INTERNSHIP REPORT

Muhammad Mouaz
2018-GCUF-09281
FOOD SCIENCE & TECHNOLOGY, GCUF
01ST MARCH 2022- 31ST MAY 2022
Government College University Faisalabad

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 Supervisory committee
Manager: Quality Assurance Department

o Mr. Naeem Aslam

External Supervisor:
o Mr.Rajab Ayub(Quality Executive)
o Mr.Shafeeq(QA Lab Analyst)
o Miss Saba(Microbiologist)

Internal Supervisor
o Dr. Muhammad Afzaal
Assistant Professor/Internship Coordinator (GCUF)

o Dr. Farhan Saeed

Associate Professor/Convener Internship Program

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 ACKNOWLEDGEMENT
All praises and thanks are for Almighty ALLAH who is entire source of all knowledge,
wisdom and numerous blessings for the last Prophet MUHAMMAD (PBUH) due to which
I become able to do this work.
I express my profound feelings of admiration from the core of my heart to my mother who
always helped me very kindly on all stages of my learning process and whose hands always
raised in prayers for me.
I feel great honor to express my sincere gratitude to respected head of department in
Mr. Naeem Aslam (Manager Quality Assurance, Dawn Bread).
I would like to express my special appreciations and thanks to my supervisor Mr. Rajab
Ayub (Quality Executive) for his continuous support during internship. I would like to say
special thanks to Him for his efforts for me to learn more and understand things practically.
I am also thankful to Mr. Shafeeq in (QA Lab), Miss Saba (Microbiologist) and the other
production staff of Dawn Bread who guided me well during my training in the factory.
I am thankful to all these persons that are sincere to me.

Muhammad Mouaz

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 EXECUTIVE SUMMARY

First light bread being one of its sorts in Pakistan furnishing with the best nature of
prepared items is one of the main organizations just as an incredible spot to learn and
dominate. During my temporary position program in first light bread I encountered myself to
get familiar with much more experiential information in the creation cycles of the business.
Aside from this, an expansive outline of commonsense work in Quality Affirmation
office in sunrise bread was loaded with information and useful experience. Well being
conventions just as creation lines, bundling norms and conditions, alongside the nature of
food creation were my significant spaces of learning. Insightful lab testing was likewise
examined and acquired during this temporary job program.
The report starts with the prologue of the company, the intention, its products, and its
structure covering all the departments, furthermore it includes information about labs and
processing section of different products. The assignment was to work with a professional
organization to get professional experience of the office routines and the working of the
organization at the initial level.
I worked there as an internee for the 12 weeks. I learned a lot of things related to its
product and there production. I leant many other things that will help me a lot when I will
start my professional career. I was assigned to work from processing sections where I
performed practices related to production of different products.

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 TABLE OF CONTENT

Sr. No. Title Page No.

1. Introduction of dawn bread 6

2. History of dawn bread 7

3. Company statement 8

4. Certifications 9

5. Product range 10

6. Quality control and quality assurance 11

7. Production line of products 13-30

8. Testing in laboratory 30-32

9. Research and development 32-34

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1. Introduction

Dawn bread is a gathering of private restricted organization. Every one of the individuals
from bunch depends on food items.
A family-possessed organization, First light comprehends the significance of nourishment
and taste, and is focused on giving the best bread items to Pakistan. Dawn Bread is a name
that has come to mean quality and newness in bread items. An example of overcoming
adversity that was composed by a family that is focused on true venture and thriving of the
country.
Dawn Group of Companies covers;

Prior to the establishment of Dawn Bread, the largest producer of bread products was the
public sector. However, this sector could not cope with the demands of the consumer and this
when, perceiving a change in the eating habits of Pakistanis, Dawn Bread was envisioned.
Even in the worst of times, DAWN’S commitment is to deliver our products 365 days per
year. DAWN made it possible to supply goods in the tough time that whole world has faced.
Where everyone is into saving their lives from corona virus, Dawn bread make sure to supply
food to all.

