Bakeries and Confectioneries
Bakeries and Confectioneries
Bakeries and Confectioneries
B akeries
and
C o nfectioneries
CONCH A COLL A R A N D
C R I S T I N A M . RO S E L L
Contents
19.1 Introduction
560
19.2 By-Products and Wastes Generated during Processing
of Food Products in Bakeries and Confectioneries:
Qualitative and Quantitative Aspects
561
19.3 Potential of the By-Products from Bakeries and
Confectioneries for Prospective Production of Biological
of Commercial Significance
563
19.3.1 Use of Cereal By-Products as Animal Feed
564
19.3.1.1 Separation of Bakery Products
566
19.3.1.2 Processing of Bakery Waste for Feed
Preparation
566
19.3.1.3 Commercial Products for Feeding
Obtained from Bakery Waste
568
19.3.2 Production of Sourdough from Bakery
By-Products
568
19.3.3 Production of Sugars or Polysaccharides
570
19.3.4 Isolation of Phytosterols from Cereal By-Products 572
19.3.5 Production of Organic Acids from Cereal
By-Products and Bakery Wastes
573
19.3.6 Production of Dietary Fiber from Cereal
By-Products
574
19.3.7 Production of Proteins and Enzymes from
Cereal By-Products
575
19.3.8 Biofuel
576
19.3.9 Miscellaneous
577
19.4 Socioeconomic Aspects of the Identified Value-Added
Processes
578
559
560
580
581
583
584
19.1 Introduction
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Table 19.1 Proximate Composition of Dried Bakery By-Products Reported by Different Authors
NUTRIENT
AL-TULAIHAN
ETAL. (2004)
Moisture (%)
Crude protein (%)
Ether extract (%)
Crude fiber (%)
Ash (%)
Calcium (%)
Phosphorus (%)
Sodium (%)
Potassium (%)
Magnesium (%)
Chloride (%)
Energy (kcal/kg)
8.43
12.22
1.32
0.108
1.38
0.18
0.15
3.2
0.45
0.08
0.12
3895
DALE ETAL.
(1990)
10.2
10.6
11.1
2.5
4.8
3630
SALEH ETAL.
(1996)
8.11
12.53
11.04
2.25
4.48
0.28
0.52
0.93
1.37
3670
PASSINI
ETAL. (2001)
KWAK
ETAL.
(2006)
6.86
8.75
15.94
0.00
1.78
0.07
0.16
11.00
8.46
8.28
1.16
1.78
566
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drying passage while crushing more finely by a rotary cutter. A gluten formula feed can also be obtained by mixing bread crumb as an
essential component with water as a formulating agent and a nutritive-assistant agent (Minoru 2004). This mixture is fed into a screw
extruder and subjected to heating followed by mixing and kneading
at 40140C. Thus, an inexpensive pellet-like gluten formula feed is
obtained having excellent digestion absorbability and shape-holding
properties. The formula feed can be used as a feed for cultivable fishes,
pets, and so on by regulating the nutritional component.
Anaerobic fermentation has been applied to bakery by-products and
wheat bran among other food wastes for improving the physicochemical characteristics of the feed using lactic acid bacteria (Lactobacillus
salivarius). Bakery waste and wheat bran were inoculated with lactic
acid at levels of 0.1%, 0.2%, 0.5%, and 1.0% and fermented anaerobically at room temperature (25C) for 1030 days (Yang etal. 2006).
The storage under nonanaerobic conditions led to microbial putrefaction with a concomitant loss of water and water-soluble carbohydrate
and increases in protein and fiber. Anaerobic fermentation with the
lactic acid bacteria led to an increase in the water-soluble carbohydrates along with a simultaneous fiber decrease, and contributed to
the overall nutritional improvement. Short-term storage (10 days) was
preferred because no additional changes in the chemical components
were obtained with long-term storage, which also induced a significant reduction in the number of total and lactic acid bacteria. On the
basis of these results, 0.2% inoculum was considered as the optimum
level for improving nutritional properties of the bakery waste and bran
using lactic acid bacteria (Yang etal. 2006).
