Industrial Bakery Research Articles

Reconditioning commercial vehicle booth from industrial bakery waste to support herbal products distribution in Menik Jaya Community Group

The Menik Jaya Community Group faces constraints in distributing herbal products, impacting sales quality and quantity. Long distances, limited transportation, and weather-related product damage pose significant challenges. Additionally, bakery industry fiberglass booth waste presents an environmental issue. This community service aimed to address these problems by: 1) Providing more effective distribution through two-wheeled commercial booths; 2) Recycling fiberglass booth waste into functional commercial booths; and 3) Enhancing the group's herbal product marketing capacity. Methods included socialization, booth-making training, and commercial booth utilization assistance. Results yielded environmentally friendly commercial booths, improved distribution efficiency, and increased community income.

Assessing the Impact of Religion and College Life on Consumption Patterns of Ultra-Processed Foods by Young Adults: A Cross-Sectional Study.

(1) Background: University students, often constrained by time and influenced by socio-economic factors such as culture and religion, frequently adopt diets centred on ultra-processed foods (UPFs), increasing the risk of long-term non-communicable diseases. This study aimed to assess UPF consumption among Spanish university students and explore the potential impact of religion and the academic year on their eating habits. (2) Methods: In a cross-sectional study of 257 university students aged 18-31, UPF consumption was assessed using NOVA food classification at the academic year's start and end. Chi-square and Wilcoxon tests analysed UPF consumption changes, while binary logistic regression identified associations between religion and weekly UPF consumption. (3) Results: Muslim students had a consumption of industrial bakery products almost five times [95% CI: 2.694-9.259] higher than that observed among Christians. Similar data were observed for artificial juice consumption (OR = 3.897, 95% CI = 2.291-6.627) and candy consumption (OR = 3.724, 95% CI = 2.051-6.762). Moreover, a greater percentage of calories and grams of saturated fats from UPFs was observed for Muslims at the end of the study. (4) Conclusions: Highlighting the impact of religion on UPF consumption among students underscores the necessity of monitoring and intervening in dietary habits to prevent undesirable long-term complications such as cardiovascular diseases.

An Investigation of Changes in the Rheological Properties of Toast Pan Bread Dough during the Various Processing Steps of Kneading in an Industrial Bakery

The dough formation during the kneading for the industrial production of toast pan bread was examined using a series of mechanical tests to assess possible transformations in its rheological properties. For this purpose, the Young’s modulus of elasticity and squeeze flow viscometry of the doughs taken from various processing stages of the kneading process were determined. The rheological properties of the dough were assessed using dynamic and creep tests. Young’s modulus data revealed the changes in the elasticity of the dough exhibited during the different steps of kneading, whereas dynamic and creep tests indicated that throughout kneading, the dough displayed the behavior of a weak solid. Elongational viscosity measurements showed that the dough exhibited pseudoplastic behavior throughout the kneading process. The doughs from the various processing steps exhibited differences in zero shear viscosity values. It is suggested that the changes occurred during the processing stages, related to the development of secondary bonding within the gluten matrix.

PRODUCT MIX STRATEGY AT GOLDEN GRAINS

Golden Grains was a Chennai-based industrial bakery producing large volumes of bread, cakes, and confectionary items for sale to contract manufacturers and retail outlets. An emphasis on being a localized city brand and contract manufacturer made its business model unique among the brand- and market-focused competition. A city-market bakery’s challenge was to ensure freshness, availability, and financial viability in a low-margin and operationally intensive industry. The operations management challenges included production planning, deciding the optimal product mix, and establishing an operational plan to ensure profitability and effective cost management of resources. Investor anxiety due to poor financial performance required top management to turn the business around, but identifying a product mix and implementation plan that satisfied operational needs while dramatically improving operating margins would not be easy.