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2. History
The first Dawn plant was set up and commissioned in Karachi in October 1981 with the
purpose of creating awareness and demand for a variety of bread products. It was not long
before the name became synonymous with 'Vitamin Enriched Bread' and a second plant was
commissioned in Islamabad in 1985.
Dawn has basically gone from one solidarity to another from that point forward: it figured out
how to catch 35% of the solidified piece of the pie of all bread items in Pakistan inside a time
of beginning, and today, buyers can get to First light's prevalent items from the southern tip
of Pakistan to Peshawar in the north.
Nothing succeeds like achievement, so next came the plant in Hyderabad in January 1987, a
year that was to observe the foundation of one more plant at Lahore, in November 1987.
After union of this development, which incorporated the dispersion of First light Bread items
to Peshawar, this quality taste and newness arrived at Lahore, where the 6th plant was
charged in February 1992.
To guarantee new items supplies in metropolitan urban areas of the nation First light Bread
set up two additional plants in Karachi and Lahore.
Presently another plant is under measure in Muridke. That is supposed to be the biggest plant
of all.
For reason for normalization, the organization related itself with FMBRA of Joined Realm in
1990 to bring to get itself the line with worldwide principles of creation, innovation,
apparatus and definition.

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03: Company Statements

• dawn bread claims its first love to be the food which

drives the company towards becoming a global food
vision manufacturing name with a promise of delivering not
only taste and quality but also a huge amount of
nutrition and balanced diet through its food products.

• dawn bread guarantee themselves to create food

with the highest care and thought and always hope
that consumers also share the same level of love for
the food as the customer satisfaction is the utmost
Mission priorty of the company. All the products at dawn are
made with highest qulity ingredients all selected
with honesty and purity, pampered at right
temperature, wrapped with full warmth and
carefully presented all across the globe.

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04: Certifications

HACCP (Hazard Analysis Critical Control Point) is an internationally

accepted technique for preventing microbiological, chemical and physical
contamination along the food supply chain. Dawn bread is also HACCP
certified and CCPs are mentioned at different places in the production
halls.

Also certified with FSSC 22000.

It has 3 pillars:
 GMPs (PRPs- ISOTS22002-1)
 FSMS (HACCP)
 Additional Requirements

Halal certification.

 YUM (FSA & QSA) certification.

 SQMS.

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5. Product Range

Dawn bread is baking industry providing large number of fresh products to its consumers.
Products of dawn bread being manufactured in their plant are:

Burger buns
Rusk
Pita bread
Bread crumbs

Fruit bun
Plain cake
Cup cakes
Plain bread
Milky bread
Bran bread
Multigrain bread
Sandwich bread
Frankfurter
Muffin

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06: Quality control and quality assurance

Food industry quality control system is a comprehensive guide for the development of the
programs and systems needed to build and manage a complete basic food safety system. It
includes separate sections for each product.

HACCP (Hazard Analysis Critical Control Point)

Hazard Analysis Critical Control Point is an international food-safety system for preventing
microbiological, chemical and physical contamination along the food supply chain. Dawn
ensures food-safety by implementing the HACCP* (international food-safety) System.

HACCP Implication in the facility

Special pre requisite programs are in place and working. (GMP’s, personnel practices,
customer complaint, chemical control, cleaning, preventive maintenance, transportation and
storage, IPM, receiving, traceability, recall/withdrawal, Allergen control, Approved Supplier.
 The company has written HACCP program that is signed by senior management.
Facility has a HACCP team with members of multiple background knowledge

