Setting the scene: A history and the position of biscuits
- Introduction
- The beginnings of biscuit manufacturing
- Ingredients and formulation development
- Engineering
- References and useful reading
PART I MANAGEMENT OF TECHNOLOGY IN BISCUIT MANUFACTURE
The role of the technical department in biscuit manufacture
- Introduction
- The requirements of the technical (or technology) department
- Selection of staff [...]
Setting the scene: A history and the position of biscuits
- Introduction
- The beginnings of biscuit manufacturing
- Ingredients and formulation development
- Engineering
- References and useful reading
PART I MANAGEMENT OF TECHNOLOGY IN BISCUIT MANUFACTURE
The role of the technical department in biscuit manufacture
- Introduction
- The requirements of the technical (or technology) department
- Selection of staff for the technical department
- Facilities for the technical department
- Liaison with other technical establishments
- Support for purchasing
- Support for training
- Management of technical developments
- Reference
- Useful reading
Quality management systems and (HACCP) in biscuit manufacture
- Quality management
- Management of product safety
- Useful reading
Quality control and good manufacturing practice (GMP) in the biscuit industry
- Principles and management
- Quality control tasks for finished product inspection
- Quality control tasks for ingredient and packaging materials
- Good manufacturing practice (GMP)
- Hygiene surveys
- References
- Useful reading
Process and efficiency control in biscuit manufacture
- Process control and efficiency
- Process audit
- Process control checks and records for plants with no continuous monitoring sensors
- Making process control measurements
- Action procedures as a result of product measurements
- Instrumentation for monitoring
- Efficiency and integrated plant control
- Outline of the instrumentation that is available
- Troubleshooting
- Energy efficiency
- References
- Useful reading and contacts
Product development in the biscuit industry
- Introduction
- Product development
- Facilities for process and product development
- Assessing products
- Establishing the product specification
- Management of product development
- References
- Useful reading
Sustainability in the biscuit industry
- Introduction
- Key drivers for sustainability in the biscuit industry
- Carbon emissions and energy use
- Reducing water use
- Reducing waste
- Packaging
- Other options for improving sustainability
PART II MATERIALS AND INGREDIENTS FOR BISCUIT MANUFACTURE
Choosing materials for biscuit production
- Introduction
- Important technical aspects
- Important commercial aspects
- Programme for the meeting with a supplier
Wheat flour and vital wheat gluten as biscuit ingredients
- Introduction
- Flour from the viewpoint of the miller
- Flour from the viewpoint of the biscuit manufacturer
- Vital wheat gluten
- References
- Useful reading
Meals, grits, flours and starches (other than wheat)
- Introduction
- Cereal based materials
- Non-cereal flours and starches
- References
- Useful reading and addresses
Sugars and syrups as biscuit ingredients
- Introduction
- Common sugar, sucrose
- Syrups
- Sugars and syrups from starches - glucose
- Non-diastatic malt extract
- Maillard reaction
- Polyols
- References
- Useful reading
Fats and oils as biscuit ingredients
- Introduction
- The role of fat in biscuits
- The chemistry and physical properties of fats
- Quality and handling issues of fats
- Key characteristics of fats for biscuits
- Quality control of fats
- General specification requirements for oils and fats
- Challenges for the biscuit manufacturer
- References
- Useful reading
Emulsifiers (surfactants) and antioxidants as biscuit ingredients
- Introduction
- Function of emulsifiers in biscuits
- Types of food emulsifiers
- Reduced fat biscuits
- General use of emulsifiers in biscuit doughs
- Application help
- Antioxidants
- References
- Useful reading
Milk products and egg as biscuit ingredients
- Introduction
- Milk and milk products
- Egg
- References
- Useful reading
Dried fruits and nuts as biscuit ingredients
- Introduction
- Dried grapes
- Other dried fruits used in biscuits
- Fruit pastes and syrups
- Tree nuts
- Peanuts, arachis or ground nut
- Health problems associated with nuts
- References
- Useful reading
Yeast and enzymes as biscuit ingredients
- Introduction
- Yeast
- Enzymes
- References
- Useful reading
Flavours, spices and flavour enhancers as biscuit ingredients
- Introduction
- Sources and types of flavours
- Suitability of a flavour material
- Flavouring of biscuits
- Flavour enhancers
- Storage of flavours and quality control
- References
- Useful reading
Additives as biscuit ingredients
- Introduction
- Common salt (sodium chloride, NaCl)
- Leavening agents
- Processing aids
- Food acids
- Colours
- Artificial sweeteners
- References
- Useful reading
Chocolate and cocoa as biscuit ingredients
- Introduction
- The flavour of chocolate
- Chocolate viscosity
- Cocoa butter, cocoa butter equivalents and hard butters
- Definitions of cocoa and chocolate products
- Types of chocolate
- Supply and storage of chocolate
- Chocolate drops and chips
- Cocoa
- Handling of chocolate and chocolate chips
- Compound chocolate
- Carob powder
- References
- Useful reading
Packaging materials for biscuits and their influence on shelf life
- Introduction
- Packaging materials
- Packaging and shelf life
