Bakery equipment : Major role in the Bakery

Bakery equipment refers to the machinery and tools used in the production of baked goods, such as bread, cakes, pastries, and other sweet and savory treats. Some common types of bakery equipment include:

1. Ovens:
- Deck ovens, rack ovens, and conveyor ovens are used for baking bread, cakes, and pastries.

2. Mixers:
- Stand mixers and planetary mixers are used for mixing dough, batter, and other ingredients.

3. Dough Preparation Equipment:
- Dough sheeter, dough cutter, and dough divider are used to prepare and shape dough for baking.

4. Proofing Cabinets:
- Used to control temperature and humidity for proofing yeast dough.

5. Display Cases:
- Used to showcase baked goods in a visually appealing way.

6. Baking Sheets and Pans:
- Used for baking and storing baked goods.

7. Cooling Racks:
- Used to cool baked goods after baking.

8. Automated Equipment:
- Automated bread slicers, bagel slicers, and cake decorating machines can increase efficiency and consistency in large-scale bakeries.

These are just a few examples of the many types of equipment used in bakeries. The specific equipment used can vary depending on the type and size of the bakery, as well as the types of products being produced.

1. BAKERY EQUIPMENT

2. Bakery organization The bakery section is one of the most important units in a catering establishment. Now a days the people are passionate to have fast food and ready-to-eat food items in their diet. The bakery products are one of the most soled products among them. At the same time bakers have been convinced to maintain the quality product and to produce new variety of consumer choice. The organization of a bakery will vary according to the size and type of the establishment. In a small bakery unit, there will be a head chief, pastry man, confectioner, baker and one or more assistant to get the job done. When you plan to start a small bakery or confectionary unit, you should consider the following points: 1. Population and purchasing capacity of the area. 2. Material availability in that area 3. Transport facility 4. Electricity and other fuels availability. 5. Availability of water 6. Communication 7. Customer needs and expectations 8. Government procedures and legal aspects of the industry .

3. Bakery equipments Nowadays many modern equipment and tools are used in the bake shop industry because the modern technology continues to develop more and more specialized and technology advanced tools to reduce labour . The bakery tools and equipments are classified under two categories: 1. Small equipment 2. Large equipment Small equipment and their use. Mixing bowls : A variety of stainless steel bowls are used for whipping eggs, mixing of creams and storage purpose. Muffin pan : The different size of baking pans with cup shaped indentation for baking muffins.

4. Savarin moulds : Small ring shaped doughnut shaped moulds for baking savarins. Ordinary and textured rolling pin : Ordinary rolling pins help roll the dough and the textured rolling pins are useful to make design over the biscuit dough, and on sheets of marzipan and pastillage. Table scraper : Use to cut pieces of dough. It is available in plastic or metals. Baking tray : Use for baking goods. It is available in various sizes. Pastry brush : Use to brush the items with egg wash, glaze etc. Bread moulds : various size of mould are used to prepare a variety of breads.

5. Tart pan : Available in many shapes and sizes. They may be made in one piece or with a removal bottom to make it easier to remove the baked tart from the pan. Bread knife : Bread knife is a flexible rounded tipped tool used in pastry section for spreading cream, glaze on cakes for mixing and bowl scraping. Pastry bag and nozzles : The plastic, nylon bag is used to pipe the fillings, cream and various toppings. Nozzles are available in different designs and are used for decorating items such as cake icings and whipped creams Sieves : These are used to shift aerate and helps remove any large foreign raw materials from dry ingredients

6. Timers : These are absolutely essential for baking Wooden spoons : To stir ingredients in a bowl. Juicer : To squeeze juice from different fruits and vegetables. Hand blender : To whisk small quantities of egg or cream. Sugar thermometer : Used to measure the temperature of the sugar or the density of the sugar syrup. Cooling wire rack : To pull sponge cakes and yeast products and thus prevents from sweetening. Beside these small equipments includes weighing scale, Madeleine cups, cream horn mould, chopping board, oven gloves and varies sizes of cake moulds.