 The facility has finished product profiles for each product type produced.
 The facility has a process Flow diagram of each product type produced.
The facility follows the seven principles of HACCP.
1. The facility has conducted and documented a Hazard Analysis for each raw material and
process step. In the case of facilities producing or exporting to the USA or other countries
with regulations, regulatory FDA requirements for HARPC (Hazard Analysis Risk Based
Preventive Controls) will be evaluated taking into consideration the defined hazard categories
or country-defined requirements.
2. Based on Hazard Analysis, the Critical Control Points are identified, and the procedures
for controlling the hazards are described. (There are 2CCP’s that have 1st CCP applied on
sifter and 2nd have applied on metal detector
3. The Critical Limits for the CCP’s are scientifically established and recorded.
4. The facility has established procedures for monitoring the HACCP program that include
identification of frequency of activities and responsible person.
5. The facility has established Deviation from the HACCP program that includes
identification of short term and long term corrective actions.
6. The facility has established procedures for verification of the HACCP program that include
identification of frequency of activities and responsible person.
7. The facility has legible documented records of monitoring, deviation and verification
activities
 The facility conducts and document trainings on the HACCP program.

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 The CCP Identified are controlled and monitored within the HACCP master plan.
 The facility conducts the review of HACCP program annually,
 Records are available.
 Records are kept one year or two times the shelf life of the product, whichever is
longer or as defined by regulatory requirements.
 Facilities that must comply with regulatory HACCP meet the defined requirements

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07: Production lines of products

Food items being made in first light were firmly inspected and seen in this time of about a
month and a half temporary position program. Proper and effective approaches to deliver and
supply food items are being carried out in first light bread under severe clean and security
conventions.
My spaces of concentration during my temporary position at first light were to intently notice
and learn however much I can in the accompanying spaces of items
 Mixing and dough making procedures
 Appropriate amount of ingredients
 Molding process of the dough
 Proofing conditions being provided
 Time and temperature combination during baking
 Baking conditions
 De-panning of products
 Conditions of cooling tower
 Packaging of products
 Metal detection after packaging

Labeling:
manufac
turing
date,
time

expiry lot
date labeling number

pricing

These boundaries are being carried out in day break bread creation corridors for every single
item being fabricated, as the fundamental concentration and point of the business is to give
individuals best of their items under safe conditions with least expense and phenomenal
nourishing profile.

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7.1 Cake Production

Ingredients

Potasium
Flour Egg Oil
Sorbate

Baking Water
Sugar Milk Salt
Powder \Ice

Cake Ingredients and their Functions

A cake's essential ingredients are separated in to two categories.
Flour, eggs, and milk give the cake structure, while sugar,
shortening, and baking powder make it tender.

Flour:
Flour gives the cake structure and holds the other components
together. Cake flour has a protein concentration of 8 to 13 percent,
which is ideal for use in baking. The pH of the water should be about
5.2.

Sugars:
Sweeteners are made from sugar. Sugars should be finely granulated
for all types to ensure an even grain and soft texture. This sort of sugar
melts quickly and produces creamy, smooth mass. Large sugar crystals
result in a gritty texture. When creaming the sugar, use twice as much
sugar and shortening to get the greatest results. Sugar has a tenderizing
or mellowing effect on cell structure.

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Shortening:
Cake shortening should have excellent creaming qualities. It must have
good emulsifying abilities. From a flavor sense, butter is the greatest of
all baking shortenings. Cake created with butter has a lesser volume
and coarser grain than cakes made with a high-quality shortening that
has creaming properties. Shortening also aids in the moisture retention
of the completed cake.

Eggs:
Eggs and flour make a skeleton that acts as a support for the cake's
frame work. Eggs also add moisture, flavor, and color to whatever
product they're utilized in. The importance of beating eggs cannot be
over stated. They should be beaten until they can hold a decent crease.
The crease is created by slicing the beaten mass with a knife. The
emulsifying capabilities of the yolk are due to lecithin.

Milk:
When milk is utilized as a dry milk solid, it gives the cake more
richness and structure. Lactose, a milk sugar, controls the color of the
crust. Milk solids add flavor and help to keep moisture in the dish. The
water in liquid milk helps to make it more palatable.

Water:
The batter's consistency is controlled by the addition of water. It also
helps to create the protein in the flour, which helps to keep the gas
from the baking powder in the flour. During baking, the water also
works as a leavening agent, creating vapor pressure. Water gives
moisture to the cake and hence governs the finished cake's eating
properties.

