YEAR OF NATIONAL RECONCILIATION

PUBLIC HIGHER TECHNOLOGICAL INSTITUTE: 'MANUEL'

AREVALO CACERES

SPECIALTY:

FOOD INDUSTRIES

DIDACTIC UNIT:
PROCESSES FOR GRAIN AND TUBER PRODUCTS

SEMESTRE:V

TEACHER: CALIXTO VARGAS

TEMA:INFORME DE ELABORACION DE PANES CROCANTES

(CARIOCA)

STUDENT:

2018
 REPORT ON GRAINS AND TUBERS PRODUCTS

INTRODUCTION

In this report, we will detail in a concrete manner all the steps that are
they have to carry out in the preparation of baking products, in this case preparation
of soft filled breads (carioca bread). During the process we will apply the good
practices using the corresponding materials and methods under the supervision of Eng.
Calixto Vargas.

[Link]:Elaboración de panes suaves embolsados

[Link]:

General:
Prepare crispy breads (Carioca bread) according to the
established legal controls

Specific:
Identify the quality of the raw material for this process
crispy soft loaves

Learn to use the inputs used during the process

of making crispy breads

Identify ways to prevent damage during the

process of making crispy breads

3. THEORETICAL FRAMEWORK:

INTRODUCTION.

The ingredients used in the bread-making process have been employed since
very ancient, even in the Stone Age a kind of cake made of water and wheat was prepared
mashed, which was very hard to digest. Little by little it was discovered that by mixing
a mass from the previous day with the initial, this cake became softer and began to lose
that grotesque shape it had. Thus begins the natural yeast thanks to what today
It is called sourdough. It was well into the 19th century that artificial yeast was discovered.
revolutionizing the concept of bakery.

The main component of the bread dough formulation is flour, which comes from
from the milling process of cereals, with wheat flour being the most important.

Definition of bread

Baking products include all types of bread with and without

fermentation, baked and unbaked, such as farmhouse bread, sandwich bread,
whole grain bread, special breads, among others (MINSA, 2010).

According to the Peruvian Technical Standard NTP 206.004 (INDECOPI, 1988), bread is the product
obtained by baking in trays, from a fermented dough made basically with
wheat flour, drinking water, salt, sugar, yeast, and lard, possibly having others
allowed ingredients and additives.

The main ingredients used in the production of par-baked bread are: flour,
water, salt, yeast, sourdough, bread improvers, and animal fats.

THE FLOUR: The characteristics of flour are a very important factor in the
obtaining a pre-cooked bread with a firm consistency. Weak flours cause
that in this type of bread, once the precooking is finished, it wrinkles and collapses.
In this case, it has to do with the protein content in the flour, that is, the amount.
of gluten. The greater the proportion of gluten in the flour, the better it will coagulate.
bread and more firm and resistant will be to sinking.

The enzymatic activity of this flour is another important factor for a good
quality. Its greater or lesser enzymatic activity will allow the formation of the crumb
during cooking before or after, that is, if there is a high activity (wheat
sprouted) will take longer to reach consistency. Thus, it is very
important that the Drop Number (determination of enzymatic activity in the
flour) is not less than 300 seconds nor more than 350. This will allow for the
In the first phase of baking, the piece of bread acquires consistency sooner.
take out of the oven even without having started to brown, in this case it will therefore have
a maximum humidity that will enable a better quality of the product. Throughout
Hello, we must take these considerations very seriously.

WATER. The water we use must be safe to drink, so it must meet the
previous properties and having a good sanitary condition. Water constitutes a
a third part of the amount of flour that is going to be used, although this is a
estimated calculation the final amount to be added will depend on a series of
circumstances, such as the type of consistency we want to achieve. Thus, if
we add little water, the dough develops poorly in the oven, while an excess
it makes the dough sticky and loosens the bread, leaving it flattened.
 Functions of water in bread making.

Water plays a fundamental role in the formation of the mass, in fermentation,

the final flavor and freshness of the bread. In the formation of the dough, since in it
dissolve all the ingredients, allowing for their complete incorporation.
It also hydrates the starches, which together with the gluten result in a dough.
plastic and elastic.