Minimal influence of milling technique in contrast to sourdough on the nutritional and organoleptic quality of bread

A number of studies have shown the effect of cereals and sourdough on bread nutritional and organoleptic quality, but the impact of the milling technique remains little studied. There are two main types of milling technic depending on the bread-making food chain. Industrial bakeries mainly use roller mills while artisanal bakeries may also use stone mill. We set up a participatory experiment with six millers and four bakers to study the impact of these two milling techniques on the quality of flours, sourdough microbiota and the quality of breads. Millers made twenty-two different flours from four different wheat grain varieties using either roller or stone mills. Each baker initiated and maintained sourdoughs with three roller-milled and three stone-milled flours during at least 32 backsloppings and then made bread. The analysis of flours revealed a typical granulometry profile linked to wheat hardness with higher particle sizes for stone-milled flours. Stone-milled flours also had a higher maltose content. However, the milling technic did not drive the composition of the sourdough microbiota. Moreover, the analysis of bread revealed that variation in bread protein fractions and in bread aroma compounds were more related to the specific baker microbial community than to the milling technique. Carbohydrate contents were clearly linked to the main LAB species metabolism. These results revealed that the sourdough microbial community shapes the organoleptic and nutritional quality of bread more than milling techniques.

Correlation between acrylamide content and colour in some baked products

The objective of this study was to quantify the concentration of acrylamide in biscuits, bread, and cake obtained from industrial and local bakeries, classified based on their colour intensity as light, medium, or dark. The analysis was performed using gas chromatography-mass spectrometry (GC-MS). Sugar, moisture, and asparagine analyses were also carried out simultaneously. The results demonstrated that the acrylamide content in biscuits, bread, and cakes varied according to the colour (light 109.9 ±Â 7.95, 214.7 ±Â 27.40, and 128.6 ±Â 7.05; medium 176.3 ±Â 15.16, 387.0 ±Â 87.71, and 804.3 ±Â 17.16; and dark 407.6 ±Â 105.13, 555.8 ±Â 16.20, and 1 015.0 ±Â 83.68 µg·kg^–1, respectively). Statistically, significant differences were observed between acrylamide content and product colour density (<i>P</i> < 0.05). It can be concluded that the acrylamide content increases as the product colour intensity rises due to the increased baking temperature at which the reaction between reducing sugars and asparagine takes place, resulting in the formation of acrylamide. The results suggest that selecting commercial bakery products based on colour may be beneficial for reducing the daily intake of acrylamide by consumers. Therefore, it is recommended to avoid dark-coloured bakery products.

Exposure Monitoring Strategies for Applying Low-Cost PM Sensors to Assess Flour Dust in Industrial Bakeries.

Low-cost particulate matter (PM) sensors provide new methods for monitoring occupational exposure to hazardous substances, such as flour dust. These devices have many possible benefits, but much remains unknown about their performance for different exposure monitoring strategies in the workplace. We explored the performance of PM sensors for four different monitoring strategies (time-weighted average and high time resolution, each quantitative and semi-quantitative) for assessing occupational exposure using low-cost PM sensors in a field study in the industrial bakery sector. Measurements were collected using four types of sensor (PATS+, Isensit, Airbeam2, and Munisense) and two reference devices (respirable gravimetric samplers and an established time-resolved device) at two large-scale bakeries, spread over 11 participants and 6 measurement days. Average PM2.5 concentrations of the low-cost sensors were compared with gravimetric respirable concentrations for 8-h shift periods and 1-min PM2.5 concentrations of the low-cost sensors were compared with time-resolved PM2.5 data from the reference device (quantitative monitoring strategy). Low-cost sensors were also ranked in terms of exposure for 8-h shifts and for 15-min periods with a shift (semi-quantitative monitoring strategy). Environmental factors and methodological variables, which can affect sensor performance, were investigated. Semi-quantitative monitoring strategies only showed more accurate results compared with quantitative strategies when these were based on shift-average exposures. The main factors that influenced sensor performance were the type of placement (positioning the devices stationary versus personal) and the company or workstation where measurements were collected. Together, these findings provide an overview of common strengths and drawbacks of low-cost sensors and different ways these can be applied in the workplace. This can be used as a starting point for further investigations and the development of guidance documents and data analysis methods.