7. Large equipments and their use: Weighing machines : Raw material measurement used in proper weighing scale is very important for the quality product for the accurate quantity. Flour sifter : Flour sifter is an essential part of food safety system (HACCP). It will aerate the flour and other ingredients for getting better volume of finish products. Spiral dough mixture : Spiral dough mixture is a specially design for making large quantity of yeast dough. There are two models of mixtures available in the market. Most models have a single vertical mixing arm or hook. Another model machine is having two agitator arm which are mounted on vertically on circular poles .

8. Planetary cake mixture : Two types of mixture are available in the market: 1. Bench model 2. Floor model These mixture usually have three operating speeds and their mixing attachments, namely 1. Wire whip 2. Flat beater 3. Dough arm Dough divider :The dough divider machine divides the bulk dough into desire size. The dough density should be even otherwise the weight might change. Single pocket divider will be easier to use. Burn divider and rounder :Burn divider and rounder divides the dough's into many pieces at once and it then automatically rounded all of them, greatly speeding the makeup of the dough products.

9. Bread slicer :Gravity feed slicer are best suited to the small, wholesale and large retail bakeries where a great number of sliced breads are produced. All types of white and sweet bread can be sliced without wastage or damage. The cut slices come out at the output end. Dough sheeter : A dough sheeter rolls out portion of dough into sheets of uniform thickness. The machine consists of a canvas conveyer belt that feeds the dough through a pair of rollers.

10. Deck oven : There are single, double and three decked oven available in the market. Types of oven, the product trays or moulds are placed on the oven floor. Bread baked directly on the flour of the ovens and not in pans is often called hearth breads. Deck oven for baking breads are equipped with steam injectors. Rotary rack oven : A rack oven is a large oven into which entire racks full of sheet pans can be wheeled for baking. They are also equipped with steam injectors. Rotary rack ovens are excellent for large scale production. It can be fired with gas or electricity.

11. Refrigerator :To store the food items at right temperature. Sorbet machine :Designed to churn puree along with sweetening and other flavourings machines. Ice-cream machines :To prepare different variety of ice-cream.

12. Mixing Mixing is one of the most important steps in bread making. A dough is mixed to distribute as equitably as possible all the ingredients. The best way to accomplish this is to dissolve or suspend the ingredients in the water as this will ‘wet’ all the flour. The main purpose of mixing a dough is to make and develop the gluten . Gluten is not in flour. The flour contains proteins the majority of which when wetted, pulled, stretched and kneaded take the form of a substance called gluten . The secret of mixing is how long to continue the mixing for optimum gluten development and water absorption. Total water absorption is not obtained until the gluten has been fully developed. Mixing depends on the design of the arms in the mixer and their speed as well as well as absorption, formula and fermentation time used and the kind of bread desired. Temperature control is essential. Straight dough's should come out of the mixer at 77  - 80  F or 25  - 26  C and the sponge at 73  - 78  F or 23  -25  C irrespective of the size of the sponge.

13. When mixing a dough it will be noticed that the machine does not labour at first. In baking this is known as the ‘Pick up’ stage . As the machine continues mixing it will be noticed that the dough becomes more and more homogeneous. As the mixing continues, the gluten is being developed and the dough seems to start what is known as ‘drying up’. At this stage the dough still feels sticky adhering to the sides of mixing bowl and the mixing arm. Mixing is continued until the dough pulls away from the mixing bowls and arm, which stage is known as ‘clean up’. When this stage is reached, as a rule, the dough is thoroughly mixed and mixing should be stopped. Also strong flours require longer fermentation time and less yeast for the proper conditioning of the gluten . This strong flour gives the best results when it is used for the sponge dough method . Inversely, weak flours take shorter mixing time , more yeast, more salt, less fermentation time and are better adopted to the straight dough method . Over mixing breaks down the gluten structure, heats the dough and slows down fermentation. Under mixing makes a dough less elastic

14. MIXERS A bakery mixer is designed to produce bread dough or cake batter by bringing dry and liquid ingredients together to form a mass with optimum rheology and handling properties . By having a properly designed mixer, high-speed bakeries are able to send doughs or batters at the required throughput to the makeup stage so that the production line runs smoothly.

