Biscuit, Cookie and Cracker Process and Recipes [1 ed.] 0128205989, 9780128205983

Table of contents :
Cover
Biscuit, Cookie and
Cracker Process and
Recipes
Copyright
Biographies
Glyn Barry Sykes (1946-2015)
Iain Davidson, Director Baker Pacific Ltd.
Baker Pacific Ltd.
Acknowledgements
Introduction
1
Crackers
Soda and saltine crackers
Description
Product specification
Recipe 1.1.1
Critical ingredients
Mixing and fermentation
Dough forming
Baking
Alternative oven band
Cracker breaking
Oil spray
Formulations for soda and saltine crackers
Recipe 1.1.2
Recipe 1.1.3
Recipe 1.1.4
Recipe 1.1.5
Recipe 1.1.6
Recipe 1.1.7
Soda cracker with liquid ferment
Cream crackers
Description
Product specification
Ingredient list
Recipe 1.2.1
Dough mixing on a horizontal high speed mixer
Preparation of the fat/flour for dusting
Lamination
Baking
Formulations for cream crackers
Recipe 1.2.2
Recipe 1.2.3
Recipe 1.2.4
Recipe 1.2.5
Recipe 1.2.6
Recipe 1.2.7
Recipe 1.2.8
Recipe 1.2.9
Recipe 1.2.10
Recipe 1.2.11
Cream cracker recipes: Sponge and dough
Recipe 1.2.12
Recipe 1.2.13
Recipe 1.2.14
Recipe 1.2.15
Recipe 1.2.16
Malkist crackers
Description
Malaysian crackers
Butter coconut
Description
Product specification
Formulation for butter coconut
Recipe 1.4.1
Two stage mixing process on a horizontal mixer
Stage 1
Stage 2
Standing time
Forming
Baking
Glazing
Cooling
Puff crackers
Description
Product specification
Ingredient list
Formulation
Recipe 1.5.1
Cornish Wafer type crackers
Description
Product specification
Ingredient list
Formulation
Recipe 1.6.1
Mixing
Stage 1
Stage 2
Standing time
Forming
Baking
Water biscuits
Description
Product specification
Ingredient lists
Formulation
Recipe 1.7.1
Mixing
Forming
Baking
Formulations for water biscuits
Recipe 1.7.2
Recipe 1.7.3 (unfermented)
Bath Oliver
Description
Ingredient list
Product specification
Wholemeal crackers
Description
Product specification
Ingredient lists
Recipe 1.9.1
Mixing
Forming
Baking
Salt sprinkler and oil spray
Formulations for wholemeal and rye crackers
Recipe 1.9.2
Recipe 1.9.3
Crispbread
Description
Product specification
Ingredient list
Formulations for crispbread
Recipe 1.10.1
Recipe 1.10.2
Mixing
Stage 1
Stage 2
Stage 3
Standing time
Forming
Baking
2
Snack crackers
`Ritz type snack cracker
Description
Product specification
Ingredient list
Formulation
Recipe 2.1.1
Critical ingredients
Mixing
Standing time
Forming
Baking
Oil spray
Formulations for `Ritz type crackers
Recipe 2.1.2
Recipe 2.1.3
Recipe 2.1.4
Recipe 2.1.5
Recipe 2.1.6 `Ritz chips
`TUC type cracker
Description
Product specification
Ingredient list
Mixing
Standing time
Forming
Baking
Oil spray
Formulations for `TUC type crackers
Recipe 2.2.2
Recipe 2.2.3
Recipe 2.2.4
Recipe 2.2.5
Three layer crackers
Description
Product specification
Formulations for three layer crackers
Recipe 2.3.1
Alternative recipes
Recipe for outer dough 2.3.1
Recipe for outer dough 2.3.2
Recipe for inner dough
Critical ingredients
Mixing
Standing time
Forming
Forming with the cut sheet laminator
Baking
Cheese crackers
Description
Product specification
Ingredient list
Formulations for cheese crackers
Recipe 2.4.1
Recipe 2.4.2
Recipe 2.4.3
Recipe 2.4.4
Recipe 2.4.5 cheese straws
Vegetable and herb crackers
Description
Product specification
Ingredient list
Formulation for vegetable and herb crackers
Recipe 2.5.1
Critical ingredients
Alternative formulations
Mixing
Standing time
Forming
Baking
Oil spray
Formulations for vegetable and herb crackers
Recipe 2.5.2
Recipe 2.5.3
Recipe 2.5.4
Sesame crackers
Description
Product specification
Ingredient list: Poppy seed and sesame crackers
Ingredient list: Poppy snack
Formulations for sesame crackers
Recipe 2.6.1
Critical ingredients
Alternative recipes
Process: Recipe (1)
Mixing
Standing time
Forming
Sesame seed application
Baking
Formulation for sesame cracker
Recipe 2.6.2
Wheat crackers
Description
Ingredient lists
Formulations for wheat crackers
Recipe 2.7.1
Recipe 2.7.2
Oyster crackers
Description
Formulations for oyster crackers
Recipe 2.8.1
Recipe 2.8.2
Fish type snack crackers
Description
Ingredient list
Formulation for fish type snack crackers
Recipe 2.9.1
Bacon snacks
Description
Formulation for bacon snacks
Recipe 2.10.1
Oil spray
Potato chips (baked and fried)
Description
Ingredient list
Formulation: Recipe 2.11.1 (baked)
Mixing
Forming
Baking
Formulations for potato snacks
Recipe 2.11.2 (baked and fried)
Recipe 2.11.3 (baked and fried)
Recipe 2.11.4 (baked and fried)
Recipe 2.11.5
Munchies potato snacks
Description
Formulation for munchies
Recipe 2.12.1
Mixing
Standing time
Forming
Baking
Vanilla snacks
Description
Product specification
Formulation for vanilla snack
Recipe 2.13.1
Little Hearts
Description
Formulation for Little Hearts
Recipe 2.14.1
Mixing
Forming
Baking
3
Semi-sweet biscuits
Semi-sweet biscuits
Description
Critical ingredients
Mixing
Forming
Baking
Cooling
Marie, Maria
Description
Product specification
Formulations for Marie
Critical ingredients
Recipe 3.2.1
Recipe 3.2.2
Recipe 3.2.3
Recipe 3.2.4
Recipe 3.2.5
Recipe 3.2.6
Golden Maria
Description
Product specification
Formulations for Golden Maria
Recipe 3.3.1
Recipe 3.3.2
Rich Tea
Description
Product specification
Rich Tea
