Prepare produce bakery-pastry,cakes products

BREAD & PASTRY PRODUCTION

Prepare and Produce Bakery Products
Prepare and Pastry Products

TRAINEE MANUAL

Polytechnic College of Davao del Sur, Inc.
Hospitality Management Department

Bread & Pastry Production 2

HOSPITALITY MANAGEMENT DEPARTMENT

BAKING &
CONFECTIONARY
ARTS

TRAINEE MANUAL

Prepare and Produce Bakery Products
Prepare and Produce Pastry Products
Prepare and Present Gateaux, Tortes and Cakes

Prepare and Display Petits Fours
Present Dessert

Trainee’s Name : _______________________________________________

Course/Year : _______________________________________________

Semester : ____________________ School Year : ______________

POLYTECHNIC COLLEGE OF DAVAO DEL SUR, INC.

Training Institution

_________________________________

Trainer/Instructor

MODULE 1
Prepare and Produce

Bakery Products

4 Bread & Pastry Production

Introduction

Prepare and Produce Bakery Products
This unit deals with the skills and knowledge required to Prepare and Produce Bakery Products
a range of settings within the hotel and travel industries workplace context.

Course Code:

FPT 121
HRM 4
GRADE 11

Nominal Hours:
30 hours

Learning Outcomes 1:
Prepare and bake yeast goods

Performance Criteria
1.1 Select required commodities according to recipe and production requirements
1.2 Prepare a variety of yeast goods to desired product characteristics
1.3 Produce a variety of yeast goods according to standard recipes and enterprise
standards
1.4 Use appropriate equipment to prepare and bake yeast goods
1.5 Use correct techniques to produce yeast goods to enterprise standards
1.6 Bake yeast goods to enterprise requirements and standards
1.7 Select correct oven conditions for baking yeast goods

Learning Outcomes 2:
Decorate and present/display yeast goods

Performance Criteria
2.1 Prepare a variety of fillings and coating/icing and decorations for yeast goods
2.2 Decorate yeast goods using fillings and coating/icing and decorations according to
standard recipes and/or enterprise standards and/or customer requests
2.3 Present/display yeast goods to enterprise standards using appropriate service
equipment

Learning Outcomes 3: Store yeast goods

Performance Criteria
3.1 Store at correct temperature and conditions of storage
3.2 Maintain maximum eating quality, appearance and freshness

Glossary

Term Explanation
Acidity
Sourness is the taste caused by the presence of acids in solution. Different types
Alcohol of fermentation produce different acids. When milk sours, lactic acid is formed,
and when vinegar is made from apples or grain, ascetic acid is formed. Sour rye
Ambient bread is made by the addition of sours or ferments containing bacteria, which
Temperature produce various acids, but mostly lactic and ascetic.
Antioxidant The alcohol formed during the fermentation of sugar by yeast is ethyl alcohol, the
same alcohol found in beer and whisky (chemically known as ethanol)
Appearance Temperature of the surrounding area, room temperature
Ascorbic acid
Baking Time A material which, when added to a product, extends the life of the product by
Boiling point protecting it against oxidisation.
Visual stimulation, whether or not it looks attractive

Vitamin C

Time taken to complete the baking process

100°C

6 Bread & Pastry Production

Term Explanation
Bake Out
Bake/Baking Bake for the full extent
Bakers Flour
Subjecting food to heat inside an enclosed area: oven
Batch
Bind Flour which produces doughs having good gas retention properties and strong,
Creaming elasticity. Usually associated with higher protein content.
Docking
A given quantity determined by the amount needed.
Dusting flour
Egg wash Combining two or more ingredients to form a mixture.

Elasticity The process of beating sugar and fat for the purpose of incorporating air.

Enzyme Punching a number of vertical impressions into a dough so that the dough will
expand uniformly without bursting during baking.
Fermentation
A flour used to prevent sticking of products to the bench or equipment.
Formula
Egg or egg yolk with some milk or water added, for brushing products prior to
Gelatinise baking to improve colouring and to give a glossy sheen when baked.

Glaze The property whereby doughs regain their original shape after having been
Gluten stretched or otherwise distorted.

Kneading A substance produced by living organisms which has the power to bring about
changes in organic materials.
Lean dough
The chemical changes of an organic compound due to the action of living
Leavening organisms (yeast or bacteria), usually producing a leavening gas.

Leavening A recipe giving ingredients, amounts to be used and a method of combining
Agent them.

Heated water entering a starch granule, rupturing it, and allowing the contents to
spill out and form a colloidal suspension.

A coating that is applied to baked products for protection and appearance.

The protein of wheat flour which combines with water forming a rubbery mass
which retains the gas and steam in baking and gives volume to the product.

To manipulate dough by folding and pressing until the required consistency is
obtained.

A dough that is not very rich in fat, sugar and eggs, or one that contains a
smaller percentage of these ingredients than the average.

Raising or lightening by air, steam or gas (carbon dioxide). The agent for
generating gas in a dough or batter is usually yeast or baking powder.

Ingredients used to introduce carbon dioxide, like yeast or baking powder.

