Bread industry:

• Manufacturing process
• Plant location

Submitted by:
Name: Prasad Mathekar
Roll No: 0916052
Mgm’s Institute Of Management, Aurangabad

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Bread is a staple food prepared
by cooking a dough of flour and water and possibly more
ingredients. Doughs are usually baked, but in some cuisines
breads are steamed, fried, or baked on an unoiled skillet. It
may be leavened or unleavened. Salt, fat and leavening
agents such as yeast and baking soda are common
ingredients, though bread may contain other ingredients,
such as milk, egg, sugar, spice, fruit (such
as raisins), vegetables (such as onion), nuts (such as
walnuts) or seeds (such as poppy seeds). Bread is one of the
oldest prepared foods, dating back to the Neolithic era. The
development of leavened bread can probably also be traced
to prehistoric times.
Fresh bread is prized for its taste, aroma, quality and
texture. Retaining its freshness is important to keep it
appetizing. Bread that has stiffened or dried past its prime is
said to be stale. Modern bread is sometimes wrapped
in paper or plastic film, or stored in a container such as
a bread boxto reduce drying. Bread that is kept in warm,
moist environments is prone to the growth of mold. Bread
kept at low temperatures, in a refrigerator for example, will
develop mold growth more slowly than bread kept at room
temperature, but will turn stale quickly due to retro
gradation.
The soft, inner part of bread is known to bakers and
other culinary professionals as the crumb, which is not to be
confused with small bits of bread that often fall off,
called crumbs. The outer hard portion of bread is called
the crust.

Cultural and political importance of bread

As a foodstuff of great historical and contemporary
importance, in many cultures in the West and Near and
Middle East bread has a significance beyond mere nutrition.
The Lord's Prayer, for example, contains the line "Give us
this day our daily bread"; here, "bread" is commonly
understood to mean necessities in general. Bread is also
significant in Christianity as one of the elements
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(alongside wine) of theEucharist; see sacramental bread. The
word companion comes from Latin com- "with"
+ panis "bread". The Roman poet Juvenal satirised
superficial politicians and the public as caring only for
"panem et circenses" (bread and circuses). In Israel the most
usual phrase in work related demonstrations is "lekhem,
avoda" [bread, work], and during the 1950s,
the beatnik community used the term bread as a
euphemism for money. In Cockney Rhyming Slang, bread
means money and is derived from the phrase bread and
honey. The word bread is now commonly used around the
world in English speaking countries as a synonym for money
(as also is the case with the word dough.)
The cultural importance of "bread" goes beyond slang,
however, to serve as a metaphor for basic necessities and
living conditions in general. A "bread-winner" is a
household's main economic contributor and has little to do
with actual bread-provision, for example. This also goes
along with the phrase "putting bread on the table". A
remarkable or revolutionary innovation is often referred to
as "the greatest thing since sliced bread". In the USSR in
1917, Lenin and his fellow Bolsheviks promised "Peace,
Land, and Bread."The term "breadbasket" is often used to
denote an agriculturally productive region.
In Slavic cultures bread and salt is offered as a welcome to
all guests. In India, life's basic necessities are often referred
to as "roti, kapra aur makan" [bread, cloth and house].
The political significance of bread is considerable. In Britain
in the nineteenth century the inflated price of bread due to
the Corn Laws caused major political and social divisions,
and was central to debates over free
trade and protectionism. The Assize of Bread and Ale in the
thirteenth century demonstrated the importance of bread in
medieval times by setting heavy punishments for short-
changing bakers, and bread appeared in the Magna Carta a
half-century earlier.

Types:

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Bread is a popular food in most societies. East Asian
societies typically prefer wheat noodles, steamed bread, or
rice. Bread is often made from a wheat flour dough that is
cultured with yeast, allowed to rise, and finally baked in
an oven. Owing to its high levels of gluten (which give the
dough sponginess and elasticity), common wheat (also
known as bread wheat) is the most common grain used for
the preparation of bread, but bread is also made from the
flour of other wheat species
(including durum, spelt and emmer), rye, barley, maize (or
corn), and oats, usually, but not always, in combination with
wheat flour. Although common wheat is best suited for
making highly-risen white bread, other wheat species are
capable of giving good black bread. Spelt bread (Dinkelbrot)
continues to be widely consumed in Germany, and emmer
bread was a staple food in ancient Egypt. Canadian bread is
known for its heartier consistency due to high protein levels
in Canadian flour.