Salt:
One of the cheapest components is salt. It has the ability to bring
Flavor to the table. It has a vital role in the palatability of baked goods
and should thus be handled with caution. It also helps to obtain color
by lowering the caramlization temperature of cake mixtures.

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Flavor:
It is impossible to establish a certain amount to be utilized due to
differences in flavor strength. It is far preferable to use a tiny amount
of food flavor than to over-flavor the cake. Spices, extracts, seeds, and
blooms of fragrant plants are three types of flavorings. Alcoholic
solutions containing aromatic aromas are known as extracts.

Leavening:
Cakes are leavened in three ways:

1. By incorporation of air during mixing.

2. By use of chemical leavening agents (Baking powder & baking soda)
3. By vapor pressure created in the oven.

Production
 The first step in making a cake is to combine all of the ingredients in a single
shaft mixer.
 This mixing procedure takes around 12-15 minutes to complete its operation
and generate a batter that meets the specifications and is lump-free.
 After the cake batter has been mixed, it is poured into the filling machine
using an elevation platform.

 The molds are moved forward by conveyor belts, and the cake batter is poured
into the molds.

 These are placed directly into the oven for baking and spend the appropriate
amount of time in the oven based on the commodity.

Small Cake 25 Large Cake:30 Cake\muffin

Minute Minute 15 Minute

 Baking temperature is same for all and is within the range of 190-200 Celsius.
 After baking, manual de-panning takes place and stay time of 10-
15 minutes is given at room temperature to cool them down a little

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 before packaging.
 Slicing in the case of bar cakes is done and packaging is
performed and metal detection is also done. Packaging is done
firstly into the plastic packs and then manually into the boxes with
manufacturing and expiry on it.

7.2 Shawarma Bread

Ingredients

Flour Yeast Gluten Oil Water Ice

Rework Calcium
GMS Vinegar Sugar Salt
dough propionate

Production
 For 6 minutes, combine all of the ingredients stated above. Both slow and quick
mixing take 4 and 2 minutes, respectively.
 Slow and rapid mixing speeds are 1 and 2 rpm, respectively.
 It starts out as rather thick dough, but after being dusted with dry flour, it progresses
and is finally thinned out after passing through multiple rollers.
 After that, rolling molders are used to cut the material into the necessary sizes.
 After that, they're put into greased trays with paraffin oil.
 After that, the trays are transported into proofing rooms that have particular
conditions (Proofing time 60- 70 minutes) (Humidity levels of 80-90 percent)
(Temperature conditions: 35-40 Celsius)
 After proofing the bread obviously moves towards baking procedure. Baking of
pita bread is done at five different temperatures.


ZONE1=200-210Celsius ZONE2=210-220Celsius ZONE3=220-225Celsius

ZONE4=220-225Celsius ZONE5=220-225Celsius

 After baking the trays are moved towards de-panning, cool and ready for packaging.

 Small bread is packed into bundle of 5.

 Medium bread is packed into bundle of 4.
 During packaging metal detection is also mandatory

 Printing of manufacturing and best before date is also part of labeling procedures.
 These are then stored in storage room for fresh good sand are ready for dispatch.

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7.3 Bread Production

Ingredients
o Flour
o Yeast
o Gluten
o Egg
o Salt
o Sugar
o Calcium Propionate
o Dough improver
o Water\ice

Bread Ingredients and Their Functions

The principles of baking bread have been established for thousands
of years. The basic ingredients are flour, yeast, salt and water.

Flour:
Wheat is grown in a variety of locations around the world. The
protein/gluten content of flour prepared from 'hard' wheat’s, such as those
grown in North America, is higher. In milling terms, hard and soft wheat’s
are analogous to strong and weak flours in baking.
In most loaves, wheat flour is the main ingredient. The quality of the flour is
very crucial in bread production because it has a considerable impact on the
final result.
Gluten formed when flour is wet and mixed, beaten, or kneaded to
give dough 'stretch.'
The gas produced by yeast fermentation is held in place by the elastic frame
work of gluten.

