WHEAT

THE FOUNDATION OF
BAKERY PRODUCTS
 INTRODUCTION
Flour plays an important role in the bakery
industry. This flour is obtained from
wheat so it is necessary to learn about
wheat.
Wheat is the most important cereal among
all the grains. From quality wheat we can
get quality flour. The quality of wheat
depends up on the following conditions
soil quality of seeds
climate
manure farming techniques
 Wheat is classified in various methods
such as
 Type
 Color

 Hardness
According to the type they are
classified as …..
 Triticum aestivum also known as hard
wheat.
 Triticum compectum also called as soft
wheat.
 Triticum durum also called as durum
wheat.
Hard wheat flour contains more proteins.
This flour is mainly used in bread making.
Soft wheat flour contains low proteins. So
this flour is mainly used in the production
of biscuits, cakes and pastries.
Durum wheat is mainly used to prepare
semolina and macaroni.
According to the color they are
classified as..
 Red wheat
 White wheat

This color variation is due to the

environmental factors.
According to the hardness it is
classified as ….
 Hard wheat
 Examples of this wheat are
 Hard red winter

 Hard red spring

 Durum

 Soft wheat
 Examples are
 Soft red winter

 Soft red spring

This photo shows hard red wheat on the left
and hard white wheat on the right
HARD WHEAT
 The characteristics of this wheat is as
follows
 More protein
 More water absorption power (WAP).

 Good mixing capacity I.e. easy to mix.

 Fermentation tolerance.

 Good gas retention power.

Hence it is mainly used for yeast products.

SOFT WHEAT
 Its characteristics are as follows
 Less protein
 Less water absorption power ( WAP )

 Poor mixing capacity

 Poor fermentation tolerance

Hence it is mainly used to make biscuits, cakes and

pastries.
STRUCTURE OF WHEAT
 The kernel of wheat is a store house of
nutrients. The wheat is classified into 3
principal parts they are ….
 Bran
 Germ

 Endosperm
BRAN
 Wheat contains 15% of bran. It is the
outer portion of wheat. It has several
layers. They are
 Epidermis
 Epi carp
 Endo carp
 Testa
 Aleurone layers
 Skin or aleurone cells

The color of the wheat is due to the testa. This layer

protects the endo sperm.
BRAN
 The aleurone layer has small cells, these cells
have enzymes, which converts starch into sugar
and it gives starch to the flour.
 Bran contains more nutritional value, even
though it is removed during the milling process,
as the sharp edges may cut down the gluten.
Hence, the gas retention power is reduced and
this in turn will reduce the volume of the bread.
 During milling bran is removed and is used as
animal feed.
GERM
 Wheat contains 2.5% of germ. It is the
sprouting section of the seed.
 During milling, germ is removed because
it has fat content that will spoil the flour
quickly.
GERM
ENDOSPERM
 Wheat contains 82.5% of endosperm. Although
primarily starch it contains the following nutrients
 Protein
 Pantothenic acid

 Riboflavin

 Niacin

 Thiamine

During milling endosperm is separated from bran and

germ.
MILLING
 Milling means conversion of wheat into
flour. There are two methods of milling
they are …
 Stone milling / home milling
 Roller flour milling
STONE MILLING
 This is an ordinary method of milling. In
this method, two circular thick stones are
used, one lying on top of the other.
 The surface of the stones are rough. This
rough surface helps to crush the wheat.
 Thus the wheat is converted into flour.
This is known as whole meal flour. It
contains bran, germ and endosperm.
STONE MILLING
QUALITIES OF WHOLE MEAL
FLOUR…
 It has more nutritive value.
 The color of the flour is dark.
 It has less shelf life.
 Small stone particles may be present in
the flour.
 The bread made from this flour, gives
delicious flavor. But such bread has a
small volume and irregular shape.
ROLLER MILLING
 It is commercial milling of wheat. Before
milling the wheat,the following steps to be
followed…
 Cleaning

 Tempering
CLEANING
 The objective of cleaning the wheat is
 To obtain pure flour.
 To avoid damaging the milling machineries.