Rich Tea Finger
Ingredient list
Formulations for Rich Tea
Recipe 3.4.1
Recipe 3.4.2
Recipe 3.4.3
Recipe 3.4.4
Recipe 3.4.5
Recipe 3.4.6
Le Veritable Petit-Beurre
Description
Product specification
Ingredient list
Petit Beurre type biscuits
Description
Formulations for Petit Beurre type
Recipe 3.6.1
Recipe 3.6.2
Tostada
Description
Product specification
Ingredient list
Formulations for Tostada type
Recipe 3.7.1
Recipe 3.7.2
Nice
Description
Product specification
Ingredient list
Formulations for Nice
Recipe 3.8.1
Recipe 3.8.2
Recipe 3.8.3
Arrowroot
Description
Product specification
Ingredient list
Formulation for arrowroot biscuits
Recipe 3.9.1
Garibaldi biscuits
Description
Product specification
Formulations
Recipe 3.10.1
Critical ingredients
Flour
Currants
Seedless raisins and sultanas
Mixing
Forming
Currant spreader
Wash-over
Baking
Cutting
Cooling
Formulations for Garibaldi
Recipe 3.10.2
Recipe 3.10.3
Recipe 3.10.4
Gala fruit cookies
Product specification
Formulation
Recipe 3.11.1
Mixing
Forming
Baking
Harvest type
Description
Product specification
Formulation
Recipe 3.12.1
Mixing
Forming
Baking
Café Noir type
Description
Ingredient list
Product specification
Formulation for Café Noir type
Recipe 3.13.1
Morning Coffee
Description
Product specification
Ingredient list
Formulation for Morning Coffee
Recipe 3.14.1
Animals
Description
Product specification
Ingredient list
Potato Biscuits
Description
Formulation
Recipe 3.16.1
Mixing
Forming
Baking
Cabin and Gem biscuits
Description
Formulations
Recipe 3.17.1 Cabin
Recipe 3.17.2 Gem
Iced gem
Description
Formulation for iced gem
Recipe 3.17.3
Hard tack biscuits, army biscuits
Description
Formulation
Recipe 3.18.1
Recipe 3.18.2
4
Short dough biscuits
Short dough biscuits
Process for a moulded short dough biscuit: Glucose
Description
Product specification
Formulation
Recipe 4.1.1
Critical ingredients
Mixing
Standing time
Rotary moulding
Baking
Cooling
Formulations for glucose biscuits
Recipe 4.1.2
Recipe 4.1.3
Digestive
Description
Product specification
Ingredient list
Formulations for digestive
Recipe digestive 4.2.1
Recipe digestive 4.2.2
Recipe digestive 4.2.3
Recipe digestive 4.2.4
Recipe digestive 4.2.5
Recipe digestive 4.2.6
Recipe digestive 4.2.7
Recipe digestive 4.2.8
Recipe digestive 4.2.9
Recipe digestive 4.2.10
Recipe low fat digestive 4.2.11
Recipe homewheat type 4.2.12
Chocolate digestive
Product specification
Ingredient list
Shortcake
Description
Product specification: Shortcake
Formulations for shortcake
Recipe 4.3.1 shortcake
Recipe 4.3.2 butter shortcake
Recipe 4.3.3 shortcake
Recipe 4.3.4 shortcake
Recipe 4.3.5 shortcake
Product specification: Shorties
Formulations for shorties
Recipe 4.3.6 shorties
Fruit shortcake
Description
Product specification
Ingredients list
Shortbread
Description
Specification: Shortbread fingers
Specification: Shortbread bites
Ingredient list
Formulations for shortbread
Recipe 4.5.1
Recipe 4.5.2
Abernethy
Description
Ingredient list
Product specification
Formulation for Abernethy type biscuits
Recipe 4.6.1
Malted Milk
Description
Product specification
Ingredient list
Frollini
Description
Ingredient list
Formulation for Frollini
Recipe 4.8.1
Ginger biscuits
Description
Product specification
Ingredient list 1
Ingredient list 2
Process
Formulations for ginger biscuits
Recipe 4.9.1
Recipe 4.9.2
Recipe 4.9.3
Recipe 4.9.4
Recipe 4.9.5
Recipe 4.9.6
Recipe 4.9.7
Cinnamon Crisp
Description
Formulation for Cinnamon Crisp
Recipe 4.10.1
Windmill biscuits
Description
Ingredient list
Formulations for windmill
Recipe 4.11.1
Recipe 4.11.2
Chocolate fingers, finger biscuits
Description
Product specification
Ingredient list
Formulation for finger biscuits
Recipe 4.12.1
Oaty biscuits
Product specification
Ingredient list 1
Ingredient list 2
Formulation for oat crisps
Recipe 4.13.1 oat crisps
Recipe 4.13.2 for oatmeal biscuits
Vanilla cookie
Description
Formulation for vanilla cookie
Recipe 4.14.1
Little Hearts
Description
Product specification
Ingredient list
5
Cookies
Chocolate chip cookies
Description
Product specification
Ingredient list
Ingredient list
Formulation
Recipe 5.1.1
Mixing
Forming
Baking
Cooling
Formulations
Recipe 5.1.2
Recipe 5.1.3
Recipe 5.1.4
Recipe 5.1.5
Recipe 5.1.6
Recipe 5.1.7
Recipe 5.1.8
Recipe 5.1.9
Recipe 5.1.10 chocolate chip with nuts
Recipe 5.1.11
Recipe 5.1.12 mini chocolate chip
Recipe 5.1.13 mini chocolate chip
Recipe 5.1.14
Recipe 5.1.15
Maryland type cookies
Description
Product specification
Ingredient list
Formulations for Maryland type cookie
Recipe 5.2.1 Maryland type
Recipe 5.2.2 Maryland type
Recipe 5.2.3 Maryland type
Oatmeal cookies
Description
Product specification for oat cookies
Oat cookies ingredient list
Oat and sultana cookies
Product specification
Ingredient list
Formulations for oatmeal cookies
Recipe 5.3.1
Recipe 5.3.2
Recipe 5.3.3
Recipe 5.3.4 (without oatmeal)
Coconut cookies
Formulations for coconut cookies
Recipe 5.4.1
Recipe 5.4.2
Recipe 5.4.3
Recipe 5.4.4
Recipe 5.4.5
Recipe 5.4.6
Cookie varieties
Description
Peanut cookies
Product specification
Ingredient list
Formulations for cookies
Recipe 5.5.1 cookies with orange flavour
Recipe 5.5.2
Recipe 5.5.3 butter rings
Recipe 5.5.4 chocolate cookie