Water controls:

The temperature of the dough, for this reason water is often added in the form of
ice flakes, to achieve the desired temperature. The temperature of the water at
the addition will be calculated with the following formula:

Flour Temp. + Water Temp. + Local Temp. = Fixed Factor

The value of this fixed factor will be obtained experimentally. It will initially be taken
a value of 75.

In fermentation, to dissolve the yeast and get it to start acting.

Water makes the properties of plasticity and extensibility of the mass feasible.
so that it can rise due to the action of the gas produced in the fermentation.

The flavor and freshness: the presence of water enables porosity and good
flavor of bread. A dough with little water would produce a dry and brittle product. The
Hydrated starches become more digestible when baked. The crust of the bread
smoother and softer due to the effects of water. The humidity of the bread gives it this freshness
characteristic, as the loss of water makes it old and heavy.

SALT. It is a natural product found in the form of crystals (salt of

mine) or in seawater (sea salt). It is made up of chlorine and sodium and is
antiseptic.

Regardless of its contribution to the flavor of bread, salt plays other roles.
papers of great importance in its preparation. It acts as a regulator of the process
of fermentation, simultaneously improves the plasticity of the dough, increasing the
hydration capacity of the flour and consequently, the yield of the
baking. It also promotes the coloration and fineness of the crust, having as
counterpart the increase in hygroscopicity. In addition, the salt restricts the
activity of acid-producing bacteria and controls the action of yeast,
regulating the consumption of sugars and thereby giving a better crust.

The proportion of salt to add will be at most 2% on a dry matter basis.

the proportion of salt is recommended to be higher with freshly ground flours or
weak.
YEAST. First of all, we must distinguish between biological yeast and
gasifying, the first ones carry out the biological fermentation of the product,
it transforms sugars into CO2, ethyl alcohol, and energy, as well as decomposing
the fermentable complex sugars into simpler ones through mediation of the
Zymase enzyme. The gasifiers are products used to provoke the
swelling or elevation of the mass without altering any component of the
flour, in the way it occurs in biology. They are alkaline compounds such as the
bicarbonato amónico, sódico, etc.

The main functions of yeast are as follows:

Production of substances that assist in the modification of structures of

the proteins of the flour (gluten), so that the cell walls are
capable of retaining the produced carbon dioxide. The reduction of the
fermentation results in the loss of some elasticity of the
mass. Plasticity is likely an acquired property like
consequence of the breaking of intermolecular bonds, maintaining the
longitudinal configuration of gluten links.

2) Development of part of the aroma and flavor, through the production of alcohols,
typical baking aromas, ethers, acetic acid, butyric acid, and lactic acid

3) Perhaps the most important function is the increase of the mass, due to the
production of CO2 (carbon dioxide) and ethyl alcohol in the form of ethane
(2C2H5OH), through the transformation of glucose.

C5H12O5 + 6 O2----> 6 CO2 + 6 H2O + ENERGÍA

Yeast can be found in the market in the following formats:

Active dry yeast: In granulated form.

Instant dry yeast.

Pressed or paste yeast.

Liquid yeast.

Baking improvers. They are agents that are added in small quantities.
as ingredients of bread, with the intention of improving the initial characteristics
of the flour, mainly referring to the color, enzyme content and
plastic characteristics of the mass.

The complete improving agent that the baker usually uses is composed of
diacetyl tartaric (E-472e), ascorbic acid (E-300) and α-amylase enzymes. These
mixtures of active ingredients provide a great oven spring of the bread.
When the rise of the bread during the baking phase is excessive, there is a risk of
that the bread wrinkles during cooling. Therefore, the use of
 improving sayings, achieving volume during fermentation and not by the
expansion of the bread during shaping.

FATS. The Spanish Food Code defines them as those products

whose major component is fat of animal or vegetable origin, or their
mixtures, which have as main constituents the glycerides of the acids
fats.