Unless foreign particles like stones, barley, oats and

iron particles are removed, the quality of flour will
be affected and iron rods may damage the
machines causing heavy loss.
CLEANING STAGES..
 Sieving
The wheat grains, large and smaller particles like
damaged wheat stone and husk are removed.
 Magnetic separator

Here iron and steel particles are removed.

 Aspirator

By using air currants the lighter impurities are

removed.
 Disc separator

This is used to separate barley, oats and other

foreign material.
 Scrubbing
Beard on the wheat is removed by brushes.
 Entoleter

Damaged grains are separated and any

insect eggs are killed.
TEMPERING
 After cleaning the wheat is sprayed with
water. After adding water, the wheat is
soaked for a short time or a longer time.
 The time varies according to the hardness
of the wheat. It is called as tempering.
The merit of tempering are….
 The moisture of the wheat is increased.
 The bran becomes elastic and the endosperm
becomes soft, so it makes the bran removal
easier.
 The endosperm is made more friable which
reduces the power required to grind it.
 Germ is also rendered tough and flaky for easy
removal.
ELEVATOR - storage and care of wheat.

PRODUCT CONTROL - chemists inspect and classify wheat, blending is

often done at this point
MAGNETIC SEPARATOR - iron or steel articles stay here.

SEPARATOR - reciprocating screens remove stones, sticks and other

coarse and fine materials.

ASPIRATOR - air currents remove lighter impurities

DE-STONER
DISC SEPARATOR - barley, oats, cockle and other foreign
materials are removed.

SCOURER - beaters in screen cylinder scour off inpurities and

roughage.

TEMPERING MIXER - moistens wheat evenly.

TEMPERING - water toughens outer bran coats for easier
separation- softens or mellows endosperm.

BLENDING - types of wheat are blended to make specific flours.

IMPACT SCOURER - impact machine breaks and removes unsound

wheat.

FIRST BREAK - corrugated rolls break wheat into coarse

particles.
broken wheat is sifted
through successive
screens of increasing
fineness.

air currents and sieves

separate bran and
classify particles (or
middlings).

REDUCING ROLLS -
smooth rolls reduce
middlings into flour.

A series of purifiers,
reducing rolls and
sifter repeat the
process.
BLEACHING - flour is
matured and color
neutralized.
MILLING PROCESS…
 The milling has two stages…
 Break milling

 Reduction milling
BREAK MILLING ….
 This is the first operation in milling process. After
tempering, the wheat passes through break
rollers.
 There are two horizontal steel rollers which
rotates in opposite direction. The surface of the
rollers are rough. One roller rotates 3/2 faster
than the other. The break milling is done in 4
and 5 stages. The first set of roller just cracks
the wheat grain. Then they are passed through
the series of break rollers, from the last series
break flour and soji, rava or semolina are
obtained. The break flour in the first 3 stages is
also known as patent flour.
REDUCTION MILLING
 After removing the above things the rest of the
semolina is passed through the reduction rollers.
The surface of the rollers are smooth. These
rollers also rotate in opposite direction but the
speed is lesser than the break rollers.
 First stage we get semolina, flattened germ and
bran. The next reduction crushes the semolina
into fine flour and the bran and flattened germs
are removed. The flour obtained is called as
straight run flour.
BLEACHING
 The flour thus obtained is called as green flour.
It contains the high moisture and slightly
yellowish color due to xanthophylls.
 The fresh flour is not suitable for making bakery
products. It has to be bleached by oxidation.
 Some bleaching agents like chlorine, chlorine
dioxide or benzyl per oxide are used to bleach
the flour.
 The bleached flour is creamish white in color.
MATURING
 The fresh flour has poor water absorption
power, poor baking quality.
 It is improved by oxidation process and is
known as maturing.
 Some chemicals like potassium bromate,
ascorbic acid are used for maturing and to
improve the above qualities.
COMPOSITION OF FLOUR
 STARCH 70%
 MOISTURE 14%
 PROTEIN 11.5%
 ASH 0.4%
 SUGAR 1%
 FAT OR LIPID 1%
 OTHERS 2.1%
 ENZYMES [ ALBHA & BETA]
Total energy content is divided into