15. How does it work ? A bakery mixer is designed to perform the following actions: Incorporate dry and liquid ingredients Hydrate dry ingredients Develop gluten (bread systems) Aerate dough/batter Set proper dough/batter temperature through friction and mechanical action

16. TYPES Dough mixers This type is designed to promote intense motion where the dough gets pulled, sheared, compressed, kneaded, and folded by the action of rotor, arm or blades against vessel walls, pins or stators . Dough mixers markedly differ from those used in other process and food applications  (e.g. liquid agitated tanks), they mostly handle Newtonian liquid products of minimal variation in composition between production runs.

17. TYPES They are capable of handling extremely viscous materials (up to 1×106 centipoise) which exhibit non-Newtonian fluid behavior. Due to the presence of gluten-forming proteins, these doughs typically show a viscoelastic behavior which has a fluid-like (viscous) and solid-like (elastic) component

18. TYPES Batter mixers Batter mixers are designed to process fluid batters for the production of layer cakes, muffins, pound cakes and other sweet baked goods. This type of mixers is not intended to be as strong as dough mixers since their function is to aerate viscous and pumpable batters to a pre-set specific gravity

19. TYPES Adequate mixers must be designed to always keep the divider fully operational and utilized. Mixer installed capacity (pieces per min) and dough load to process determine the cycle time. Mixing time should be as close to that of the divider to eliminate waiting and idle times where  dough might stand for too long and becomes gassy. The following formula can be used to calculate the number of pieces of dough that a mixer can deliver:                                                      

20. DOUGH DIVIDING Dough dividing implies the transformation/portioning of bulk or large masses of dough into countable or single pieces of dough that can be better handled and/or manipulated throughout the production line . Dough pieces are divided volumetrically. This means, the bulk mass of dough is conveyed via a screw feeder. The rotating speed of the screw or dough pump determines the rate or mass flow of dough to be divided. The volumetric processing makes dough consistency and density vital factors for a accurate operation.

21. DOUGH DIVIDING The dough is cut or divided into single pieces either by: Filling a chamber or barrel with a bulk mass of dough, and then cutting off and pushing the excess (piston dividing) Forcing a bulk mass of dough through an orifice at a fixed rate, and cutting protruding pieces from the end at regular intervals (extrusion and knife dividing) 2

22. DOUGH DIVIDING The specific weight of the dough pieces are usually set 13–15% heavier than the finished product weight to compensate for : Fermentation  losses caused by yeast metabolism Baking losses due to evaporation of water and ethanol solutions Losses during cooling due to evaporation of water

23. DOUGH DIVIDING Dough dividing is essential for the production of yeast-leavened bakery products such as: Buns Rolls White  pan  bread Whole wheat pan bread

24. DOUGH DIVIDING Dough dividers intended for high-speed or large-scale production bakeries are equipped or fitted with automatic weight-checking mechanisms to check the dough at the beginning, middle, and end of each batch, or monitoring weight in a continuous fashion . The running speed of dough dividers can be set manually by a human-machine interface (HMI) or centrally pre-set, according to the production line speed.

25. DOUGH ROUNDING Dough rounding is the second step in the make-up stage after dough dividing. During rounding, the divided dough piece is shaped into a ball for easier handling, and in some cases, coated with dusting flour to prevent dough pickup in the equipment’s product-contact surfaces, e.g., belt conveyors. This step is between the  dough divider  and intermediate proofer.

26. DOUGH ROUNDING Dough rounding is an essential step in the production of yeast-leavened bakery products such as: Buns and rolls Pan breads Pizza This operation is sometimes carried out manually in small bakeshops, or mechanically in large-scale production bakeries.

27. SHEETING In baked goods production dough sheeting is the act of flattening a dough piece. The starting dough piece can be used for either  pan bread  or  laminated   products. Sheeting can be done mechanically using dedicated machines, or manually.  The most basic design for a dough sheeter consists of two stainless steel rollers between which the dough is passed for sheeting instead of rolling by hand with a rolling pin.

28. SHEETING In breakmaking bakeries, a sheeter consists of a series of gauge rolls (usually two sets) that gradually transform a rounded dough piece into a dough disk. The dough piece is then curled and molded into a cylinder- or loaf-type piece that suits pan dimensions for  final proofing .

