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Novel baking technologies: Bread, biscuit and cake manufacturing
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Monday, 28 October, 2024, 16 : 00 PM [IST]
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Saranya S, S Bhuvana and S Anandakumar
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Around the world, baked goods are consumed as basic diet. Considering their richness in carbohydrates, dietary fibre, fats, vitamins, proteins, minerals and antioxidants that are crucial for human nutrition. With regard to the interaction between operational variables (Equipment parameters like configuration), Process variables (energy intake, analysing span), and Product variables (sensory characteristics, quality criteria), a scientific and wide ranging point of view is required for the best design and optimisation of the baking process. The three main steps used in the production of bread and bakery products are milling, kneading and baking these stages has significant impact on the quality of the products. Also, industry 4.0-enabled manufacturing system has introduced in many of the bakery plants to support data collection and intelligent decision making during optimisation and new product development. The 3D printing technologies are introduced to the bakery industry to make customised design of bakery products and designer foods.
Roller mills
Compared with conventional stone ground mill the roller mill findings show a better optimal falling number, greater flexibility, reduced heat generation, and improved dough rheology for roller mill. The roller mill has three sections, the first section is break system, operates by opening the kernel and scraping the endosperm from the bran to segregate endosperm from bran and germ. The second is sizing section, it helps by grating the bran from endosperm. Third is reduction system, here the endosperm is crushed and sheared until the flours reach a specified level of refinement. The results clearly show every part of the roller mill conveys different flours that has great rheological properties, dough stability and bread characteristics and higher kneading resistance, this equipment can be used as an alternative for traditional milling equipment in terms to getting larger yield of flour (Cappelli, Mugnaini, and Cini 2020).
Low temperature kneading
The kneading procedure is the subject of an impressive amount of research. Studies in this area have looked at a variety of strategies, including the use of alternate refrigerants in dough kneading, real-time measurement of kneading process, the development of novel kneading machines and techniques, and testing of prospective improvements. It is found, that by keeping the dough’s temperature low while kneading have better advantages over conventional method. There has been several investigations on various refrigeration systems such as coolants, carbonic snow and cooling – water jackets. An innovative solution for process controller that could automate the kneading process was put forth by Aljaafreh et al. (2017).
The design is predicated on current sensing and online reinforcement learning with operator input. The components, such as an electric current gauge, an on/off control transmission, button control devices, and an embedded system, needs to be modified just minimally for the method to work. The variation in the current load during kneading can reveal important details regarding the efficiency of the process. Since the machine's load fluctuates with the dough's extension resistance, the kneading process can be tracked using a reasonably priced current sensor.(Cappelli, Bettaccini, and Cini 2020)
Improved version of electric baking unit
In a recent research conducted, a better version of electric baking unit was fabricated for baking cakes and biscuits and got successful results. By installing heating components inside the electric oven after they have reached the desired temperature, it has been discovered that food can be baked there. The electric oven was utilised for baking a variety of products. Depending on the dimensions and shape of the cakes and biscuits, baking time ranged from 15 to 28 minutes for cakes and 18 to 35 minutes for biscuits. As a result, it was discovered to be much cheaper than gas ovens. It is also responsible for producing evenly baked food with equipment that is relatively quite easy to clean and maintain.(Rana et al. 2023)
Infrared heating
Optimised design of infrared heating is made instead of conventional baking unit in this study conducted by Emmanuel et.al.2014. Substantial heat transfer co-efficient can be attained with infrared heat, despite the weight loss that results from using quite a bit of convective heating. This infrared heating was implemented in bread making method and the results are excellent in terms of vital outcomes like baking time, weight loss, total energy input and heat input to the product. (Emmanuel Purlis 2014)
Microwave baking of bread
Using Microwave energy to bake bread is an intriguing alternative to conventional baking machine since considering it can save time and space, has a low energy cost, and produces crust less bread. Furthermore, the internal temperature rises more quickly (at higher heating rates) in products that are microwave-baked, which accounts for the decreased overall baking time (by around one-fourth) and increased energy savings. When compared to traditional baking, MW baking attain higher heating rates of up to 40°C/min as compared to 6–10°C/min.(Bou-orm et al. 2021)
Vacuum Cooling Chambers
As freshly baked bread that is hot, collapses and loses its shape, structure, and porosity when mechanically impacted, cooling is done to the bread to provide it mechanical qualities that will allow cutting and packaging. Most common practice of cooling includes natural and air-conditioned cooling, which has disadvantages like the process of cooling consumes high time periods, large size and weight of the equipment, high energy consumption, uneven cooling, and complex system of conveyors. Utilising a vacuum-based method of cooling is a novel way to rapidly cool food, especially bread. Its benefits include swifter cooling, increased volume, longer shelf life, and enhanced structural and mechanical qualities. (Awarded et al. 2021)
Reduction of acrylamide contamination