fat, total 6%
protein, total 14
carbohydrate, available %
80
alcohol %
0%
sugar alcohols 0%
STARCH
 Starch is not soluble in water until starch is
heated to about 140 F with six times of its weight
of water. Then the starch cells will swell and the
cell wall will burst. Now the starch becomes
soluble in water and this process is called as
gelatinisation. Starch act as a filler, as it gives
rigidity to bread dough. Starch combines with
lipid and gluten to retain the gas during
fermentation. During milling 6% amount of
starch cells are crushed and damaged due to
the rollers or type of the wheat or moisture etc.
water absorption power of the flour mainly
depends upon the damaged starch.
 The damaged starch should not be more than 7
to 9% for bread making. The damaged starch is
not essential for cake or biscuit making.
 Hot bread directly from the oven cannot be
sliced immediately because the starch is not
sufficiently stable and must be allowed to slightly
harden. When the bread cools down starch cells
shrink and becomes rigid so that the bread can
be sliced easily.
MOISTURE
 An ideal moisture content of flour is 14%. The
source of moisture is from the tempering or from
the package materials or from the humidity.
 If more moisture is in the flour it will reduce the
storage life and will induce insect infestation and
it may get fungus and bacteria and also it will
reduce the WAP of the flour. This will result in
less yields during the production.
PROTEIN
 Flour contains soluble and insoluble proteins.
Flour protein consists of
 Albumin
 Globulin
 Gliadin
 Glutenin
 Soluble proteins are useful in providing nourishment
to yeast during fermentation process for its growth
and reproduction. The insoluble protein form a
rubbery material when water is added with flour, so
when it is mixed and kneaded well, a rubbery material
is developed. This is called as gluten. It gives
structure to the baked products. Gliadin give
extensibility and glutenin gives strength and it holds
the gas during baking operation.
 The quality of the flour is decided by the gluten
content. If gluten content is more in flour then it
is suitable for high structured products like
bread.
 This bread making flour should have the gluten
from 10 to 11.5%.
 If the flour contains less gluten, then the flour is
suitable for lower structured product like cake
and biscuits.
 This flour requires low gluten content that is 7 to
10%.
ASH
 The source of ash content in flour is from the
bran. If the flour contains more ash it means it
has more bran.
 Too much ash gives dark color to the flour and
also cuts the gluten. Flour with higher ash
content will not retain as much gas during
different stages of processing and this affects
the volume and gives poor texture to the
products.
SUGAR
 Naturally flour contains a small quantity of
sugar. That is sucrose and maltose.
 It is used as yeast food to produce
carbon di oxide gas.
FATS OR LIPIDS
 This should not be more than 1% in flour.
 It contains coloring pigment carotene
which gives color to the flour. There is a
higher quantity of oil or fat in the low grade
flour then in the high grades.
 The fat or oil when separated from the
flour is pale yellowish liquid without taste
or smell.
ENZYMES
 Flour contains alpha amylase and beta amylase.
 These enzymes hydrolyze starch and convert it
in to simple sugar.during fermentation the
simple sugar is used by the yeast to produce
alcohol and carbon di oxide.
 The gas production depends upon the amount
of enzymes found in the flour.
 Indian flours have less alpha amylase. These
enzymes are necessary for producing good
quality bread.
 If these enzymes are less, the bread will have
poor volume and dull crust color.
TYPES OF FLOUR
 Bakers use two primary types of white wheat
flours. There are
 Hard flour / strong flour
 Weak flour / soft flour.
 From hard wheat we get hard flour. This type of flour
contain 11.2 to 11.8% protein, 0.45 to 0.50% ash,
1.2% fat and 74 to 75% starch. The higher protein
found in strong flour indicates a higher level of gluten.
This type of flour is mainly used for yeast products.
 From soft wheat we get soft flour. This type of flour
contains 8.4 to 8.8% of protein, 0.44 to 0.48 of ash
and 76 to 77 % starch. Due to the less protein content
the flour is mainly used in low structured product like
biscuit, cookies, sponges, short and sweet pastes.
Apart from these there are other
types of flour. They are classified
 High ratio flour
This is also known as special cake flour. This type
of flour absorbs high liquids, fats and sugar than
the normal flour.it is normally manufactured for
special order and it is used in special recipes.
This flour is normally bleached with chlorine gas.
 Whole wheat flour

