Industrial Bakery Research Articles

Inhalable β(1→3)glucans as a non-allergenic exposure factor in Dutch bakeries

Objectives:To obtain an overview of inhalable β(1→3)glucans levels in Dutch industrial bakeries and explore possible associations with reported respiratory health effects in bakery workers.Methods:β(1→3)glucan levels were analysed in 186 personal...

Mathematical Model of Sugar Uptake in Fermenting Yeasted Dough

Fermentation prior to freezing significantly reduces the shelf life of frozen dough, measured as a decline in proofing power. Changes during fermentation caused by yeast metabolism have previously been described empirically on a dough weight basis and have not been mathematically modeled. In this work, yeast metabolites were quantified in fermenting dough and their concentrations were estimated in the aqueous environment around yeast cells. The osmotic pressure in the aqueous phase increases by 23% during 3 h of fermentation, which depresses the freezing point by 1 degrees C. The rise in osmotic pressure and the accumulation of ethanol may affect phase equilibria in the dough, baking properties, and the shelf life of frozen dough. Predictive modeling equations fitted sugar concentration data accurately. It was found that the preference of baker's yeast for glucose over fructose was stronger in fermenting dough than in liquid fermentations. The usefulness of the model in industrial bakery formulation work was demonstrated.

Rapid detection of fungal α-amylase in the work environment with a lateral flow immunoassay

Occupational allergen exposure assessment usually requires airborne dust sampling at the worksite followed by dust extraction and enzyme immunoassay (EIA) analysis at the laboratory. Use of semiquantitative lateral flow immunoassays (LFIAs) may allow a more rapid detection procedure with direct on-site demonstration of a bioallergen exposure hazard. In a field study, we evaluated a recently developed LFIA for fungal alpha-amylase, an important bakery allergen. Airborne and surface dust (wipe) samples and samples from flours and baking additives used at the workplace were collected in 5 industrial bakeries and tested in the LFIA for fungal amylase. For comparison, amylase was measured in sample eluates with the reference EIA method. Sensitivity of the LFIA was 1 to 10 ng/mL, and of EIA, approximately 25 pg/mL. In LFIA, most flour samples, 84% of wipe samples, 26% of personal airborne dust, and none of the 26 ambient air dust samples produced a visible reaction. Wipe samples from dough-making areas and flour samples gave the strongest reactions. All extracts with >5 ng allergen per milliliter showed a positive LFIA reaction. The LFIA for fungal amylase is an easy and rapid method to demonstrate the allergen directly at the worksite in less than 10 to 20 minutes. Similar LFIA methods may be used for other occupational allergens in other work environments. Lateral flow immunoassays for occupational allergens may be of great value in occupational hygiene surveys to demonstrate directly to workers and supervisors the hazards of work-related bioallergen exposure.

Learning routines in innovation processes

PurposeThis paper aims to generate both a theoretical and an empirical basis for a research model that serves in further research as an analytical tool for understanding the complex phenomenon of learning at different levels in a work organisation. The key concept in this model is the routine concept of Nelson and Winter.Design/methodology/approachA review of the literature in the academic fields of educational sciences, industrial sciences, economics, social psychology and sociology is used to develop a conceptual model that could serve as an analytical instrument to describe the ongoing dynamics, i.e. learning processes at different levels. The theoretical findings were tested against empirical data of an industrial bakery in order to evaluate if the theoretical concepts help to identify possible mechanisms that account for parallel learning processes at different levels.FindingsThe paper gives an overview of possible key concepts that helps in explaining what happens at the intersection between individual and team, and team and organisation. This paper concludes that the concept of routines is the most sufficient for understanding the coordinating mechanism between the different aggregation levels in an organisation.Research limitations/implicationsAs organisations are modelled as a set of interlocking routines, innovation can be understood as the change of routines. The central question in future research is: “How do routines change?”Originality/valueBy taking a multi‐disciplinary approach, economic theories on innovation and educational theories on learning are combined. Such combination seems fruitful to bridge individual and organisational learning.