Yeast:

For yeast to flourish, it needs moisture, food, and temperature. The yeast
will develop if these conditions are met. Its role in the baking processes
 Produce carbon dioxide gas to enable the dough to rise

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  Expand the dough’s cellular net work to form bread crumb

 Give bread its characteristic flavor and aroma

Salt:
Salt is one of the most common additives used in production.

 Salt is an essential ingredient in bread, because of its ionic

nature, in the control of product water activity and therefore
mold-free shelf-life

 It is used in very small amounts to give bread flavor.

 It also helps to strengthen the gluten

 It helps fermentation to produce bread of good volume and texture.

 It enhances flavor and restricting yeast activity. Salt limits the

activity of yeast in dough and so recipes should be balanced to
take this in to account.

 Salt affects the crumb and the overall texture by stabilizing and
strengthening the gluten.

Water:
 Water is used to produce the dough.

 It is important that the correct quantity of water is used when

making bread because it affects the dispersal of the other
ingredients.
It plays an important function in the synthesis of complexes such as gluten in
bread and fermented dough’s during the mixing process.

Sucrose:
 Sucrose confers sweetness

 Color to baked products

 It also has a key function in structure formation.

 The higher the sucrose concentration, the more significant

the delay in the gelatinization temperature of the starch.

 An important role for sucrose is the effect on the water

activity of the baked product

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Emulsifiers:
Vegetable oils are used to make all emulsifiers. They are utilized to promote
dough stability as well as improve loaf volume and crumb structure, as well as
keep the softness of the loaf:
- E471:Mono-and di-glycerides of fatty acids

- E472 (e): Mono- and di-acetyl tartaric acid esters of mono- and
di-glycerides of fatty acids

- E481:Sodium stearoyl-2lactylate

- E482:Calcium stearoyl-2-lactylate

- E322:Lecithin

Enzymes:
Enzymes maybe added to the bread dough:

 To supplement the enzymes naturally present in the flour and

minimize variations caused by environmental factors such as
climate and soil quality.
 Enzymes are destroyed by heat. They are there for regarded
as processing aids

Preservatives:
 Preservatives like acetic acid (vinegar) are commonly used in
commercial baking to keep the product fresh.

Bread improvers:
Bread improvers and dough conditioners are often used in
producing commercial breads:

 To reduce the time needed for rising

 To improve texture and volume.

Ascorbic acid, hydrochloride, sodium met bisulfate, ammonium

chloride, different phosphates, amylase, and protease are all
regularly employed as bread improvers.
Production
Bread manufacture begins with the proper proportioning of ingredients in the
mixing hall. In the mixing hall, two types of mixers are now in use, both of

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which are responsible for correct ingredient mixing. The mixing procedure
takes 10 minutes for a single spiral and 7 minutes for a double spiral.
 Following the mixing procedure, the dough is elevated into the hopper
and then passed through the divider.

 The divider is adjusted to the desired dough weight and splits the
dough into equal masses, which are subsequently rounded using
rollers.

 These circular lumps of dough are then forced to fall into cups for an
intermediate proofing time of 5 to 7 minutes to make it smoother.

 Molds come in a variety of shapes and sizes.

 The dough is given the proper proving conditions.
 Humidity of 85-90 percent, temperature of 40 degrees Celsius, and
duration of 90-100 minutes
 Once the proving time is over, the bread is placed in the oven with the
molds covered to prevent the bread from losing its shape due to oven
spring and to ensure uniform look and texture.
 There are four main steps of bread baking. Once the bread is entirely
cooked, it is moved to the de-panning stage.

 Bread is brought to its slicing point after exiting the cooling towers.

 After packing, the bread undergoes a final metal detection test.

 Before it goes to shipment, it is printed with important information like

production and best before date.

