PROJECT REPORT

ON

“PRODUCTION & QUALITY OF BAKERY PRODUCTION”

AT

KS BAKERS PVT. LTD

Submitted in partial fulfillment of

Requirements for the award of the degree

of MASTER OF SCIENCE

In

FOOD SCIENCE AND NUTRITION

By

D. BALANANDU (111722820030)

To

DEPARTMENT OF M.SC FOOD SCIENCE AND NUTRITION

LOYOLA ACADEMY DEGREE AND PG COLLEGE

ALWAL, SECUNDERABAD - 500010.

(Autonomous an affiliated to Osmania University)

Re-accredited with ‘A’ Grade (3.50/4.00) by
NAAC A “College with Potential for Excellence”
by UGC

HYDERABAD

JULY2024
 ACKNOWLEDGEMENT

It is always a pleasure to remind the fine people in the LOYOLA ACADEMY for their sincere support
and guidance which we received to uphold our training in the industry.

First of all, thanks to our parents for giving their encouragement, enthusiasm and invaluable assistance to
us. Without their support, we might not be able to complete our training properly.

We express our sincere gratitude to REV FR Dr. L. JOJI REDDY S.J (PRINCIPAL OF LOYOLA
ACADEMY), REV Fr PRABHU S.J (VICE PRINCIPAL PG OF LOYOLA ACADEMY).

We also express our deep gratitude to Dr. KAVITHA WAGHRAY (Dean of life sciences) Dr. G.
GLADVIN SIR (Head of Department of Food Science and Nutrition, PG) and other teaching faculty at
Loyola Academy, Department of Food Science and Nutrition, PG for their continuous support and
guidance.

We are highly indebted to Mr. SANDEEP REDDY (MD KS BAKERS PVT.LTD), Mr. GOPENDRA
(Plant head) and Mr. SANDEEP KUMAR (Quality manager) for their guidance and constant supervision
as well as for providing necessary information regarding the training and also for their support in
completing the training.

We would like to express our gratitude towards the top management of KS BAKERS for their kind
cooperation and encouragement. We also express our sincere thanks to the industry persons for giving us
such attention and time.

Finally, we sincerely thank all other unnamed who helped us in various ways to have a good training in
the industry.

2
 DECLARATION

We hereby declare that the project entitled “PRODUCTION & QUALITY OF BAKERY PRODUCTS”,
submitted in partial fulfillment for the award of the degree M.Sc. Food Science and Nutrition is the
original work done by us.

SIGNATURE:

D. Balanandu. (111722820030)

3
 Date: 24-06-24

TO WHOMSOEVER IT MAY CONCERN

This is to certify that Mr. Donepudi Balanandu (Reg no.111722820030) Student of Loyola academy,
Secunderabad, Telangana has successfully completed her internship in Production & Quality in our
organisation from 14th May 2024 to 24th June 2024

During her tenure her attitude and performance was good.

We wish her all the best in her future endeavours.

For Ks Bakers Pvt. Ltd,

KS BAKERS PVT .LTD

PLOT NO 16E and 17E/1 Sy No 20 and 22,
IDA Phase 1, Patancheruvu, Sangareddy,
Telangana, 502319
CIN: U15410TG2012PTC08000

4
 LOYOLA ACADEMY

Autonomous and affiliated to Osmania University)

Re-Accredited with “A” grade by NAAC(III cycle)
A” College with Potential of Excellence” by UGC

CERTIFICATE

This is to certify that this is the bonafide record of work done at KS bakers Pvt. Ltd .during the second year
second semester during the academic year 2023-2024 by D. BALANANDU UID: 111722820030 in partial
fulfillment of the requirements for the award of the degree of MSc Data science of Loyola Academy, during
academic year 2023-2024. The project report has been approved as it satisfies the academic requirements in
respect of project work prescribed for the MSc.Food science and Nutrition.

D.BALANANDU (111722820030)

INTERNAL EXAMINER EXTERNAL EXAMINER

Mrs.Shirley Lillian.
MSC.Food Science &Nutrition

Signature of HOD. Signature of Principle

Mr . Dr . G . Gladvin Rev.Fr.Dr.L.JOJI REDDY SJ
HOD. Food Science & Nutrition Loyala Acadamy

5
ABSTRACT

In the present study we have worked on breads, buns, cakes and icing. This study presents a comphresive
quality analysis of these bakery products, evaluating key parameters to ensure their sensory, textural, and
nutritional properties. This study provides insides into the characteristics that define exceptional breads,
cakes and icing. The sensory evaluation encompassed a panel of trained panellist examined the aroma,
flavour, appreance, and overall appeal of various breads, cakes, and icing formulations. Breads with well-
balanced crunchiness in their crust and soft, airy crumb were favoured, while cakes achieving a
harmonious balance between tenderness and resilience. Icing samples underwent scrutiny for consistency,
sweetness and visual appeal. The results achieve the significance of ingredient quality, preparation
techniques, and nutritional content in achieving bakery products that meet both sensory and nutritional
exceptions.