One problem that assumes significance in recent times is the
increasing level of dioxin in the feed. Several incidents in Europe
with dioxins were reported, starting with contaminated feed
and resulting in contaminated food for human consumption. In
2003, a rapid alert was issued by the European Union, reporting
the presence of elevated dioxin levels (3.313.3ng TEQ/kg) in
dried German bakery waste which was used in animal feed. Part
of that bakery waste was used by a Dutch company for theproduction of different types of feed. In that reported case, the source
of the dioxins was found to be the waste wood used for the drying of the bakery waste (Hoogenboom et al. 2004). Further, the
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ery by-products are sometimes marketed as individual feed ingredients, or as a mixture of two or more feedstuffs. In fact, there is a
maizegluten feed which is a mixture of steep water, bran, gluten, and
germ meal. In addition, high-energy ingredients can be obtained for
feeding. An example is the one registered as Cookie Meal (http://
www.bakeryfeeds.com) that nutritionally increases the quality of
the feeding pellets by providing proteins, fats, fibers, minerals, and
vitamins.
19.3.2 Production of Sourdough from Bakery By-Products
The use of waste bread in the production of fresh bread with desirable
bakery effects was well understood even in the 1950s. Currently, the
addition of waste bread to the bread dough in the preparation of fresh
bread involves grinding certain proportions of waste bread. Although
waste bread is a valuable nutrient, only a very small proportion can be
reused owing to the general attitude in the trade. Moreover, in some
countries, regulations allow only a maximum of 3% of stale bread to
be added when processing fresh bread. Nevertheless, the use of stale
or surplus bread for the sourdough processing has become a more
accepted alternative. The resulting product obtained by a bacteriological fermentation process is a completely new substance that can
be used for the preparation of bread and bakery products. In a study
conducted using bacteria that form homofermenting and/or heterofermenting lactic and acetic acid, for example, Lactobacillus brevis
and Lactobacillus fermenti, fermenting dough was made from waste
bread, such as pieces cut off crisp bread (Wilhelm 1986). The acid
value of that dough varied from about 20 to 30, such that it can be
used to replace traditional, natural, or crystalline dough acidifying
agents completely or partially. That fermenting dough was observed
to be particularly suitable for improving the baking properties of
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pentosans in wholemeal and refined flour, and the bread baked with
it had excellent improvements in flavor.
A different recycling process was proposed by Felch (2000), which
uses stale bread and/or cakes as the starter for producing yeast and
sourdough. The stale bread and/or cake is then hydrolyzed by either
using enzymes or acidic hydrolysis, and subjected to purification if
required. Following hydrolysis, the liquid syrup fraction is separated
and mixed with water under aerobic conditions with steeping yeast,
and is converted into yeast biomass. In a second separation stage, the
yeast is drawn off. The hydrolyzed fraction separated from the syrup
in the first stage is mixed with milled rye products and water, and is
then converted into sourdough using a sourdough starter culture and/
or process fluid, preferably with lactic acid bacteria.
Baked goods, and especially breads based on milled wheat or rye
products, can also be subjected to sequential processing for obtaining an
assortment of products that can be used back in the bread-making process. For recycling bakery products, Meuser (1998) and his colleagues
(Meuser and Martens 2009) proposed the following steps: (a)preparation of the starting material; (b) preparation of a fermentation substrate
by enzymatic hydrolysis of the starting material; (c) fermentation of
the hydrolysate with acid-forming bacteria (Lactobacilli delbrkii), and
finally performing one of the following steps: (i) recovery of bakers
yeast, (ii) recovery of an acid liquor, (iii) recovery of ballast substances,
(iv) recovery of ethanol, and (v) recovery of CO2. The end products
of this process are recovered separately, and used for making baked
goods. This process indicates potential scope for the bread factories to
use the returned and remainder bread economically within the frame
of a holistic concept of the preparation and marketing.