Term Explanation
Moulding
Moulding Manipulation of dough to provide a desired size and shape.
Oxidization
Proof Manipulating dough into the desired shape.
(American)
The colouring of certain fruits due to exposure to air.
Prove
(Australian) The rise of yeast doughs during proving, usually referred to as the amount of
increase in volume of the product after being shaped and before going to the
Prover oven: half prove = 50% increase in volume three-quarter prove = 75% increase
Leavening full prove = doubling in volume.
Agent The rise of yeast doughs during proving, usually referred to as the amount of
Quark increase in volume of the product after being shaped and before going to the
Rich Dough oven: half prove = 50% increase in volume three-quarter prove = 75% increase
full prove = doubling in volume.
Shortening A cabinet into which yeast goods are placed before baking.
Sifting
Ingredients used to introduce carbon dioxide, like yeast or baking powder.
Skinning
Slack dough A mild tasting curd cheese. It is moist in texture and used in fillings and toppings.
Water
absorption One that contains more than average of the enriching ingredients fat, sugar and
eggs.
Zest Fat or oil used to tenderise baked products.
Zitron
To pass through a fine sieve for effective blending, for aerating and to remove
foreign or oversized particles.
The drying out and forming of skin on uncovered doughs.

A dough containing excess water.

Water required to produce a dough of a desired consistency. Flours vary in
ability to absorb water. This depends upon the age of the flour, moisture content,
wheat from which it was milled, storage conditions and milling process.
The finely grated oily coloured outer skin of washed, untreated citrus fruit.

The candied fruit of the cedrat tree, green to yellow in colour; the flavour of its
fleshy aromatic part is desirable in European festive baking.

8 Bread & Pastry Production

Learning Outcomes 1:
Prepare Bakery Products

1.1 select required commodities according to recipe
and production requirements

Flour

Wheat is the prime grain that flour is obtained from for the baking industry. White flour is the
most popular flour. This is because other parts of the wheat grain are harsh and are unpopular
with the general public. This is not to say they are not good to eat.

The following information relates to doughs for bread and yeast goods, not pastry.

Flour consists of the following elements on average:

Starch 64 – 71%
Protein 9 – 14%
Sugar 2 – 4%
Moisture 11 – 15%
Fat 1 – 2%
Enzymes naturally occurring in wheat flour

STARCH 64% – 71%, provides main body structure through gelatinisation – bursts (through
heat) and swell.

Starch is broken down by enzymes into simple sugars, which are to be used by yeast as food.

PROTEINS Soluble: 9 – 14%

Gluten is formed when insoluble proteins (Glutenin and Gliadin) are hydrated with moisture,
normally water.

The combination of these two proteins allows the flour to ‘take up’ water and hold the moisture
within the gluten structure. When this gluten is developed it becomes tough and elastic
allowing bread dough to expand and hold gas produced during fermentation

In unleavened dough like pastry this gluten structure allows for it to be stretched out over a
large area without breaking.

It is grey, tasteless and is tough and slightly elastic.

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Glutenin - gives strength.
Gliadin - provides elasticity.
SOLUBLE PROTEINS: 1% –2%, Albumin, Globulin and Protease.

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SUGAR

Sucrose 2 – 4%: all plant material naturally contains sugar.
1.5 – 2% is sufficient for gas production up to 5 hours (Bulk
Ferment Time) plus glucose, plus dextrose (inversion of cane
sugar).

If flour is low in these sugars, malt can be added to formulae, to
allow longer Bulk Fermentation Times. (BFT)

MOISTURE 11 – 15%

The natural proportion of water depends on conditions of growth, storage and milling. Wheat is
a hard grain and needs to be soaked in water to aid the milling process.

There are laws pertaining to the amount of moisture allowed in flour. In Australia it cannot be
more than 15%.

FAT 1– 2%; this contains carotene, the colouring pigment of flour.

ENZYMES

Diastatic – Amylase change starch in sugars.

Proteolytic – Conditions the proteins

Responsible to soften the gluten, dough tolerance is reduced and could cause collapsing of
the bread, especially in wholemeal products.

Factors influencing flour behaviour:

 Quantity and quality of gluten
 Diastatic capacity, the ability to change starch into sugars to provide food for the yeast

to ferment through enzymatic activity.

Salt

Salt is a natural mineral that consists of 6 parts chlorine and
4 parts sodium.
Functions of Salt are:

 Controls fermentation
 Toughens gluten (stabilising it)
 Increases volume
 Enhances flavours in bread and provides product with its characteristic flavour
 Controls dough – lack of salt results in doughs which are sticky and are difficult to

handle

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 Increases shelf life: acts as an antiseptic - suppresses activity of bacteria, is
hydroscopic – attracts moisture

 Improves crust colour.

12 Bread & Pastry Production

Yeast

Baker’s yeast, Saccharomyces cerevisiae, is manufactured specially for
the production of Yeast Goods.
It is a unicellular organism yet each microscopic cell contains a multitude
of enzymes capable of carrying out the most intricate series of chemical reactions.
Because it is a living organism, baker’s yeast is very perishable and must have optimum
storage conditions.
Compressed yeast should be stored in dark and cool conditions, it is best used for up to two
weeks after manufacture, as it slowly loses its strength.
Yeast produces carbon dioxide and Ethyl alcohol, by changing sugars.
The activity of yeast is destroyed at temperatures above 55°C. and may be severely impaired
at temperatures over 45°C.
Production of Flavour
Imparts flavours during fermentation through flavour substances such as organic acids, esters,
alcohols and ketones.
Nutrition
Yeast is rich in protein and B Vitamins. It must not come into direct contact with salt, sugar or
fat.
Available Forms of Yeast

 Compressed
 Dried
 Creamed or liquid.
Rate of Fermentation and Yeast Activity
These are controlled by the following:
 Sugar quantity:
 Up to 5.0% speeds up fermentation
 Over 5.0% slows down or retards fermentation

Bread & Pastry Production 13

 Water added to the dough:
 More water makes softer doughs - faster rate
 Less water makes tighter doughs - slower rate
 Dough temperature:
 The warmer the dough temperature, faster rate of fermentation
 The cooler the dough temperature the slower the rate of

fermentation
 Acidity:
 4 – 6 pH range. Outside these, activity is slower
 Yeast Quantity:
 Lower quantities of yeast will result in longer proof.
Amounts of salt and fat also inhibit the rate of fermentation or the activity of yeast.
Remember: yeast is a living thing. It needs to be cared for and used properly.