It is milled from whole wheat grain and no bran or

germ is removed during milling. When using this
flour, it requires more liquid than mentioned in
the recipe.
 Whole meal flour / brown flour
In this mixture of refined flour, the content of bran
and wheat germ are more. It can also be made
by combining wheat and whole wheat flour.
 Self raising flour

It contains certain quantity of baking powder. If we

use this flour we should reduce the baking
powder quantity from the given formula.
Characteristics of good quality
flour…
 Color
color should be creamish white in color. A good
quality flour will reflect the light when it is exposed
under light. Bleaching the helps to get the color.
 Strength

There are two types of flour they are

strong weak flour
It depends upon the gluten quantity and quality
present in the flour. For making bread, strong flour
is preferred and weak flour is preferred for making
cakes and confectionery products.
 Tolerance
This is the ability of the flour to withstand the
fermentation and / or the mixing process in
excess of what is normally required to mature its
gluten property.
 High absorption power

This means the ability of the flour to hold

maximum amount of water. If the flour has less
WAP the bread will not be of good quality and
will have less yield.
 Uniformity

If the quality of flour used is not uniform then the

quality of the product will differ. So constant
monitoring and adjustment are required to get a
satisfactory result.
PASTRIES
 Pastry means the way fat is introduced into the
flour. Pastry is made out of flour, fat, sugar, egg
and water. There are different types of pastries
they are
 Short crust pastry
 Puff pastry
 Flaky pastry
 Philo / filo pastry
 Choux pastry
 Danish pastry
Short crust pastry
 It is the basic pie dough. It is
type of biscuit. It is made out of
flour, fat / butter, salt,
chemicals and little quantity of
egg or cold water.
 The basic ratio of short crust
pastry is 1 part of sugar, 2
parts of fat and 3 parts of flour.
MAKING OF SHORT CRUST
PASTRY
Methods
 Rub in method
Sift the flour. Fat and flour are
rubbed together until the mixture
turns like bread crumbs. Mix sugar
and add enough egg or water to
make the dough.
 Creaming in method

Cream the fat and then add the rest

of the ingredients.
 Boiling method

Boil the fat and water. Mix the

mixture into the flour.
PUFF PASTRY
 It is the mixture of flour, salt, sugar, chilled
water and some food acid like lemon juice,
vinegar and tartaric acid and this dough is
sheeted and laminated with fat to get the
flakiness.
Methods
 French method