29. SHEETING Dough sheeting for optimum crumb grain Dough sheeting modifies the original arrangement of polymeric gluten strands by extending or stretching them on a horizontal axis due to compression forces. Ideally , the dough piece is sheeted out as thin as required without tearing the dough, bursting gas cells, or damaging the gluten network, both key aspects for optimum gas retention during proofing and baking. 1

30. SHEETING Besides the obvious effect on dough shape, one key purpose of sheeting is to subdivide the gas cells incorporated and trapped in the dough during  mixing . Gas cells subdivision, provided proper emulsification, coalescence phenomena in the expanding dough is further limited so a finer crumb grained and blisterless product can be achieved in the baked product.

31. Dough Temperature Dough temperature is one of the most important things to watch if good bread is to be produce. The cold doughs take a longer fermentation time, an intermediate proof and proofing time but the bread produced from cold doughs are good and give excellent yield. Hot dough will absorb less water which means less yield of bread, and the dough and bread made from a hot dough will crust heavily. Dis -advantages of Hot Dough's Less yield Dough crusting Long proofing period Less volume Shorter ‘Shelf life’ Off taste Requires more time as especially Less appetizing appearance

32. Fermentation Fermentation is brought about by the action of minute forms of plant life which are called yeast . The growth rate of yeast plant is affected by its environments including temperature at which it is allowed to grow. At about 40  F, or about 5  C , the action of yeast practically ceases. The most favourable temperature for the action of yeast in bread dough's is between 75  F to 85  F or about 24  C to 30  C . But in order to ensure uniform results in the fermentation of dough's, it is necessary to hold the temperatures, and allow them to ferment in a place where the temperature is constant. The quantity of yeast has an influence on the rate of fermentation. It is poor economy to use too small an amount of yeast and to employ a long fermentation as this results in poor flavour. Generally, two per cent of bakers compressed yeast based on the weight of the flour, with a normal fermentation time, will produce a dough having normal tolerance which will yield good bread of excellent flavour.

33. During fermentation the enzymesof the yeast act on the starch and sugars to form carbon dioxide gas . If uniform results are to be obtained, it is imperative that proper temperature and humidity conditions be maintained in the fermentation room. Normal temperature for the fermentation room should be about 78  - 80  F or about 26  C and the humidity about 70 – 75%. Punching is done to equalize dough temperature, expel carbon dioxide and to introduce fresh air in the bread dough. The first punch is usually given at the end of one hour and thirty minutes to two hours. Over fermented dough's are inclined to become soft and sticky. Under fermented dough's do not bake out properly and the crumb is darkish and very close. Proofing is really the stage where the production of gas in the dough is at the final stage giving volume to the bread. Average proof box temperature is normally 95  -98  F or about 35  –36  C and the humidity is 80-83%.

34. Under proofing will produce bread of small volume. Excessive over proffing of bread will cause shrinkage and at times the bread may collapse in the oven. An unfermented , also known as young dough will not stand as much normal proofing as a properly fermented dough and it should be proofed less than normal, regardless of heat. Bread made for an over-fermented dough also known as old dough should be given full proof and if possible baked in a hot oven.

35. FERMENTATION ENCLOSURES In baking, fermentation enclosures, also known as proofers, are warm, humid spaces used to encourage yeast activity and dough rising, leading to a lighter, more flavorful final product . Fermentation enclosures, or proofers, are designed to maintain a warm, humid environment that is ideal for yeast fermentation. Yeast thrives in these conditions, producing carbon dioxide, which creates the bubbles that cause dough to rise.

36. FERMENTATION ENCLOSURES Importance of fermentation : Dough development: Fermentation helps develop the gluten structure, leading to a more extensible and airy dough. Flavor development: The fermentation process produces a variety of compounds that contribute to the unique flavors of baked goods. Improved texture: Proper fermentation results in a lighter, more airy crumb texture. Shelf life: Fermentation can also extend the shelf life of baked goods.

37. FERMENTATION ENCLOSURES How to use a proofer: Place the dough in the proofer, ensuring it's covered to prevent drying out. Maintain the desired temperature and humidity (typically between 70-115°F or 20-45°C). Monitor the dough's rise and adjust the proofing time accordingly. Alternative to proofing: a dough retarder is a refrigerator used to control the fermentation of yeast when proofing dough.

38. BREWING EQUIPMENT