The recycling of stale or surplus bread has acquired such importance that even commercial products are available for upgrading this
waste. A starter launched as Sonextra Sustain (Sonneveld 2010) can
efficiently generate sourdough from stale or surplus bread, complying
with the holistic concept of the production. This starter, 3.8% on stale
bread basis, generated a sourdough that could be added to the normal
bread recipe which ultimately delivers extra taste, flavor, and softness
(up to 20% softer after 3 days), without deterioration in the bread quality, such as crumb structure and volume. Among other claims, the
supplying company indicated that the pH lowering during sourdough
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fermentation is fast enough to prevent rope formation by Bacillus subtilis and Bacillus cereus, but without delivering acid taste to the final
bread when added up to 20% on flour basis in the final bread recipe.
Optimum fermentation periods are also decreased by a factor of 34
(from 3648h to 12h), enabling the bakery to process the leftover and
waste bread within 24h.
19.3.3 Production of Sugars or Polysaccharides
Wheat bran from mills and bakery waste such as broken pieces and
crumbs of baked goods are an adequate feedstock for the production
of chemicals due to a high yield of almost 80g glucose/100g substrate. Wheat bran constitutes a significant underutilized source of
sugars and hence it is considered as a source for obtaining sugars or
different polysaccharides.
Industrial wheat bran is composed of the outer coverings of the
grain, the aleurone layer, and the remnants of the starchy endosperm.
It consists mainly of starch, arabinoxylans, cellulose, -glucans, protein, and lignin. Therefore, recovery of the maximum amount of
sugars from hemicellulose, cellulose, and glucan necessitates application of different treatments. Enzymatic liquefaction with thermostable -amylase followed by saccharification with amyloglucosidase
released between 20 and 34g glucan/100g wheat bran, depending on
the extraction rate during milling (Palmarola-Adrados etal. 2005).
After filtration, the solid material must be hydrolyzed for recovering
the sugars from the cellulose and hemicellulose. Palmarola-Adrados
etal. (2005) compared the efficiency of different hydrolysis methods
(acid hydrolysis with 1% sulfuric acid, enzymatic hydrolysis, thermal
pretreatment followed by enzymatic hydrolysis, thermal pretreatment under dilute acid conditions followed by enzymatic hydrolysis)
for sugar production and observed that arabinose, xylose, and glucose were released from all the treatments although yield of sugar
was significantly affected by the treatment conditions. The highest
yield (53g total sugar per 100g starch-free bran, which was equivalent to 31g total sugar per 100g wheat bran) was obtained with the
thermal pretreatment under dilute acid conditions followed by enzymatic hydrolysis. This treatment released arabinose:xylose:glucose in
the proportion 2.5:4.3:3.1. Acid hydrolysis also supported very high
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22g/L succinic acid was produced. The addition of MgCO3 into the
wheat-derived medium improved the succinic acid production further
to more than 64g/L. Increasing the inoculum concentration to 20%
did result in the production of 62.1g/L succinic acid (Dorado etal.
2009). Results indicated that A. succinogenes cells were able to utilize
glucose and maltose in the wheat hydrolysate for cell growth and succinic acid production. These results demonstrated that the SSF-based
strategy is a successful approach for the production of a generic feedstock from wheat, and that this feedstock can be efficiently utilized for
succinic acid production. The proposed process could be potentially
integrated into a wheat-milling process to upgrade the wheat flour
milling by-products (WFMB) into succinic acid, one of the future
platform chemicals of a sustainable chemical industry.