- Indices of failure (IoFs)
- Package requirements to address (IoFs)
- References
- Useful reading
PART III TYPES OF BISCUITS
Classification of biscuits
- Introduction
- Classification based on enrichment of the formulation
- Conversion of units
- Reference
- Useful reading
Cream crackers
- History and introduction to cream crackers
- Mixing and fermentation of cream cracker doughs
- Dough piece forming
- Baking of cream crackers
- Yields from fermented doughs
- References
- Useful reading
Soda crackers
- Introduction
- Dough preparation
- Outline of typical soda cracker manufacturing techniques
- References
Savoury or snack crackers
- General description
- Manufacturing technology
- Post-oven oil spraying
- Useful reading
Matzos and water biscuits
- Matzos
- Water biscuits
- Typical recipes
- Useful reading
Puff biscuits
- General description
- Puff dough preparation
- Baking of puff biscuits
- Puff biscuit production techniques
- References
- Useful reading
Hard sweet, semi-sweet and Garibaldi fruit sandwich biscuits
- General description of this group of biscuits
- Ingredients and recipes
- Dough mixing
- Mixer instrumentation
- Dough piece forming
- Instrumentation of the forming machine
- Baking
- Flavouring of biscuits
- Cooling and handling of biscuits
- Continental semi-sweet biscuits
- Garibaldi or fruit sandwich biscuits
- References
- Useful reading
Short dough biscuits
- Description of the group
- Recipes and ingredients
- Dough mixing
- Dough piece forming
- Instrumentation of the forming machine
- Baking
- Factors affecting dough piece spread during baking
- References
- Useful reading
Deposited soft dough and sponge drop biscuits
- Description of deposited biscuits
- Description of sponge batter drops
- Typical recipes
- Useful reading
Wafer biscuits
- Introduction
- The wafer oven or wafer baker
- Wafer sheet production
- Batter mixing
- Batter handling
- Batter deposition and baking
- Sheet handling, creaming and cutting
- Process control of wafer production
- Hollow rolled wafer sticks
- References
- Useful reading
The position of biscuits in nutrition
- Introduction
- Biscuits in our diets
- The evolution of biscuit nutrition
- Different biscuits for different people
- Food labelling can help – only when you understand it
- References
- Useful reading
Miscellaneous biscuit-like products
- Introduction
- Products that are made on a type of biscuit plant
- Products that are not made on conventional biscuit plant
- References
PART 4 BISCUIT PRODUCTION PROCESSES AND EQUIPMENT
Bulk handling and metering of biscuit ingredients
- Introduction
- Bulk handling
- Some technical aspects of bulk handling
- Process control in bulk storage
- Metering of ingredients to mixers
- References
- Useful reading
Mixing and premixes in biscuit manufacture
- Introduction
- General conditions for mixing
- Process control and instrumentation of mixers
- Considerations in the selection of a mixer
- Types of mixer available for biscuit doughs
- Integrated mixing schemes in the future
- Premixes
- References
- Useful reading
Sheeting, gauging and cutting in biscuit manufacture
- Principles
- Sheeters
- Gauge rolls
- Multiple roller gauging units
- Dough relaxation units
- Cutting
- Cutter scrap dough handling
- Dough piece garnishing and panning
- Control of biscuit cutting machines
- Operator maintenance requirements
- Useful reading
Laminating in biscuit manufacture
- Principles and techniques of laminating
- Types of automatic laminator
- Is laminating really necessary?
- Process control during laminating
- Useful reading
Rotary moulding in biscuit manufacture
- Introduction
- General description of the rotary moulding machine
- The formation of the dough piece
- Dough piece weight control
- Differential speeds of moulding roller and extraction roller
- Common difficulties that may be encountered with rotary moulders
- Instrumentation of a rotary moulder
- Disadvantages of a rotary moulder
- The soft dough rotary moulder and Rotodepositor
- Printing on dough pieces
- Reference
- Useful reading
Extruding and depositing of biscuit dough
- Introduction
- General description of extruding and depositing machines for doughs
- Process control of extruded and deposited biscuits
- Sponge batter drops and lady finger biscuits
- Useful reading
Biscuit baking
- Introduction
- Changes to the dough piece during baking
- Oven conditions
- Typical baking profiles
- Types of oven
- Preparation and care of oven bands
- Measurement and control in baking
- Post oven oil spraying
- References
- Useful reading
Biscuit cooling and handling
- Introduction
- Checking
- Methods and speeds of cooling
- Biscuit handling prior to packaging
- References
- Useful reading
Secondary processing of biscuits
- General considerations
- Sandwich creams
- Icing
- Jams, jellies, caramels and marshmallows
- Chocolate and chocolate flavoured coatings
- References
Biscuit packaging and storage
- Introduction
- Functions of a pack
- Types of primary packages
- Collation and feeding to wrapping machines
- Biscuit size variations
- Post wrapping operations
- Process and quality control
- Storage
- Robotics
- Useful reading and address
Recycling, handling and disposal of waste biscuit materials
- Management of waste
- Sources of waste materials
- Estimating the size of the problem
- Recycling
- Disposal of waste materials which are not recycled
PART 5 SUPPLIERS’ PRESENTATIONS
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