Bread Baking Process Research Articles

Comparative Analysis of Different Burner Concepts in a Locally Manufactured Bread-Baking Oven

The supply and control of heat within an oven with minimal loss is an integral process in optimizing the bread-baking process. Research over the years reports on measures to control heat, however, there is limited data on optimizing burner designs for efficient heat supply. Challenged with enhancing the functionality of a bread baking oven made locally, three different burner concepts (i.e., U, H and Rectangular shaped) were designed, fabricated and evaluated in a locally manufactured bread baking oven. The study investigated the three burner configurations to enhance the locally manufactured ovens' environmental sustainability, cost-effectiveness, and efficiency. The study also assessed each burner design concept's performance in relation to heat distribution, fuel consumption, and emissions through thorough experimentation and analysis. Thermocouples were used to determine the temperature differences within the oven and outside the oven walls to verify heat losses. The results showed that the concept burner design can be used to bake bread with good quality parameters like colour, texture and taste within efficient baking time. Computational Fluid Dynamic (CFD) analysis performed on the proposed burner design concepts in relation to heat flow show that continuous flow of heat was assured during baking. Also, simulation performed on the baking trays show an acceptable stress and strain levels as well as favorable factor of safety, indicating that the designs proposed is suitable for the purpose. Data analysis performed on the heat generated within the oven chamber considering the lower and upper trays for all the burners evaluated can be ranked in terms of percentage as RB > HB > UB (41.39% > 30.72% > 27.89%). Based on the study conducted, the authors can suggest the best design concept for heat generation in locally manufactured ovens should be rectangular-shaped.

Baking-inspired pore regulation strategy towards a hierarchically porous carbon for ultra-high efficiency cationic/anionic dyes adsorption

Converting waste resource into porous carbon toward contaminant capturing is a crucial strategy for realizing “treating waste with waste”. Inspired by bread baking process, the soybean meal activated carbon (SAC) with multimodal pore structures was developed via thermally remodeling the pores of waste soybean meal. The obtained SAC-3-800 has ultra-high specific surface area (3536.952 m2/g), as well as a hierarchically porous structure. SAC-3-800 exhibits extremely high adsorption capacity for methylene blue (MB) (3015.59 mg/g), methyl orange (MO) (6486.30 mg/g), and mixed dyes (8475.09 mg/g). The hierarchically porous structure enabled fast adsorption kinetics of SAC-3-800 for MB and MO (∼30 min). Additionally, SAC-3-800 shows excellent dynamic adsorption and regeneration performance, exhibiting great potential for industrial applications. This work showcases a feasible method for synthesizing hierarchically porous carbon with outstanding adsorption performance that can simultaneously achieve efficient treatment of dye-wastewater and value-added utilization of waste resources.

Flatbread baking process under time-varying input power in a home-scale electric oven: 3D CFD simulation with experimental validation

This study investigates the flatbread baking process in a home-scale electric oven by developing a three-dimensional transient numerical model using the finite volume method along with the discrete ordinates (DO) model, evaporation–condensation mechanism, and realizable k-ε model for the turbulent regime through the oven chamber. The validity of the proposed numerical model has been examined through a comparison with experimental data provided in this study, considering both scenarios with and without bread in the oven, where good agreement is observed between the numerical and experimental findings. Using the validated model, a qualitative and quantitative analysis is performed to study the flatbread baking process, focusing on temperature distribution within the oven and the bread as well as the degree of starch gelatinization during the baking process. The consideration of input power patterns is crucial in terms of both energy consumption and bread quality, making it imperative for electric oven designers. Consequently, under a fixed energy consumption of the oven, various time-varying input powers are employed to assess the bread baking process. For this purpose, six different scenarios are designed including constant elements power, linear/stepwise increase/decrease in elements power, and ON/OFF modes with constant power. The results demonstrate that employing time-varying input power profiles characterized by linear and stepwise decrease yields superior performance to control the baking process and quality of bread. However, preheating the oven prior to dough baking could potentially mitigate the impact of the input power profile type on the resulting final product.