Internal environment of a bakery and its analysis

The Delta Group with its daughter company Delta Pekárny, a.s., belongs to the most significant firms in the Czech food processing industry and it is number one baking company in the Czech market of fresh, long-shelf-life and frozen bakery products. The Delta Group associates eleven industrial bakeries in the Czech Republic and four in Slovakia, in addition to mills, Delta Frozen Products frozen-pastry plant, Delibake and Harry’s Delta sweet long-shelf-life bakery products’ plant, Vegilife company producing healthy food, Eureca Shops running Paneria, Fr. Odkolek fast-food outlets and Le Patio restaurants. In order to consolidate its status of a strong and successful Central-European company capable to meet all requirements of its customers, the company must perform a continuous analysis of external and internal environment.

A rapid lateral flow immunoassay for the detection of fungal alpha-amylase at the workplace

Fungal alpha-amylase is a flour supplement which is added to improve the quality of bakery products. Various studies have shown that exposure to this enzyme is an important risk factor for the development of bakers' allergy and this allergy is reported to be one of the most frequent causes of occupational asthma. A rapid assay was developed to monitor exposure to occupational allergens directly at the workplace. The sensitivity of the developed assay is 0.32 ng amylase mL(-1) in a buffer system with the commercially available alpha-amylase preparation Fungamyl 1600S as the standard. Initial validation tests (n = 33) were performed with airborne and settled dust from an industrial bakery. The new lateral flow immunoassay detected amylase in 22 of the 26 samples regarded as positive in an enzyme immunoassay, and was negative for all seven enzyme immunoassay-negative samples, while the four lateral flow immunoassay-negative/enzyme immunoassay-positive samples all had levels below 2 ng mL(-1). The sensitivity of 2 ng mL(-1) of the amylase lateral flow immunoassay is sufficient for first screening purposes and, therefore, this simple and rapid assay may allow direct on-site demonstration of work-related hazards of bio-allergen exposure. This would be particularly useful in occupational hygiene practice, especially in traditional or small-scale bakeries which lack the technological skills for testing the exposure to respiratory allergens.

Microorganisms Involved in the Fermentation Process of Panettone Sourdough Maintaining in Japan

Samples of panettone sourdoughs manufactured in an industrial bakery located in Japan were investigated. The sourdough starter called mother sponge was imported from Italy and propagated continuously in Japan. According to traditional practice in Italy, panettone sourdoughs were prepared. Microflora was composed of Yeast (106-107cfu/g) and LAB (107-108cfu/g). All the fermentation process, predominant yeasts has the feature of no maltose fermentation and no growth at 37°C. Predominant LAB fermented maltose and has requirement of Tween 80 for growth. DNA-DNA hybridization data exhibited they were Candida milleri and Lactobacillus sanfranciscensis. Furthermore L. sanfranciscensis forming L-lactate was isolated from panettone sourdough. And lactate dehydrogenases took part in isomer of lactate produced by them. It was confirmed that the native microflora of the panettone mother sponge was successfully preserved in Japan.

How to improve food quality management in the bakery sector

In the food industry, quality assurance (QA) systems are applied to ensure food safety and food quality to prevent liability claims and to build and maintain trust of consumers. Bakeries apply QA systems such as Hygiene code, HACCP (Hazard Analysis Critical Control Points), ISO (International Organization for Standardization) and BRC (British Retail Consortium), but for them to be able to decide which system suits their specific situation (i.e., context) most and how this system should be implemented, they lack the necessary insight into the interdependence of contextual factors of bakeries and the quality management level at which these bakeries operate. This article reports on these aspects. The contextual factors that were studied include QA system, size of organization, degree of automation and type of product group. The level of food quality management between groups of bakeries differing in these contextual factors was analysed. Differences between groups of bakeries were found in the level of the quality management activities, control of strategy, allocation of supplying raw materials, supply control, planning of production and control of execution of production tasks. Bakeries that applied BRC, bakeries with 150 employees or more, industrial bakeries, and confectionery and biscuit bakeries performed some of these activities at a higher quality level than the other groups of bakeries. The study shows that by using the instrument IMAQE-Food, bakeries can select suitable quality management activities and QA systems for their specific situation to achieve effective quality management.