Recipe 5.5.5 shortbread rout press
Recipe 5.5.6 butter thins
Recipe 5.5.7 fruit cookie
Recipe 5.5.8 butter pecans
Recipe 5.5.9 fruit cookie
Infant rusk
Description
Product specifications
Formulations for infant rusks
Recipe 5.6.1
Recipe 5.6.2
Mixing
Standing time
Forming
Baking
Alternative shapes
6
Danish butter cookies
Description
Product specifications and formulations
Swirl cookie
Recipe 6.2.1 swirl cookie
Pretzel
Recipe 6.2 pretzel
Vanilla cookie
Recipe 6.3 vanilla cookies
Coconut and currant cookies
Recipe 6.4 coconut and currant cookies
Chocolate chip cookies
Recipe 6.5 chocolate chip cookies
Production
Mixing
Forming
Baking
Cooling
Packaging
7
Sandwich biscuits
Cream sandwiches
Description
Product specification
Ingredient list
Formulations
Recipe 7.1.1 biscuit base 1
Recipe 7.1.2 biscuit base 2
Cream processing
Recipe 7.1.3 raspberry cream filling
Biscuit sandwiching process
Biscuit cream sandwich machines
Cookie capper machines
Sandwich cooling
Biscuit sandwiches: Raspberry, orange, lemon, butter cream, vanilla cream
Formulations
Recipe 7.2.1 raspberry biscuit base
Recipe 7.2.2 raspberry biscuit base
Recipe 7.2.3 raspberry biscuit base
Recipe 7.2.4 raspberry cream filling
Recipe 7.2.5 lemon cream base
Recipe 7.2.6 lemon cream filling
Recipe 7.2.7 orange cream base
Recipe 7.2.8 orange cream base
Recipe 7.2.9 orange cream
Recipe 7.2.10 orange cream
Recipe 7.2.11 orange cream
Recipe 7.2.12 butter cream base
Recipe 7.2.13 butter cream
Recipe 7.2.14 vanilla cream
Bourbon
Description
Product specification
Ingredient list
Formulations for Bourbon
Recipe 7.3.1 Bourbon base 1
Recipe 7.3.2 Bourbon cream 1
Recipe 7.3.3 Bourbon base 2
Recipe 7.3.4 Bourbon cream 2
Recipe 7.3.5 Bourbon base 3
Recipe 7.3.6 Bourbon base 4
Cheese crackers
Description
Product specification
Ingredient list
Formulations
Recipe 7.4.1
Recipe 7.4.2
Recipe 7.4.3 biscuit shells
Recipe 7.4.4 cheese cream filling
Chocolate alfajor
Description
Specification and formulation
Product specification
Recipe 7.5.1 alfajor biscuit (rotary moulded)
Recipe 7.5.2. alfajor filling
Recipe 7.5.3 alfajor coating
Chocolate cookie sandwiches
Description
Ingredient list
Product specification
Formulations
Recipe 7.6.1 cookie
Recipe 7.6.2 chocolate cream
Fudge and caramel cookies
Product specification
Formulation
Recipe 7.7.1 fudge cookie
Recipe 7.7.2 caramel cream
Coconut sandwiches
Formulations
Recipe 7.8.1 coconut sandwich base 1
Recipe 7.8.2 coconut sandwich base 2
Recipe 7.8.3 coconut rout press dough
Recipe 7.8.4 coconut base
Recipe 7.8.5 coconut and oatmeal base
Crunchy cookie creams
Description
Product specification
Ingredient list 1
Ingredient list 2
Ingredient list 3
Formulations
Recipe 7.9.1 ginger crunch base 1
Recipe 7.9.2 ginger crunch base 2
Recipe 7.9.3 ginger cream 1
Recipe 7.9.4 crunch base 4
Recipe 7.9.5 crunch base 5
Recipe 7.9.6 cream 2
Custard cream
Description
Product specification
Ingredient list
Formulations
Recipe 7.10.1 custard cream base 1
Recipe 7.10.2 custard cream filling 1
Recipe 7.10.3 custard cream base 2
Recipe 7.10.4 custard cream filling 2
Recipe 7.10.5 custard cream base 3
Recipe 7.10.6 custard cream base 4
Recipe 7.10.7 custard cream filling 3
Fig bars
Description
Product specification
Formulations
Recipe 7.11.1 fig bar base 1
Recipe 7.11.2 fig bar base 2
Recipe 7.11.3 fig jam 1
Recipe 7.11.4 fig jam 2
Recipe 7.11.5 fig jam 3
Jaffa type cake
Description
Product specification
Ingredient list
Process
Mixing for base cake
Depositing
Baking
Cooling and jam depositing
Formulations
Recipe 7.12.1 cake base 1
Recipe 7.12.2 cake base 2
Recipe 7.12.3 jam
Lemon puff
Description
Product specification
Ingredient list
Process based on product specification 2
Mixing
Forming
Baking
Formulations
Recipe 7.13.1 lemon puff
Recipe 7.13.2 lemon cream
Mint creams
Description
Formulations
Recipe 7.14.1 Sandwich base
Recipe 7.14.2 mint cream 1
Recipe 7.14.3 mint cream 2
Oreo type sandwiches
Description
Product specification
Formulations
Recipe 7.15.1 Oreo type base 1
Recipe 7.15.2 Oreo type base 2
Recipe 7.15.3 Oreo type cream
Process
Mix biscuit base on spindle mixer
Forming
Mix cream on spindle mixer
Shortbread creams
Description
Formulations
Recipe 7.16.1 shortbread base
Recipe 7.16.2 shortbread cream
Appendix 1.
Ingredients: An introduction
Flour
Wheat flour
Wheat gluten
Starch
Corn flour
Oats
Soya
Sugars
Sucrose
Sugar specifications
Glucose syrup
Cane syrup 80%
Invert syrup 70%
Fructose syrup 80%
Malt extract 80%
Dough fats and oils
Vegetable fats
Butter
Coconut oil
Other ingredients
Whole egg powder
Lecithin
Yeast (fresh)
Ammonium bicarbonate (`vol) (NH4)HCO3
Sodium bicarbonate (`soda) NaHCO3
ACP-Acid calcium phosphate
SAPP-Sodium acid pyrophosphate
Salt (NaCl)
SMS-Sodium metabisulphite Na2S2O5
Proteolytic enzyme
MRP-Material recovered from production
Bibliography
Appendix 2.
Biscuit, cookie and cracker manufacturers listed in Glyn Sykes notes provide a guide to his wide international experience ...
Appendix 3.
Galleries
Photos of leading products
Gallery 1 Crackers
Gallery 2 Semi-sweet biscuits
Gallery 3 Short dough biscuits
Gallery 4 Cookies
Gallery 5 Danish butter cookies
Gallery 6 Sandwiches
Index
A
B
C
D
F
G
H
I
J
L
M
N
O
P
R
S
T
V
W
Back Cover