Switched max-plus linear-dual inequalities for makespan minimization: the case study of an industrial bakery shop1

In this paper, an industrial bakery shop is modeled by switched max-plus linear-dual inequalities (SLDIs). SLDIs are timed discrete event systems suitable for describing flow shops with time-window constraints and switching operating modes, where each mode corresponds to a job type. We consider the scheduling problem of minimizing the makespan of the shop, and we show that the application of methods based on the max-plus algebra leads to a faster solution compared to standard techniques. The results of the paper are general, in the sense that they can be applied to any permutation flow shop with time-window constraints.

The generally recognized as safe (GRAS) microalgae Haematococcus pluvialis (wet) as a multifunctional additive for coloring and improving the organoleptic and functional properties of foods.

This work proposes the application of astaxanthin-rich H. pluvialis wet paste (HPW) as a partial substitute for wheat flour in the preparation of filloas, a dish that combines the basic ingredients of industrial bakery. The nutritional and color profile of HPW-enriched samples was evaluated by comparative analysis with a mixture of synthetic food dyes. The highest content of carotenoids (798 ± 12 μg g-1) and fatty acids (76 ± 2 mg g-1) was obtained for a filloa fortified with H. pluvialis in contrast to a non-significant dye response. Subsequently, the color stability of the fortified filloa was evaluated over time (3, 6 and 9 days), as well as its physicochemical properties and microbiological profile. As a result, HPW provided filloas with a longer shelf life, brightness (*L), and texture, in comparison with a mixture of synthetic dyes. In addition, an inhibitory effect of HPW towards mesophilic aerobic microorganisms in the food was obtained.

Hegemonic masculinities and femininities in food industry packaging

ABSTRACT The aim of this study is to analyze the formal and graphic elements around the hegemonic masculinities and femininities of the packaging of industrial bakery and biscuit products aimed at children and young people. A content analysis was conducted on 10 of the most widely consumed brands of industrial bakery and biscuit products in Spain and widely present on the international market. In addition, a scale of dominant masculinity was developed as a tool to analyze the most egalitarian narratives on the packaging. The results suggest that there are unequal narratives linked to hegemonic masculinity and femininity. The use of blue and yellow, the latter not having a traditional link to masculinity, is related to men in terms of aggressiveness and bravery stereotypes. The women represented on packaging with these same colours are presented in terms of sympathy or kindness, as well as stereotypes connected to beauty. The products contain homogeneous stereotypes and are associated more with men than with women. However, 2 out of 10 brands do not insert characters linked to sexual attributes or gender stereotypes. Therefore, our findings suggest that hegemonic gender scripts are inscribed on packaging less obviously than in other traditional media.

Comparative characterization of the gluten and fructan contents of breads from industrial and artisan bakeries: a study of food products in the Spanish market.

BackgroundThe consumption of wheat/gluten is associated with adverse reactions for human health. Gluten and fructans are identified as the major compounds triggering and worsening adverse reactions to wheat, which are increasing, and as a consequence, avoidance of gluten/wheat is the common strategy of many individuals of the western population. Although bread is a product of daily consumption, there is a lack of information on the gluten and fructan contents and the influence of artisanal or industrial processes.ObjectiveThe aim of this study is to carry out a comparative characterization between artisan bakeries and hypermarkets in Spain for gluten and fructan contents in daily sold breads.DesignA total of 48 types of bread highly consumed in Spain sold in artisan bakeries (long fermentation) and hypermarkets (short fermentations) were selected for comparing the gluten and fructan contents. Methods such as reverse phase-high performance liquid chromatography (RP-HPLC), R5 monoclonal antibody (moAb), and fructans protocols were used for the quantification of these compounds.ResultsGreat variation for the content of gluten and fructans has been found between all bread categories. Although breads produced using long fermentation (artisan bakeries) contain significantly lower gluten, they have higher fructans than those using short fermentations (hypermarkets). Durum wheat breads had the lowest content of gluten. Moreover, spelt breads from artisan bakeries had the lowest content of fructans but not those from hypermarkets.DiscussionIn this study, we report the comparative characterizarion of the breads of the Spanish market. These food products presented variation in the amount of gluten and fructans, ligated in most of the cases to the nature of the providers: artisan bakeries against hypermarkets. Depending on the type of bread, the differences for the daily consumption of gluten and fructan can be 4.5 and 20 times, respectively.ConclusionsWe found strong differences for gluten and fructan contents among breads. These information may contribute to designing strategies to improve the management of gluten and fructans in bread.

