FROZEN BAKERY PRODUCTS (food technology)

FROZEN BAKERY PRODUCTS (food technology)

1. FROZEN BAKERY PRODUCTS

2. INTRODUCTION
•Frozen dough products, with widely known frozen dough products such as
refrigerated cookies and brownies, sweet rolls, biscuits, dinner rolls, and pizza,
sold as if freshly baked to the consumer.

3. FROZEN BAKERY PRODUCTS
•FROZEN BREAD
•FROZEN MUFFINS
•FROZEN PIZZA DOUGH
•FROZEN COOKIES
•FROZEN DOUGHNUTS
•FROZEN BREAD ROLLS

4. HACCP(HAZARD ANALYSIS AND CRITICAL
CONTROL POINTS)
•Hazard analysis and critical control points (HACCP) is a systematic preventive
approach to food safety from biological, chemical, and physical hazards in
production processes. Here’s a basic outline tailored to the production of frozen
bakery products, such as breads, cakes, pastries, and similar items.

5. 1.HAZARD ANALYSIS
•Biological hazards: Includes bacteria like salmonella or listeria, which can be
present in raw ingredients (E.G., Eggs, flour).
•Chemical hazards:Pesticide residues, allergens (gluten, nuts, dairy), and
improper use of food additives.
•Physical hazards: Foreign objects like metal fragments, glass shards, or plastic
pieces that could contaminate the product during processing.

6. 2. IDENTIFYING CRITICAL CONTROL
POINT(CCP)
•CCP1: raw material receiving –checking the quality and safety of ingredients (e.G., Flour, eggs,
flavorings).
•Ccp2: mixing and blending –ensuring additives and allergens are correctly handled and
measured.
•Ccp3: baking –reaching the appropriate internal temperature to reduce microbial hazards.
•Ccp4: quick freezing –rapidly reducing the temperature to prevent bacterial growth.
•Ccp5: packaging –proper sealing and protection of the product to avoid contamination.
•Ccp6: storage and distribution –maintaining temperature controls to prevent thawing and
refreezing.

7. 3. Establish critical limits for each CCP:
For example, ensure the internal temperature of bakery products reaches a
sufficient level during baking (e.G., 190°F/88°C for breads) to kill harmful
bacteria, and that frozen products are maintained at -18°C or below during storage
and transport.
4.Establish monitoring procedures: Implement protocols to routinely check
temperatures, cooking times, and other critical parameters at each CCP
5.Establish corrective actions: Define actions to be taken when monitoring
shows that a CCP is not within the established limits. For example, if a batch
fails to reach the correct internal temperature during baking, it may need to be
rebakedor discarded.

8. 6. Establish verification procedures:regularlyreview and verify the
effectiveness of the haccpplan. This could include scheduled testing, third-
party audits, or cross-checks of critical equipment like freezers and ovens.
7. Establish record-keeping and documentation procedures:keepdetailed
records of CCP monitoring, corrective actions taken, verification activities, and
staff training. Implementing a HACCP plan for frozen bakery products ensures
a proactive approach to food safety, addressing potential hazards before they
cause harm. This plan should be tailored to specific products and production
processes, taking into account local regulatory requirements and industry best
practices.

9. FROZEN BREAD ROLLS
Frozen bread rolls are a popular bakery item that
offers convenience and freshness. These rolls are
typically made from yeast-leavened dough and
come in various shapes and sizes.
They're a versatile staple that can be thawed,
proofed, and baked to perfection, creating a
warm, fluffy addition to any meal

10. INGREDIENTS
THE BASIC INGREDIENTS FOR FROZEN BREAD ROLLS INCLUDE
•FLOUR
•WATER
•YEAST
•SUGAR
•SALT
•FAT (LIKE BUTTER OR OIL)
•ADDITIONAL INGREDIENTS SUCH AS MILK, EGGS, OR FLAVORINGS

11. PRODUCTION PROCESS
•Mixing: the ingredients are mixed together to form a dough.
•Kneading: the dough is kneaded to develop gluten, which gives the bread its
structure.
•Proofing: the dough is allowed to rise, which is crucial for developing flavor and
texture.
•Shaping: the dough is shaped into rolls of desired sizes and shapes.
•Baking:the rolls are partially baked to set their structure but not fully cooked.
•Freezing: the partially baked rolls are quickly frozen to preserve freshness.