Keywords: bakery cakes, icing, breads, quality, sensory evaluation, nutritional properties.

6
 INDEX

S.NO TITLE PAGE

NO
1 Chapter 1 Introduction 11
2 1.1 Company Profile 12
3 1.2 Objectives 12
4 Chapter 2 Review of literature 13-14
5 Chapter 3 Materials and Methodology 15
6 3.1 major raw materials 16-18
7 3.2 minor ingredients 19-20
8 3.3 dry ingredients 20
9 3.4 Ready to eat products 20
10 3.5 Equipment’s used 21
11 3.6 Manufacturing process 21-27
12 Chapter 4 Quality Assessment 28
13 4.1 Risk assessment 29-49
14 4.2 quality analysis 50-53
15 4.3 Sensory evaluation 54
16 Chapter 5 Results 55
17 5.1 proximate analysis of bread 56
18 5.2 Proximate analysis of plum cake 57
19 5.3 Proximate analysis of kaju biscuits 58
20 Chapter 6 summary 59-60
21 Chapter 7 Conclusion 61-62
22 Chapter 8 References 63-68

7
 CHAPTER 1

INTRODUCTION

8
1.1 COMPANY PROFILE

KS Bakers Private Limited is incorporated on 29 March 2012. It is in Hyderabad. It is involved in

Manufacture of food products like Bakery, Pizzas, Burgers, etc.

Directors of KS Bakers Private Limited are Mr. Sandeep Reddy Katla, Sathyanarayana Reddy Katla
and Vijaya Katla.

Objectives: Bakery and confectionary technology

1. Raw material

2. Bakery products

3. Confectionary products

4. Equipment’s used in bakery and confectionary products

5. Safety standards

9
 CHAPTER 2
REVIEW OF LITERATURE

10
 2.1 REVIEW OF LITERATURE
Angela Dettori, et, al explored how consumers saw quality being influenced by the advancement in
customary items in the bread and cake industry. They survey whether enhancing conventional items is a
successful technique, particularly in culinary businesses. The outcomes demonstrated the negative
connection between clients saw quality and enhancing customary items in conventional ventures
implanted in shut settings. The current examination explains the shadowy side of development in
conventional businesses, for example, the bread, bread kitchen and cake industry, and it uncovers how
custom assumes a significant part in those areas.
Have analyzed the effect of the ongoing pandemic on the hospitality industry. While the hospitality
business is gradually recuperating, the Coronavirus emergency keeps on applying significant effects on
how neighborliness organizations work. And other scholars have explored the effects of culinary trends
on product innovation in the bakery industry. The fundamental patterns in bread, pastry kitchen, and cake
development are identified with wellbeing, joy, and accommodation. They dissect what culinary patterns
mean for item development in bread and other baked items. New cooking and driving gourmet experts
consider bread and pastry shop not exclusively a supplement to the dishes served in their eateries, but
also a crucial part of their advancement contributions.
Patrick A. et, al Expanding on past examination on nation contrasts and online verbal, it inspects the
impact of language and country on the volume, valence ,and support of client surveys. An
investigationof32,555surveys across five nation locales of Amazon.com challenges past presumptions
about verbosity contrasts between nations. Likewise discover proof of reaction predispositions that
influence starting valence and the supportiveness of surveys. Finally, it exhibits and clarify how utilizing
global data sector production formerly distributed, single-country study can yield new bits of knowledge
into customer auditing conduct.
Shikha Sota et, al Study the review and classification of consumer relationship management in the
hospitality industry. They audit research articles distributed in the region of Client Relationship
management (CRM) in the cordiality business to efficiently survey the whole accommodation CRM
writing to distinguish effective subjects and patterns. The examination papers were investigated and
grouped dependent on their time of distribution, diary of distribution, information bases, subjects and key
topics that arose throughout the long term.
Dennis R.Heldman and Richard W.Harel (1997) in their book entitled “Principals of Food processing”
describes the food processing as conversation of raw material or ingredients into a consumer food products.
They focus on details of existing food processing industry in America is reviewed and the steps in
manufacturing has been also analyzed. The author explains the food processing as the conversation process
required to ensure food products safety and extend self life. However, from this literature it is found that only
conceptual information has taken into consideration without any analytical aspects.
11
Da-Wen-Sun (2006) in his book entitled “Emerging Technologies for Food processing” focus on modern
and innovative tools and techniques for food processing units. The author has contains a critical review of
the use of chemicals in biological preservation in this book. Discussion of non thermal processing techniques
has been explained, Innovations in food refrigeration are covered. Here, the author is not taken into account
operational and functional aspects of management.
NIIR board(2012)entitled in their another book “Food Packaging Technology” we get all the information
about packaging technology and its types. In the current trend of people, they are getting more concerned
with the hygiene and quality of packaging for better contains. Best packaging is preserves or protects the
food. Second thing, quilted packaging is attracts to the consumers to buy the products. In modern trade
business, packaging of product is very important. Their policies of packaging are rigid for supplier or
manufacturer.