19.3.6 Production of Dietary Fiber from Cereal By-Products
Cereal milling by-products, mainly bran and husk/hull, are traditional sources for dietary fiber isolation and purification. Nowadays,
there is a trend to seek new sources of dietary fiber, such as agronomic by-products (fruits, vegetables, leguminous, plants) that have
traditionally been undervalued (Rodrguez etal. 2006). Today, they
are considered as a promising source of functional compounds. Cell
wall materials contain between 60% and 90% dietary fiber, whereas
the bran fractions of some whole-grain cereals, such as oats, wheat,
and rice, contain 1632%, 3545%, and 2033% total dietary fiber,
respectively. This is hindered by the fact that the yield of cell wall
material from fruit and vegetables on a fresh weight basis is very
low (14%) (Redgwell and Fischer 2005). Grigelmo-Miguel and
Martn-Belloso (1999) have compared the characteristics of dietary
fiber from by-products of processing fruits and greens and from cereals. The dietary fiber constituents and dietary fiber concentrates of
apple, pear, orange, peach, artichoke, and asparagus and of wheat and
oat bran were measured using an enzymatic-gravimetric method. In
addition, the water-holding capacity of the dietary fiber concentrates
and cereals was estimated by centrifugation. Dietary fiber concentrates of fruits and greens showed a high content of total dietary fiber
(3559g/100g), insoluble dietary fiber (2144g/100g), and soluble
dietary fiber (1014g/100g). The soluble fraction was found to be
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A process for the microbial bioconversion of cereal milling by-products into proteinaceous material for human consumption has been
patented (Moo-Young etal. 1990). The by-products were aerobically
fermented by the fungus Neurospora sitophila at suitable temperature,
pH, and nutrient conditions over a period sufficient to grow microbial biomass protein. The resulting microbial biomass product had
a relatively high content of protein, dietary fiber, ergosterol, natural
flavor compounds, and B vitamins. The biomass lacked animal fat
and cholesterol. As animal feed, this product appears to be competitive with soy meal and fish meal. As a human food, this product
appears to be suitable for special health-conscious groups who seek
vegetarian, high-fiber, and/or low-cholesterol diets. More recently,
dos Santos et al. (2004) evaluated whether SSF is the best system
for producing enzymes. They found that the technique is appropriate for the production of enzymes and other thermolabile products,
especially when higher yields can be obtained than in submerged fermentation. Using SSF, the production of glucoamylases from wheat
bran has been accomplished (Pandey 1991). Nowadays, gelatinization is coupled with liquefaction, which is possible by the action of
thermostable amylases. Sodhi etal. (2005) determined that the productivity of thermostable amylases from Bacillus sp. was affected by
the nature of the solid substrate (wheat bran, rice bran, corn bran,
and combination of two brans). Maximum enzyme production was
obtained on wheat bran supplemented with glycerol (1.0%, w/w),
soybean meal (1.0%, w/w), l-proline (0.1%, w/w), vitamin B complex (0.01%) and moistened with tap water containing 1% Tween40. Sangeetha etal. (2004) have studied the production of fructosyl
transferase by Aspergillus oryzae employing a wide variety of agricultural by-products as substrates. They found that, among them, the
best results were obtained when rice bran, wheat bran, corn germ,
spent coffee, and tea were used supplemented with yeast extract and
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Cereals and various industrial waste products from the bakery industry appear to be among the most promising raw materials for future
substitution of the conventional ones that are used in the petrochemical and fermentation industry (Polman 1994). The bioconversion
of crops and residues to fuels and chemicals is receiving increasing
attention due to the perceived need for the reduction of consumption.
The term biofuel refers to liquid, gas, and solid fuels produced from
biomass. Biofuels include bioethanol, biomethanol, vegetable oils,
biodiesel, biogas, biosynthetic gas, biooil, biochar, FishcherTropsch
liquids, and biohydrogen (Demirbas 2008). Bioconversion of waste
residues (by-products) from cereal processing industries requires biocatalysts and enzymes which degrade xylanosic and cellulosic material. However, one of the major drawbacks of this process is that
the yeast used for fermentation can utilize only hexose as sugars,
while many milling by-products and bakery waste contain significant
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Some other products can also be obtained from the recycling of cereal
by-products. Delrue etal. (1998) described an additive composition
for enhancing the strength and/or stability of food products. The
additive composition comprises a cooked cereal by-product, in which
the edible starch is gelatinized to an extent, and can be added at a
level of at least 0.5% to masa (corn dough which has usually been nixtamalized) or other cereal grain flour or dough. A new food has been
also obtained by reusing bread crust and waste bread (overproduced
bread) as raw materials (Shinji and Yoshikazu 2003). Those materials
are gelatinized, melted, and kneaded with a heated screw extruder
at a water content of 875wt% and 30180C under a pressure of
015MPa and extruded through a forming die attached to the tip
end of the cylinder barrel of the extruder. The processed food is a
dough food or a processed food having plate, rod, granule, or foamed
shape. Recently, a multistep process was applied for the enzymatic
treatment of the leftover bread to produce syrup which serves as a
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Bread is the single largest item in the consumers waste bin. It has been
estimated that in Italy the annual amount of bakery waste is about
110,000130,000 metric tons per year, of which 70% is produced in
Northern Italy (Cevolani 2004). In 2009, it was reported that U.K.