Water

 Hydrates gluten forming proteins (Gliadin and Glutenin)
 Dissolves and disperses salt and sugars and carries sugars to the yeast which it can

only use in liquid form
 Provides moisture for yeast to grow
 Hydrates dry yeast and disperses both dry and

compressed
 Controls dough temperature
 Controls dough consistency
 Wets and swells starch during baking (gelatinisation) – makes it available to analyse

enzymes
 Controls enzyme activity (enzymes are active only in liquid or semi liquid mediums)
 Increases shelf life
 Contributes to eating qualities.
Bread Improvers
 Ensures additional food supply for yeast
 Contains malt which is changed into maltose and changes starch into simple sugar

easily fermentable by yeast

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 Contains chemical stimulants ensuring adequate source of nitrogen – essential for
building up protein in newly forming yeast cells

 Modifies gluten so that the dough is mature as it comes from the mixer. This is required
to hold increased CO2 Gas produced by the fermenting yeast.

Dough Improvers basically assist in 2 areas –
 GAS PRODUCTION
 GAS RETENTION

This is what makes a yeast dough rise.

Bread & Pastry Production 15

Optional ingredients and their functions

Milk powder Malt products
Soya flour Emulsified fats
Margarine Shortening
Currants Bran
Nuts Gluten (dry/wet )
Bacon Mould inhibitors
Jams Egg
Honey Seeds
Sultanas Coconut
Cheese Mixed peel
Spices Crumb softeners
Various grains Sugar

These extra ingredients may be added to a basic yeast formula to improve product qualities in
the following areas:

 Improve eating qualities
 Add nutritional value
 Add visual appeal
 Improve keeping qualities
 Add and improve flavour.

Fats

Fats are added in varying proportions to bread and yeast goods. The % below are just
an indicative amount.

Fat is a generic term; it can mean oil, butter, margarine, shortening. Each have their
own advantages and disadvantages, cost and flavour benefits. Storage requirements
also are important.

Level:

 Bread, normal 2%
 Buns 5 – 7%
 Fruit Loavel 9 – 15%
 Croissants 45%

16 Bread & Pastry Production

 Brioche up to 50%

The addition of fat to Yeast Goods will improve bread quality and although fat is not an
essential ingredient, it is important in assisting the slicing of the product, especially when
slicing bread, by lubricating the slicer blades.

Fat contributes to the volume, softer texture, brighter crumb colour and
better keeping qualities. There are many fats available to the baking
industry and some are specially manufactured to contain other
compounds such as emulsifiers (TEM and SSL). Some fats contain
sugar and others may contain water.

It should always be remembered that butter provides better flavour to the product when
deciding upon what type of fat to use.

Effects of fat

 Improves slicing

 Softer crumb

 Shorter eating crumb

 softer crust

 Better keeping qualities

 Increases volume

 Shorter eating crust

 Emulsified fats retard crumb

 Enhances firmness.

Sugar

Level:
 Up to 5% increases fermentation
 Over 5% retards fermentation.

Effects of sugar
 Softens crumb
 Sweetens
 Increases crust and whiter crumb colour
 Increased levels slacken or weaken the dough
 Greater water retention (stays moist, therefore better shelf-life)
 Better eating qualities, but high quantities result in bread flavour loss.

Bread & Pastry Production 17

18 Bread & Pastry Production

Milk Powder

Level:
“Food Standards” stipulate that Milk Bread must contain 4% non-fat milk solids on the dry
crumb.
The purpose of this regulation is to increase the food value in protein and mineral content,
therefore Skim Milk Powder (reduced fat) is mostly used.
Effects of Milk Powder in the baked products:

 Brighter and softer crumb
 Reddish brown (foxy) crust colour, due to lactose (milk sugar),

which cannot be used by yeast as food
 Increased nutritional value and flavour
 Greater volume (due to strengthening of gluten strands by the

case in protein)
 Slight sweetness (due to lactose).

Eggs

Eggs can be purchased as follows:
 Shell Egg
 Liquid Egg or Egg Pulp
 Frozen Egg

Effects of eggs
 Moistening
 Enriching due to fat in the yolk
 Increased nutritional value
 Emulsifying, due to lecithin in the yolk, therefore better keeping qualities

 aids structure, due to the proteins, which coagulate at 65 to
70oC

 Better colour and appearance to baked product
 Better eating qualities
 Better keeping.
As egg is added to a formulae, water has to decrease (in re-formulations)

Bread & Pastry Production 19

Bran

Bran is the by-product of the brake system after all the available endosperm has been
removed. Bran can vary in particle size and composition, depending on both wheat type and
the efficiency of the milling system. Some bran is sold for Human Consumption as it is a good
source of insoluble dietary fibre.
Effects of Bran

 Darker crumb colour
 Lower volume, due to the non-gluten forming proteins
 Increased water levels
 Shorter mixing times
 Higher fibre intake, assisting in bowel function.