White bread is made from flour containing only the central

core of the grain (endosperm).

Brown bread is made with endosperm and 10% bran. It can

also refer to white bread with added colouring (often
caramel colouring) to make it 'brown'; commonly labeled in
America as "Wheat" bread (as opposed to "Whole Wheat"
bread.)

Wholemeal bread contains the whole of the wheat grain

(endosperm and bran). It is also referred to as 'whole grain'
or 'whole wheat' bread, especially in North America.

Wheat germ bread has added wheat germ for flavoring.

Whole grain bread can refer to the same as 'wholemeal

bread', or to white bread with added whole grains to
increase its fibre content (i.e. as in "60% whole grain
bread").

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Roti is a whole wheat based bread eaten in South
Asia. Chapatti is a larger variant of Roti. Naan is a leavened
equivalent to these.

Granary bread is bread made from granary flour.

Trademarked to Hovis, it is made from malted white or
brown flour, wheat germ and whole grains.

Rye bread is made with flour from rye grain of variable

levels. It is higher in fiber than many common types of bread
and is often darker in color and stronger in flavor
In Scandinavia, Germany, Finland, the Baltic States,
and Russia, rye is a popular type of bread.

Unleavened Bread or Matzah used for the Jewish feast

of Passover, does not include yeast, thus it does not rise.

Sourdough bread is made with a starter.

Quick breads:
Quick breads usually refer to breads chemically leavened,
usually with both baking powder and baking soda, and a
balance of acidic ingredients, and alkaline ingredients.
Examples include: pancakes and waffles, muffins and carrot
cake, Boston brown bread, and zucchini and banana bread.

PLANT LOCATION:

Every entrepreneur is faced with the problem of deciding the

best site for location of his plant or factory.

Plant location
Plant location refers to the choice of region and the selection
of a particular site for setting up a business or factory.
But the choice is made only after considering cost and
benefits of different alternative sites. It is a strategic
decision that cannot be changed once taken. If at all
changed only at considerable loss, the location should be
selected as per its own requirements and circumstances.
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Each individual plant is a case in itself. Businessman should
try to make an attempt for optimum or ideal location.

An ideal plant location

An ideal location is one where the cost of the product is kept
to minimum, with a large market share, the least risk and
the maximum social gain. It is the place of maximum net
advantage or which gives lowest unit cost of production and
distribution. For achieving this objective, small-scale
entrepreneur can make use of location analysis for this
purpose.

PLANT LAYOUT:

The efficiency of production depends on how well the various

machines; production facilities and employee’s amenities are
located in a plant. Only the properly laid out plant can
ensure the smooth and rapid movement of material, from
the raw material stage to the end product stage. Plant layout
encompasses new layout as well as improvement in the
existing layout. It may be defined as a technique of locating
machines, processes and plant services within the factory so
as to achieve the right quantity and quality of output at the
lowest possible cost of manufacturing. It involves a judicious
arrangement of production facilities so that workflow is
direct.

Importance:
Plant layout is an important decision as it represents long-
term commitment. An ideal plant layout should provide the
optimum relationship among output, floor area and
manufacturing process. It facilitates the production process,
minimizes material handling, time and cost, and allows
flexibility of operations, easy production flow, makes
economic use of the building, promotes effective utilization
of manpower, and provides for employee’s convenience,
safety, comfort at work, maximum exposure to natural light
and ventilation. It is also important because it affects the

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flow of material and processes, labor efficiency, supervision
and control, use of space and expansion possibilities etc.

Essentials:
An efficient plant layout is one that can be instrumental in
achieving the following objectives:
a) Proper and efficient utilization of available floor space
b) To ensure that work proceeds from one point to another
point without any delay
c) Provide enough production capacity.
d) Reduce material handling costs
e) Reduce hazards to personnel
f) Utilize labor efficiently
g) Increase employee morale
h) Reduce accidents
i) Provide for volume and product flexibility
j) Provide ease of supervision and control
k) Provide for employee safety and health
l) Allow ease of maintenance
m) Allow high machine or equipment utilization
n) Improve productivity

FACTORS INFLUENCING LAYOUT

While deciding his factory or unit or establishment or store, a

small-scale Businessman should keep the following factors in
mind:
Factory building: The nature and size of the building
determines the floor space available for layout. While
designing the special requirements, e.g. air conditioning,
dust control, humidity control etc. must be kept in mind.
Nature of product: product layout is suitable for uniform
products whereas process layout is more appropriate for
custom-made products.
Production process: In assembly line industries, product
layout is better. In job order or intermittent manufacturing
on the other hand, process layout is desirable.