Using some fat is not a basic rule, but we can observe that
as the bread is much more flexible and tender, which helps us to lengthen the
duration of bread once baked, one of the main problems of bread
partially cooked as it becomes hard shortly after cooking. For this raw material
what is added during kneading in small quantities is low-fat margarines
melting point

PHYSICAL CHEMICAL CRITERIA OF BREAD

4. RAW MATERIALS AND SUPPLIES IN THE PREPARATION OF BREADS
CRUNCHY (carioca)

Raw material and supplies Percentage Quantity (g)

baker
Wheat flour 100% 3000
Mejorador 0.5% 15
Water 60% 1800
Sugar 1.5% 45
Salt 2% 60
Fresh yeast 3% 90
Manteca 1.5% 45

5. MATERIALS, EQUIPMENT, AND INSTRUMENTS

Materials, equipment, and instruments Quantity

Vol. 3
Baking palettes 2
Rollers 4
Spoon 1
Jars 2
Large bags 4
Teams
Balance 1
Freezer 1
Mixer - kneader 1
Dough cutter – doser 1
Oven 1
Steel tables 1
 PRODUCTION SYSTEM

ENTRY Indirect materials:

Electricity
RAW MATERIAL AND SUPPLIES Spare parts
Combustible
EXIT

Wheat flour PROCESS:

Enhancer S
PREPARATION OF CRISPY BREADS (CARIOCA BREAD)
Water E Product: breads
Sugar PLANT: Workshop of WORK: WORKERS crisps (Carioca bread)
Salt panification Ing. – inspector: Calixto
Fresh yeast Vargas
Lard Est. – apprentice:

C.E C.S
C.P
Control a the
entry (C.E)
CONTROL
Control during
the process (C.P)
Valor agregado
Control of the
output (C.S)
6. FLOWCHART FOR BREAD MAKING
Soft fillings

RECEPTION OF RAW MATERIALS AND SUPPLIES

HEAVY ON INGREDIENTS

10 – 12 minutes at less than 27°C

Mixing and kneading of the ingredients

BOLTED AND SHAPED OF THE DOUGH

DIVISION AND WEIGHING OF THE MASS

MASS FERMENTATION
10-15 min Ambient Temperature

MOULDING

2nd FRAGMENTATION

INTERMEDIATE FERMENTATION
2 - 3 hours T° 30 C

CUTOFF FROM THE DOUGH

FINAL FERMENTATION
BAKED
200° C for 15 minutes

BREAD COOLING

PACKAGING

ALMACEADO
7. PROCEDURE:

RECEPTION OF RAW MATERIAL AND SUPPLIES

Reception is the first step to be able to carry out and develop a product where
he will do a brief quality check of the raw materials and supplies of which
will be used during the preparation of crunchy breads (Carioca); If missing
only one of these, that bread could not be made. They are flour, water,
yeast and salt. These ingredients are responsible for the characteristics of
appearance, texture, and flavor of the bread.

WEIGHT OF THE INGREDIENTS

The weighing of the ingredients was done according to the quantity.

of percentages indicated taking into account the percentage of the dough in the flour;
the calculated ingredients must be precise as an incorrect calculation could lead to
I achieve undesirable alterations to the product to be developed.

Mixing and Kneading (Formation of the Dough)

During the kneading process, various effects occur that subsequently

they will characterize the bread:

Homogenization: first, all the dry input is mixed, then added

water and yeast; finally the fat is added causing a change in
the natural state of raw materials transforming all the
ingredients into a single body called dough, cleaning all the
sides of the mixer. After effective mixing for 10-12 minutes, you
proceed to kneading (more mixing speed) 7-8 min. Until it
develop all the rheological properties of the dough (elastic mass, soft,
etc). The final temperature of the mass must not exceed 27 °C.

A dough is well kneaded when:

It is held in a single body to the arms of the kneader.

Stretching a portion of it is enough.
elasticity to form a thin film of dough.
White pores are observed that indicate a good
oxygenation.
As a result of kneading, we obtain a fine and elastic dough.

REST.
Once the dough is kneaded, it is removed from the mixer bowl and placed
on a previously greased steel table the surface; it is left to rest
the entire mass should be kneaded for an average of 10 minutes, as long as it is covered.
WEIGHT DIVISION OF MASS
The division is carried out in two stages:
Division and weighing of a large mass.
Volumetric subdivision later.