NPCS Board (2012) describe in his book entitled “Modern Technology on Food Preservation (2edition)”
about preservation, means transform raw ingredient into food or transform food into other form for
consumption. Canning, drying are the traditional methods of preservation. we come to know the new
methods of preservation. Also we can see photograph of machineries used in food preservation.

12
 CHAPTER 3
MATERIALS
AND
METHODOLOGY

13
RAW MATERIALS

3.1.1 PROCURMENT OF RAW MATERIALS

Perishable materials such as egg, milk and milk products, chicken, fruits and vegetables were procured by
ordering online through big basket, swiggy instant mart and zomato.
Non- perishable products such as dry ingredients which included flours, sugar, spices, salt,
Icing materials, decorative items etc. were procured from wholesale market through local vendors.

3.1.2 LIST OF RAW MATERIALS:

 Maida flour
 Sugar
 Eggs
 Palm oil
 Butter
 Invert Syrup
 Salt
 Liquid glucose
 Choco chips
 Vanilla powder
 Tutti fruity

3.1.3 FUNCTIONS OF INGREDIENTS

3.1.3.1. MAIDA:

Maida is one of the major ingredients the biscuit manufacturing process.

The major function of the flour in biscuit baking is:

a) To firm the dough during mixing, holding all the ingredients uniformly distributed in
the dough.
b) To form the structure of the biscuits during baking.

The word flour refer to the powder obtained from the grinding of cereal grains, in terms of parts of the
grain used in flour – the endosperm or protein rich part and bran or fibre part are the types of flour. The
white flour is made only from endosperm, whereas brown flour is made of germ and bran and the flour
made of
14
entire grain is known as whole grain flour. Maida has very high level of protein known collectively as
gluten which plays an important role. When the dough is made from flour and water, gluten develops into
a thick, cohesive and elastic mass. Each variety of biscuit needs a specific type of flour because the gluten
proteins do effect and influence the dough characteristics. These various types of flour is based on their
physio- chemical, chemical and rheological properties of the wheat flour.

3.1.3.2. SUGAR:

Sugar is commonly thought of as a sweetener agent, but in baked goods it is involved in several other
processes sugars usually undergo a series of browning reactions and a brown crust is formed on the surface
if the product. The major functions of sugar in biscuits are:

a) Impart sweet taste to the biscuits.

b) It has a softening action on the gluten.
c) Hardens the biscuits texture.
d) Contribute to the colour of biscuit i.e., caramelization of sugar leads to
browning of the biscuits.
e) Acts as the food for the yeast during fermentation of the fermented dough biscuits.

Usually, granular sugar is being used to get a surface crack in the biscuits. The increase in sugar levels
result is softening of gluten which ultimately leads to the reduction in the water quantity requirement.
Sugars also helps in giving a crisp texture to the biscuit

Figure 6

15
3.1.3.3 Egg:

i) Ensure that egg shells are not cracked upon receipt. Discard cracked eggs.
ii) Storeeggsinthechilleruntiltheyareneeded.Ifyouneedtostoreeggsatroomtemperature, use
the current batch of eggs and replenish the stocks daily.
iii) Wash hands, utensils and surfaces thoroughly with sanitizing solution and water
after handling eggs and before any contact with other food to prevent cross-
contamination.
iv) If you are breaking eggs for future use (also known as ‗pooling ‘), pool the number
of eggs you require just before use.
v) Prepare raw eggs away from other food, especially cooked/ready-to-eat food to
avoid cross-contamination.
Wash or clean all eggs before use to avoid any food cross-contamination.