Citation preview

Biscuit, Cookie and Cracker Process and Recipes

Biscuit, Cookie and Cracker Process and Recipes

Glyn Barry Sykes Iain Davidson Director, Baker Pacific Ltd.

Academic Press is an imprint of Elsevier 125 London Wall, London EC2Y 5AS, United Kingdom 525 B Street, Suite 1650, San Diego, CA 92101, United States 50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom © 2020 Elsevier Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions. This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library ISBN 978-0-12-820598-3 For information on all Academic Press publications visit our website at https://www.elsevier.com/books-and-journals

Publisher: Charlotte Cockle Acquisitions Editor: Nina Rosa Bandeira Editorial Project Manager: Emerald Li Production Project Manager: Omer Mukthar Cover Designer: Victoria Pearson Typeset by SPi Global, India

Biographies Glyn Barry Sykes (1946–2015)

Glyn Sykes had a long and distinguished career in baking. After studying Food Technology and gaining certificates in bread-making and flour confectionery in United Kingdom, Glyn became a graduate of the Biscuit and Cracker Manufacturer’s course in United States. Glyn was appointed a Committee Member of the professional associations: Cake and Biscuit Alliance, London and the Flour Milling and Bakery Research Association and a member of the working party at the Camden and Chorley Wood Food Research Association. Glyn published articles in Food Technology International and Biscuit Business magazine. Glyn’s career in the biscuit industry started in 1965 with training in United Biscuits Ltd. in the Biscuit Development Department. Glyn subsequently worked overseas as Biscuit Development Manager at Bakers Biscuits Ltd., South Africa and later as Production Manager for Cadbury Schweppes Hudson in New Zealand. On returning to the United Kingdom in 1984, he joined Burtons Gold Medal Biscuits as Biscuit Development Manager. xv

xvi Biographies

In 1986 he joined Baker Perkins Ltd. as Chief Process Technologist. His responsibilities included product development and training at the Food Process Centre in Peterborough and the process commissioning of Baker Perkins biscuit, cookie and cracker production lines. This task enabled Glyn to achieve experience with over 50 biscuit making companies in 30 countries including: Argentina, Australia, Belgium, Canada, China, Colombia, Denmark, Finland, Germany, Hong Kong, India, Indonesia, Iran, Ireland, Italy, Ivory Coast, Japan, Korea, Malaysia, Netherlands, Pakistan, Saudi Arabia, Spain, Sri Lanka, Switzerland, Taiwan, Thailand, Trinidad, United Kingdom, United States, Vietnam. Glyn developed his own biscuit making technology from his wide international experience. During his career he kept detail notes on the products and processes, including a wide range of recipes. His work has now been made available by his family to assist and support future developments in the biscuit, cookie and cracker industry world-wide.

Iain Davidson, Director Baker Pacific Ltd. Iain graduated from the School of Industrial Design (Engineering) at Royal College of Art in London in 1965 and joined Baker Perkins Ltd. He was Industrial Design Engineer, working in the Technical Department on the design of new biscuit, bakery and candy processing machines until 1975, gaining a thorough technical knowledge of the machines and processes. In 1975, Iain was appointed Market Development Manager at Baker Perkins, involved in developing the Baker Perkins forward planning for new business, product development and acquisitions. In 1979 Iain became International Sales Manager with responsibility for the business in Asia and Africa. In 1990 Iain was appointed Regional Manager Asia Pacific for Baker Perkins and re-located to Indonesia and later in 1997 to China. His appointments included Managing Director of Baker Perkins (Hong Kong) Ltd. and Director of Baker Perkins Japan KK. In 1990 Iain negotiated an agreement with the Liaoning Foreign Trade Corporation in Dalian to establish a manufacturing facility for biscuit ovens. This was successful in manufacturing ovens under the supervision of Baker Perkins Japan KK engineers.

Biographies

xvii

Baker Pacific Ltd. In 2000 Iain left Baker Perkins Ltd. and established his own company in Indonesia, PT Baker Pacific Mandiri. The company provided consultancy in the biscuit and confectionery industries in Asia. As the business outside Indonesia grew, Baker Pacific Ltd. was established in Hong Kong in 2004 and is now our principal operating company, providing process technology and machinery for the biscuit, chocolate and candy industries. The company established a manufacturing facility for biscuit ovens and manufactured ovens in China, India and Indonesia. During recent years, Iain has provided training programmes for technical staff in biscuit bakeries, both courses presented on site and also provision of presentation materials for in house programmes. Iain has completed a technical manual ‘Biscuit Baking Technology, 2nd Edition’ published in 2016 and Biscuit, Cookie and Cracker Production published in 2017 by Academic Press, an imprint of Elsevier.

Acknowledgements The files and notebooks written by Glyn Sykes during his career in the biscuit industry have been kindly made available for this book by his family. We trust that it will be a valuable contribution to many employed in the biscuit, cookie and cracker industry. I wish also to record the extensive support that we have enjoyed from our many colleagues at Baker Perkins Ltd and their important contribution to this book. In addition we wish to thank all who have contributed to the book with advice, information and images. Iain Davidson

xix

Introduction Glyn Sykes and I worked together at Baker Perkins Ltd. from 1986. I was involved in projects throughout Asia and Glyn was responsible for the process commissioning of the biscuit, cookie and cracker lines supplied from the United Kingdom. Subsequently Glyn supported our projects for Baker Pacific Ltd. in China, Malaysia, Indonesia, Thailand and Vietnam.

Recipes Glyn had wide international experience and provided recipes and process knowledge for each of his projects. The recipes included in the book are taken from Glyn’s notebooks and I have included any relevant accompanying notes. Recipes marked ‘Confidential’ have been omitted. For each project, Glyn used recipes from his previous experience and always modified them to suit the particular ingredients and equipment available. The recipes are therefore guides only and will require expert development for each new application.

Process The introductions to each chapter in the book and the processes described are based on various projects undertaken by Glyn Sykes for Baker Pacific Ltd. These introductions describe the principal features of the process. It should be noted that the process information is a guide only and depends on the specification of the production equipment used for the project. In particular, data on mixing times and baking times and temperatures are given for the particular project and the equipment used for the trials.

Ingredient lists The ingredient lists are taken from the packaging of a specific product of the type described and can be useful in developing a similar product.

Images The images of the products in the text and galleries are given to indicate the type and typical appearance of each type of product. Glyn’s process data and recipes given are for similar, but not identical products. xxi

xxii Introduction

We trust that the information provided will be of valuable assistance to those developing new biscuit, cookie and cracker products.

Disclaimer The authors do not accept liability for any omissions, errors either of content or interpretation, nor accept any liability or responsibility for any consequences whatsoever arising from the use of information contained in this document.

Chapter 1

Crackers

FIG. 1.1 Crackers.

1.1 Soda and saltine crackers

FIG. 1.2 Soda crackers.

1.1.1

Description

Soda and saltine crackers are a traditional product in United States, where they are made in very large volumes. The process has several important characteristics:

▪ A two stage mixing process known as ‘sponge and dough’ ▪ A long fermentation, usually 24 h Biscuit, Cookie and Cracker Process and Recipes. https://doi.org/10.1016/B978-0-12-820598-3.00001-9 © 2020 Elsevier Inc. All rights reserved.

1

2 Biscuit, cookie and cracker process and recipes

▪ Fast baking time, around 2.5 min, on a compound balanced weave CB5 preheated oven band ▪ Soda crackers are baked in strips or sheets and are broken into individual crackers (usually in pairs) after baking

FIG. 1.3 Process flow.

1.1.2 Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: pH: Moisture:

91
44 mm 5.6 mm 6.25 g Evenly blistered Pale creamy colour with darker blisters, evenly spaced Open and flaky, with a crispy bite Mild, fermented flavour 7.2–8.0 2.5%

Recipe 1.1.1 Sponge Flour (strong) Fresh yeast Dough fat Lecithin Malt extract 80% Water Dough Flour (weak) Dough fat Soda Salt

66.7 0.17 5.00 0.53 0.95 28.0 33.3 5.00 0.60 1.50 141.75

Critical ingredients The flour used in the sponge is 10–11% protein. A weaker flour (8.0–9.0% protein) is usually used for the dough and will give a product with a softer bite. A stronger flour produced with 30% of hard wheat will give an open texture and a harder cracker.

Crackers Chapter

1.1.3

1

3

Mixing and fermentation

The sponge and dough are usually mixed on vertical spindle mixers. Two or three spindle machines are used with slow mixing speed, 25 rpm. The gentle mixing action incorporates the ingredients well without undue work input at the sponge stage.

FIG. 1.4 Vertical spindle mixer from Dingson Food Machinery www.dsm-mc.com.