 Scotch method

 English method
FRENCH METHOD
 Make a dough with flour, salt, food acid, chilled
water and some % of fat.
 Give rest for ½ hour. During this period the
remaining margarine is made into square block
and should be kept in the refrigerator for setting.
 Sheet the dough into square, slightly larger than
the fat pieces.
 Keep the fat block in the center of the dough.
The sides of the margarine should face the
corner side of the sheeted dough.
 Fold the dough from all the corner sides so that
it covers the fat.
 Chill it for ½ hour.
 Turn upside down and sheet it in square shape,
and bring the ends center and again fold it over.
 Cover and chill it for ½ hour. Then the same
process is repeated twice.
 After final sheeting the dough is chilled for one
hour.
 Sheet the dough and cut into desired shapes
and give rest for ½ hour before baking.
SCOTCH METHOD
 Chop the fat into small pieces.
 Mix this into flour and mix water. Knead it and
form a dough.
 Cover it with damp cloth and cool it for half an
hour.
 Sheet the dough into square shape and bring
the edges to the center and again fold over.
 Cool it and repeat the same process twice.
 Cut and give rest before baking.
ENGLISH METHOD
 Prepare the dough with flour, salt, food acid,
chilled water and some % of fat.
 Cover the dough with damp cloth and allow it to
rest for 30 minutes.
 Sheet the dough in to rectangular and mark it as
A , B and C.
 Spread the remaining 1/3 of the fat on A and B.
 Fold the C on B and A on C.
 Cover it and allow it to rest for half an hour.
 Repeat the same process twice and the sheet it
into desired shape.
FLAKY PASTRY
 The dough is made with flour, fat or
lard and chilled water.
 Dough is rested and is rolled into a
rectangular shape and mark it as 3
equal parts.
 Divide the fat into 3 equal parts and
proceed in the same way as that of
the English method.
 Give rest and then give a blind
folding.
 Again rest it and then sheet it and
then cut it in to desired shape.
PHILO / FILO PASTRY
 A plain paper thin pastry made
with flour, water and melted
butter. This dough is sheeted
and sprinkled with fruit and
nuts.
 Roll like Swiss roll and cut in to
desired sizes.
 Place in a tray, give egg wash
and then bake it.
 It can also be deep fried.
CHOUX PASTRY
 A hallow shell which is crisp
while eating. It can be piped
in different shapes and filled
with cream, custard and
coated with melted chocolate,
glace or fondant icing and
also decorated with nuts.
 The ingredients are flour, fat /
butter and eggs.
 Can add sugar or salt if
desired.
Method
 Take a thick bottom bowl and heat water and fat,
don’t allow it to boil.
 Sift the flour twice so that the air is incorporated
which helps in raising the pastry when baked.
 Beat eggs and add just before mixing the
mixture and add gradually with beating
continuously.
 Maintain the correct consistency and pipe this in
desired shape in a greased tray.
 Bake it at high temperature immediately and
then reduces the temperature.
 Don’t shake the tray during baking.
 It can be stored for one week.
DANISH PASTRY
 A sweet yeast dough
laminated with fat and cut
into different shapes and
use chocolate, cheese or
any sweet filling.
 Ingredients used in making
are
 Strong flour
 Sugar
 Yeast
 Fat
 water
Method
 Make a flying fermentation to check the yeast
activity.
 Mix all the ingredients and make a smooth
dough.
 Give rest for 15 minutes.
 Sheet the dough cut into small squares and fold
like French method and sheet it and cut into
desired shape.
 If filling is used the pastry should be rolled or
sealed properly. Other wise the filling will comed
outside.
 Place it on a greased tray, give egg wash and
and allow it to proof till it double its size.
 Bake it at 200 C for about 10 to 15
minutes.
 After baking give sugar syrup wash for
shinning and softness.
BREAD MAKING METHODS
 Straight dough method
 Salt delayed method
 No dough time method
 Sponge and dough method
 Ferment and dough method
STRAIGHT DOUGH METHOD

 Mix all the ingredients in one stage and knead it

until the flour protein is well developed.
 Then the dough is allowed to ferment for a
predetermined time.
 The fermentation period depends on the quantity
and quality of yeast, water, salt, strength of flour,
temperature etc.
 If the fermentation is up to 5 hours it is called as
short process method, if it takes place more
than 5 hours then it is called as long process
method.
SALT DELAYED METHOD
 Mix all the ingredients except the salt and fat.
Because salt has a controlling effect on
enzymatic action of yeast.
 Due to the absent of salt the speed of
fermentation is enhanced and gluten is matured
in a reasonable short time.
 For this method three fourth of the mixing should
be given initially and one fourth of the mixing is
given at the time of adding salt.
 Salt is added at the knock back stage. The
method of adding salt is applied as per the
convenience of individual bakery.
 Following are the ways of adding salt…
 Sifted on to the dough
 Mixed with water