3.1.3.4. Palm oil:

Palm oil, like all fats, is composed of fatty acids, esterified with glycerol. It is an edible vegetable oil
derived from the mesocarp (reddish pulp) of the fruit of the oil palms. This oil is solid at room
temperatures. Palm oil have certain specific functional properties that make it important in food
manufacturing. It not only contributes to the taste and flavour of the product, but it contributes to the heat
stability, resistance to oxidation, texture and smoothness of the product. Importantly the palm oil virtually
contains no Trans fatty acids.

Figure 7
16
3.1.3.5 Invert Syrup:

 Invert syrup is a sweetener prepared by acid hydrolysis/ enzymatic hydrolysis of a solution of

white sugar. It contains equal proportion of reducing sugars glucose and fructose.
 Relatively large quantities of syrups is used in all short doughs. The crystal inhibition
characteristic and humectants properties which extend the shelf life of the product.

 Invert syrup impart better colour because of its low caramelization temperature and it also takes
part in Millard reaction to impart brown colour. It also has a higher degree of sweetening power
relative to sucrose.

3.1.3.6. Salt:

 Salt has several functions in baked goods. It modifies flavour, increases crust colour and controls
the rate of yeast fermentation and enzyme activity.
 Salt also strengthens gluten, making it more cohesiveness and less sticky. With salt present, gluten
holds more water and carbon dioxide, allowing the dough to expand without tearing.
 This means that salt prevents excessive tearing when gluten stretches so bread is easier to handle
and has a better volume and a finer crumb.
 The dough mixes faster and cooler as there is less resistance and frictional heat generated during
mixing.
 Once salt is added, the dough tightens and is more difficult to stretch, but it will stretch further
without tearing.

3.2.1 Minor ingredients:

3.2.1.1 Whole Milk Powder:

With the Fun Cakes Whole Milk Powder you add a creamy texture and a touch of
extra sweetness to your treats. It also makes your cakes, brownies extra creamy by
adding a bit more moist.
A little whole milk powder is also often added to batter to make the treats colour
golden brown more quickly and more beautifully in the oven. Because of the heat,
the milk sugar in the whole milk powder can caramelize, ensuring a richer taste and
beautiful brown colour.

17
 3.2.1.2 Liquid Glucose:

Liquid glucose ensures good preservative qualities, enhanced shelf life and
smooth texture of the products. it tends to replace sugar in the formulation of many
bakery, fondants &confectionary products:
cakes & bakery fresh products: in the baking industry, the liquid glucose syrup is
indispensable to control the properties of the product. it allows the cakes, pies and
biscuits to absorb water, prevent drying and extend shelf life.
liquid glucose syrup essentially imparts texture, taste, shine and extended shelf life to
the different products. liquid glucose syrup keeps the cake soft while adding
sweetness. in addition, the liquid glucose syrup prevents the biscuits from drying out,
keeping the biscuits crisp and preventing the water from crystallizing in the ice
cream

3.2.1.3. Finagel:

FINAGEL - CAKE GEL It is a batter aerating agent and hence improves cake. It gives strength and
stability to the batter resulting in a cake with excellent volume, structure and good shelf life.

3.2.1.4 Lecithin:

Lecithin is widely used in commercial baking. It's an emulsifier, an ingredient that helps other ingredients
to mix more easily and remain mixed. Bakeries add lecithin to bread and other baked goods to improve
batters, or to keep them from staling.

3.3 Dry ingredients like wheat flour, sugar:

i) Conduct a visual inspection during procurement to ensure the raw materials received
are free from foreign material such as stone, glass, hair, jute thread, etc. This can be
done by appropriate test sieves.
ii) Raw material should be stored in a room that has the required humidity and
temperature and the store room should be away from non-food materials to prevent
cross- contamination.

18
3.4 Ready-to-eat products containing lightly-cooked or uncooked eggs (e.g. mayonnaise,
cream, icing, mousse, butter):

i) Prepare only what is required in small batches. Estimate the demand to avoid
over- production and prolonged storage.
ii) Use liquid egg or egg powder instead of shell eggs where possible.
iii) Observe good personal hygiene practices when preparing/handling the ready to-
eat products.
iv) Store the finished products in covered containers in the chiller at 4°C and below.
Ensure they are stored on separate shelves above raw food (including shell
eggs).
v) Take out what is necessary from the chiller in small batches. Minimise the time
products that are left out of the chiller. Store the products in the chiller as soon
as possible after use.