FIG. 1.5 Vertical spindle mixer from Apinox Srl. This picture belongs to Apinox Srl. Italy. This mixer has been specifically designed for the production of soda cracker, cream cracker with two stages, fermented dough and delicate dough.

4 Biscuit, cookie and cracker process and recipes

The sponge is mixed as an ‘all in’ mix. The yeast should be dispersed in water before feeding to the mixing bowl. The dough is mixed to a temperature of 30–35 °C, which is the optimum temperature for the action of the yeast. The sponge is fermented for 18 h at a temperature of 30–35 °C and an RH of approximately 80%. During this time the pH value will change from about 5.8 to 4.0 and the temperature of the sponge will increase. After the fermentation of the sponge, the dough tub is taken back to the mixing room. The additional ingredients for the dough are added, including the sodium bicarbonate. Gentle, slow speed mixing is required until an homogeneous dough is made. Over-mixing will reduce the spring and give a hard, tough product. After mixing, the dough is returned to the fermentation room for up to 6 h. With the addition of the soda, a large change in the pH occurs and the dough will reach a pH of over 7.0.

1.1.4 Dough forming The dough is laminated, usually with 4–6 layers of around 4.0 mm thickness.

FIG. 1.6 Laminated dough sheet.

The dough is then gauged with a maximum reduction at each gauge roll unit of 2:1. Excessive reductions of the dough thickness will prevent good lift or spring of the cracker. Typical settings for the gauge roll gaps are: Gauge roll 1: Gauge roll 2: Gauge roll 3:

10 mm 5 mm 2 mm

A relaxation conveyor is used to relax the tension in the dough sheet before cutting, as the soda cracker doughs are subject to considerable shrinkage after cutting and during baking. The dough sheet is cut with a ‘scrap-less’ cutter. Each cracker shape is perforated (not cut through), so that the dough sheet remains complete.

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5

FIG. 1.7 Scrapless cutting roll from Errebi Technology Srl, Italy.

A small amount of edge scrap is cut off and this is diverted by side scrap wheels to the scrap return system. A cross scrap conveyor is used to convey the scrap to the return conveyor. The dough sheet may be cut through across its width with one revolution of a large diameter cutting roll so that the dough sheet is divided into lengths of approximately 1.0 m in the oven. This allows shrinkage to occur during baking without random breaks in the dough sheet, which may cause problems at the cracker breaker.

1.1.5

Baking

The baking of soda crackers normally follows the US practice with a direct gas fired oven and compound balanced weave oven band (20.5 kg/m2). Typically, a CB5 band is used with pre-heat to give a high band temperature of over 150 °C at the feed end of the oven. Heat is immediately conducted into the bottom of the dough sheet, initiating a fast and strong lift or spring to give the open, flaky texture of the cracker.

FIG. 1.8 Baker Perkins Direct Gas Fired oven with pre-heat burners.

6 Biscuit, cookie and cracker process and recipes

A considerable amount of water must be evaporated from the soda cracker dough and this is achieved by a high temperature in the middle of the oven (minimum 300 °C on a direct gas fired oven). The fast baking time and high water evaporation require a powerful oven. Soda cracker ovens have a burner capacity of over 30 kW per m2 of oven band area. The first zones will have a burner capacity of 45–50 kW per m2 of oven band area. Temperature profile: Baking time:

300/300/280/250 °C 2.5 min

Alternative oven band Good quality crackers can also be baked on a Z47 wire-mesh band with preheat. The process details are similar, but the baking time is longer, usually 4.0 min. 1.1.6 Cracker breaking The baked sheet is broken into lateral strips by a weighted roller positioned over the oven stripping conveyor. The wire-mesh conveyor is supported by rollers before and after the cracker breaker roll. The sheet of crackers is depressed by the breaker roll and breaks into separate strips.

FIG. 1.9 Cracker breaking roll at the oven end.

After cooling, the cracker strips are ‘flip stacked’ by differential belt speeds between the final cooling conveyor and the packing table. After stacking the strips must be correctly aligned. Usually side guide rolls or belts are used to nudge the strips into a central position for breaking. The strips are depressed by breaker wheels aligned with the perforations in the cracker sheet and break at the perforations. The products are normally broken into pairs.

1.1.7 Oil spray Soda crackers are oil sprayed immediately after baking. The cracker strips are transferred from the oven stripping conveyor to the oil spray machine, where a mist of fine oil is sprayed on the top and bottom of the crackers. Coconut oil or palm kernel oil is used.

Crackers Chapter

FIG. 1.10 Oil spray machine from tna solutions Pty Ltd.

1.1.8

Formulations for soda and saltine crackers

Recipe 1.1.2 Sponge Flour Shortening Yeast (fresh) Proteinase 18 Water Ferment at 29 °C for 18 h Dough Sponge Flour Malt syrup Salt Sodium bicarbonate Skimmed milk powder Water

57.300 8.359 0.081 0.022 21.300

42.689 3.841 1.321 1.153 0.512 2.134 138.712 Ferment at 29 °C for 5 h Dough temp. 26 °C pH 7.3

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8 Biscuit, cookie and cracker process and recipes

Recipe 1.1.3 Sponge Flour, strong 64.000 Malt 0.500 Yeast 0.100 Enzyme Mother sponge 0.750 Water 26.000 Ferment at 26 °C RH 80–90% for 19 h Dough Sponge 90.000 Flour, weak 36.000 Fat 10.000 Salt 1.240 Sodium bicarbonate 1.020 MRP 5.600 143.860 Ferment for 4 h Final dough temp. 31 °C

Recipe 1.1.4 Sponge Flour 66.660 Fat 6.679 Dextrose 0.474 Yeast (dried) 1.169 Water 33.000 Ferment 18 h at 32 °C RH 85% Dough Flour 33.340 Fat 6.678 Salt 1.486 Sodium bicarbonate 0.474 Enzyme 0.015 Ferment 4 h at 32 °C RH 85%

Recipe 1.1.5 Sponge Flour, soft Vegetable fat Sugar Fresh yeast Instant yeast Yeast food Enzyme Water Ferment for 11 h at 29.9 °C

70.000 6.000 0.400 0.250 0.090 0.200 0.013 24.000

Crackers Chapter Dough Flour, strong Flour, soft Sugar Whey powder Salt Sodium bicarbonate Monocalcium phosphate Ammonium bicarbonate Water

10.000 20.000 0.600 0.600 1.200 0.800 0.100 0.050 7.000 141.303

Ferment for 5 h at 29.9 °C Dough temperature 33.9 °C

Recipe 1.1.6 Sponge Flour 9% protein 70.000 Shortening 4.000 Malt 1.000 Lecithin 0.100 Yeast 0.200 Enzyme 0.028 Water 25.000 Ferment 19 h at 26 °C and RH 80% Dough Flour 30.000 Meal 3.000 Shortening 4.000 Malt 1.000 Corn syrup 1.000 Whey powder 1.500 Sodium bicarbonate 0.600 Salt 1.200 Ferment for 6 h at 26 °C and RH 80%

Recipe 1.1.7 Soda cracker with liquid ferment Flour Shortening Sugar (Fine) Mace spice Salt Ferment Flour Water

98.400 11.617 0.093 0.087 0.968 1.000 8.712

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10 Biscuit, cookie and cracker process and recipes Activated yeast slurry Flour Water Dried yeast Dextrose Sodium bicarbonate Water

0.613 7.293 0.548 0.194 0.355 13.230 143.110 Ferment at 28–30 °C for 3–4 h Final dough temp. 35–38 °C

1.2 Cream crackers

FIG. 1.11 Cream crackers.