Epidemiological characteristics of salmoneilosis in Vojvodina

Salmonella infections are the most common food-born diseases transmitted from animals to humans. Epidemics of salmonellosis occur after eating improperly cooked contaminated foods. A descriptive epidemiological method was used to analyse epidemiological characteristics of salmonellosis in Vojvodina in the period 1978-2003. During this period there were 26,851 cases of salmonellosis (mean annual incidence of 51.1/100,000 and mean annual mortality of 0.9/100,000). Mean annual case fatality ratio during this period was 0.1%. The specific incidence was highest in 12-24 month-old children (251/100,000), and lowest in the oldest age group (13.9/100,000). Lethality was highest in children younger than 1 year, and persons older than 50 years (84%). The number of cases registered in food-born epidemics makes 41.7% of all registered cases. A mayority of 772 registered epidemics were small epidemics among families, relatives and friends. The great epidemics with large number of infected persons were due to an industrial bakery with 1713 ill persons and a public restaurant with 311 ill persons during the 80's. An epidemic was due to sandwiches from an industrial bakery distributed through the whole territory of Vojvodina with the highest incidence of salmonellosis in 1987 (137.7/100,000). The most common serotype was S. Enteritidis (69.7%), but 68 more serotypes were isolated. The most common cause of epidemics were eggs and egg products (76.2%). Salmonella spp. was isolated from food in small number of epidemics (less than 20%), because epidemics were discovered usually 2 or 3 days after their beginning.

Exposure to inhalable dust, wheat flour and alpha-amylase allergens in industrial and traditional bakeries.

This study was designed to characterize exposure to inhalable dust, wheat flour and alpha-amylase allergens in industrial and traditional bakeries. The study included 70 bakeries from the northern part of Belgium. Based on the degree of automation and a clear division of individual job tasks, four bakeries were identified as industrial and the remaining 66 were identified as traditional ones. Personal, as well as stationary, samples of inhalable dust were collected during full shift periods, usually 5-7 h. The portable pumps aspirated 2 l/min through Teflon personal dust samplers (Millipore, pore size 1.0 microm) mounted in PAS-6 sampling heads. In the collected samples the inhalable dust, wheat flour and alpha-amylase allergens were determined. Wheat flour allergens were measured using enzyme-linked immunosorbent assay inhibition and an antiwheat IgG4 serum pool. The alpha-amylase allergens were measured using a sandwich enzyme immunoassay with affinity-purified polyclonal rabbit IgG antibodies. In total, 440 samples (300 personal and 140 stationary) were processed. The highest inhalable dust exposure was observed in traditional bakeries among bread [geometric mean (GM) 2.10 mg/m3] and bread and pastry workers (GM 1.80 mg/m3). In industrial bakeries the highest dust exposure was measured in bread-producing workers (GM 1.06 mg/m3). Similar relations were observed for wheat flour and alpha-amylase allergens. Bread baking workers in traditional bakeries had the highest exposure to both allergens (wheat flour GM 22.33 microg/m(3), alpha-amylase GM 0.61 ng/m3). The exposure to wheat flour and alpha-amylase allergens in industrial bakeries was higher in bread baking workers (wheat flour GM 6.15 microg/m3, alpha-amylase GM 0.47 ng/m3) than in bread packing workers (wheat flour GM 2.79 microg/m3, alpha-amylase GM 0.15 ng/m3). The data presented suggest that, on average, exposure in the Belgium bakeries studied-industrial as well as traditional-is lower than or similar to bakeries in The Netherlands, Canada, Sweden, the United Kingdom and Finland. Furthermore, the exposure levels in traditional bakeries seem to be higher than in industrial bakeries.

Accident risks in disturbance recovery in an automated batch‐production system

AbstractAccident risks in automated production systems occur mainly during system disturbance. However, few studies have dealt with this issue. We were able to investigate it by studying accident risks during the recovery of incidents occurring in the running of an automated bread production system in an industrial bakery. This problem was examined through worker interviews. The main results indicate that the accident risks associated with system disturbance are due to accessibility problems and the need to operate quickly to avoid production shutdowns or material damage. Different solutions have been implemented to reduce the disturbances and accident risks. The development of these solutions seems related to the managers' and operators' concepts of what constitutes a disturbance. © 2002 Wiley Periodicals, Inc.