3.5 Equipment’s used in Food Processing Unit

a. UNIFILLER–Used only for liquids and semi liquids to fill the cups
b. SPIRALMIXERS–To knead the ingredients and make the dough
c. PLANETARYMIXERS–Sponge mixing for cakes
d. BUNDIVIDER–Dough cutting machine according to their weights
e. BREADMOULDER–To mould the bread
f. PUFFSHEETER–To prepare the moulds or dough into sheets
g. BISCUITMACHINES–To prepare biscuits
h. PROOFER–It increases the humidity so that the size of the mould bulges. Average
time is 20 mins whereas when kept at normal temperature it takes 2-3 hours. Proofer is
only used to increase the size of the product
i. OVENS–In ovens, 1 trolley consists of 18 trays. Average oven temperature is
180 degrees centigrade. It is used for baking the product and colour also change.

19
3.6 Manufacturing process flow charts:

i) Bread Manufacturing Flow

Diagram:

Store (Raw materials)

↓
Sorting, grading, and weighing
↓
Dough mixing
↓
Cut the dough according to the required weights
↓
Make them into rolls
↓

Place them in a box

↓
Proofer
↓
Baking
↓
Cutting
↓
Packaging

Flowchart 1

20
3.6.2 Manufacturing if cake:

Receiving and quality inspection of raw materials

↓
Storing of raw materials
↓
Weighing and pre-preparation of ingredients as per standardised recipe
↓
Batter
making
↓
Batter scaling, deposition and levelling into moulds

↓
Baking
↓
Cool at ambient temperature and forced cooling of cooling
↓
Slicing and packing
↓
Quality evaluation
↓
Storage
↓
Loading and dispatch of finished products

Flowchart

21
Premixing

i) Flour should be sieved through minimum 32 mesh and the sieve should be cleaned
regularly
ii) If weevils are found, such consignments should be rejected.
iii) There should be a periodic cleaning mechanism to prevent cross-
contamination and dust generation and to ensure safe collection of unwanted
materials like dust, dirt, foreign objects if any.
iv) (Good Practices; such as vacuum cleaning, collection of debris through hypochlorite
can be used)
v) Sugar to be passed through magnetic grill before use and periodic cleaning of
magnetic grill to beensured.
vi) Sugar bags to be free from any external contamination like dust, dirt, rice bran, etc.
vii) Egg trays to should be free from dirt or pests
viii) Broken egg- shells to be stored in plastic bags and disposed off at regular intervals.
ix) Fruit cuts to be washed with ozonized water before use.
x) Potassium sorbate to be dissolved thoroughly in water before use. Only
freshly prepared sorbate tionto be used.

Mixing

i) Mixing room should be clean & dry without any spillage

ii) All mixing utensils should be free from grease and old batter. This is ensured
by using washing before use.
iii) Mixing bowls, beaters and scrappers to be washed with hot water at least once in 24
hours
iv) Egg whisk to be added in mixing through strainer only. The strainer to be
cleaned with hot waterat least once in each shift followed by swabbing with
hypochlorite solution. The strainer is to be dipped in 500ppm Sodium
Hypochlorite solution, when not in use.
Mixing room floor to be cleaned with hot water followed by mopping
with hypochlorite solution.
Baking

i) Baking room should be clean & dry. This room is to be mopped with
22
 ii) 500ppm Sodium Hypochlorite solution, at least once in each shift
iii) Ozoniser at the baking room to be maintained at 5gm per hour level
iv) Cake cooling trolleys are to be mopped with 500 ppm hypochlorite solution daily.

Cooling

a) Room temperature cooling of cakes at ambient room

i) This room should be clean & dry and mopping of floor to be done with
500 ppm hypochlorite solution at least once in each shift
ii) After baking, bar cakes are to be transferred immediately to the ambient room
iii) Positive pressure at ambient room is to be maintained
iv) Ozoniser at this room is to be maintained at 2 gms per hour level
v) UV lights to be always put on during cooling of cakes. Personnel entry is
to be restricted in this room
vi) Work men unloading cakes should use a disinfect ant solution to disinfect ant
their hands.

b) Forced cooling at slab cooling room

i) This room should be clean & dry and weekly sanitization to be done
with 500 ppm hypochlorite solution
ii) UV lights should always be put on during cooling of cakes. Personnel
entry is to be restricted in this room
iii) Temperature of this room to be maintained at 8-10 degree Centigrade.
The same is to be noted & recorded.