Comparative study of different bread baking methods: Combined ohmic – infrared, ohmic – conventional, infrared – conventional, infrared, and conventional heating

Developing bakery techniques is essential to improve the qualitative and quantitative parameters of the bread baking process. In this study, the influence of different baking methods was evaluated on baking kinetics, energy consumption, mechanical properties, volume expansion, and sensory parameters of the bread. The results showed that ohmic-conventional method increased the baking time compared with conventional baking. The baking time of the combined infrared–conventional was 63.0–73.7% lower than the conventional method. The maximum values of specific energy consumption and volume expansion were found in the combined ohmic-conventional method. The specific volume expansion, firmness, and shearing force of the baked samples under infrared-conventional conditions were higher than the infrared and infrared-ohmic conditions. The maximum energy efficiency was obtained using the oven-infrared method. The sensory evaluation indicated that the baked samples in the infrared-conventional method had higher scores of taste and flavor than the other baking methods (p < 0.05). Future studies to optimize the baking parameters on bread quality are recommended for improved results.

Comparative Study on Rheological Properties of Wheat Flour Types for Industrial Usage

&lt;span lang="EN-US"&gt;Wheat, &lt;em&gt;Triticum aestivum&lt;/em&gt; is one of the grains consumed worldwide as a staple food used in a variety of processed commodities. &lt;/span&gt;&lt;span lang="IN"&gt;The r&lt;/span&gt;&lt;span lang="EN-US"&gt;heological properties of the raw commodity will define the end product’s characteristics, whether it is of high quality or not. Moreover, the processes of, e.g., grinding, crushing, etc., of grain will also determine the flour’s content, which will further go on for other processes and be delivered to the consumer in the end product. &lt;/span&gt;&lt;span lang="IN"&gt;To that end&lt;/span&gt;&lt;span lang="EN-US"&gt;, the properties and effects of different wheat flour contents were analyzed for different types of flour 550, 1050 and whole grain flour available in Germany. These samples were analyzed to select the best-suited commodity for industrial purposes. Falling number, gluten percentage, starch content, viscosity and farinograph were determined for flour &lt;/span&gt;&lt;span lang="IN"&gt;during&lt;/span&gt;&lt;span lang="EN-US"&gt; baking test and bread volume for its products. Three types of flour with different content percentages were tested for comparison &lt;/span&gt;&lt;span lang="IN"&gt;to&lt;/span&gt;&lt;span lang="EN-US"&gt; find the best-suited type for the baking purpose among them. Among the types 550, 1050 and whole grain flour, the parameters are fitter for bread baking process is 550 type as the results show falling number = 450.25; 334; 296.87; starch (%) = 75.45; 69.72; 64.75; gluten (%) = 38.65; 31.84 and 21.44, and bread volume is 400, 340 and 300 ml respectively. This study suggested that flour with more starch content and a falling number will produce a reasonable volume and more appealing bread regarding sensory attributes.&lt;/span&gt;

Identification of postbaking mold contamination through onsite monitoring of baking factory environment: A case study of bakery company in Taiwan

Food spoilage due to postbaking mold contamination is a major concern in the bakery industry. This study investigated how postbaking mold contamination occurs by conducting onsite inspections through a case study of bakery company in Taiwan . Basic information about the company hygiene management was obtained through interviews, and data on air and food contact surface (FCS) contamination by mold during the bread baking process were collected through onsite sampling. Furthermore, the temperature and humidity of the factory environment and changes in product water activity were also monitored. Total 11 types FCS with 396 plates and airborne sampling 540 plates in total were collected. This study revealed that baking and packaging gloves constituted the FCS with the highest postbaking mold contamination, and the highest air mold contamination occurred in the slicing/packaging room. Moreover, the mold contamination levels in air and the FCS in the same rooms or in different rooms were also correlated, indicating possible cross-contamination between air and the FCS. Overall, the obtained data indicated that comprehensive environmental monitoring is necessary for reducing the prevalence and growth of mold and involves monitoring FCSs and the air quality, temperature, and humidity of the baking environment. Such data can help identify the key control points and to redesign strategies to minimize bread molding. • Gloves and airborne mold could lead to postbaking mold contamination. • Cross-contamination between air and the FCS should be prevented. • The developed findings leads to bread with improved safety and extended shelf-life.