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 Bread Faults, Their Causes & Remedy:
The following gives some of the more prominent faults in bread section.

Shape
Bread faults Reasons
Poor volume  Too much salt
 Too little yeast
 Weak flour under or over mixing
 Improper fermentation or proofing
 Oven too hot
Too much volume  Too little salt
 Too much yeast
 Over proofing
Poor shape  Too much liquid
 Improper moulding
 Improper proofing
 Too much steam in the oven
Burst or split crust  Over mixing
 Under fermentation
 Improper moulding
 Oven too hot
 Not enough steam in oven
Flat taste  Too little salt

Crumb and Texture

Faults Reasons
Poor flavor  Inferior, spoiled or rancid
ingredients
 Under or over fermentation
Too dense crumb  Too little yeast
 Under proofing
 Too much salt
 Too little liquid
Too coarse or open crumb  Too much yeast
 Incorrect mixing time
 Poor moulding
 Too much flour used for dusting
Gray crumb  Fermentation time too long or
temperature too high

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 Crust
Faults Reasons
Too dark  Too much sugar
 Under fermentation
 Oven temperature too high
 Baking time too long
 Insufficient steam at the beginning
of baking
Too pale  Too little sugar
 Over fermentation
 Over proofing
 Oven temperature too low
 Baking time too short
 Too much steam in the oven
Too thick  Too much sugar
 Over fermentation
 Baked too long or at a low
temperature too little steam
Blisters on crust  Too much liquid
 Improper fermentation
 Improper shaping of loaves

7.4: Burger Production

After the whole process of mixing, the dough which his according to the
standards is ready to move into the production processes.

Mixing
Mixing of ingredients together into to make as well suitable dough for the
production process of burger buns. All the ingredients from recipe mix are
incorporated well in this step.

Types of Mixing
Two types of mixing processes are being carried out:
1. Sponge dough
2. Straight dough

Sponge Dough
In this method partial quantity of ingredients are first added to proceed
towards the initial fermentation process by resting the dough in sponge station.

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 Ingredients in sponge dough include:

 Flour

 Gluten

 Yeast

 Water/Ice
All of these are added in bowl and mixing takes place for almost 6 minutes
Slow mixing 3 minutes
Fast mixing 3 minutes
Sponge temperature is 20-22 Celsius.
After 6 minutes of mixing it goes into the sponge station for resting period of 120-150
minutes.
During this time sponge undergoes the process of fermentation and rises in volume
due to the production of Co2.
Sponge is prepared with around 45 kg of flour.
The remaining amount of ingredients and 120 kg of flour is then added along with the
addition of oil for the production of smooth texture dough.

Oil being used is high quality Paraffin Oil

NOTE: Salt is not added in sponge preparation as it is considered to be anti-fermentation
agent and can inhibit the growth of microbes present in yeast leading towards the poor
fermentation process of sponge.

Straight Dough Method

In this method the process of mixing takes place by incorporating all the ingredients together
in one bowl. Ingredients being used in direct mixing include:
 Flour
 Yeast
 Sugar
 Salt
 Gluten
 Water
 Ice
 Oil
 Dough improver

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  Calcium propionate
Time and temperature conditions are set according to the environment for this type of mixing
process. Generally, time interval for direct mixing is 7 minutes 30 second.

Slow mixing 1 minute

Fast mixing 6 minutes 30 seconds
Note: Calcium Propionate also abbreviated as CP is being used as a preservative in the
production of burger buns to inhibit the mold or fungal growth in finished end product and
enhance the shelf life of the product.

Stages of Mixing

1. Homogenization:
The initial one minute of slow mixing basically indicates the process of homogenization in
which all ingredients to incorporate well with each other.

2. Hydration:
It majorly depends upon the water absorption characteristics of flour. Addition of water is
one step closer towards the smooth texture dough.

3. Development of gluten:
Hydration also compliments in this process in which gluten structure starts to develop and
elastic properties are imparted to the dough.