23
3.6 A. GMP PRACTICES:

a) All pieces of food contact equipment’s viz. Dough mixers, conveyors,

rounder’s, dough dividers, racks, proofing equipment’s, oven, rollers,
slicers, sifters etc. should be clean and in good repair.
b) All the equipment’s and their surroundings should be free from dirt, dust
and evidence of rodent or insect activity
c) All equipment’s should have smooth edge and devoid of spot welding and any
paint flakes.
d) Inspection, cleaning ports on flour conveyor systems should be accessible and easy
to open.
e) Conveyor systems should be free from pest activity
f) Proofing equipment should be free from evidence of insects or rodents
g) Temperature and humidity of proofing equipment, ovens and cooling area should
be maintained
h) Baking pans or storage bins should be clean
i) Equipment’s should be cleaned before use
j) Utensils like spoons, beaters, pans, bowls, trays, spatulas etc. should be
clean and free from adulterants
k) Utensils and equipment washing facilities should be clean and adequate
and should be kept in a designated place.
l) Cleaning agents and compounds should be labelled properly and
kept separate from food items to prevent cross-contamination
m) Weighing practices should be accurate to ensure the declared quantity of
contents would be achieved.
n) All high temperature equipment should be equipped with high-temp cut-
off devices which cut off the fuel or power source if the upper safe limit is
exceeded.
o) Working area as well as the outside premises should be free from spilled
powders or liquids, trash etc. which may attract or harbour pests, rodents
or micro-organisms.
p) Protective Equipment:
 For silo cleaning and for other heavily dust-laden activities, a
fine dust Mask should be used
24
  Heat protection gloves should be used in the case of work with ovens.

• Working practices for reducing flour dust

i) Applying the separating flour on the work surface by sprinkling,
rubbing in or with a sieve, instead of by throwing flour (fine
dust technique)
ii) Gently sweeping of the excess separating flour on the work surface
into a suitable container, instead of casting it onto the flour
iii) Using closed containers for storing flour
iv) When using goods in sacks, adding a second pressure-relieving cut (on
the underside of the sack) when emptying.
3.7 B. Technical measures for reducing flour dust

Mixing  Closed system in flour delivery and in dough production.

space:  Regular cleaning of the dust filter in the case of the
cyclone and exclusive use of original filters
 Sufficiently long cloth or fabric hose for the flour
delivery, and maintenance of it.
Workequip  Dust protection lid on the kneading machines instead of grills (if
ment: the diameter of the kneader is larger than 510 mm)
 The use of automatic flour sprinklers for the individual
machines; set them correctly and carry out regular
maintenance.
 The exhaust air from the motors of the bakery machines
must not be led over the flour containers.
 Access guards in roll or bread plants, through closed
components or corresponding grills (closed coverings or
cladding are preferable to
grilles, on account of the better protection they offer against dust).

Technical  The technical ventilation measures are restricted to dust

ventilation extraction and vapor traps.
plan for  Depending on the quantity (volume flow) of the
reducing extracted air, mechanical provision of incoming air is
hazardous necessary.

25
substances  Minimum requirements made of the ventilation plant:
i. Vapor traps over bakery ovens and fat-frying devices
ii. Spot flour dust extraction in the case of bread tin
dusting and in the case of individual processing
machines that produce large amounts of dust.
iii. Mechanical supply of incoming air
iv. Mechanical extraction of general waste air (if necessary)
v. free flowing ventilation openings capable of being regulated
vi. free flowing ventilation openings not capable of
being regulated, due to production circumstances
(gates at dispatch
vii. Sugar grinding system should be equipped with proper
dust collection system to avoid any fire hazard.

26
 CHAPTER 4
QUALITY ASSESSMENT

27
4.1 QUALITY ANALYSIS:

4.1.1 Determination of moisture

content Principle
The moisture content is the loss in weight of a sample when heated underspecified
conditions.

Apparatus

Wiley Laboratory Mill, intermediate model, equipped with 18 or 20-meshscreen or any

other mill that will grind to same degree of fineness without under exposure to
atmosphere and without appreciable heating.
Oven (either gravity-convection or mechanical convection). Capable of being maintained
at 130°C (+1°) and provided with good ventilation. Thermometer shall be so situated in
oven that tip of bulb is level with top of moisture dishes but not directly over any dish.
Moisture dishes having diameter of 55 mm. and height of 15 mm. They should be of
heavy- gauge aluminium with slightly papered sides and Provided with tightly fitting so pin
covers. Before using, dry for 1hr at 130°C, cool in desiccators, and obtain tare weight.