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Type of machinery: General purpose machines are often
arranged as per process layout while special purpose
machines are arranged according to product layout
Repairs and maintenance: machines should be so arranged
that adequate space is available between them for
movement of equipment and people required for repairing
the machines.
Human needs: Adequate arrangement should be made for
cloakroom, washroom, lockers, drinking water, toilets and
other employee facilities,
Proper provision should be made for disposal of
effluents, if any.
Plant environment: Heat, light, noise, ventilation and other
aspects should be duly considered, e.g. paint shops and
plating section should be located in another hall so that
dangerous fumes can be removed through proper ventilation
etc. Adequate safety arrangement should also be made.
Thus, the layout should be conducive to health and safety of
employees. It should ensure free and efficient flow of men
and materials. Future expansion and diversification may also
be considered while planning factory layout.

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The Manufacturing Process:

Mixing and kneading the dough

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1 The sifted flour is poured into an industrial mixer.
Temperature-controlled water

is piped into the mixer. This mixture is called "gluten" and

gives bread its elasticity. A pre-measured amount of yeast is
added. Yeast is actually a tiny organism which feeds off the
sugars in the grain, and emits carbon dioxide. The growth of
the yeast produces gas bubbles, which leaven the bread.
Depending on the type of bread to be made, other
ingredients are also poured into the mixer. Modern mixers
can process up to 2,000 pounds (908 kg) of dough per
minute.

2 The mixer is essentially an enclosed drum that rotates at

speeds between 35 to 75 revolutions per minute. Inside the
drum, mechanical arms knead the dough to the desired
consistency in a matter of seconds. Although modern bread
production is highly computerized, the ability of the mixing
staff to judge the elasticity and appearance of the dough is
critical. Experienced personnel will be able to determine the
consistency by the sound of the dough as it rolls around the
mixer. The mixing process takes about 12 minutes.

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Fermentation: 3 Three methods are used to ferment the
dough. In some plants, the high-speed machinery is
designed to manipulate the dough at extreme speeds and
with great force, which forces the yeast cells to rapidly
multiply. Fermentation can also be induced by the addition
of chemical additives such as 1-cysteine (a naturally
occurring amino acid) and vitamin C. Some breads are
allowed to ferment naturally. In this instance, the dough is
placed in covered metal bowls and stored in a temperature-
controlled room until it rises.

Division and gas reproduction

4 After the dough has fermented, it is loaded into a divider
with rotating blades that cut the dough into pre-determined
weights. A conveyer belt then moves the pieces of dough to
a molding machine. The molding machine shapes the dough
into balls and drops them onto a layered conveyer belt that
is enclosed in a warm, humid cabinet called a "prover." The
dough moves slowly through the prover so that it may "rest,"
and so that the gas reproduction may progress.

Molding and baking

5 When the dough emerges from the prover, it is conveyed
to a second molding machine which re-shapes the dough
into loaves and drops them into pans. The pans travel to
another prover that is set at a high temperature and with a
high level of humidity. Here the dough regains the elasticity
lost during fermentation and the resting period.

6 From the prover, the pans enter a tunnel oven. The

temperature and speed are carefully calculated so that when
the loaves emerge from the tunnel, they are completely
baked and partially cooled. While inside the tunnel, the
loaves are mechanically dumped from the pans onto
shelves. The baking and cooling process lasts approximately
30 minutes.

Slicing and packaging

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7 The bread continues to cool as it moves from the oven to
the slicing machine. Here vertical serrated blades move up
and down at great speeds, slicing the bread into consistently
sized pieces.

8 Metal plates hold the slices together while picking up each

loaf and passing it to the wrapping machine. Pre-printed
plastic bags are mechanically slipped over each loaf. At
some bakeries, workers close the bags with wire twists.
Other plants seal the bags with heat.

Websources:
http://www.madehow.com/Volume-2/Bread.html
http://en.wikipedia.org/wiki/Bread

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