Novel computational tools in bakery process data analysis: a comparative study

We studied the potential of various machine learning and statistical methods in the prediction of product quality in industrial bakery processes. The methods included classification and regression tree, decision list, neural network, support vector machine and Bayesian learning algorithms as well as statistical multivariate methods. Our data originated from two industrial bakery processes: a sourdough rye bread and a Danish pastry process. In our studies, the Naive Bayesian algorithm turned out to be the best classifier building algorithm while the partial least squares (PLS) method was the best regression method. The prediction accuracy of these models improved significantly by pruning the original set of variables. In this study, two response variables could be predicted on a level that justifies further study: rye bread pH could be predicted with high accuracy with Naive Bayesian Classifier, and Danish pastry height could be predicted with a moderately high correlation with PLS.

Industrial applications of the air bottoming cycle

An air bottoming cycle (ABC) was proposed in the late 1980s as an alternative for the conventional steam bottoming cycle. Now this cycle is being considered as a compact and simple bottoming cycle in various applications: as an upgrading option for simple-cycle gas turbines in the offshore industry; as a hot-air cogeneration plant; or as a heat recovery installation at high-temperature furnaces. This paper evaluates the technical and economic feasibility of the ABC in the cogeneration scheme, where hot air from the air turbine is supplied to food processing industries (industrial bakeries and milk powder factories). Another application is the heat recovery unit of a glass-melting furnace. In this option the air turbine driven by waste heat also provides pre-heated air to the furnace. Based on the results of this study, two demonstration projects are scheduled for realization with support from a governmental agency and industrial partners.

Unusual type of burn injury caused by industrial bakery ovens

Unusual type of burn injury caused by industrial bakery ovens

Strengths and limitations of localizing food production as a sustainability-building strategy — an analysis of bread production on the island of Gotland, Sweden

In this paper we analyze the environmental consequences of local small-scale versus centralized large-scale bread production and the potential for self-sufficiency in bread in a Swedish island community. Mills and bakeries located on the island of Gotland in the Baltic Sea were compared with large-scale production systems on the Swedish mainland. The results show that bread production in local bakeries requires more total energy input per kilogram of bread than the industrial bakery, mainly due to inefficient technology. On the other hand, the analysis shows that emissions of CO 2, SO 2 and NO x are smaller from bread produced in the small local bakeries than from big bakeries on the Swedish mainland. This is because the transportation routes are much shorter for bread from the small bakeries and because oil is more frequently used for heating the ovens in large and medium sized bakeries. The present local production of flour on Gotland does not satisfy the local demand, but there is a potential for increased self-sufficiency. Farms on the island produce large amounts of bread grain, but only a small fraction (2%) is used in local flour production, while the rest is exported or used as animal fodder. Thus the region has a large potential to produce enough flour for its local population and thus to become less dependent on imports. However, using more locally produced bread grain to produce flour in local mills, improving energy efficiency in small-scale mills and bakeries, changing consumer behavior and internalizing environmental costs of transportation are crucial measures in achieving this goal.

Effects of Nitrogen and Sulfur Fertilization on Commercial‐Scale Wheat Quality and Mixing Requirements

ABSTRACTThe effect on physical dough properties of nitrogen and sulfur fertilizer applied during cultivation was observed in two trials using the bread wheat (Triticum aestivum) cultivar Otane. Wheat flours from both trials were evaluated for physical dough properties under laboratory conditions and also under industrial conditions in the second trial. The laboratory and industrial optimum mechanical dough development (MDD) work input (WI) significantly increased when nitrogen (N) fertilizer was applied without sulfur fertilizer (S) during crop cultivation. With combined N and S fertilization, laboratory and industrial WI remained close to levels for grain grown without fertilizer. Reductions in extensigraph resistance to extension (Rmax) and increases in extensigraph extensibility (Ext) due to S fertilization also were observed. None of the observed changes in WI, Rmax, or Ext due to S fertilization significantly affected end‐product quality as measured by loaf volume, crumb grain, and bake score. The nexus between WI and Rmax was weakened by combined N and S fertilization in the first trial, but remained strong in the second trial. Both WI and Rmax increased as N fertilizer and flour nitrogen increased, but at different rates. This observation indicated that by applying N fertilizer to improve dough strength, a disproportionate and disadvantageous increase in WI also resulted, which could be tempered by S fertilization. In this regard, an optimum N:S fertilizer ratio of 3:1 was indicated, although this ratio would be dependent on the balance of available N and S in the soil. Flour N:S ratios <12.5 kept WI to levels desirable in an industrial MDD bakery. Correlations between laboratory WI, mixograph development time (except in the SN1 trial), and farinograph development time were significant. The 125‐g MDD mixers appeared to be more responsive when measuring mixing requirements than the mixograph and farinograph to variations in quality due to environmental and agronomic influences and correlated better with industrial performance.