1.2.1 Description The cream cracker was first developed in Ireland by Joseph Haughton in 1885 and manufactured by William Jacob in a small bakery. Jacob’s remain a popular brand in United Kingdom and Ireland. The brand is now owned by Pladis. Cream crackers are usually eaten with butter, cheese and other savoury toppings. They are now widely consumed in South America, Asia and Australasia. Popular brands are Arnotts, Khong Guan, Hup Seng, Hwa Tai, Maliban, Mayora (Roma), Britannia Biscuits, Bakers of Durban. Malaysian cream crackers, originally made with many laminations on manual dough brakes with filling between the laminations and oil sprayed, are distinctive.

1.2.2 Product specification (1) Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: Moisture:

(2)

68
66 mm 66
66 mm 6.4 mm 6.3 mm 7.7 g 8.3 g Evenly blistered Pale cream or darker biscuit colour with dark blisters Open and flaky, with a crisp bite Mild flavour 1.5–2.5%

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Ingredient list Wheat flour, palm oil, salt, sodium bicarbonate, yeast. Recipe 1.2.1 Flour strong Vegetable fat Sugar fine Yeast fresh Malt extract Salt Sodium bicarbonate Water at 32 °C Water to adjust dough temp. Fat flour dusting Flour strong Vegetable fat Salt

1.2.3

100.000 15.200 1.400 1.400 1.000 1.150 0.060 4.400 26.000 150.610 100.000 34.000 2.000

Dough mixing on a horizontal high speed mixer

Make a suspension of the yeast and water at 32 °C In the mixer bowl, add the fat, sugar, malt, salt and remaining water Mix on slow speed for 2 min Add flour and sodium bicarbonate Mix on slow speed for 3 min and then on high speed until the dough is clear (6) Transfer the dough to a tub and prove for 4 h at 32 °C and an RH of 70–80%

(1) (2) (3) (4) (5)

Finished dough temperature 29–30 °C pH 5.8–6.2.

Preparation of the fat/flour for dusting The fat should be in a plastic state at 20 °C or less. Care should be taken to avoid oiling when mixing with the flour. Mix for 10–20 min depending on the temperature of the mixing room. After mixing, sieve the mixture and store at 2–3 °C for 24 h before use.

1.2.4

Lamination

Six laminations with the fat/flour mixture between the laminations.

12 Biscuit, cookie and cracker process and recipes

Add 18 kg of fat/flour dusting to 100 kg of dough.

FIG. 1.12 Fat/flour spreader attached to Baker Perkins cut sheet laminator.

1.2.5 Baking Direct Gas Fired oven. Traditionally cream cracker was baked on an open 5
5 mesh oven band. Baking time: Baking profile: Final moisture content:

3.5–4 min 300/290/270/270/270 °C 1.5–2.5%

1.2.6 Formulations for cream crackers Recipe 1.2.2 Flour, strong Flour, medium Shortening Malt extract Yeast, fresh Salt Sugar, fine Sodium bicarbonate Water

50.000 50.000 14.268 3.571 1.417 1.787 1.429 0.087 28.600 151.159

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Recipe 1.2.3 Flour, medium Shortening Malt Yeast Salt Sodium bicarbonate Water Layering dust Flour, weak Shortening Salt

100.000 16.800 0.900 1.720 1.456 0.360 34.000 155.236 100.000 20.000 1.800 121.800

Proof 2.5 h

Recipe 1.2.4 Flour, strong Flour, weak Shortening Yeast Malt Salt Sodium bicarbonate Water

52.430 47.570 14.232 2.040 1.029 1.198 0.262 33.330 152.091

Proof 2.75 h

Recipe 1.2.5 Flour Fat Salt Yeast Malt flour Water

100.000 17.000 1.250 1.600 0.900 32.000 152.750

Proof 2.5 h

Recipe 1.2.6 Flour Fat Salt Sodium bicarbonate Malt extract Water MRP

100.000 14.210 1.319 0.298 0.042 29.600 2.572 148.041

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14 Biscuit, cookie and cracker process and recipes

Recipe 1.2.7 Flour Fat Malt flour (diastatic) Sugar (pulverised) Yeast Salt Sodium bicarbonate Water Layering dust Flour Fat Salt

100.000 14.286 3.371 1.428 2.143 1.190 0.089 28.500 151.007 100.000 32.140 1.780

Recipe 1.2.8 Flour Shortening Malt flour (diastatic) Yeast Sodium bicarbonate Sugar, fine Salt Water

100.000 14.300 3.600 1.400 0.090 1.400 1.200 35.100 157.090 Ferment for 4 h at 29 °C RH 75% Layering dust Flour 100.000 Shortening 32.600 Salt 1.800

Recipe 1.2.9 Flour Fat Margarine Butter Malt Golden syrup Skimmed milk powder Yeast Salt Sodium bicarbonate SAPP Lecithin MRP Water

100.000 6.000 10.000 2.000 0.778 1.444 2.400 1.778 1.400 0.400 1.000 0.200 1.000 32.000 160.400

Crackers Chapter Layering dust Flour Butter Margarine Salt

100.000 20.280 16.260 1.625 138.165

Recipe 1.2.10 Flour Fat (liquid at 45 °C) Salt Malt (diastatic) Sodium bicarbonate Yeast, dried Lecithin Ascorbic acid Water

100.000 13.461 1.923 1.923 0.385 0.769 1.923 0.027 28.800 149.211 Ferment for 3.5 h at 32 °C Layering dust Flour 100.000 Margarine 27.950 Salt 1.706

Recipe 1.2.11 Flour, strong Flour, weak Fat Yeast Salt Sodium bicarbonate Biscuit dust Water

83.000 17.000 17.857 2.381 1.190 0.089 2.143 30.500 154.160 Rest for 20 min. No proofing.

