mauley's technology of - verbundzentrale des · pdf filecontents ix 17 flavours, spices and...

Woodhead Publishing Series in Food Science, Technology and Nutrition:
Number 217
Mauley's technology of
biscuits, crackers and cookies
Fourth edition
Edited byDuncan Manley
Consultant, Duncan Manley Limited, Stamford
Email: [email protected]
Oxford Cambridge Philadelphia New Delhi
WOODHEAD
PUBLISHING
Woodhead Publishing Limited, 2011

Contents
Contributor contact details xvii
Woodhead Publishing Series in Food Science, Technologyand Nutrition xix
Preface to the fourth edition xxvii
Preface to the third edition xxix
Preface to the second edition xxxi
Preface to the first edition xxxiii
1 Setting the scene: A history and the position of biscuits 1D. Manley, Consultant, Duncan Manley Ltd, UK1.1 Introduction 1
1.2 The beginnings of biscuit manufacturing 31.3 Ingredients and formulation development 6
1.4 Engineering 7
1.5 References and useful reading 9
Part I Management of technology in biscuit manufacture 11
2 The role of the technical department in biscuit manufacture 13
D. Manley, Consultant, Duncan Manley Lid, UK
2.1 Introduction 13
2.2 The requirements of the technical (or technology)
department 15
2.3 Selection of staff for the technical department 16
2.4 Facilities for the technical department 18
2.5 Liaison with other technical establishments 19
2.6 Support for purchasing 20
2.7 Support for training 20
2.8 Management of technical developments 212.9 Reference 22
2.10 Useful reading 22

vi Contents
3 Quality management systems and hazard analysis critical control
point (HACCP) in biscuit manufacture 23
D. Manley, Consultant, Duncan Manley Ltd, UK3.1 Quality management 23
3.2 Management of product safely 25
4 Quality control and good manufacturing practice (GMP) in the
biscuit industry 29
D. Manley, Consultant, Duncan Manley Ltd, UK
4.1 Principles and management 29
4.2 Quality control tasks for finished product inspection 31
4.3 Quality control tasks for ingredient and packaging materials.... 32
4.4 Good manufacturing practice (GMP) 34
4.5 Hygiene surveys 39
4.6 References 40
5 Process and efficiency control in biscuit manufacture 41D. Manley, Consultant, Duncan Manley Ltd, UK and M. Wilkes,MW Associates, UK
5.1 Process control and efficiency 41
5.2 Process audit 45
5.3 Process control checks and records for plants with nocontinuous monitoring sensors 45
5.4 Making process control measurements 50
5.5 Action procedures as a result of product measurements 52
5.6 Instrumentation for monitoring 52
5.7 Efficiency and integrated plant control 52
5.8 Qutline of the instrumentation that is available 54
5.9 Troubleshooting 65
5.10 Energy efficiency 665.11 References 67
5.12 Useful reading and suppliers of instruments 67
6 Product development in the biscuit industry 69
D. Manley, Consultant, Duncan Manley Ltd, UK
6.1 Introduction 69
6.2 Product development 70
6.3 Facilities for process and product development 736.4 Assessing products 776.5 Establishing the product specification 866.6 Management of product development 876.7 References 92
7 Sustainability in the biscuit industry 93R. Brightwell, United Biscuits, UK7.1 Introduction 93
7.2 Key drivers for sustainability in the biscuit industry 94

Contents vii
7.3 Carbon emissions and energy use 98
7.4 Reducing water use 987.5 Reducing waste 1007.6 Packaging 1017.7 Other options for improving sustainability 102
Part II Materials and ingredients for biscuit manufacture 105
8 Choosing materials for biscuit production 107D. Manley, Consultant, Duncan Manley Ltd, UK8.1 Introduction 107
8.2 Important technical aspects 1078.3 Important commercial aspects 1078.4 Programme for the meeting with a supplier 108
9 Wheat flour and vital wheat gluten as biscuit ingredients 109D. Manley, Consultant, Duncan Manley Ltd, UK and B. Pareytand J. A. Delcour, Katholieke Universileit Leuven, Belgium9.1 Introduction 109
9.2 Flour from the viewpoint of the miller 1109.3 Flour from the viewpoint of the biscuit manufacturer 1279.4 Vital wheat gluten 1319.5 References 131
10 Meals, grits, flours and starches (other than wheat) 134D. Manley, Consultant, Duncan Manley Ltd, UK10.1 Introduction 134
10.2 Cereal-based materials 135
10.3 Non-cereal flours and starches 139
10.4 References 141
10.5 Useful reading and addresses 141
11 Sugars and syrups as biscuit ingredients 143D. Manley, Consultant, Duncan Manley Ltd, UK11.1 Introduction 143
11.2 Common sugar, sucrose 145
11.3 Syrups 15311.4 Sugars and syrups from starches - glucose 15411.5 Non-diastatic malt extract 158
11.6 Maillard reaction 158
11.7 Polyols 15811.8 References 159
12 Fats and oils as biscuit ingredients 160G. Atkinson, AarhusKarlshamn UK Ltd, UK111 Introduction 160
12.2 The role of fat in biscuits 161