Fatty acids including trans content of commercial bakery products manufactured in Spain.

Fifteen samples of the most common industrial bakery products sold in Spain were analyzed for their fatty acid composition. Saturated fatty acids occurred in the largest proportions in all samples (mean = 52.8%), followed by monounsaturated (mean = 23.5%) and polyunsaturated fatty acids (mean = 17.2%). A small percentage of trans fatty acids, which were found in all samples, showed a mean value of 5.7%. According to their fatty acid composition, that is, their saturated, monounsaturated, and polyunsaturated fatty acid contents, the statistical analysis (discriminant analysis) showed three groups of samples, suggesting that the fat incorporated in these samples was obtained from different sources.

Life cycle assessment of bread produced on different scales

A case study of white bread has been carried out with the purpose of comparing different scales of production and their potential environmental effects. The scales compared are: home baking, a local bakery and two industrial bakeries with distribution areas of different sizes. Data from the three bakeries and their suppliers have been collected. The systems investigated include agricultural production, milling, baking, packaging, transportation, consumption and waste management. Energy use and emissions have been quantified and the potential contributions to global warming, acidification, eutrophication and photo-oxidant formation have been assessed.

Trends in the mediterranean diet in children from south-east Spain

In order to determine the alimentary habits of a sample group of schoolchildren for later comparison with the model Mediterranean diet, 167 children aged 6–9 from the region of Murcia, a typically Mediterranean area located in the south-east of Spain, were collected cross-sectionally, using the stratified random sampling technique. Children were interviewed on their recall of food intake over the previous 24 hours. Data were expressed in “Spanish portions” from the six food groups considered essential for a qualitative balanced diet. Our results indicate that the number of portions in the Fruits and Vegetables groups was less than that recommended ( P < 0.001), while in the Milk, Meats and Cereals groups the intake was adequate. 13,7% of the total cereal intake was from industrial bakery products. In the Fats group, the number of portions was higher than that recommended. The intake of pulses, traditionally considered one of the bases of the Spanish Mediterranean diet was below the recommended level, and was even less than that in other, non-Mediterranean, regions of Spain. the consumption of fish by Murcian children was less than one third of that of meat. In conclusion, the diet of the Murcian schoolchild population differs increasingly from the Mediterranean ideal. It is important to persuade the people responsible for these dietary changes to follow traditional alimentary habits as closely as possible, while allowing for adaptation to modern times.

Respiratory symptoms and airway responsiveness in apparently healthy workers exposed to flour dust

Our aim was to measure the levels of exposure to wheat flour dust in a modern industrial bakery, and to assess the relationship between respiratory symptoms, sensitization to wheat flour antigens and airway responsiveness in the workforce. Forty four flour-exposed male workers and 164 unexposed controls were examined. Inspirable dust concentrations were measured using personal samplers. Respiratory symptoms were assessed by questionnaire, sensitization to wheat flour antigens by skin-prick tests, and methacholine airway challenge (MAC) test using an abbreviated method. Subjects were labelled MAC+ if forced expiratory volume in one second (FEV1) fell by 20% or more. The linear dose-response slope (DRS) was calculated as the percentage fall in FEV1 at last dose divided by the total dose administered. Inspirable dust concentrations were within acceptable limits in all working areas but one. The proportion of subjects with one or more symptoms and with airway hyperresponsiveness was significantly greater among flour-exposed workers than among controls. Using logistic or linear regression analysis, airway responsiveness was found to be strongly related to working at the bakery and to the baseline level of lung function. A positive skin-prick test was found in only 11% of flour-exposed workers and 6% of controls. In conclusion, our data show that despite exposure to relatively low concentration levels of inspirable flour dust, subjects working in the baking industry are at risk of developing both respiratory symptoms and airway hyperresponsiveness.