12. •Packaging: Frozen bread rolls are typically packaged in airtight packaging to
prevent freezer burn and maintain freshness. They may be sold in bulk packs or
individually wrapped for convenience.
•Storage and Shelf Life:Frozen bread rolls should be stored in the freezer at 0°F
(-18°C) or below. When properly stored, they can last for several months.
•Preparation:To prepare frozen bread rolls, they are thawed and then baked in a
preheated oven according to the instructions provided on the packaging. This
allows the rolls to finish baking and develop a golden crust.
•Variations:Frozen bread rolls come in various types, including dinner rolls,
sandwich rolls, and specialty rolls with added ingredients like herbs, cheese, or
seeds.
•Usage:Frozen bread rolls are convenient for home use as they can be baked
fresh whenever needed. They are also used in food service settings such as
restaurants, cafeterias, and catering businesses.

13. PREPRATIONOF FROZEN BREAD ROLLS
•Thawing: Remove the frozen bread rolls from the freezer and let them thaw at
room temperature for about 1-2 hours, or until they are soft and pliable. You can
also thaw them in the refrigerator overnight for a slower thawing process.
•Proofing (optional):If the bread rolls are not pre-proofed (partially risen before
freezing), you may need to proof them after thawing. Place the rolls on a baking
sheet, cover them with a clean cloth, and let them proof in a warm, draft-free
place for about 30-60 minutes, or until they have doubled in size.

14. •Baking: Preheat your oven to the temperature specified on the packaging
or in the recipe. Place the thawed and, if necessary, proofed bread rolls on a
baking sheet lined with parchment paper, leaving some space between them
for expansion. Bake in the preheated oven according to the instructions,
usually around 10-20 minutes, or until they are golden brown and sound
hollow when tapped on the bottom.
•Cooling:Remove the baked bread rolls from the oven and let them cool on
a wire rack for a few minutes before serving.
•Optional Glazing:If desired, you can brush the warm bread rolls with
melted butter or a simple sugar glaze for added flavor and shine.

15. •Par-Baking:Products are partially baked before freezing, allowing them to
be quickly finished in the oven before serving.
•Freeze-Drying:Some products, like certain types of bread, are freeze-dried to
remove moisture and prolong shelf life.
•Individually Quick Frozen (IQF): Products are frozen individually rather
than in a batch, preventing them from sticking together and allowing for easy
portioning.

16. •Cooling Conveyor:After baking, products are rapidly cooled to prevent over-
baking and maintain freshness.
•Packaging Design: Packaging materials are chosen to protect products from
freezer burn and maintain quality during storage.
These techniques help ensure that frozen bakery products maintain their quality,
taste, and texture when they are thawed and prepared for consumption.

17. TECHNIQUES
•Several techniques are used for frozen bakery products to ensure they maintain
quality, texture, and flavor after freezing. Some common techniques include
1.Flash freezing: products are quickly frozen at very low temperatures to
minimize ice crystal formation, which can affect texture and quality
2.Modified atmosphere packaging (MAP): packaging is adjusted to reduce
oxygen levels and maintain product freshness during storage.
3.Vacuum packaging: air is removed from the packaging to prevent freezer burn
and extend shelf life.

18. QUALITY PARAMETERS
Checking the quality of frozen bread rolls involves several parameters to ensure
that they meet expected standards for flavor, texture, appearance, and safety.
1.Visual inspection:
•Appearance:Check for uniform size and shape. The surface should be smooth
without excessive cracks or odd shapes.
•Color:Look for an even color appropriate to the type of roll. There should be no
signs of freezer burn, which appears as grayish-brown leathery spots.