1.2.7

Cream cracker recipes: Sponge and dough

Recipe 1.2.12 Sponge Flour Sugar Malt extract Glucose 42DE

40.000 1.625 0.997 1.246

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16 Biscuit, cookie and cracker process and recipes Yeast, fresh Water

1.372 17.769 63.009 Mix sponge at low speed for 1 min. Mix at high speed for 2 min Ferment for 6–8 h Dough Flour 60.000 Sponge 140.000 Fat 14.996 Sodium bicarbonate 0.744 Salt 1.625 217.365 Mix dough on vertical spindle mixer. Ferment for 4–6 h

Recipe 1.2.13 Sponge Flour, strong Yeast Water at 40 °C Dough Flour, weak Vegetable fat Margarine Cream powder Sodium bicarbonate Salt Water

50.000 1.500 36.000 50.000 10.000 10.000 0.250 0.200 0.100

158.050 Layering fat/flour Flour 50.000 Margarine 15.000 Fat 10.000 Layer with 100 g of dusting to 1000 g of dough

Recipe 1.2.14 Sponge Flour, strong Yeast Water at 27 °C Dough Flour, medium Flour, strong Shortening Salt Sugar, fine

21.433 2.142 21.425 45.000 50.000 28.570 17.858 1.244 1.787

Crackers Chapter Malt (diastatic) Skim milk Sodium bicarbonate Water

0.716 1.425 0.173 7.140 108.913 Sponge: mix 15 min, ferment 1 h Dough: mix 20 min, ferment 3 h at 30 °C

Recipe 1.2.15 Sponge Flour Salt Yeast Water Dough Flour Fat Malt extract Salt Sodium bicarbonate MRP Water Layering dust Flour Fat

50.000 0.156 0.023 20.250 50.000 13.800 0.043 1.203 0.307 2.650 10.125 148.557 100.000 27.000

Recipe 1.2.16 Sponge Flour Fat Sugar Whey powder Lecithin Yeast Enzyme (protease) Water at 10 °C Ferment for 15 h Dough Flour Sponge Fat Invert syrup Malt extract Salt Sodium bicarbonate Lecithin Ferment for 5 h

63.000 8.250 0.741 1.000 0.083 0.370 0.004 29.600 103.048

37.000 103.000 8.250 2.222 4.074 1.222 0.555 0.083 156.406

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18 Biscuit, cookie and cracker process and recipes

1.3 Malkist crackers

FIG. 1.13 Malkist crackers.

1.3.1 Description Malkist crackers are generally made with a cream cracker recipe and process. The crackers are sugar topped and glazed by a hi-rate burner section at the oven end. These burners may be gas or electric. Other versions of Malkist have alternative toppings. Meat floss or abon is a popular topping in Indonesia.

FIG. 1.14 Meat floss (abon).

1.3.2 Malaysian crackers

FIG. 1.15 Malaysian cream crackers.

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Malaysian crackers have been traditionally made by laminating on dough brakes with multiple layers. Today most are laminated on cut sheet laminators. The Malaysian cream crackers are often oil sprayed.

1.4 Butter coconut

FIG. 1.16 Butter coconut crackers.

1.4.1

Description

Very popular in South East Asia. A crisp, sweet cracker with coconut flavour.

1.4.2

Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: Moisture:

68
38 mm 5.6 mm 5.0 g Shiny, sugar glazed Golden Very light and crisp Sweet with good coconut flavour 1.5%

Formulation for butter coconut Recipe 1.4.1 Flour Vegetable oil Butter Lecithin Caster sugar SSDMP

100.000 2.070 2.070 0.207 20.704 1.035

20 Biscuit, cookie and cracker process and recipes Enzyme (Bio Bake BSC) Enzyme (Profix 100P) Salt Ammonium bicarbonate Coconut essence Fine desiccated coconut Water

0.031 0.031 0.518 4.555 0.104 10.352 33.126 174.803

Note: Powdered sugar for topping 19% of dough weight.

1.4.3 Two stage mixing process on a horizontal mixer Stage 1 Oil, butter, coconut, flavour, ammonia in 50% of the water, lecithin, sugar, salt and milk powder. Mix at slow speed for 1 min and at high speed for 1 min. Stage 2 Add flour and enzymes. Mix at slow speed for 2 min and approximately 6 min at high speed to a temperature of 35 °C. Standing time Stand the dough for 120 min, maintaining the dough temperature after mixing.

1.4.4 Forming The dough is laminated with four laminations, approximately 3 mm thick. No fat/flour filling is used. The following are the recommended gauge roll settings. Gauge roll 1: Gauge roll 2: Gauge roll 3:

6.0 2.6 1.3

1.4.5 Baking Baking time: Temperatures: Moisture:

6.0 min 210/220/250/250/180 °C Less than 1.5%

1.4.6 Glazing Post bake heaters are required to melt the sugar for the glazed surface.

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1.4.7

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Cooling

A ratio of cooling to baking time should be at least 1.5:1 to avoid checking.

1.5 Puff crackers

FIG. 1.17 Puff cracker.

1.5.1

Description

Puff crackers are light, open and flaky. Sweet crackers may be dusted with sugar before baking to give a glazed surface.

FIG. 1.18 Butter puff crackers.

1.5.2

Product specification Dimensions: Thickness: Weight: Appearance: Texture: Moisture:

68–69 mm diameter 10 mm 10.0 g Pale with darker blisters Very light with open texture 1.5%

22 Biscuit, cookie and cracker process and recipes

Ingredient list Wheat flour, vegetable oil (palm), wheat starch, salt. Formulation Recipe 1.5.1 Flour, strong Flour, medium Margarine Tartaric acid Cold water Margarine Malt extract Salt Cold water

50.000 50.000 11.000 0.200 0.200 43.000 2.500 1.500 36.000 194.400

1.6 Cornish Wafer type crackers

FIG. 1.19 Cornish Wafer type crackers.

1.6.1 Description A very light, flaky cracker, usually eaten with cheese or other savoury topping.

1.6.2 Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Moisture:

66–68 mm 6.5–7.17 mm 8.3 g Evenly dockered and blistered Pale cream Open and flaky 3.0%

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Ingredient list Wheat flour, vegetable oil (palm), wheat starch, salt. Formulation Recipe 1.6.1 Flour, weak Fat (P.K.O) Whey powder Salt Biscuit dust Water chilled

1.6.3

100.000 41.670 0.694 1.688 9.115 40.360 193.527

Mixing

Mix on a horizontal mixer.

Stage 1 Add flour (30%) vegetable fat flakes, whey powder, salt and mix at slow speed for 1 min. Stage 2 Add remaining flour and chilled water and mix for 4.5 min at slow speed. Dough temperature: 20 °C. Standing time 20 min. 1.6.4

Forming

Laminate with 7–14 layers. Two laminators are used at right angles to the production line, each producing seven layers. The first laminator is followed by 3 gauge roll units with reductions in dough sheet thickness to 24, 12 and 4.5 mm. This dough sheet is then laid on to the second layered dough sheet. The laminated sheet is then machined by a set of gauge roll units to reduce the dough sheet thickness to 24, 20, 12, 6, 2.2 mm. The dough sheet is rotary cut with separate printing and cutting rolls.

FIG. 1.20 Cornish Wafer texture.

24 Biscuit, cookie and cracker process and recipes

1.6.5 Baking Oven band: Baking time: Zone temperatures:

5
5 wire mesh 4.25 min 110/230/310/330/330/230/160 °C

1.7 Water biscuits

FIG. 1.21 Water biscuits.

1.7.1 Description A plain cracker eaten with cheese or other toppings. A crisp, hard bite.

1.7.2 Product specification (1) Diameter: Thickness: Weight: Colour: Texture: Moisture:

(2)

68 mm 57 mm 5.2 mm 4.5 mm 5.3 g 2.9 g Pale, almost white with dark blisters Open, flaky, quite hard 1.0–2.5%

Ingredient lists (1) Wheat flour, vegetable oil (palm), salt. (2) Wheat flour, palm oil, salt, glucose syrup, sodium bicarbonate. Formulation Recipe 1.7.1 Flour Vegetable fat Salt Water

100.000 7.386 1.420 27.000 135.806

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1.7.3

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Mixing

‘All in mix’ on a horizontal mixer. Stand dough for 8 up to 18 h at 18 °C.