Determination of salt content in traditional and industrial Moroccan white bread by inductively coupled plasma mass spectrometry.

Introductionevaluating the sodium content of staple foods is essential for implementing a salt reduction strategy. In Morocco, bread is a major contributor to sodium intake. However, currently few studies have been carried out to assess the salt content in bread. Our study aimed to estimate the sodium and salt content of white bread available in artisanal and industrial bakeries in the twelve regions of Morocco.Methodsit is a cross-sectional study of the sodium content of white bread available for sale in artisanal and industrial bakeries in Morocco (N=120). Inductively coupled plasma mass spectrometry (ICP-MS) was used to quantify the sodium content of the bread. The percentage of samples meeting the recommendations and bread contribution to the daily salt intake was calculated.Resultsthe results of our study show that the mean levels of sodium and salt added to bread samples were 5.7 ± 1.5 g/Kg and 14.5 ± 3.7 g/Kg, respectively. With an average of 4.4 ± 0.5 g/Kg and 11.2 ± 1.2 g/Kg for artisanal bread and an average of 7.0 ± 0.8 g/Kg and 17.8 ± 2.1 g/Kg for industrial bread, respectively. Daily salt intake from bread consumption (500 g/d/person) is estimated at 5.6 g/d (52.8% of total salt intake) for artisanal bread and 8.9 g/d (84% of total salt intake) for industrial bread.Conclusionbread salt content in Morocco exceeds the recommended threshold of the national federation of bakery and pastry and health authorities. Further efforts are necessary to increase knowledge and awareness of bakers and to teach them how to reduce salt content without affecting the flavor and the quality of their products.

Occupational rhinitis and asthma in bakers: a cross-sectional study in the former Katanga province of DR Congo.

Bakers are at high risk of rhinitis and asthma, but the prevalence of these occupational diseases is not well known in Sub-Saharan Africa. We investigated the prevalence of occupational rhinitis and asthma among industrial bakers in the former province of Katanga. In a cross-sectional study conducted in eight towns from October 2018 to September 2019, we included 276 male workers from 18 industrial bakeries and 113 male controls (35 butchers and 78 bread sellers), all nonsmokers. Participants replied to a validated questionnaire (European Community of Respiratory Health Survey II), administered face to face, and performed spirometry at the work place. In 15 bakers with symptoms of work-related asthma, records of self-measured peak expiratory flow (PEF) 4 times per day during 4weeks were analyzed by the OASYS (Occupational Asthma System) protocol. The bakers and controls did not differ by age (32.2 ± 7.3 y vs 32.8 ± 10.3 y). According to the questionnaire, work-related rhinitis and asthma were significantly more prevalent among bakers (31% and 5%, respectively) than among controls (2% and 0%, respectively). However, the groups did not differ significantly with regard to spirometric parameters. Based on PEF records, 10 out of 15 were positive for occupational asthma (OASYS score > 2.5), so the rate of occupational asthma was 3.6% in this study. This first study in DR Congo demonstrates the existence of occupational rhinitis and asthma among industrial bakers in Katanga. Further epidemiological studies are needed to clarify the extent and risk factors of baker's asthma in the area. In the meantime, advocacy and implementation of appropriate occupational hygiene measures are warranted to protect bakery workers in DR Congo.

Genome-Assisted Characterization of Lactobacillus fermentum, Weissella cibaria, and Weissella confusa Strains Isolated from Sorghum as Starters for Sourdough Fermentation.