Development and performance evaluation of tube-type direct solar oven for baking bread

Solar ovens are not widely used for baking bread. There are some attempts to bake bread using solar energy and obtained a promising result. The aim of this research was to develop and test a tube type direct solar oven that a potential to be easily fabricated and largely produced at a low cost locally in the developing world. The developed solar oven has an overall dimension of (diameter and length) 0.1 m × 1 m and the height of the parabola is 0.35 m. Simulation of the design to obtain the focal point and bread baking process was done using SOLTRACE and COMSOL soft wares, respectively. Both simulation and experiments revealed that almost all the rays fall over the trough. Similarly, COMSOL software showed the baking process which was verified through experimental work. The prototype took 67 min s to reach its stagnation temperature of 127 °C, with an F1 of 0.32. Three WBT tests were taken at different days and the result showed that the direct tube solar oven overall thermal efficiency of 43.9%, 42.1% and 38.3% at an average solar isolation of 305 W/m2, 259 W/m2 and 232 W/m2, respectively. The tube type direct solar oven has better efficiency compared to most of the direct type solar cookers. This is due to the air tight cover around the oven which reduces the thermal loss of the oven to ambient air, which is also a cause for the oven’s good performance under low solar isolation. Further bread baking test showed that the solar oven has an overall utilization efficiency of 35.0% at an average solar isolation of 396 W/m2. The time taken for baking is 16 min longer than its COMSOL analysis. This is due to the difference in design and prototype, especially while producing an air tight cover locally. Addressing this and other performance improvement issues, the solar oven could be disseminated to the wider community especially for people living in the rural parts of the developing world.

Research progress on the formation mechanism and detection technology of bread flavor.

With a long history of fermentation technology and rich flavors, bread is widely consumed by people all around the world. The consumer market is huge and the demand is wide. However, the formation mechanism of bread baking flavor has not been completely defined. In order to improve the breadmaking process and the quality of bread, the main flavor substances produced in bread baking, the formation mechanism, and the detection technology of bread baking flavor are carefully summarized in this paper. The generation conditions and formation mechanism of flavor substances during the bread baking process are expounded, and the limitations of some current bread flavor detection technologies are proposed, which will provide theoretical basis for effectively regulating the generation of flavor substances in the bread baking process and making bread with good flavor and rich nutrition in the future.

Anthropological Study of Bread Baking in Tehran and Its Evolution Over Time

Wheat is the main ingredient of hundreds of different food, medicine and industrial products, and bread, as the most important product of wheat, has been recognized as a salubrious food such that each one of us may eat bread several times a day during our lives, and each time enjoy it more profoundly than ever before. Being known as a vital dietary product, bread has been investigated from various viewpoints. In the present sturdy, attempts are made to investigate the evolution of bread baking process in Tehran (District 1) from an anthropological perspective and explore its overt and covert functions and its role in everyday life of people. As for methodology, the present research falls within the category of ethnographic studies. In the present study, bread has been investigated from the viewpoint of functionalism school (due to its function in our everyday life) and the structuralism school (due to its impact on various structures in society). The findings of documentary studies as well as in-depth interviews and observations indicate that bread, as the staple food of Iranian people, can play a cultural and dogmatic role in many social, cultural and economic structures. Keywords: Bread - Baker - classic bread - Industrial bread - Anthropology - Tehran DOI: 10.7176/RHSS/12-14-01 Publication date: July 31 st 2022

Anthropological Study of Bread Baking in Tehran and Its Evolution Over Time

Wheat is the main ingredient of hundreds of different food, medicine and industrial products, and bread, as the most important product of wheat, has been recognized as a salubrious food such that each one of us may eat bread several times a day during our lives, and each time enjoy it more profoundly than ever before. Being known as a vital dietary product, bread has been investigated from various viewpoints. In the present sturdy, attempts are made to investigate the evolution of bread baking process in Tehran (District 1) from an anthropological perspective and explore its overt and covert functions and its role in everyday life of people. As for methodology, the present research falls within the category of ethnographic studies.In the present study, bread has been investigated from the viewpoint of functionalism school (due to its function in our everyday life) and the structuralism school (due to its impact on various structures in society).The findings of documentary studies as well as in-depth interviews and observations indicate that bread, as the staple food of Iranian people, can play a cultural and dogmatic role in many social, cultural and economic structures. Keywords: Bread - Baker - classic bread - Industrial bread - Anthropology - Tehran DOI: 10.7176/DCS/12-6-01 Publication date: June 30 th 2022