Dried Fruit

Dried fruits evolved as a way of preserving excess fruits
when they were in abundance to be enjoyed when fruits
were not readily available because of the season.
European seasons are extreme so little food is grown in
winter. Drying of fruits made them available for Christmas
and Easter celebrations.
Almost any dried fruit or nut can be added to yeast goods.
Most commonly dried fruits used are sultanas, currants, raisins, mixed peel and dates.
All fruit should be washed prior to use and then thoroughly dried, to avoid discolouration of the
dough.

Nuts

The most commonly used nuts are hazelnuts, walnuts, almonds and
peanuts.
Nuts have a very high fat content. Large amounts used in bread making
need the addition of extra yeast and also extra gluten.
Effects of dried fruits and nuts

 Eating qualities
 Texture
 flavour

20 Bread & Pastry Production

 Colour
 Increased moisture
 Increased shelf life
 Better visual appeal.

1.2 Prepare a variety of yeast goods to desired
product characteristics

Variety of Yeast Goods

Yeast goods are defined as a sweet dough product. Bread is produced with yeast and is the
savoury version.

A sweet yeast product would be any dough with more than 5%
sugar and increased levels of fat.

Some plain doughs that are served with savoury products like
a hamburger is actually a ‘bun’ and not a ‘roll’.

Many products are classed as yeast goods.

Activity

The student should research the following and find required information
Evolution of the product. Was it:

 Cultural?
 Religious?
 Commemoration of an event?
Very few products were just invented. They evolve over time.
In the modern world customers crave variety and producers are able to introduce new varieties
from other countries very easily.

 Baba  Bienenstich  Brioche  Buchty

 Chelsea bun  Cholla  Colomba di pasqua  Croissant

 Doughnut  Gugelhof  Hot Cross buns  Panettone

 Pignoli  Streauselkuchen  Stollen  Savarin

Bread & Pastry Production 21

Panatone

This delicate and porous rich festive bread is studded with sultanas
and flavoured with candied citrus peel.

It is baked in tall cylindrical moulds and can be served with cream or fresh mascarpone.

To develop rich yeasty flavours, the dough is sometimes prepared in several stages with
prolonged maturing times in between.

Gingerbread doughs

This dough is a multipurpose dough and can be used for a variety of products. By adding
different spices and/or fruit, different shapes can be given or cut out and after baking coated
with icings or chocolate. The dough is also suited for making gingerbread
houses.

It is important not to overheat the honey at the initial stage, as it may
crystallise, rendering it useless for the dough. The honey is best heated
to 65°C, then allowed to cool to 35°– 40°C, to avoid burning the flour.

The flavour of the gingerbread will improve if the dough is prepared well ahead of use, adding
the raising (lifting) agents only just prior to using the dough.

Always use quality spices in order to achieve optimum flavour.

Gingerbread dough is baked at 180°C.

Honey cake (Israel)

This cake is traditionally served on the Sabbath and at festivals, the
particularly at the beginning of the New Year, in order to sweeten
hope for a happy year ahead.

Tsoureki (Greece)

This traditional sweet bread can be found during any major religious festival.

Its flavouring components can be many, as each family or baking professional have their own
favourite.

Most popular are orange, lemon, vanilla, cinnamon, allspice, aniseed, cloves and mace, either
singly or in any combination.

22 Bread & Pastry Production

The traditional shape is a round or braided loaf.
To simplify cutting and storing (it keeps for up to one week), the
dough can also be formed into long loaves. Cut into slices and
toasted is a popular way of serving this bread.

Bread & Pastry Production 23

Stollen (Germany)

A product popular in many European countries around
Christmas time and originating from Germany, stollen is made
from a heavy (rich in fat) yeast dough.

Some varieties contain mainly sultanas (and some candied
peel) and almonds, others almonds only or a poppyseed or nut
filling.

The cleaned sultanas are usually steeped in rum for enhanced flavour. So as not to break or
damage the fruit, they are worked under the dough last.

A somewhat tighter ferment is worked with the other ingredients to a dough, which should also
on the firm side. This hinders the flattening out (losing the intended traditional shape) of the
stollen during baking.

For uniformity and better control of the shape, special stollen moulds (tins) can be used.

After resting the dough, it is scaled into intended portion sizes and moulded round, then
worked into a roll with flat ends. Your Trainer can demonstrate the shaping of a stollen.

Baba and Savarin

Babas and savarins are very light and soft sweet yeast products, oval shaped for babas and
flat round circle shaped for Savarins. As the sponge is very soft and runny it is preferred to use
a piping bag to fill it into the special moulds.

After baking it is soaked with stock syrup and/or rum, then glazed with apricot jam and
decorated.

Babas and Savarins are usually served as dessert or for afternoon tea.

Danish Pastries

These pastries are made with a yeast dough laminated with butter (or other fats), then turns
given similar to puff paste, resulting in light and crisp pastries. They are produced in many
different shapes and sizes with a variety of fillings and toppings.

Fillings used may be custard, jam, cheese, fruit, poppyseed, marzipan and nuts with the
possible addition of dried fruit and candied peel.

24 Bread & Pastry Production

Crescent Croissants:
of
structure shaped pastries
laminated delicate, flaky
prepared from
Croissants yeast dough.
plain or
savoury) are consumed
filled with filled (sweet or
and/or or cut open and
light meats, cheese
salads (snacks,
meals).