19. 2.Texture:
•Consistency:After baking, the rolls should have a uniform texture. The crust
should be crisp, and the crumb (interior) should be soft and airy.
•Elasticity: The bread should spring back when pressed lightly. If it remains
compressed, it might be too dense or underproofedbefore freezing.
3.Taste and Aroma:
•Flavor: The rolls should taste fresh and have the characteristic flavor of the bread
type without any off-flavors.
•Odor: Smell the rolls both before and after baking. There should be no unpleasant
odors. A yeasty, bakery-like smell is typical and desirable.

20. 4.Thawing and Baking Performance:
•Thawing: Note how well the rolls thaw. They should not become soggy or
lose shape.
•Baking: Observe how the rolls bake. They should rise properly and not
collapse or explode. The crust should develop a nice golden color.
5.Packaging Integrity:
•Seal: Ensure the packaging is intact with no tears or holes. A compromised
package can lead to freezer burn and dehydration.
•Label Information: Check for clear labeling including ingredients, baking
instructions, expiration date, and storage guidelines.

21. 6.Safety and Compliance:
•Hygiene: Ensure that the production and packaging environments follow
food safety and hygiene standards.
•Allergen Information: Verify that all potential allergens are clearly stated on
the packaging.
•Nutritional Information: Review the nutritional content, especially if
dietary restrictions are a concern.
7.Freezer Burn and Ice Crystals:
Examine the surface of the bread rolls for signs of freezer burn and check for
excessive ice crystals inside the packaging, which can indicate that the product
has been stored for too long or has thawed and refrozen.
These factors, you can effectively assess the quality of frozen bread rolls. It’s
important to follow the manufacturer's recommendations for storage and
preparation to ensure the best quality and taste.

22. BLAST FREEZING
•One commonly used technique for producing
frozen bakery products is blast freezing.
•This method is crucial for maintaining the quality,
texture, and flavor of baked goods once they are
prepared and before they are consumed.

23. HOW BLAST FREEZING WORKS
•Quick freezing: Blast freezing rapidly
brings the temperature of freshly baked
or prepared bakery products down to -
18°C (0°F) or lower. This speed is key
because it quickly passes through the
critical temperature range (from +5°C
to -5°C), where ice crystals form within
the product.

24. •Small Ice Crystals: The rapid cooling forms smaller ice crystals, which are
less damaging to the cellular structure of the bakery items. Large ice crystals,
which can form in slower freezing methods, puncture cells and cause
moisture loss, resulting in a dry texture upon thawing and reheating.
•Preservation of Quality: By minimizing ice crystal formation and
structural damage, blast freezing preserves the moisture content, texture,
and flavor of the bakery products. This means that once the product is
thawed and reheated, it retains much of its original freshness and appeal.

25. APPLICATIONS
Blast freezing is used for a wide range of bakery products, including:
•Breads and rolls: Ensures that the texture and crust retain their quality.
•Cakes and pastries: Preserves the moisture and structural integrity, preventing
the sogginess that could occur with slower freezing.
•Pies and dough: Keeps the fat from separating from the dough, ensuring that the
baked product has a consistent texture.

26. BENEFITS
•Extended shelf life: allows bakery products to be stored for extended periods
without significant loss of quality.
•Convenience: products can be prepared in advance, frozen, and quickly brought
to sale or served condition with minimal additional preparation.
•Reduced waste: products are preserved longer, reducing the need to discard
unsold fresh goods.
Blast freezing is thus a pivotal technique in the frozen food industry, helping
manufacturers offer high-quality, convenient bakery products that closely mimic
the freshness of just-baked goods.

27. CONCLUSIONS
This is attributed to the additives ability to alter ice crystallization and
recrystallization characteristics in frozen dough. Knowledge on development of ice
crystallization and recrystallization during freezing and frozen storage,
respectively, is useful to enable optimization of freezing conditions and reduction
in temperature fluctuations to maintain yeast viability and frozen dough quality.

28. THANK YOU!