Effects of Processing Technique on Physical and Organoleptic Properties of Whole Meal Bread

Whole meal bread made up from whole grains mostly consumed due to health purpose. The aim of this study was to determine the effect of processing technique on physical (colour, moisture content, pore size, texture and specific volume) and organoleptic properties of whole meal bread. Three treatments which B1, B2 and B3 of whole meal bread were prepared which represent the processing technique straight dough, sponge and dough, and sourdough, respectively. Whole meal bread between B1 and B2 with B3 showed significant (p &lt; 0.05) increased in density (276.58, 270.35, 647.84 g/cmᶾ), hardness (747.16, 747.16, 2425.75 g/cmᶾ) and chewiness (495.71, 519.98, 2843.73 g) respectively. Variations were observed for crumb (internal) and crust (external) colour from 33.77 to 39.63 (L-value), 3.08 to 9.80 (a-value) and 25.38 to 10.82 (b-value), 23.65 to 27.94 (L-value), 2.27 to 2.95 (a-value), 9.26 to 13.11 (b-value) respectively. Hence, straight dough method produced whole meal bread with higher value of specific volume (3.58 cmᶾ/g), moisture content (24.66 %), lightness of crumb (23.65) and chewiness (495.71 g). Thus, results showed that straight dough method was the most efficient and acceptable method for bread baking process in order to get the good physical and organoleptic properties of whole meal bread.

Microencapsulation May Preserve the Viability of Probiotic Bacteria During a Baking Process and Digestion: A Case Study with Bifidobacterium animalis Subsp. lactis in Bread.

The high sensitivity of probiotic bacteria (PB) to many environmental factors limits the number of food products where they can be incorporated. This study aimed to examine the capability of a unique three-layered microcapsule structure to protect PB against extremely elevated temperatures and low pHs to allow their incorporation into bakery goods. The microcapsules were prepared first by granulation of a Bifidobacterium lactis (BL) strain, as a model PB, to form a core, and then coating the core with three consecutive protective layers. The physical features and the shape of the microcapsules obtained from three sequential preparations were characterized using various methods. A viable cell count was utilized to evaluate the efficiency of the microcapsule structure to protect the bacteria during a bread-baking process carried out at 180°C for 40min and also during the exposure to simulated gastric fluid (pH 1.2) for up to 1h. The results showed that whereas the free bacteria (unprotected BL) encountered a significant viability loss under these conditions, the microencapsulated BL presented superior resistance.

Numerical simulation of bread baking in a convection oven

The paper reports on a numerical study conducted to simulate the bread baking process in an industrial convection oven. This involves predicting the unsteady multiphase flow and heat and mass transfer fields within the oven while accounting for changes in bread properties and volume. The clean air and combustion gases circulate inside the oven in two separate compartments. In the clean section, the rotational motion of the blower needed to move air around is modeled following a rotating reference frame approach, while the increase in bread volume is accounted for by a dynamic mesh. Moreover, to predict the motion of the grid, a general model for loaf expansion is developed based on the changes in the volume of the bread’s water and carbon dioxide content during baking. In addition, the bread is modeled as a porous material and therefore generated solutions account for the loaf porosity, volume expansion, water evaporation and condensation, starch gelatinization, and release of carbon dioxide. The numerical solution is validated by demonstrating, for one bread, that predictions are in good agreement with experimental measurements. Finally, numerical results for the full setup are reported in the form of hydrodynamic and thermal fields in the oven, contour plots of temperature and volume fraction of water and carbon dioxide along cross-sections of the baking chamber and the bread, bread deformation, and transient profiles of average quantities. It is found that generated results are in agreement with work reported in the literature demonstrating that the developed model can be used to optimize the performance of the oven and the bread baking process.