4. Arrival of time:
Time when dough is smooth and well texture enough to leave the mixer and proceed towards
further processing.

Molding
• The dough is then sent into an elevator machine, where it goes through a
divider that is adjusted to the necessary weight and sliced into uniform and
equal mass using a set of blades/knife.
• An equal lump of dough is next passed through a set of rollers, which have
the primary role of rounding the dough; it is then dusted with dry flour so that
it does not adhere to the conveyer and the operation may continue without
interruption.

• During the intermediate proving step, this spherical and dusty ball of dough
is moved into the cups to smooth it out.
• After this, another set of rollers is used to form the dough into a flat, formed
mass that can be pressed into the moulds and carried forward.
• After being greased, trays for moulding burger buns are moved into the area.

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 Paraffin Oil works nicely with it.
• Sensors detect these trays once they have been greased, allowing the flat
dough to travel precisely into the moulds within the tray.

• A vacuum machine is also used to remove any surplus dry flour, resulting in
a smooth surface on the buns.
• There is also a shaking platform, which performs its tasks by shaking the
trays and preparing the dough to be placed in the moulds ‘centers.
Proofing
Proofing can be defined as a process in which the dough is allowed to rest
and rise a final time before baking. During this rest period yeast ferments
the dough and produces gases, there by leavening the dough.

Proofing chamber is maintained at combination of temperature and

humidity conditions for a specific period of time depending upon the
requirement of the product.

 Humidity 80-90% Temperature 30-37C

Time Requirements 55-60minutes
Over and under proofing time and temperature requirement along with the
humidity levels within the proofer are important to maintain so that product
is leaving at optimum conditions.

Seeding
 This water showering process is done to ensure the optimum sticking
of seeds, mixed herbs, corn meal etc. Onto the buns.

 Different types of seeds are

 Sesame seeds
 Black sesame seeds
 Mixed herbs
 Corn Meal
 Proper and efficient cleaning of the seeding machine and surrounding
place along with the conveyer belt is mandatory before changing the
type of seeds. It is crucial step in order top revenant cross contamination
from the residual seeds of the previous process.

 Seeding standard for burger buns is 20-30/square inch

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 Baking
In burger hall for the baking process of buns Tunnel type oven is used
where the trays are removed onto the conveyer belt and the whole process
takes about 7.5 minutes to completely bake the buns.

ZONESOFBAKING

 It is responsible for  It is responsible for

oven spring  It is responsible the color
process.  It is responsible for the cooking development of the
for the killing of of product. product.
 Removal of
moisture and all kinds of  Baking takes  Caramelization
alcohol also takes bacteria. place process takes
place.  Temperature Here in this zone. place.
 Temperature range range is 260-270  Temperature  Temperature range
is 235-245Celsius Celsius in this range is 245- is 240-250 Celsius
in this zone. zone. 255 Celsius in in this zone.
this zone

ZONE1 ZONE2 ZONE 3 ZONE4

De-Panning
After baking, the product is transported to the other end of the oven by a conveyer belt. Over
these conveyer belts, pressure pumps are attached to create enough pressure to release the
buns from the trays.
Suction pumps are then fitted, which mechanically pull the product from the trays and allow
for de-panning.

Cooling Process of Bun

o After de-panning the buns are moved into the cooling towers.
o Where the total spent for buns is around15-20 minutes.
o Final temperature of the product before they are packed should be 30-36
Celsius

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Packaging
After cooling to the correct temperature range, they are sent to the packing machine, where
they are wrapped in plastic wraps. Depending on the company's needs and demands, four-
packs or two-packs of buns are produced. They are printed with the following information
once they have been packaged:

Manufacturing Manufacturing
time date

Best before
QR code
date

These packets are subsequently inspected by a metal detector, which is the third crucial
control step in the morning manufacturing process.
These individual packets are then manually inspected before being placed in large carton
boxes, ensuring that there are no defects or issues.
The carton boxes are then taped shut and ready to be sent to retailers.