Brioche
Yeast dough rich in butter and eggs, traditionally in the shape of a large ball with a smaller one
on top. Its smooth, delicate crumb structure is directly related to the high content of butter and
eggs.
Brioche is very versatile and can be made in a variety of shapes, some versions with added
dried fruit.
Served at breakfast (individual or toasted slices), as an entree (with a savoury filling or as an
accompaniment), as a dessert (filled with cream, mousse and/or fruit), as a lining for charlottes
or for covering pies and meat and fish dishes.

Buchty
Buchty is a fine flavoured egg and butter enriched breakfast treat, very similar to brioche. It can
be either eaten with cured meat or jams, toasted or plain. Buchty is often used in airline
catering due to its long shelf life and due to the fact that it is suitable for any meal.

Bread & Pastry Production 25

Common practice is:
 to batch buchty on trays, same way as for scones, which makes them very similar to
scones as there is mostly no side crust with the exception of the sides of the tray

26 Bread & Pastry Production

1.3 Produce a Variety of yeast goods according to
standard recipes and enterprise standards

Fruited yeast products and buns

Europe is the origin of most of the specialty products. Each of the products has a history and
also reasons, apart from the eating qualities, why it was created and why it is still produced
today.

The standard recipe for buns and fruit buns was usually the basis for many products, and is
still regarded by many as a suitable medium for a range of popular products such as buns,
fingers, scrolls, loaves and large items such as Boston buns.

Although the fermentation process is still the means of aeration, formulae and ingredient
specifications for the above products vary somewhat from bread.

Variations in ingredient quantities influence the fermentation process greatly, particularly fat
and sugar levels.

As these both can have a detrimental effect on fermentation, more yeast is usually required.

Traditionally, religion has played an important part in development of ‘special’ products.

Yeast goods containing dried fruits would be produced in seasons such as Christmas and
Easter. These are Christian religious festivals and when something special is to be produced
extra special ingredients should be used.

Dried fruits were developed as a way of preserving in times of
plenty to be used when fresh fruits were not available, Christmas
and Easter are ideal times to use these expensive dried fruits.

The range of product varieties available has been greatly
influenced by the demand for European products

Speciality Yeast Goods

Stollen, Easter Plaits, Pignoli, Three Kings Cake, Panatone, 1st of August Bread, Pinca,
Colomba

These speciality products are usually sold only on special occasions like Christmas, Easter
and New Year’s Day

All these products are very common in Europe and have religious tradition, mostly Catholic or
Jewish.

On Easter, for example after Lent (period of abstinence), a full flavoured rich bread was given
with ingredients which were not allowed during Lent (pignoli)

Bread & Pastry Production 27

Usually specialty sweet yeast products are very rich because of large amounts of butter and
fruit used.

Due to the richness of the specialty products, a sponge or ferment is used rather than a no
time dough as fat and/or acids retard the yeast. In some recipes a sour dough is even used to
ensure fermentation (Panatone).

28 Bread & Pastry Production

Special ingredient functions

Fats

The degree of richness of fruited yeast products and buns is
determined to a great extent by their ratio of fat, which affects their
flavour, crumb texture and storage life. A good quality cake
margarine or other emulsified fat is most suitable

When using the ‘instant’ dough process, an improver that is specifically designed for this
process will give the best results.

Sugar

The proportion of sugar added usually depends on the type of product, and in particular
depends on, the amount of dried fruit used, as this also greatly influences the sweetness of the
product. Caster sugar is the best choice for most doughs because it dissolves far more readily
during the mixing process.

Perhaps the most important factor relating to the amount of sugar in
the dough formula is its effect on yeast activity and the final prove
rate.

Sugar addition above 5% of flour weight may slow fermentation
appreciably, while more than 10% sugar will require the maximum
yeast quantity in the dough.

Because sugar is hygroscopic it tends to rapidly absorb dough water therefore depriving the
yeast of the moisture required to dissolve the sugars on which it feeds.

Naturally, this affects the proving process as well.

Fruit

Dried fruits should be washed and well-drained before added to
doughs.

This will reduce water absorption from the dough, increase yield,
improve eating quality, and increase volume by producing more
steam in the product during baking.

Gluten

The addition of heavy fruits to doughs can have a detrimental to
effect on the shape of the finished product. Gluten can be added
strengthen the dough structure to produce a more bolder
product.

Excess sugar can also affect the dough structure so extra gluten will
help this effect as well.

Bread & Pastry Production 29

30 Bread & Pastry Production

Production

Water temperature for required Finish Dough Temperature (FDT)

The ideal FDT for no-time, rapid or instant doughs is 27°–29°C.

The variation of water temperature is known as your experience figure
because the required water temperature to finish a dough at a pre-determined figure is based
on bakery conditions and the baker’s experience. These include:

1. Climatic conditions
2. Bakehouse environment
3. Dough size
4. Mixer speed
5. Flour temperature
6. Mixing time
7. Specialty ingredient additions–gluten, conditioners, etc.
8. Experience.

Note: In subsequent topics, students should refer back to these notes when calculating dough
quantity and required water temperature for FDT.

Calculating required water temperature for required dough temperature

Example:

Required FDT 31ºC

Multiply by 2 x2= 62ºC

Subtract flour temp 21ºC

Equals required water temp. = 41ºC

Actual:

Required FDT 28ºC
56ºC
Multiply by 2 x2= __________

Subtract actual flour temp __________
__________
Subtract Experience

Calculated req. water temp

Actual water temp. used

Bread & Pastry Production 31

Dough yield calculations

When bakers talk about a ‘1 kilogram’ dough, this weight actually applies to the flour content of
the dough only.