The rounded dough was left resting on the table for 10 minutes.
40 - 45 g each piece, as longer times will cause an increase in the
temperature, fermentation principle, and high acidity, causing the doughs
they are excessively sticky, with variable weights, uneven bark color
and absence of the characteristic flavor of bread.

MOLDING

Carioque bread, after resting, was rolled out with a rolling pin (stick of
broom) achieving an elongated shape of 15-20 cm long by 7-8 cm of
wide. Then it rolled up, subsequently placing itself in the trays always the
final part of the roll down avoiding deformation during fermentation
What will happen in 2-3 hours.

FERMENTATION
The fermentation was carried out for 2-3 hours in the fermentation chamber at a
temperature of 30 – 32 °C.
In any bread fermentation, three stages must occur.
fundamentals:
First stage: It is a very fast fermentation and lasts relatively little.
time. It starts in the mixer shortly after adding the yeast, already
that the S. cerevisiae cells begin the metabolism of the first
free sugars present in the flour.

• Second stage: It is the longest stage and it is considered that the enzymes ...
amylase, B-amylase, glucosidase, and aminoglucosidase act on the
starch.
At this stage is where the largest amount of fermentation occurs.
alcoholic alongside which, although to a lesser extent, other types also occur
complementary fermentations such as butyric, lactic, or acetic.
time can be understood from the rest of the pieces to fermentation
in chamber or cellar, these times being quite long.

Third stage: It is a fermentation that is usually short in duration, although

it has a lot to do with the size of the piece, since it is completed when in
the interior of the piece reaches 55 °C because at that temperature, the
cells
 of yeast, they die. Thus, we can say that this stage occurs
finally, in the oven.

DOUGH CUTTING.
Once the fermentation time has passed, two diagonal cuts are made.
perpendiculars on the top of the fermented dough with the help of a
knife; always preventing the fresh mold from deforming.

BAKED.
At this stage, the dough pieces undergo a series of transformations of a type
physical, chemical and biological, so that in the end we obtain a product
edible and with good organoleptic and nutritional characteristics. The
breads obtained were baked at 220 °C for 5 min. and then reduced to 180 °C for 10
After 10 min. of the total 15, constant steam will be supplied to avoid
let it burn.

COOLING OF BREAD.
It is an essential stage for the subsequent packaging because if we packaged with the
a hot pan would form a film of water on the surface of the bread due to
from the evaporation of its constitutive water, which favors growth
microbial.

PACKAGING - STORAGE.
After cooling, it was packaged in cardboard bags for later consumption.

[Link]

Weight of the mixture Units produced Performance

initial
6900 g unit of 45 g 100 %
approx. per unit

[Link]

. It was identified and determined that the raw material and inputs used
during the process they were in good condition so
contributed to efficient preparations

. They learned to use the inputs according to the parameters of the NTP.
206.004 not primarily exceeding in mass enhancers.
 . The most accurate ways to avoid material damage were identified with
the product for which the ingredients were mixed according to
its chemical and technological fusion that acts in the production of breads
soft

[Link]

It is recommended to use the inputs according to the timing and characteristics.

from the raw materials (wheat flour) such as water, enhancers, yeast, sugar.
To ensure our products are delivered with ideal characteristics for a
fast fermentation in the dough requires the use of yeast at 2 - 3 %.
Do not use enhancers excessively or exceed the established margins by the
standards, as it alters the final quality of the product
For the preparation of crunchy bread, the baking temperature must be
exceed 180°C - 220°C and must be a constant intake of steam to prevent
the product burns. so that it has the characteristics proper to bread
crispy.

[Link]

Calvel, R 1980. La panadería Moderna. Editorial Americalce-España.

J. Mesas, M. Alegre. (2002). "Bread and Its Process of

Preparation. Sci. Technol. Food. Vol. 3. No. 5, pp. 307-313

Medina C. (2015). "Partial Substitution of Wheat Flour with Flour

From Oats for Bread Making. Polytechnic University of
Valencia. Valencia - Spain

NTP 206.004

Tavara F. (2015). "Verification of Sanitary Standard RM No. 1020 -

2010/Minsa In The Production Of Commercially Marketed Sliced Bread
City of Sullana. Piura - Peru