Expiry Date Duration on Products

Sr. No PRODUCT CHAIN EXPIRY DATE

1 Local Supply Buns 6Days
2 ATA Product 6Days
3 Restaurant Chains 4Days
4 McDonalds 3Months

McDonalds' need for a three-month expiration term is controlled by a simple change in

storage temperature. They're kept frozen to lengthen the product's shelf life without affecting
its physical, chemical, or sensory qualities.

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7:Testing in Laboratory
Dawn bread laboratory sections conduct a variety of chemical and microbiological tests to
assure food safety and to give safe and nutritious goods to customers.
 Moisture
 pH
 Falling Number
 Gluten Analysis
 Specific Gravity testing
 Impurity Testing
 Specific Gravity Testing

The tests listed below are done at the Dawn laboratory testing unit as part of their quality
control check to ensure that food is safe for customers to ingest.

Moisture

Equipment Required
Moisture analyzer
Method
 Electricity supply is provided to moisture analyzer to turn it on.
 Then dish his placed into it to provide the sample.
 Minimum 2grams of sample is provided in order to conduct the test.
 Lid is close and heating’s appears on the display.
 Heating electrodes in the equipment provides heat to the sample and all the
moisture is removed in this way.
 Wait until the moisture analyzer be expand show its results.

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p.H
Equipment Required
 p.H meter
 Weighing Scale

Method
 Sample to be analyzed for pH is taken and weighed by the use of weighing scale.
 5 grams of sample is required for testing.
 Addition of 50ml of distilled water is done to mix the contents together.
 Once a homogenized solution is made it can be used for testing.
 One drop of solution is poured onto the pH meter and three concurrent readings
are taken.
 In order to achieve more accurate results

Falling Number

This test is preformed to check the activity of enzyme present in flour i.e. alpha
amylase activity.

Purpose for Assessing Falling Number

 Establish flour standards

 During the preparation of the dough, there may be complications with dough
handling.
 Effect on the properties of water absorption
 Activation of enzymes in flour

Equipment of Falling Number

The equipment used in falling number consists of three components:

 Grinding Machine
 Main Chamber
 Cooler

Effect of Enzyme Activity

Flour with a proper enzyme concentration is critical for optimal production operations;
nevertheless, changes in enzyme activity can cause a variety of problems.

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A lower concentration of enzyme activity results in the formation of an exceedingly soft
product, whereas a higher concentration results in the synthesis of an exceptionally hard
product.
Equipment & Material Required

o Falling number equipment

o Weighing scale
o Moisture analyzer
o Distill water
o Test tubes
o Corks
Method
 Depending on the moisture content of the flour, take a sample
size. Generally, sample sizes between 6.97 and 7 games are
employed.
 Combine this sample with 25 ml of distil water in a test tube.
 Place the cork in the test tube and give it a quick shake.
 After 4 seconds of shaking, place the test tubes in the
apparatus.
 The apparatus configuration consists of distilling water at
100°C (boiling temperature).
 In the apparatus, there is a 60-second agitation.
 The enzyme activity measuring procedure begins.
 Within 5-7 minutes, the equipment will offer the findings.

9.Research and Development

Purpose
Development of new products
Improvement of previous products.

Basic purpose
o Increase in sale
o Increase in profit.
o To compete against competitors
o We study time and temperature relationship and process.
o We increase yeast in winter and decrease yeast in summer .

Innovative product
To modify already produced product.

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 To develop new purpose -based product.
 To attract customers, product with attractive shape and color.

Steps to new product development

Easily availability of raw materials.
Cost effective
Consumer demand
Focus medium class

Purpose of creaming in cake

 For air incorporation.
 For high volume and light texture production

 For gumminess for mastication

Purpose of Caramelization
 Color (browning)
 Flavor as a by-product.

Purpose of Millard reaction

 Flavor components.
 Color as a by-product.

Proofing purpose
 Volume
 Crust hardening

Cooling
 By radiation (heat radiate out)

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