When all the other ingredients are added, the total dough weight is referred to as the
expected yield (from 1 kilo of flour).

TOTAL DOUGH WEIGHT = EXPECTED YIELD

In calculating the ingredient weights for a given amount of dough
(the required yield) we use the expected dough yield from1 kilo of
flour using the following formula:

New base weight of flour = required yield/expected yield

Example: Use the following dough formula to calculate the actual quantities of ingredients for
the required yield.

Ingredient % 1kg Fact Required
or

Flour 100 1.000 4.1 4.100
Salt
Improver 2 0.020 4.1 .082
Yeast
Water 1 0.010 4.1 .041

4 0.040 4.1 .164

60 0.600 4.1 2.460

Total 1.670 6.847

Expected Yield Total Dough Weight

F.D.T.27 degrees C. Finished Dough Temperature

Required yield is the number of units to be produced multiplied by the scaled unbaked weight:

3 units @ a scaled weight of 0.520 kg (3 x 0.520 = 1.560 kg)

4 units @ a scaled weight of 0.300 kg (4 x 0.300 = 1.200 kg)

5 units @ a scaled weight of 0.800 kg (5 x 0.800 = 4.000 kg)

Gives the total Required yield (dough weight) = 6.760 kg

New base weight of flour = required yield / expected yield

= 6.760 ÷ 1.670 = 4.047904 factor Round up to = 4.1 factor

Apply factor 4.1 to all ingredients 4.1 x 1.000kg flour = 4.100

Add up the new recipe and the total weight should be sufficient to produce the required dough
weight.

32 Bread & Pastry Production

Bread & Pastry Production 33

Dough making process

Modern production of doughs varies from country to country. Most are based on the
rapid dough system where additives like dough improvers are added to speed up the
process of fermentation.

Here we will discuss two dough making processes

 Rapid or ‘no time’ process (ADD Process)
 Ferment and dough process.
Both work well and should be considered when deciding what
dough is going to be used.

Activated Dough Development Process

Rapid Dough (ADD Process)

 Mix all ingredients including the addition of an A.D.D. bread improver until the gluten
protein is well developed.

 Rest for +/- 10-30 minutes (covered to prevent skinning or chilling)
 Process as usual.
Effects of the ADD process

 Yeast level from 3% upwards, depending on size of product
 Requires A.D.D. bread improver
 Warmer dough temperatures 2 8 – 30ºC. Gluten strengtheners are used to enable the

process to be effective.
 The gluten structure is modified by chemicals to produce a mature dough as it is taken

from the machine
 Ascorbic Acid strengthens (matures)
 L Cysteine or Metabisulphite softens (mellows)
 Space Saving - dough room/mixing area
 Increased bread yield – doughs do not slacken and can

include more water as well as no fermentation weight
loss.
 Divider accuracy improved – less gas evolution than in other types of dough
 If processing equipment breaks down there is less loss due to only one dough being in
process at a time. In B.F.P. doughs there will be a number of doughs in fermentation at
the same time

34 Bread & Pastry Production

 Labour Saving, due to production efficiency and no Knock
Back and BFT

 Loss of flavour, due to the production process
 Increased cost of products (improver).

Bread & Pastry Production 35

Ferment and dough process

Normally used to raise enriched breads, with high quantities of sugar and fat. Ferment
provides ideal conditions for yeast to multiply before adding the sugar to the dough.

Using the F&D process overcomes the retarding effect of fat and sugar on yeast.

FERMENT DOUGH

Made in
two stages

Stage 1: Stage 2:

Contains: Process to a dough
with remaining
20% of the flour Add Ferment ingredients:
All water

All yeast
Up to 5% sugar

Ferment for 30 minutes,
(doubled in size)

After Bulk
fermentation
(doubled in size),

dough is ready to be
scaled off

Effects of the Ferment and Dough process

 Fast fermentation, due to ideal conditions in the ferment
 No improver required
 No need for special equipment
 Improved flavour, colour, volume and texture
 Maturing is natural and takes place by the enzymic activity in

the ferment
 Loss of yield, due to moisture loss during fermentation
 More space is required for fermentation in the dough room
 Increased production cost, due to two mixes.

36 Bread & Pastry Production

Bread & Pastry Production 37

Setting a Ferment

Disperse yeast in water, whisking vigorously to break down lumps. Add small sugar to
stimulate the yeast

Mix in flour, mixing to produce a smooth batter then whisk to aerate to stimulate the action of
the yeast.

Cover and allow to rest in warm environment 32°C for approximately 25-35 mins

Allow the ferment to stand until it begins to fall away (starts to sink in the middle). This will take
approximately 25 minutes depending on the environment.

For many years the ferment and dough method was traditional because it ensured a thorough
ripening of the dough, particularly when slower types of yeast were used.

Yeast requires Dextrose sugar (Glucose) before it can ferment, but
because it contains enzymes which are capable of changing both
Cane sugar (Sucrose) and Malt sugar (Maltose) into dextrose,
almost any sweet material (except milk sugar) can act as a food
material.

Wheat flour contains 2.5% of these sugars, so any flour, water and yeast mixture will ferment.

Important to note: The optimum is approximately 12.5%; anything above this will have a
retarding effect on the dough.

When doughs are made with high sugar levels additional yeast must be used.

This is the experience component.

Remember: Yeast is a living organism, Nothing is constant.