A Comparative Assessment of the Baking Quality of Hybrid and Population Wheat Cultivars

The study assessed the quality parameters of grain and flour, the rheological properties of dough and the quality of bread prepared from flour of hybrid cultivars of wheat in comparison with population cultivars of wheat. As the interest in wheat hybrids cultivars from the agricultural and milling industry is growing, their technological value of grain and flour was evaluated at two levels of nitrogen fertilisation (N1—110 kg/ha, N2—150 kg/ha). Increasing the fertilisation (N2) produced a significant influence on the crude protein and gluten content in the flour, as well as the moisture of the crumb and the yield of the dough without impacting other rheological traits and parameters of bread baking process. The performed principal component analysis (PCA) allowed for identification of the best cultivars among the studied wheat cultivars (Hybery and Hyvento). The hybrid cultivar Hyvento was characterised by favourable qualitative traits of the grain (vitreousness, crude protein content) and rheological parameters of the dough (bread volume), however, it had lower baking quality parameters. Among the hybrid cultivars, the best applicability for baking purposes was Hybery due to the favourable values of the baking process parameters and bread quality (bread yield, bread volume, Dallmann porosity index of crumb). Hybrid cultivars of wheat can therefore be used for the production of bread and be an alternative in agricultural production for population cultivars, which will contribute to filling the knowledge gap for the hybrid wheat cultivars.

Optimization and quality attributes of novel toast breads developed based on the antistaling watermelon rind powder

In the current research, production of watermelon rind (WMR) powder was studied as a promising additive to improve the quality characteristics of toast breads. The main formulation (WMR (4.6–11.4%)), and bread-baking process (temperature (166–233 °C) and time (17–33 min)) parameters using response surface methodology (RSM) were optimized to retard the acceleration of staling rate in toast breads. The second-order polynomial regression equations (R2 > 0.939) were adequately fitted for all response variables. The highest moisture (22%), volume (1431 cm3), and organoleptic acceptability (8.10) values and the lowest firmness (10.50 N) and total color difference (9.80) values were achieved under the following conditions: WMR concentration of 9.06%, baking temperature of 206.66 °C and baking time of 20 min. The analysis of dough farinographic and extensographic characteristics showed a significant more water absorption (72.5%), development (6.7 min) and stability (7.8 min) time, and extensibility (143 mm) values for the optimal sample compared to the control. Scanning electron microscopy demonstrated that the thicker cell wall induced by WMR in the optimal bread (183.54 μm) than the control (78.39 μm) was able to maintain air bobbles during the storage time. A negligible staling rate was also found for the optimal breads with the lowest moisture, textural, color and sensory changes.

Evaluation of thermal inactivation parameters of Salmonella in whole wheat multigrain bread

This study was conducted to validate a simulated commercial whole wheat multigrain bread baking process at 375 °F (190.6 °C) oven temperature for 35 min to inactivate Salmonella, and to determine the thermal inactivation parameters of a 7-serovar Salmonella cocktail in whole wheat multigrain bread dough. A ≥5-log CFU/g reduction in Salmonella population was achieved by 15 min, and no viable Salmonella was detected after enrichment plating by 16 min. The aw of the bread crumb (0.96) after baking and 60 min of cooling was similar to that of pre-baked bread dough, whereas the aw of bread crust decreased to 0.81 at the end of baking and cooling. The D-values of the Salmonella cocktail in bread dough were 59.6, 20.0 and 9.7 min at 50, 52 and 55 °C, respectively; and the z-value was 6.5 °C.

Tools design of bread production process to minimize musculoskeletal disorders based on OCRA method

Less supportive working methods may lead operators inconvenience while working. This discomfort can be caused by a non-ergonomic work environment. Bread baking process is done manually using human energy. This work is done repeatedly for a long time, thereby posing a risk of musculoskeletal disorders. This is at risk of causing pain in some parts of the worker's body. Ergonomic work facilities and equipment are essential to minimize risk at work. The result of NBM (Nordic Body Map) questionnaire indicate that the biggest complaint is on the right back of the worker's arm and shoulders. In baking process, the operator must bend almost 90 degrees. This posture can cause health problems, especially musculoskeletal. Based on observations using the OCRA (Occuptional Repetitive Action) method, the OCRA index value for the right hand is 8.56 and for the left hand is 7.84, with the red area and the average category of risk. Therefore, a trolley is designed in this study as a tool to minimize musculoskeletal complaints, using workers anthropometric data.