Sourdough fermentation of bakery products is a well-established and widespread technique to confer an added value to the resulting food. In recent decades, gluten-free raw materials have gained more attention due to the diffusion of food disorders such as coeliac disease, but, at the same time, they present difficult manipulation and scarce technological properties because of the absence of gluten. For this reason, the present work was aimed at selecting starter cultures for sourdough application that are isolated from fermentation of sorghum flour. Three isolates of Lactobacillus fermentum, Weissella cibaria, and Weissella confusa were selected for the following properties: exopolysaccharide synthesis, acidification, CO2 production, and amylase activity. The investigated phenotypic characteristics were confirmed by genomic analyses, which also highlighted other potentially beneficial features for use in bakery products employment. These strains, together with bakery yeast, were used for bread preparation using sorghum and wheat flour and after 24 h of fermentation the resulting dough was analyzed to assess the improvement of its characteristics. The presence of lactic acid bacteria (LAB) had a great impact on the final dough, and the best preparation, from a rheological point of view, resulted in one made of sorghum and wheat flour with added LAB and bakery yeast, whose resulting characteristics were similar to all wheat flour doughs. The results of this study suggest a potential application of the selected starters in sorghum composite bread and should be validated with data from large-scale pilot tests conducted in industrial bakeries.

Knowledge and Attitude towards the Gradual Reduction of Salt in Bread – an Online Survey

Abstract Background Bread is one of the main sources of salt intake in Portugal. Based on this evidence, a protocol signed between national Health Sector and the Associations of Industrial Bakeries, in 2017, established gradually decrease salt in bread until 2021. This measure also targets schools’ available bread, this should not exceed 1g salt, to end of 2018. A pilot Health Impact Assessment (HIA) aims to assess the potential impact on salt reduction in bread on the eating habits of children (6-18 years) and their families. Methods A questionnaire is being performed to assess the effect of this measure. The first version was designed by a panel of 11 experts (content validity), following the plain text principles. A external specialist revised it for facial validity. A pilot was tested. Thereafter, a REDCap online survey of “Knowledge and Attitude towards the Gradual Reduction of Salt in Bread” questionnaire was finalized. The target group is the parents or guardians of children and young persons, of School Clusters in the south of Portugal. Results Final online survey totalizes 33 items, divided into four blocks: 1.Knowledge and General literacy data, 2.Domestic Consumption, 3.Scholar consumption and 4.Sociodemographic. An adult responsible for the child/young person should answer the survey. Access is possible through a REDCap link, using computers available in the School Cluster, or other manner suitable for the purpose. Conclusions This survey will contribute to the identification of modifiable behaviors related with salt intake. Such evidence may eventually provide the opportunity for new strategies in this area. Key messages Health Impact Assessment as a procedure to assess the effects of measures and policies on human health. Questionnaires are a rapid tool to access perceptions, attitudes and knowledge.

A cross sectional study of salt content in bakery bread in Zagreb, Croatia.

Reducing salt content in bread is the essential part of a national strategy for salt reduction with the goal of long-term national general health improvement. In this study we have analysed salt content in three types of bread available in 25 small and five national industrial bakeries in Zagreb, Croatia. Samples of white wheat bread, dark wheat bread, and other types of bread were collected, and the salt content was determined with the Mohr method. Salt content varied widely between bakeries, with an average content of 2.30±0.22 g per 100 g of bread, which is almost twice the threshold content (1.4 %) defined by the Croatian National Regulation on Cereals and Cereal Products. Further efforts are necessary to teach bakers how to reduce salt content without affecting quality or flavour. These should go hand in hand with continuous monitoring of how the legal provisions are implemented.

Automated electrical demand peak leveling in a manufacturing facility with short term energy storage for smart grid participation

Demand side management of energy is a vital function in the smart grid that allows for greater integration of renewable energy resources, and is facilitated with economic incentives in energy and demand pricing schedules. Manufacturing systems can take advantage of these incentives to reduce their energy costs through active energy management. This paper is a simulation analysis on the implementation of a novel algorithm that levelizes the maximum power load of an industrial bakery that operates under an on-peak demand price structure. The algorithm takes advantage of an untapped thermal energy storage resource in the facility, a chilled glycol buffer tank, to level the short intra-day power oscillations that the facility experiences. One of the key advantages of the algorithm is that it does not require precise demand forecasting or complex control algorithms, such as model predictive control. Even with substantial error in peak power estimates (5%), the algorithm is expected to result in at least a 2% peak reduction. Under ideal prediction, the algorithm reduces the on-peak facility power maximum by 7.3% of the possible 9.0% reduction the storage can provide. Further, the algorithm uses very few facility specific inputs, and can readily be adapted for any facility with short intra-day oscillatory power profiles and untapped storage capacity. The key insight of the paper is the employment of a novel algorithm to leverage untapped energy storage in manufacturing facilities to transform them into smart grid participants with no major capital investment.