Remember

The fermentation stage is when a lot of the dough flavour is developed so choice of method is
important.

For doughs that have large amounts of ingredients that retard the growth of the yeast, the
ferment method is better for flavour development.

Dough mixing

These doughs need to be well developed before the fruit is added.

Do not mix excessively after adding the fruit, as this may cause the fruit to break up,
particularly if it has been washed

Rest period

A recovery time of approximately 10 minutes following mixing will
ensure that the dough is suitable for processing

38 Bread & Pastry Production

Moulding
The dough pieces should be adequately moulded and/or rolled. However excessive handling
will produce roughly finished products.

Bread & Pastry Production 39

Baking pans and trays
There are two options for tray or pan preparation. Trays and pans
may be well-greased with animal or vegetable oil, or lined with
silicone paper.

However baked products should be removed from paper before
glazing.

Final prove
A temperature of 30° – 40°C with a relative humidity (RH) of 80 – 85% to prevent skinning is
recommended.

Excessive steam in the final prove will cause the formation of a tough, leathery crust and
should be avoided at all times.

Over-proving weakens the dough structure and could cause it to collapse in the oven

Baking
Due to the high sugar content, an oven temperature of approximately 190° – 210°C is usually
most suitable for buns and loaves.

To prevent the crust toughening and the possible collapse of the products, steam injection
should not be used.

Buns should only be baked enough to prevent collapse or shrinkage
after removal from the oven.

The shiny surface usually associated with this type of product is
best obtained by washing immediately after baking with a sugar
syrup or bun wash

Bun wash or glaze
A water and sugar syrup may be used with the addition of 25g per litre of powdered gelatine.

This will prevent excessive stickiness, which causes most packaging problems.

As the dry, shiny surface is dependent on the evaporation of the moisture in the wash and the
subsequent increase in viscosity of the sugar solution, it is important to apply the hot wash
immediately after removing the product from the oven.

Decoration

Decoration will be similar but slightly different for each product. Moist yeast product is
produced to be consumed on the day or soon after being produced.

40 Bread & Pastry Production

1.4 Use appropriate equipment to prepare and bake
yeast goods

Ovens

Bakery goods are baked in special ovens with a large flat base. Sometimes they will be brick
for breads but for pastries you need an oven with more versatile heating elements.

There is much better and wider choice with modern ovens. There are deck ovens, electric, gas
and woodfired.

There are rack ovens that will take an entire rack full of trays. These
will pick a rack up off the floor and rotate the rack in the oven. They
are fan forced which distributes the heat better throughout the oven.

Brick floored electric ovens have been notorious with irregular heat on
base with ‘hot spots’ and ‘cold spots’ in the ovens.

Proofer and Retarders

These are enclosed areas where the moulded dough is placed to prove.

Prove: The meaning is: if the dough rises then it has proved to
be good.

Warm environment with high humidity is required as this will
allow the yeast to reproduce and make the dough rise and
increase in size.

Modern proofers will also retard.

Retarders:

This is a chilled environment with high humidity that will
hold the dough and not allow the yeast to grow.

Modern proofer/retarders will work together, hold the raw
dough in a chilled environment and then will turn off the
chilling and turn on the heater and allow the yeast to grow,
expand the dough to its full capacity, ready to bake.

This oven can take trays with built in rack or will take an entire rack as shown in photo.

Bread & Pastry Production 41

Mixers

Spiral Dough mixer Planetary Mixer

Bun Dividers and roller Baking Deck oven

42 Bread & Pastry Production

1.5 Use correct techniques to produce yeast goods
to enterprise standards

When a customer purchases a product from bakery it is based on two reasons:
 They like the look of the product; visual stimulation
 They purchased before and want the same thing again.

If the product is not consistent then the customer will not be satisfied and will then
complain.
Consistency in product manufacture is achieved by the following:

 Correct weighing of Ingredients
 Formula balance
 Bakery products are consistent when formula balance is maintained
 Scaling weights accurately
 Mixing the dough/batter the same every time
 Cutting or weighing to correct size
 Moulding to correct shape
 Baking the same every time.
These are the skills and techniques that will return a
consistent bakery product everytime.
After baking, the product might need to be cut again into portions.
Everything must look the same
Then, when all is ready for sale, everything must be sold the same way:
Either:
 By portion, each individually
 By weight, kilogram or gram.

Bread & Pastry Production 43

Recipe for good
baking

 Weigh all not
ingredients. Do
measure them.
What is the
difference?

 Weight is measured by scaling
ingredients on the same set of weighing scales

 Measuring is done with cups and is by volume. Weight is inconsistent each time.

Example

 1 kilo weighs 1 kilo
 200gm weighs 200 gm
 1 cup of water measures 250 ml, it weighs 250 gm.
But

1 cup of flour measures 250 ml but it weighs 120 gm – 150 gm depending on several factors

Let’s deal with the weight difference.

Volume measuring by cup is good but the density of each ingredient is different so you get a
different weight from each ingredient.

Water weight is the same as volume; 1 kilo measures 1 litre; 1 litre weighs 1 kilo.

Dry Ingredients all have a different density so therefore the weight of the same volume is
different. For example: 1 cup weighs?

Sugar 225 gm Flour 150 gm Almonds Whole 120 gm

Rice, 220 gm Honey 375 gm Almonds, 125 gm
uncooked ground

The standard for measuring one cup volume: level to top of cup, not packed.
Consistency of results in baking comes with consistent measurements: WEIGH!