Effect of (−)-epigallocatechin gallate (EGCG) extracted from green tea in reducing the formation of acrylamide during the bread baking process

This is the first study to investigate the extent of reduction in acrylamide formation during baking with the addition of (−)-epigallocatechin gallate (EGCG) extracted from green tea, and to determine whether EGCG influences the texture and colour attributes of bread, or interacts with other ingredients. EGCG powders were added to white bread formulations at the concentrations of 3.3, 6.6 and 9.9g·kg−1. The amount of acrylamide in the bread was analysed using liquid chromatography-mass spectrometry. EGCG addition significantly reduced the acrylamide formation by 37% compared to the control and decreased the moisture content of the bread by 6%. It did not affect its texture attribute, but increased the lightness and the yellowness and decreased the redness of bread crust (with contrasting results in crumb). It also decreased granule size and porosity. In conclusion, EGCG fortification is a feasible method to decrease acrylamide formation in baked bread.

Abstract 2118: The food additive agent potassium bromate prevents growth and aggressive phenotypes by targeting multiple molecular signatures in breast cancer cells

Abstract Potassium bromate (KBrO3) is by-product of ozone that has found multifunctional purpose in modern society. It is used as disinfectant in drinking water, a bleaching agent to improve flour, a component of cold-wave hair lotion and an ingredient in the production of fish paste and fermented beverages. Potassium bromide has also been used in America for bread-baking as a safe food additive since 1914. Despite the commercial value of this chemical, some studies suggest that KBrO3 could be a carcinogen. During the bread-baking process, Potassium bromate is normally converted into a stable and inert compound, potassium bromide (KBr). However, due to incomplete reduction, the residual KBrO3 remains in the bread, which eventually acts as a potential carcinogen to humans. Interestingly, our studies, in breast cancer cells, found contrasting results. We found that KBrO3 delays growth of ER-α positive luminal type breast cancer cells and triple-negative breast cancer cells (TNBC) via inducing apoptosis in a dose-dependent manner. KBrO3-induced apoptosis is mediated via targeting BCL-2/Bax and Caspase-3 signaling pathway. Moreover, aggressive phenotypes such as migration, invasion and sphere-forming ability of breast cancer cells are significantly impaired by KBrO3-treatment via targeting multiple molecular signatures in breast cancer cells. The growth inhibition effect of KBrO3 is also documented in a tumor xenograft model. Collectively, our findings provide a rationale for the basic and pre-clinical evaluation of the role of KBrO3 in breast cancer progression and therapy. Citation Format: Priyanka Ghosh, Gargi Maity, Snigdha Banerjee, Sushanta Banerjee. The food additive agent potassium bromate prevents growth and aggressive phenotypes by targeting multiple molecular signatures in breast cancer cells [abstract]. In: Proceedings of the American Association for Cancer Research Annual Meeting 2017; 2017 Apr 1-5; Washington, DC. Philadelphia (PA): AACR; Cancer Res 2017;77(13 Suppl):Abstract nr 2118. doi:10.1158/1538-7445.AM2017-2118

Application of Tunable Diode Laser Spectroscopy for the Assessment of Food Quality.

Adequate food packaging is important to ensure food quality and prolong the shelf life of food. Frequently, the method of modified atmosphere packaging (MAP) is used. We used a tunable diode laser spectroscopy technique to detect the oxygen content in food packages, e.g., in packaged milk and bread. Different detection geometries were adopted to be able to collect scattering light that had passed through the gas volume in the packages, and to avoid the disturbance of ambient air. Furthermore, studies of the bread-baking process have been performed by measuring the water vapor signals in a fermenting dough. The results demonstrate that the technique has a great potential for nonintrusive assessment of food quality and the bread-baking process.