The acrylamide contamination in baked food products has been found to be reduced by the application of pre-treatments, post-baking processing, and alternative baking technologies like a vacuum baking, high-voltage electrical discharge (HVED), supercritical CO2 extrusion process (SCFX), power ultrasound, infrared, microwave, radio frequency, ultrasound assisted baking and halogen lamp baking. Scaling up revolutionary baking processes and ensuring pre-treatments are cost-effective, however, is still a difficult task. A trivial, unique and environmentally beneficial extrusion method is SCFX. In this approach, SCFX minimises the baking, leavening, proofing, and toxicant reduction times. HVED introduces a novel non-thermal method for producing dynamic solid shocks by using an electric arc. There is evidence to support the use of HVED as a best treatment to reduce 5-HMF and acrylamide levels since it is a highly complex method for preventing the production of Maillard reaction intermediates and amodari chemicals when cooking. These novel equipment used in bakery industry provide enormous advantages to the product by lessening the baking time, reducing loss of essential nutrients, improving overall quality of the product, and achieving sustainability goals by minimising energy consumption. (Devu et al. 2022)
Artificial intelligence
Rapid increase in automation never left bakery industry untouched. By enhancing production and efficiency through the use of an Automatic Control System (ACS), operations in the bread manufacturing sector are increased. It's necessary to use key modern techniques in the manufacturing of bread to save energy and the fuel. Another strategy is to strengthen the authenticity of information and resource efficiency when creating bread products. Robotics are used as ACS. Sensors and Visualisation systems (VS) are being used to find rheological properties of dough like length and time of dough proofing, proofing temperature, humidity of the proofing case and weight of dough. After slicing the bread, the interior is typically checked using an imaging device to determine the bread's baked quality. The loaf's quality is assessed by its dimensions and dough porosity. These tools help to keep a close watch on bakery goods, and depending on the type and quantity of bread, they aid in real-time data analysis. 3D bread quality x-rays are utilised technological advances to assist with food inspection. It functions by detecting the bread and producing a 3D digital model that reveals internal flaws.(Addanki, Patra, and Kandra 2022)
Machine vision based intelligent oven
An intelligent oven was designed which consists of image processor, this image processor helps us to control and identify the quality of food, through processing the structure and texture of the product, it can evaluate staling of bread, successful image processing could deliver quantifiable data on baked items within the oven.(Mehdizadeh 2022). In production lines of a biscuit plant, an Overall Equipment Effectiveness (OEE) monitoring system, integrated diagnostic and prognostic method was successfully applied. This integrated strategy offers reliable information on the state of each biscuit manufacturer in a line, and the results are consistent. The design/models is useful to predict the failure frequency, deficient products percentage, bottleneck, breakdown losses of various sections like packaging and health conditions of the equipment can also be predicted.(Amrani 2020)
Industry 4.0-enabled manufacturing system
The revolutionary data collection method and intelligent decision assistance offered by the creative production control system is designed for this study. The technology has been effectively incorporated into the organisation's current machinery and equipment. With this real-time data processing system, temperature of the oven is collected for each batch of baking biscuits/crackers, and have also observed and collected the data’s like the quality of the baked biscuits, environment conditions, surface temperatures and humidity. This data have been used as input for machine learning algorithms. The results obtained demonstrate, the control system have the ability to precisely forecast the baking conditions needed to yield a consistent product. While operators and data scientists now have a better knowledge of the data, the outcomes of the analysis enhance efficiency and consistency, which raises performance and profitability for the food business.(Konur 2021)
3D Printing for creating cake
In comparison to the conventional cake decorating method, 3D printing can not only produce one-of-a-kind artistic designs but also successfully address the issue of variations in decorators' individual skill levels, increase the effectiveness of cake decorating, and consequently lower the labour costs associated with processing cream cake and pastry. Masbernat (2021) has developed a carrot-purée dough that serves as a food ink model for printing 3D cakes. Different textures, shape, sizes and consumer appealing designs of the cakes can be obtained with this technique. The alterations in the texture, shape of the 3D cake owes to the baking temperature and time. (Masson and Blumenthal 2021)
Cake VR: Social VR Cakes
Development, utilisation, and professional assessment of Cake VR, a social virtual reality application that enables users to collaborate virtually with pastry chefs on the design of cakes. This research was conducted in the Netherlands, allowed their participants to design their dream cake in a simulated world (in a virtual bakery) and the chosen chefs were allowed to recreate the cake in the real world and then send the cake to the particular location for celebration. CakeVR has increased communication efficiency during cake modification and improved shared understanding during the co-design process by enabling natural gestural conversations, readily apparent 3D object manipulations, and immediate 3D visualisations. (Mei and Cesar n.d.)
The Indian bakery market stood at a value of approximately US$10.1 billion in 2022. The market is further estimated to grow at a CAGR of 9.6% between 2023 and 2028 to reach a value of US$17.44 billion by 2028. Bakery processing equipment of the future will offer manufacturers improvements in efficiencies and reduction in downtime. Equipment manufacturers recognise that fulfilling bakers’ and snack processors’ many equipment needs won’t be easy. The Indian bakery market is being supported by the thriving biscuits and cookies sector in the region with the increase in population and the hype in the demand for products, there is a constant need for the industries to adopt various automated equipment and technologies that can deliver the products at high rate, less time, enriched nourishment and advanced acceptability among consumers.
(The authors are associate professors, Department of Food Packaging & System Development National Institute of Food Technology, Entrepreneurship and Management - Thanjavur (NIFTEM-T) Tamil Nadu)
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