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Bakery Industry - Processing & Hazard Identification

Bakery Industry - Processing & Hazard Identification

Bakery Industry in India: Growth and Potential


The bakery industry in India has witnessed significant growth due to rising demand for high-quality, nutritious, and additive-free products. As the second-largest producer of food globally, India has immense potential in the food processing sector.


Market Overview

  • Bakery products such as bread and biscuits constitute over 82% of total production.
  • The sector is categorized into bread, biscuits, and cake.
  • Around 1.3 million tons of bakery products are produced annually.
  • While large-scale food processing plants exist, many consumers prefer fresh products from local bakeries.


Emerging Trends

  • Increasing demand for whole wheat, gluten-free, and organic bakery products.
  • Consumers prefer healthy, natural, and additive-free options.
  • Major brands like Britannia and Parle dominate, holding nearly 40% market share.
  • The sector is expected to grow at a CAGR of 2% in the coming years.






Bread Processing: Step-by-Step Manufacturing


Bread production follows a systematic and controlled process to ensure consistency and quality. The major steps include:


 




2.1 Weighing

Ingredients are weighed as per standard formulation, ensuring accurate composition.


2.2 Mixing

  • All dry and wet ingredients are thoroughly mixed.
  • Salt is added last to prevent yeast deactivation.


2.3 Kneading

  • Kneading helps develop the gluten network and traps carbon dioxide bubbles.
  • It ensures dough elasticity and structure formation.


2.4 Primary Proofing

  • Dough is kept at 27°C to allow yeast fermentation.
  • Proofing results in doubling the dough size.


2.5 Folding & Rising

  • Ensures uniform shape and gas distribution.
  • Dough is divided into equal portions and folded to remove excess stickiness.


2.6 Shaping

  • Dough is shaped into long rolls and placed in tins.
  • This process ensures even air pocket distribution.


2.7 Final Proofing

  • Dough is maintained at 34°C and 85% RH for optimal yeast activity.
  • Ensures sufficient dough rise before baking.


2.8 Baking

  • Baked at 200-260°C with steam injection to prevent crust hardening.
  • Maillard reaction occurs, imparting a golden-brown color.


2.9 Spraying

  • Water is sprayed on freshly baked loaves to enhance crust shine.


2.10 Cooling

  • Loaves are cooled to below 30°C using filtered air to ensure microbial safety.


2.11 Packaging

  • Bread is either sliced and packed or packaged as a whole.
  • Hot packaging is avoided to prevent microbial contamination.


Hazard Identification in the Bakery Industry


3.1 Microbial Risks

  • High moisture and temperature create an ideal environment for microbial growth.
  • Proper hygienic food processing areas are crucial to prevent contamination.





3.2 Equipment Contamination

  • Condensation in ventilation units can lead to fungal growth.
  • Poorly designed equipment may cause product stagnation and microbial contamination.


3.3 Food Hazards & Adulteration

  • Food hazards include biological, chemical, and physical contaminants.
  • Unintentional contamination can occur during harvesting, processing, and transport.


3.4 HACCP in Food Processing

  • HACCP (Hazard Analysis and Critical Control Points) is mandatory for food manufacturing consultants.
  • No food factory or food processing plant can operate without HACCP compliance


Conclusion: Future of the Indian Bakery Industry


The Indian bakery industry is poised for sustained growth, benefiting both consumers and manufacturers.

  • Consumers will enjoy a wider range of nutritious and innovative bakery products.
  • Food industry consultants and food processing experts will play a crucial role in maintaining quality and safety.
  • The industry will expand globally, overcoming challenges and leveraging modern food processing technology.


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