consumers waste bin holds/contains seven million slices of bread
every day (Partos 2009). U.K. bakeries correspond to 782,000mT/
year of avoidable food waste, which costs around 1.5 million euros.
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Since the twelfth century, bread in the United Kingdom has been
regulated by prescribed quantities and is sold in 400 or 800g or multiples of 400g thereafter. However, the European directive 2007/45/
EC offered some freedom to the bakers and retailers, allowing different bread sizes. The same report indicates that this EC regulation
contributed, in the United Kingdom, to a decrease in the amount of
daily bread waste because people can buy the bread they use. There
is great pressure on the bakery industry to design solutions to combat waste, owing to their important contribution to the total food
waste. Over the last decade, the European legislative requirements for
waste disposal are becoming increasingly restrictive (EC Regulation
1493/1999), and accordingly there is a pressing need for the proper
disposal of waste material. In addition, owing to the increasing necessity to take into consideration the various aspects aimed at preventing environmental pollution, promotion of economic motives, and
need to conserve energy and new materials, several new methods and
policies for waste handling and treatment have been introduced into
the recovery, bioconversion, and utilization of valuable constituents
from food processing wastes. Besides their pollution and hazardous
aspects, milling, bakeries, and confectionery processing wastes do
have a potential for recycling raw materials, for conversion into useful
products of higher value as a by-product, as raw materials for other
industries, and for their use as food or feed/fodder after biological
treatment, as it has been shown in the preceding sections.
Different goals in product development and food production
highest product quality and safety, highest production efficiency,
and minimizing the negative environmental impactare integrated
in the holistic concept of food production (Laufenberg etal. 2003).
The recycling of residues is important to every manufacturing branch
and has high developing potential. A systematic reduction of product
losses and emissions is profitable under both economical and ecological aspects, and special attention is given to the recovery of valuable
substances or product losses and internal process water recycling
(Laufenberg etal. 2003). The need for sustainable production of products using renewable, nonhazardous materials and energy efficiently,
while conserving biodiversity, is fulfilled by the green/clean production processes. Clean production systems are circular and use fewer
materials and less water and energy; as a result, resources flow through
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economic growth from adverse environmental impact. Industrial biotechnology is changing the way energy, chemicals, and other products are produced. Through engineered biocatalysis, biotechnology
is enabling the use of previously unusable renewable materials and
production of novel products. Functionally acceptable products that
are less polluting and persistent than conventional counterparts are
emerging. All this is being achieved with reduced environmental
impact and enhanced sustainability. Undoubtedly, biotechnology is
set to transform industrial production to a basis that is more compatible with the biosphere (Gavrilescu and Chisti 2005).
19.6 Specific Case Study: Valorization of Specific By-Product
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Bread
returns
Water
Starch hydrolysis
Protein hydrolysis
Lactic acid fermentation
Feed
Fermentation
substrate
Aerobic fermentation
Liquid yeast
Anaerobic fermentation
Ethanol
Carbon dioxide
Liquid sour
Figure 19.1 Simplified flow sheet for the recycling of bread returns. (Adapted from Meuser, F.
1998. Process for recycling bakery products, more specially rests of bread and bread remainders.
International patent number EP0821877, filed July 11, 1997, issued February 4, 1998.)
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