1. Air tight desiccator containing activated alumina.

2. Balance, accurate to at least 1 mg.

28
Method

Grind a 30 to 40 g sample in mill, leaving minimum possible amount in mill. Mix rapidly
with spoon or spatula and transfer immediately a 5gportion to tared moisture dishes.
Cover and weigh dishes at once. Subtract tare weight. And record weight of sample.
Dismantle and clean mill between samples.
Uncover dishes and place them with covers beneath on shelf of oven. Insert shelf in oven
at level of thermometer bulb. Heat for exactly 60 min. afteroven recovers its temperature
of 130°C.
Remove shelf and dishes from oven, cover rapidly (using rubber finger insulators), and
transfer to desiccator as quickly as possible. Weigh dishes after they reach room temp.
(45- 60min, usually).Determine loss in weight as moisture (see equation 1). Replicate
determination must checkwithin0.2% moisture.

Calculation

(A- B)
Moisture (%) = ———— ×100
(A- C)

Where, A=wt. of flour + Aluminum dish before drying

B=wt. of flour + Aluminum dish after drying
C= wt. of aluminum dish

Standard values in flour

ISI… 13.0% PFA…

14.0%

29
4.1.2 Determination of ASH:

Principle

Total ash is the inorganic residual remaining on incineration in a muffle furnace. This
reflects the quantity of mineral matter present in the flour. Acid insoluble ash reflects
added mineral matter in milled products such as dirt, sand, etc.

Procedure

Weigh 10 g of the sample into a weighed silica dish. Incinerate it over a burner or in the
muffle. Keep the dish in a muffle furnace maintained at 550-600°C until light grey ash
results or to a constant weight, cool in a desiccator and weigh.

Rapid method Reagent:

Alcoholic Magnesium Acetate Solution

Dissolve 15 g Magnesium Acetate Tetra Hydrate (Mg (C2H3O2) 4 H2O) in alcohol and
make up to 1 litre.
Determination
Weight 10g of flour into a weighed silica dish. Add 10ml of the reagent. Let the mixture
stand for about 2 minutes. Evaporate the excess alcohol in a water bath and keep in
muffle furnace maintained at 750°C-850°C for 30-45 minutes. Remove the dish, cool in a
desiccator and weigh. Determine the blank on10ml of the solution. Deduct blank from
ash.

30
4.2.3 Acid insoluble Ash

Boil ash obtained in method 1 with 25 ml HCl (1: 2.5) for 5 minutes on a water bath,
covering the dish with watch glass. Filter through ashless filter paper (No. 40). Wash the
residue with water until free of acid. Ignite at 600°C for 20 min, cool and weigh

Calculation

W3-W1
Ash = ———— × 100
W2-W1

Where, W1=Wt. of silica dish

W2=Wt.ofsilicadish+sampleW3
= Wt. of silica dish +ash

W4-W1
Acid insoluble ash (%) =————×100
W2-W1

Where, W4=Wt. of silica dish + acid insoluble ash.

W2-W1

Where, W1=Wt. Of silica dish

W2=Wt.ofsilicadish+sampleW3
= Wt. Of silica dish +ash

W4-W1
Acid insoluble ash (%) =————×100
W2-W1

Where, W4=Wt. of silica dish + acid insoluble ash.

31
4.3 SENSORY EVALUATION:

Sensory evaluation is a science that measures, analyzes, and interprets the reactions of people
to products as perceived by the senses. It is a means of determining whether product
differences are perceived, the basis for the differences, and whether one product is liked more
than another.
Sensory evaluation is a crucial aspect of bakery industry that involves assessing and
analyzing the sensory attributes of bakery products such as taste, texture, aroma, appearance
and overall quality. This allows bakery professionals to understand consumer preferences,
improve product formulation and maintain consistent quality standards.

32
 Sensory Taste Texture Aroma Appearance Overall
attributes/ quality
Products
Bread 4 5 5 5 5

Cakes 4 4 5 5 4

cookies 5 5 5 5 4

Puffs 4 5 5 4 4

Table 4.3
Table 4.3, show the sensory evaluation conducted for breads, cakes, cookies and puffs using
5 pointer hedonic scale.