 It may be creamed with fat and mixed with the total

dough.
NO DOUGH TIME METHOD
 In this method the dough is not fermented in the
usual manner.it just allowed to rest for 30
minutes.
 Because of this less fermented time, yeast
quantity should be increased to achieve the
production of gas and conditioning of gluten and
by making the dough little slacker and warmer.
 Now a days the bakers use this method for
emergency. When bread is made by this method
the bread has poor keeping quality and lacks
aroma.
SPONGE AND DOUGH
METHOD
 In this method the ingredients are mixed in two
stages – in the first stage a part of flour (60%),
proportionate amount of water all the yeast and
yeast foods are mixed together.
 This sponge is fermented for a predetermined
time.
 When the sponge is ready it is then mixed with
the remaining 40 % flour, sugar, salt, fat etc.
 Mixing operation should be carried out to the
right degree. After mixing it is allowed to rest for
30 to 45 minutes.
FERMENT DOUGH METHOD
 This is the variation of sponge dough method.
Very often a bread formula contains milk, milk
powder, eggs substantial quantity of fat and
sugar.
 The ferment is made separately and mixed with
the dough along with the remaining ingredients
and allowed to ferment for the second stage of
fermentation.
PROCESSING
 Flying fermentation
 Mixing
 Bulk fermentation
 Knock back
 Dividing and rounding
 Molding and panning
 Final proofing
 Baking
 Depanning
 Cooling
 Slicing
 Packing
CAKES & SPONGES
 CAKE is a product obtained by
baking a leavened and
shortened batter, containing
flour, egg, sugar, shortening,
milk and other liquids, flavoring
and leavening agents.
 Cake making ingredients are
classified as
 Essential ingredients- flour,
sugar, shortening / fat, egg.
 Optional ingredients- baking
powder, milk, fruits.
AS PER THE FUNCTIONS THEY
ARE CLASSIFIED AS…
 STRUCTURE BUILDERS – flour, eggs,
milk.
 TENDERIZERS- fat, sugar, baking
powder.
 MOISTONERS – milk, egg.
Different methods of cake
making
 Sugar batter method
 Flour batter method
 Blending method
 Sugar water method
 Boiled method
 All in process method
SUGAR BATTER METHOD
 In this method fat and sugar are creamed
together. Fat should be plastic in nature and
should be powdered.
 Fat should not be granular and to be used only
in room temperature.
 Because granular fats will have poor whipping
quality.
 Fat is creamed to incorporate air.
 Equal amount of powdered sugar is added
gradually and continue creaming.
 When the mixture becomes light, fluffy and
bright stop creaming.
 Now well beaten eggs are added gradually. If
added at the same time it will curdle. Curdled
batter can be rectified by adding small amount
of flour.
 Flavoring agents can be added now.
 Now flour can be sieved with dry ingredients and
added to the mixture and mixed gently.
 To adjust the dropping consistency of the batter
milk / water can be added.
FLOUR BATTER METHOD
 In this method fat and flour are creamed
together in which quantity of the flour should not
exceed the quantity of the fat.
 Fat should be plastic and flour should be added
in it gradually.
 They are creamed until light and fluffy.
 Besides egg and equal quantity of sugar is
whipped to stiff forth.
 This mixture is added to flour and fat mixture.
 The egg and sugar mixture should be added in
small portion, although the chances of curdling
is less.
 At this stage the remaining sugar is dissolved in
milk or water and added to the mixture.
 Color or flavor can also be added at this stage.
 Lastly the remaining flour can be mixed gently in
the mixture.
 Gentle mixing will lead to a good textured cake
in this method.
BLENDING METHOD
 In this method emulsified shortening, flour,
baking powder and salt are whipped
together to a light and fluffy consistency.
 Sugar, milk / any other liquid, color and
flavor are mixed together and added to the
previous mixture.
 Eggs are added at the last and the whole
mass is mixed to a smooth batter.
SUGAR WATER METHOD
 In this method all the sugar and half the
quantity of water is mixed in a bowl till all
the sugar is dissolved.
 The remaining ingredients ( flour,
shortenings, leavening and flavoring
agents) will be added.
 Egg is added at last to clear the mixture.
BOILED METHOD
 This method is used for making good quality
Madeira cake and genoise sponge.
 Butter / margarine is melted in a bowl till the
melted fat boils, as it boils remove from the fire
add 2/3rd of flour and mix thoroughly.
 Besides eggs and sugar are whisked to a stiff
consistency. Color and flavor can also be added
now.
 This egg mixture is added to the fat and flour
mixture in 5 equal parts in each part it should be
mixed properly.
 Remaining flour can be added at this stage.
ALL IN PROCESS METHOD
 In this process all the ingredients are put into the
mixing bowl together and the machine is
switched on. Wire whip is used for mixing the
ingredients.
 By controlling the mixing time and the speed the
mixture is aerated.
 Use of emulsified fats and special cake flour
( flour having soft gluten forming proteins ) will
result in good cake batter.
 ½ minute slow speed – so that all the dry
ingredients are moistened without flying off from
the bowl.
 2 minutes at fast speed – for break up of
ingredients and well aeration.
 2 minutes at medium speed – for breaking larger
air cells to small and for evenness also.
 1 minute at slow speed – to eliminate large air
cells and to convert it into fine air cells.