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 30 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 30.9 Hollow rolled wafer sticks 30.10 References 30.11 Useful reading 31 The position of biscuits in nutrition H. 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 – only when you understand it 31.6 References 31.7 Useful reading 32 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 Part IV Biscuit production processes and equipment 33 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 34 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 35 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 36 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 37 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 roto depositor 37.10 Printing on dough pieces 37.11 Reference 37.12 Useful reading 38 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 lady finger biscuits 38.5 Useful reading 39 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 40 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 41 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 42 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 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 which are not recycled Part V Suppliers’ presentations Click here for ordering details |