44 Bread & Pastry Production

Bread & Pastry Production 45

1.6 Bake yeast goods to enterprise requirements and
standards

Product characteristics that customers look for come from the following:

Colour of the product when it is finally removed from the oven is important to the visual
appeal of the product. Colour stimulates the senses and encourages the customer to
purchase.

Appearance is about form and shape. It is important that all pieces have the
same appearance.

Consistency and texture is about how it feels in the mouth when the
customer is consuming the product

Moisture content adds to the shelf life and mouthfeel of the product.

Mouth feel and eating properties.

This is achieved by maintaining consistency of production. Nobody is allowed to move away
from the given formula, shape or design.

Enterprise standards will vary from enterprise to enterprise. Consistency is the key to retaining
customers.

Buns plain and fruited buns and scrolls

When proving they need to be 75% to 90% proofed before being placed into the oven.

When baked they should have a dark golden brown colour and when glazed with sugar syrup
upon removal from the oven this will impart a pleasing gloss to the product.

If the product has spread while baking and appears wider at the base it means that the product
was overproofed before being placed into the oven.

Danish Pastry

These pastries will have a golden colour when baked due to lower
sugar content in dough.

The shape should be ‘contained’ in the shape in which they were
moulded.

Croissant

Golden brown finish with a light flaky texture. When squeezed they should give a crunch.
When cut the texture should be open and irregular in shape

Baba and Savarin

46 Bread & Pastry Production

These will have a closed texture that will open up as the pieces are soaked in flavoured sugar
syrup before serving.

Bread & Pastry Production 47

Stollen

Stollen is a traditional rich East European/German Christmas product, oval shaped with three
segments. It can be filled with almond paste, quark or cream cheese or left plain.

After baking it is dipped or brushed with butter, covered with
icing sugar and left to mature in an airtight container, to
develop the flavour (similar to a fruitcake). The butter will also
slow down the staling process and help extend the shelf life.
Characteristics:

 Compact, dense texture with a short crumb. Due to high fat content, very good eating
qualities.

Panettone

Is a light Fruit bread, originated in Milan, Italy.

Panettone is available all year around, but traditionally consumed during Christmas and
characterised by its rich flavour and unique shape, which is a tall cylinder.

French Brioche is similar in texture and richness to the Panettone, but without fruit and not as
light.

Panettone can be raised with yeast, but is traditionally made with a sour dough.

Due to the richness of the product a ferment or sponge and
dough is required to achieve the texture and the volume
characteristics.

Panettone has a shelf life of up to several weeks, if protected
from drying out by wrapping it Celloform, when they are cold.
Storing will also mature the product and improve the flavour.
Characteristics:

 Tall cylindrical shape with a rough surface
 Light large porous texture due to b.f.p.
 Rubbery eating qualities.

48 Bread & Pastry Production

1.7 Select correct oven conditions for baking yeast
goods

Yeast goods will be baked in an oven temperature ranging from 180ºC – 220ºC.
This is because they contain sugar. Products baked with sugar will darken on the crust quicker
than bread.
To control the browning of the crust the product is baked at a lower temperature:

 Appearance
 Colour on the outside crust
 Colour adds to the appearance.
Too dark and it is burnt:
 It will taste bitter.
Underbaked it will look pale and uninviting:
 A well-baked product will have a bold appearance.
Dextrinization: is produced by the action of heat and steam on the starch. The dextrin is a
carbohydrate smaller in size than starch.
This is also referred to as the Malliard Reaction after the French chemist, Louis Camille
Maillard (1876-1936).
The process is a reaction between reducing sugars such as maltose and glucose, not
sucrose, with amino acids present in the dough on the crust of the loaf.
This is responsible for the glaze and bloom on the crust.

Bread & Pastry Production 49

Work Projects

It is a requirement of this Unit that you complete Work Projects as advised by your Trainer.
You must submit documentation, suitable evidence or other relevant proof of completion of the
project by the agreed date with your Trainer.
The student will need to choose 5 different yeast goods recipes and 1 recipe must be a
laminated dough to bake.
There is a need for a plan of action to be supplied before commencement showing the recipes
to be used. With these recipes all ingredients need to be listed
1.1 List all ingredients required for production:

 Remember the role of the ingredient.
1.2. List all equipment required to complete the selected recipes:

 Make an accurate list of all equipment required
 Think laterally and leave nothing to chance.
1.3. Mix mould and bake the selected recipes:
 Speak to trainer regarding the amount that is required for assessment.

50 Bread & Pastry Production

Summary

Prepare and Bake Yeast Goods

Select commodities according to recipe requirements
Correct selection of the required ingredients needs to be undertaken to be able to
produce product with required characteristics and to enterprise standards and
expectations.

Prepare a variety of yeast goods to desired characteristics
Various yeast goods have various characteristics. Interpretation of recipes and
terminology needs to be achieved in order to produce product with required
characteristics.

Produce a variety of yeast goods according to standard recipes
Use appropriate equipment
Understanding of how equipment works and the use of professional grade equipment
is required.

Use correct technique
Development of technical skills is required in order to be able to produce quality
product

Weighing
Blending
Moulding.
are all skills that need to be developed.

Bake goods to enterprise standards and requirements
Different standards will apply at different enterprises. Industry standards incorporate
the following:

Colour of the product
Appearance
Consistency
Moisture content
Mouth feel.

Select correct oven temperatures
Different product requires different oven settings, heat and humidity settings.
Different settings produce different characteristics.
The higher the sugar content the lower the heat settings.