Contents Preface 1 Introduction 1.1 Vocational qualifications 2 Background to the biscuit industry 2.1 What are biscuits? 2.2 How are biscuits made? 2.3 2.4 2.5 Ingredient storage areas 2.6 How a factory is arranged What your company requires from the factory Your contribution when working with ingredients 3 Hygiene and safety aspects 3.1 Safety of food products 3.2 Sources of contamination 3.2.1 People 3.2.2 Emptying containers 3.2.3 Small items of equipment 3.2.4 Plant machinery 3.2.5 3.3.1 Floors 3.3.2 Machine guards 3.3.3 Electrical connections 3.3.4 Strain injuries 3.3.5 Dust 3.3.6 Building maintenance Buildings and general factory areas 3.3 Safety of people 4 Wheat flour and other cereals 4.1 Introduction 4.2 Wheat flour ix 1 2 8 8 8 8 10 10 11 12 13 13 13 13 14 14 14 15 15 16 vi Biscuit, cookie and cracker manufacturing manuals 4.2.1 Types of wheat flour 4.2.2 Uses and functions of wheat flours for biscuits 4.2.3 Common dough and baking problems related to flour quality 4.2.4 Delivery and quality testing of flour 4.2.5 Storage of flour 4.2.6 Handling of flour 4.3 Oats 4.4 Rye flour 4.5 Starches 4.6 Soyaflour 5 Sugars and syrups 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 Types of crystalline sugars 5.1.1 Sucrose, ‘sugar’ 5.1.2 Lower sugars Relative sweetness Types of Syrup 5.3.1 Syrups based on sucrose 5.3.2 Syrups derived from starch 5.3.3 Other syrups Uses and functions of sugars and syrups 5.4.1 Uses in biscuit doughs 5.4.2 Uses in biscuit filling creams 5.4.3 Uses in jams and jellies 5.4.4 Use in marshmallow 5.4.5 Uses in chocolate 5.4.6 Function of sugars in biscuits Importance of sucrose particle size Delivery and quality testing of sugars and syrups 5.6.1 Crystal sugars 5.6.2 Syrups Storage and handling of sugars and syrups 5.7.1 Crystal sugars in bulk 5.7.2 Crystal sugars in bags 5.7.3 syrups Other sweeteners 6 Fats, oils and butter 6.1 Fats and oils 16 20 20 22 23 24 26 27 27 28 29 29 29 29 30 30 30 30 31 31 31 32 32 32 32 32 33 34 34 35 35 35 36 36 37 30 38 Contents vii 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 Butter and butter oil Margarine Rancidity Bulk handling of fats Plasticised and boxed fat Sandwich cream fats Spray oil fats Use of emulsifiers and antioxidants 7 Dairy products 7.1 Milk 7.2 7.3 Skimmed milk powder, SMP 7.4 Evaporated milks 7.5 Whey powder 7.6 Cheese and cheese powder 7.7 Butter and butter oil 7.8 7.9 Eggs Full cream milk powder, FCMF' Use of milk products in biscuits 8 Dried fruit and nuts 8.1 Dried grapes 8.1.1 Currants 8.1.2 Thompson seedless raisins and sultanas Other dried fruits used in biscuits 8.2.1 Dates 8.2.2 Glack cherries 8.2.3 Crystallised or candied ginger 8.2.4 Crystallised or candied peel 8.2.5 Fruit pastes and syrups 8.3.1 Almonda 8.3.2 Brazils 8.3.3 Cashews 8.3.4 Coconut 8.3.5 Hazelnuts 8.3.6 Peanuts 8.3.7 Walnuts and pecans 8.2 8.3 Nuts 38 39 40 41 42 43 44 44 46 46 46 47 48 48 48 49 49 50 52 53 53 54 55 55 55 55 56 57 57 57 57 57 58 58 58 59 9 Yeast 60 viii Biscuit, cookie and cracker manufacturing manuals 10 Enzymes 10.1 Safety aspects of handling proteinase enzymes 11 Flavours and spices 1 1.1 Introduction 11.2 11.3 Spices and herbs 11.4 Essential oils 11.5 Oleo resins 1 1.6 Synthetic flavours-GRAS 11.7 Other flavouring substances 11.8 1 1.9 Flavouring of biscuits 11.10 Flavours applied after baking 1 1.1 1 Flavours in creams and jams 1 1.12 Flavour enhancers 11.13 Storage and critical quality points Sources and types of flavour Form of the flavouring material 12 Chemicals 12.1 Salt, sodium chloride 12.2 12.3 12.4 Acid salts 12.5 Ammonium bicarbonate, ‘Vol’ 12.6 Fruit acids 12.7 Sodium metabisulphite, ‘Natron’ 12.8 Emulsifiers Baking soda, sodium bicarbonate, ‘soda’ Acid salts used as baking powders 13 Chocolate and cocoa 13.1 Types of chocolate 13.2 13.3 13.4 Chocolate flavoured coatings 13.5 Cocoa Supply and storage of chocolate Chocolate drops, chips and chunks Useful reading and additional study Index 62 63 64 64 64 65 65 65 65 66 66 66 67 68 69 67. 70 70 71 71 71 72 73 73 74 75 75 75 76 77 77 79 80