Food Plant Layout and Sanitation - Presentation

FOOD PLANT LAYOUT &
SANITATION
PRESENTED TO: MAM SAMIA TAHIR
PRESENTED BY: GROUP # 1
GROUP MEMBERS
 ALI MURTAZA SHAH

 MUTTIULLAH
 MUHAMMAD HAMMAD
 MUHAMMAD ARSLAN
 SHAHBAZ ALI
 RAI SHAHZAD
PRESENTATION TOPIC:
BAKERY INDUSTRY (LAYOUT)
CONTENT
 INTRODUCTION
 INDUSTRY STATUS IN PAKISTAN
 CONSTRAINTS
 COMPLETE PLANT LAYOUT
INTRODUCTION
 The bakery industry usually refers to the grain-based
food industry..
 Grain-based foods may include
 Breads
 Cakes
 Pies
 Pastries
 Baked Treats
INDUSTRY STATUS IN PAKISTAN
 The bakery industry reached a market value of USD 7.22 billion in 2018.
 Bread and Biscuits form the major baked foods.
 80% of total bakery products produced in the country.
BAKERY ITEMS
 Major Bakery Items are:
 Bars
 Breads
 Buns
 Biscuits
 Cookies
 Cakes
CONSTRAINTS OF BAKERY INDUSTRY
 Bakery products not only serve as ready to eat convenient food.
 The growth of bakery industry could be much greater if some of the problems faced.
The major problems are:
(i) Non-availability of quality raw materials
(ii) Lack of knowledge of raw materials for specific product applications
iii) Poor understanding of process equipments and process technology
iv) Enhance and maintain the quality of the finished products.
BREAD FORMULATION TYPES
Many different types of bread formulation.
 Pan bread:
This type of bread is popular in the economically developed countries including USA,
Canada, United Kingdom and European nations.
 Hearth bread or sour bread:

This category of bread is produced with or without lactic acid fermentation. Hearth
breads are baked in an open hearth. These breads are popular in France,
CONTINUE…..
 Flat bread or roti/chappati:
This category of bread is popular in Asian countries. The product is unfermented
and flat. This baked on a flat hot pan.
 Rolls and other small fermented breads:

These products generally have higher levels of sugar and fat in the formulation.
They have sweeter taste and softer bite characteristics.
LAYOUT
LAYOUT DESIGN FOR RAW MATERIAL COLLECTION
 Proper and efficient utilization of available floor space
 To ensure that work proceeds from one point to another point without any delay.
 Provide enough production capacity.
 Utilize labor efficiently
 No wet floor
 Provide ease of supervision and control
RAW MATERIAL SAFETY
 As a good practice, Certificate of Analysis (COA) should also be procured from the
supplier mentioning its batch number, date of manufacturing, expiry date and testing
parameters.
 Use of loose grounded spices and cooking oil is prohibited.
 Raw material should be stacked properly.
 Records of raw material or ingredient or any other material used in processing shall be
maintained for inspection and traceability
RAW MATERIAL TESTING
 All incoming material should be examined at the point of receiving for physical integrity
and product information mentioned on the label.
 Where necessary, laboratory tests should be made to establish fitness for use.
 Material should be inspected, tested or covered by COA to verify conformity with specified
requirements prior to the acceptance or use.
 The method of verification should be documented.
 Packaged raw material must be checked for expiry date/best before/use by date, packaging
integrity and storage conditions before accepting them and stored accordingly.
INGREDIENTS PROCESSING
 Egg shells should not be cracked upon receipt. Discard cracked eggs.
 Storage of eggs in chiller until they are needed.
 When eggs are required to store at room temperature, current batch of eggs to be used with
daily replenishment of stock.
 Cleaning of the drums containing liquid/semi-liquid raw materials for removal of debris and
droppings before taking into FBO storage.
 Material carried by tanker with broken seal or without seal is not acceptable.
 Nuts received are free from fungal or insect infestation
BAKERY FLOOR PLAN
STRAIGHT FLOOR PLAN:
A straight floor plan is the most efficient and economical floor plans, and it’s highly
recommended for bakery industries
 The fixtures and displays are positioned at right angles, making the most efficient use of both
the floor and wall space
 Commonly unused areas, like corners, can be used for display and shelving
 It’s highly customizable
 This plan is less costly to create than other floor plan types
SIEVING
The purpose of the bakery sieve is to be able to withstand
large and heavy batches of ingredients, like flour and sugar.
 The flour is generally sieved before using in bread

primarily for following reasons
 To aerate the flour
 To remove coarse particles and other impurities
 To make flour more homogeneous.
MIXING
 Equipment: Mixers
 Mixing involves the complete mixing of the ingredients
 The process of mixing involves hydration and blending
Main Purpose of Mixing:

 Blend and disperse liquid and dry ingredients to form a
homogeneous mixture
 Hydrate (starch, gluten-forming proteins and
arabinoxylans) present in flour.
 Incorporate and entrap air in the form of discontinuous gas
bubbles within the dough.
MIXING
TYPES OF MIXERS USED:
Horizontal Mixer:
 Capability of producing the largest volume of dough
 Consumer less time
 Work on continuous process principle
 Dough exit with the present exit cylo
Spiral Mixer:
 Mix in a rotating bowl that moves around a spiral-shaped blade.
 Consume less electrical power than other.
MIXING
Planetary Mixer
 Contain a central mixing wand that rotates around a
stationary bowl.
 Wand attachment can be changed as needed.
 The mixing bowl is easily detached and moved quickly.
DOUGH CONVEYING
 It is the transfer, flow, or movement of amounts of
dough via conveying equipment
 For continuous flow process, conveying belts are
mostly used
 The Large masses of dough produced during
mixing weights several tons moved along the
production line by conveyors
 This reduces or eliminates the need for the manual
labor involved in dough handling
FERMENTATION
 Equipment: Fermenter
 Controlled Environment setup
 Achieved by YEAST (Saccaromyces cerevisiae)
 Alcoholic Fermentation is carried out
 The yeast in dough breaks down the sugars to carbon
dioxide and ethanol. The gas produced during
fermentation leavens the dough
 Yeast performs well at 30 – 35 degree C and relative
humidity of 85 % and above. The optimum pH range for
yeast is 4 to 6
KNEADING
 Equipment: Dough Kneader Machine
 Consists of a large stainless steel bowl and a
high speed mixer with machine arms
 Arms are made and level up in such a way
that they can easily carry out kneading and
stretching
 Helps in stimulating the yeast activity
DIVIDING
 Equipment: Dough Divider Machine
 Divides the bulk of the dough into individual dough pieces of
similar volume and weight
ROUNDING
 Equipment: Dough Rounder Machine.
 When dough leave divider, it is irregular in shape
 Carries the dough in the upward round trough and move dough
in the rolling motion
PROOFING
 Equipment: Proofer
 Also known as Proofing oven and Proofing Cabinet
 Consist of number of trays, connected with the conveyer
belt with the overhead enclosure
 Equipped with proper controllable temperature and
humidity setup
 Hot Water is used
 Average time at this stage ranges from 5 to 20 min
BAKING
 Equipment: Baking OVEN
 Heart of the Bakery Industry
 The construction and design depends upon the nature
of product to be baked
 Temperature ranges 220 – 250 degree C
 Time range from 25 to 30 minutes
COOLING
 Equipment: Bread Coolers
 A room with suitable conditions
 Contain racks similar to the rack oven
 Generally air conditioned hence enclosed except
exterior panel
 Facilitates the flow of natural convection air current
through racks
 Improve the cooling rate
SLICING
 Equipment: Bread Slicer
 Bread loaf cannot be sliced properly by hand.
 Must use bread slicer named as reciprocating slicers.
 Straight blades mounted on two frames
 Which moves up and down in opposite direction at
high speed
 Motion imparted to by small machine
 Slicing performed by gently pushing the loaf through
blades
PACKAGING MACHINE
 Bakery products are packed in polythene bags
 A plate type electric heater attach to table which
seals the bags
 Preferred in small bakery industry
 Seals bag in two arms of machine
CONCLUSION
 Pakistan rank 5th globally in status of bakery industry in Pakistan.
 Bakery Industry also provide benefits to the farmers of the country.
 More Bakery industries, more raw material input.
 In complete layout, proper management is very much required.
THANK YOU!

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FOOD PLANT LAYOUT &

 ALI MURTAZA SHAH

 Hearth bread or sour bread:

 Rolls and other small fermented breads:

 The flour is generally sieved before using in bread

Main Purpose of Mixing:

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