viii Contents
12.3 The chemistry and physical properties of fats 16412.4 Quality and handling issues of fats 17112.5 Key characteristics of fats for biscuits 17212.6 Quality control of fats 17512.7 General specification requirements for oils and fats 17812.8 Challenges for the biscuit manufacturer 17812.9 References 179
13 Emulsifiers (surfactants) and antioxidants as biscuit ingredients 181D. Manley, Consultant, Duncan Mauley Ltd, UK
13.1 Introduction 181
13.2 Function of emulsifiers in biscuits 182
13.3 Types of food emulsifiers 18213.4 Reduced fat biscuits 186
13.5 General use of emulsifiers in biscuit doughs 18713.6 Application help 18813.7 Antioxidants 189
13.8 References 190
14 Milk products and egg as biscuit ingredients 191D, Manley, Consultant, Duncan Manley Ltd, UK14.1 Introduction 191
14.2 Milk and milk products 19214.3 Egg 19814.4 References 198
15 Dried fruits and nuts as biscuit ingredients 200D. Manley, Consultant, Duncan Manley Ltd, UK15.1 Introduction 200
15.2 Dried grapes 201
15.3 Other dried fruits used in biscuits 20415.4 Fruit pastes and syrups 20515.5 Tree nuts 20515.6 Peanuts, arachis or ground nut 20715.7 Health problems associated with nuts 20715.8 References 20815.9 Useful reading 208
16 Yeast and enzymes as biscuit ingredients 209D. Manley, Consultant, Duncan Manley Ltd, UK16.1 Introduction 20916.2 Yeast 209
16.3 Enzymes 21216.4 References 214

Contents ix
17 Flavours, spices and flavour enhancers as biscuit ingredients 216D. Manley, Consultant, Duncan Manley Ltd, UK17.1 Introduction 216
17.2 Sources and types of flavours 217
17.3 Suitability of a flavour material 21917.4 Flavouring of biscuits 21917.5 Flavour enhancers 220
17.6 Storage of flavours and quality control 22117.7 References 221
18 Additives as biscuit ingredients 223D. Manley, Consultant, Duncan Manley Ltd, UK18.1 Introduction 223
18.2 Common salt (sodium chloride, NaCl) 22418.3 Leavening agents 22618.4 Processing aids 22818.5 Food acids 231
18.6 Colours 232
18.7 Artificial sweeteners 233
18.8 References 234
19 Chocolate and cocoa as biscuit ingredients 235D. Manley, Consultant, Duncan Manley Ltd, UK19.1 Introduction 235
19.2 The flavour of chocolate 236
19.3 Chocolate viscosity 23719.4 Cocoa butter, cocoa butter equivalents and hard butters 23819.5 Definitions of cocoa and chocolate products 24019.6 Types of chocolate 24019.7 Supply and storage of chocolate 24119.8 Chocolate drops and chips 24219.9 Cocoa 243
19.10 Handling of chocolate and chocolate chips 24419.11 Compound chocolate 24419.12 Carob powder 24519.13 References 245
20 Packaging materials lor biscuits and their influence on shelf life 247G. L. Robertson, Food*Packaging*Environment and Universityof Queensland, Australia
20.1 Introduction 247
20.2 Packaging materials 248
20.3 Packaging and shelf life 255
20.4 Indices of failure (IoFs) 260
20.5 Package requirements to address indices of failure (IoFs) 260
20.6 References 267

x Contents
Part HI Types of biscuits 269
21 Classification of biscuits 271
D. Manky, Consultant, Duncan Manley Ltd, UK21.1 Introduction 271
21.2 Classification based on enrichment of the formulation 272
21.3 Conversion of units 278
21.4 Reference 278
22 Cream crackers 279
D. Manky, Consultant, Duncan Manky Ltd, UK22.1 History and introduction to cream crackers 27922.2 Mixing and fermentation of cream cracker doughs 28122.3 Dough piece forming 28622.4 Baking of cream crackers 28922.5 Yields from fermented doughs 29222.6 References 292
23 Soda crackers 293
D. Manky, Consultant, Duncan Manley Ltd, UK23.1 Introduction 293
23.2 Dough preparation 29423.3 Outline of typical soda cracker manufacturing
techniques 29523.4 References 297
24 Savoury or snack crackers 298D. Manky, Consultant, Duncan Manky Ltd, UK24.1 General description 29824.2 Manufacturing technology

mauley's technology of - verbundzentrale des · pdf filecontents ix 17 flavours, spices and...

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