Types of Carbohydrates Intake during Pregnancy and Frequency of a Small for Gestational Age Newborn: A Case-Control Study

The objective of this study was to assess the relationship between consumption of different types of carbohydrates (CHO) during pregnancy and the risk of having a small for gestational age (SGA) newborn. A retrospective matched case–control design was carried out with a total of 518 mother-offspring pairs. A total of 137 validated items were included in the food frequency questionnaire (FFQ). Conditional logistic regression models were used to calculate crude odds ratios (cORs) and adjusted odds ratios (aORs) with 95% confidence intervals (CIs). Having more than 75 g/day of brown bread showed an inverse association with SGA (aOR = 0.64, CI 0.43–0.96). In contrast, an intake of industrial sweets more than once a day (aOR = 2.70, CI 1.42–5.13), or even 2–6 times a week (aOR = 1.84, CI 1.20–2.82), increased the odds of having a SGA newborn. During pregnancy, the higher the increase of wholegrain cereal and bread, the lower the possibility of having a SGA newborn, but the opposite occurred with refined sugar products—just consuming industrial bakery products or pastries twice a week increased the odds of having an SGA infant. Case–control studies cannot verify causality and only show associations, which may reflect residual confusion due to the presence of unknown factors. It is possible that a high consumption of sugary foods is a marker of a generally poor lifestyle.

Use of a Selected Leuconostoc Citreum Strain as a Starter for Making a "Yeast-Free" Bread.

The aim of this study was the characterization and selection of bacterial strains suitable for the production of a “yeast-free” bread. The strains Leuconostoc citreum C2.27 and Weissella confusa C5.7 were selected for their leavening and acidification capabilities and individually used as starters in bread-making tests. Liquid type-II sourdoughs, singly inoculated with the two selected strains, were characterized and employed for bread-making, through the set-up of a biotechnological protocol without the use of baker’s yeast as a leavening agent. Aiming to verify the ability of the selected strains to dominate the fermentation process, bacteria and yeasts were isolated from liquid sourdoughs and doughs, genetically characterized and identified. Both the selected strains were suitable for the production of bread, even if L. citreum C2.27 showed the highest leavening capacity and was able to dominate the dough microbiota. The effects of different salt concentrations on the selected strain performances were also investigated. The applicability of the developed protocol, adapted for the production of the typical Apulian bread, “puccia”, and the suitability of the strain L. citreum C2.27 were confirmed at pilot scale in an industrial bakery. The puccia bread, which was produced with the liquid sourdough fermented with L. citreum C2.27, without baker’s yeast and salt, was similar in appearance to the conventional product containing baker’s yeast and was judged positively by a sensory analysis.

Changeability of the manufacturing systems in the food industry – A case study

Like other industries, the food industry currently faces increased demand for low-cost product variety. One potential response to this demand is increasing the changeability of the manufacturing setup. This paper has the purpose to explore how four changeability enablers (re-configurability, scalability, standard interfaces, and flexibility) impact four measures of changeability (changeover time, ramp-up time, ease of implementing minor product changes and ease of introducing radically new products) in the food industry. To do so, the paper conducts a nonparametric Kendall’s tau correlation test using data collected from 18 production lines via questionnaires addressed at plant managers from six different plants part of the same industrial bakery. The results indicate that changeability enablers cannot support all outcomes simultaneously, and that trade-offs between certain enablers and outcomes may exist. In addition, the results indicate that perishability might play a crucial role in the degree and type of changeability enablers a food manufacturer can adopt.