33
 CHAPTER 5
RESULTS AND DISCUSSION

34
5. RESULTS

These are the results for the proximate analysis done:

5.1. BREAD:

s.no Test parameter Units Test method Results

1. Moisture % IS 12711:1989 29.64
2. Ash % IS 1011:2022 RA 2009 2.48
3. Acid insoluble ash % IS 1011:2022RA 2009 0.40
4. Fat % IS 1011:2022 RA 2009 5.42
5. Protein % IS 7219:1973 9.68
6. Alcoholic acidity % IS 1155:1968 0.06
7. Carbohydrates % AOAC method 986.25 52.78
Calculation method

Table 5.1.1

From table 5.1.1 we can conclude that bread contains approximately 29.64% moisture, 2.48%
ash, 0.40% acid insoluble as, 5.42% fat, 9.68% protein, 0.06% alcoholic acidity, 52.78%
carbohydrates.
This proximate analysis was conducted using IS and AOAC method.

35
5.2 PLUM CAKE:

S.no Test parameters Units Test method Results

1. Moisture % IS 12711:1989 21.26

2. Ash % IS 1011:2022 RA 2009 3.56

3. Acid insoluble ash % IS 1011:2022 RA 2009 0.8

4. Fat % IS 1011:2022 RA 2009 24.26

5. Protein % IS 7219:1973 12.45

6. Alcoholic acidity % IS 1155:1968 0.1

7. Carbohydrates % AOAC method 986.25 38.47

Calculation method

Table 5.1.2
From table 5.1.2, we can say that plum cake contains, 21.26% moisture, 3.56% ash, 0.8%
acid insoluble ash, 24.46% fat, 12.45% protein, 0.1% alcoholic acidity, 38.47%
carbohydrates.
This analysis was conducted using IS and AOAC method.

36
5.3 KAJU COOKIES:

S.no Test parameters Units Test method Results

1. Moisture % IS 12711:1989 3.82

2. Ash % IS 1011:2022 RA 2009 2.54

3. Acid insoluble ash % IS 1011:2022 RA 2009 0.56

4. Fat % IS 1011:2022 RA 2009 18.56

5. Acidity extracted by fat % IS 1011:2022 RA 2009 0.08

( as oleic acid )
6. Protein % IS 7219:1973 11.28

7. Carbohydrates % AOAC method 986.25 63.80

Calculation method

table 5.1.3
From table 5.1.3, we can say that kaju cookies contain, 3.62% moisture, 2.54% ash, 0.56%
acid insoluble ash, 18.56% fat, 0.08% acidity extracted by fat, 11.28% protein, 63.50%
carbohydrates.
This analysis was conducted using IS and AOAC method.

37
 CHAPTER 6
SUMMARY AND CONCLUSION

38
6.1 SUMMARY:
KS BAKERS Private Limited is a Baking Industry which operates round the clock involved
in manufacturing products like cookies, muffins, breads, and buns, cakes, pizza base, ready
to serve, lunch box among which breads, buns, and pizza bases are the major products
manufactured and supplied to other states and to the local stores. Other products are
produced based on the orders received and supplied to the local stores according to the
request of customization and requirement. Sensory evaluation was performed for all the
products, quality was done for few products. HACCP standards, GMP practices, Risk
assessment was observed for the industry. A two-month internship underwent involved an
overall observation of entire plant and their operations. The production of some of the
products like breads, cakes, icing, cookies manufacturing was observed and understood. We
also had industrial audit which was conducted by FSSAI, they observed if the company was
meeting FSSAI standards and regulations.

6.2 CONCLUSION:

This internship has provided me with the opportunity to witness the entire journey of a
recipe from conception to display on shelves. I have learned to measure and combine
ingredients, master the intricate of dough fermentation and perfect the art of shaping and
decorating various baked products. Beyond the technical skills, I have also learned about the
importance of teamwork, time management and maintaining high standard of cleanliness
and hygiene in a professional bakery setting. This internship has increased my knowledge
and the research and study I have done will be useful in my future professional work and
studies.

39
6.3 FUTURE SCOPE:

The future of the bakery industry holds tremendous potential for growth and innovation.
With evolving consumer preferences, technological advancements, and changing lifestyles,
the bakery industry is poised to undergo significant transformations. Several key trends and
opportunities shape the future scope of the bakery industry:

Health and wellness, innovation of ingredients, personalization and customization,

sustainability, health focused snacking, etc.

Bakeries can adapt to changing consumer demands and preferences while carving out their
unique niche in the market. It's a sector where creativity, innovation, and a commitment to
quality will continue to drive success.

40
CHAPTER 7
REFERENCES

41
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