1.7.4

Forming

(1) Laminating: Sheeter followed by 4 gauge rolls to feed layering section. (2) Four laminations, followed by 4 gauge roll units. (3) Rotary cutter

1.7.5

Baking

Direct Gas Fired Oven with open mesh band. Baking time: Temperatures:

1.7.6

2 min 260/260/315/230 °C

Formulations for water biscuits

Recipe 1.7.2 Flour, strong Shortening Invert syrup Salt Sodium metabisulphite Water

100.000 3.750 2.500 1.500 0.028 33.000 140.778

Mix 6 min in High Speed Mixer. Mix 22 min in Vertical Spindle Mixer. Yeast (2.0 kg) may be added to recipe and dough proofed for 5 h

Recipe 1.7.3 (unfermented) Flour, weak Flour, strong Sugar, fine Glucose Fat Margarine Milk powder Salt Water

50.000 50.000 2.500 2.000 4.500 3.500 1.500 1.000 25.000 140.000

26 Biscuit, cookie and cracker process and recipes

1.8 Bath Oliver

FIG. 1.22 Bath Oliver biscuit.

1.8.1 Description A plain, hard biscuit usually eaten in England with cheese. It was invented by William Oliver of Bath around 1750. It became famous and associated with the English aristocracy.

Ingredient list Wheat flour, butter oil, palm oil, ammonium bicarbonate, salt, dried whole milk, barley malt extract, yeast. 1.8.2 Product specification Dimensions: Thickness: Weight: Appearance: Texture: Moisture:

1.9 Wholemeal crackers

FIG. 1.23 Wholemeal and rye crackers.

80 mm diam. 5.5 mm 11.2 g Pale, even colour Crisp and light 4.0%

Crackers Chapter

1.9.1

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Description

Crackers with wholemeal and rye flour, topped with salt.

1.9.2

Product specification Dimensions: Thickness: Weight: Appearance: Colour: pH Moisture:

70
70 mm 4.1 mm 7.7 g Small blisters Rich even wholemeal 6.1 2.5–3.0%

Ingredient lists (1) Wheat flour, rye meal, vegetable oil (palm), yeast, dried wheat gluten, lactose, salt, sodium bicarbonate, lactic acid, natural flavourings. (2) Wheat flour, wholewheat flour, sunflour oil, multigrains (cracked wheat, brown rice, rye, brown linseed, millet), sugar, ammonium bicarbonate, sodium bicarbonate, barley malt extract, salt, onion powder, flavouring. (3) Wheat flour, palm oil, malted barley flour, glucose syrup, sugar, wholemeal wheat flour, rye, sesame seed, sugar beet fibre, ammonium bicarbonate, sodium bicarbonate, salt. Recipe 1.9.1 Flour Rye flour Yeast Lactic acid Proteolytic enzyme Gluten Lactose MSG Salt Sodium bicarbonate Pepper Yeast flavour Water

1.9.3

64.000 36.000 3.400 0.252 0.018 1.600 2.240 0.122 1.444 0.538 0.048 0.040 32.580 142.282

Mixing

Mix on a horizontal high speed mixer (1) Mix flour, fat and water with salt, lactose, yeast, MSG, gluten, flavours. (2) Add soda, enzymes and lactic acid mix at low speed. (3) Add rye flour and mix for approx. 8 min Dough temperature approx. 33 °C. Stand dough for 1–1.5 h.

28 Biscuit, cookie and cracker process and recipes

1.9.4 Forming Laminate: 4–6 laminations of approximately 2.2 mm thickness. 3 gauge roll units to achieve a final dough sheet thickness of 1.4 mm. Rotary cut.

1.9.5 Baking Baking time: Temperatures:

4.5–5.0 min 260/270/220/185 °C

1.9.6 Salt sprinkler and oil spray Topping of flake salt. Oil spray with Cremex® fat at 60–70 °C to achieve 12.5–13% of the cracker weight.

1.9.7 Formulations for wholemeal and rye crackers Recipe 1.9.2 Flour, soft Rye flour Gluten powder Vegetable fat Lactose Yeast Sodium bicarbonate Salt Lactic acid Enzyme Flavours (yeast, pepper) Water

67.000 33.000 1.470 13.590 2.050 4.282 0.490 1.333 0.233 0.053 0.082 37.000 160.583

Flour, soft Wholemeal flour Vegetable fat Glucose 42DE Malt extract Ammonium bicarbonate Sodium bicarbonate Salt Water

50.000 50.000 14.060 8.750 7.750 2.800 0.700 6.600 37.000 177.660

Recipe 1.9.3

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1.10 Crispbread

FIG. 1.24 Crispbread.

1.10.1 Description A flat, crisp, low fat cracker, often containing rye, wholemeal and other local flours. Crispbread is usually eaten with a variety of toppings.

1.10.2 Product specification Dimensions: Thickness: Weight: Appearance: pH Moisture:

91
38 mm 4.5 mm 5.6 g Regular docker pattern, small blisters 6.9 3.0–4%

Ingredient list Wheat flour, palm oil, barley and barley malt extract, kibbled rye, glucose syrup, ammonium bicarbonate, sodium bicarbonate, chive flakes, salt, natural flavourings, wheat starch. 1.10.3 Formulations for crispbread Recipe 1.10.1 Biscuit flour Bread flour Butter Margarine Golden syrup Glucose

67.000 33.000 4.794 5.137 4.795 4.623

30 Biscuit, cookie and cracker process and recipes Malt Whey powder Lecithin Sodium acid pyrophosphate Salt Sodium bicarbonate Ammonium bicarbonate Yeast Water

1.027 2.055 0.332 0.462 1.370 0.500 2.312 2.568 36.000 165.975

Bread flour Crushed wheat Butter Margarine Pura agave syrup Glucose Malt extract Semi-skimmed milk powder Salt Yeast Lecithin Sodium bicarbonate Ammonium bicarbonate Sodium acid pyrophosphate Water

33.000 67.000 5.000 5.000 4.750 4.750 1.000 2.000 1.330 3.330 0.330 0.500 0.867 0.427 30.000 159.284

Recipe 1.10.2

1.10.4 Mixing Horizontal mixer.

Stage 1 All ingredients, except ammonia, yeast and water. Mix low speed 0.5 min. Stage 2 Add ammonia dissolved in water. Mix low speed 0.5 min. Stage 3 Add yeast dissolved in water and remaining water. Mix 2 min low speed and 5 min high speed. Final dough temperature: 32–36 °C. Standing time 50 min.

Crackers Chapter

1.10.5 Forming Two laminators. Total laminations 4
2 ¼ 8. Biscuit cutting machine: Final dough thickness 1.2 mm.

1.10.6 Baking Direct Gas Fired oven. Z47 type wire mesh band. Baking temperatures: 210/230/240/210/180 °C. RF radio frequency drier is used after the oven.

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Chapter 2

Snack crackers

FIG. 2.1 Snack crackers.

2.1 ‘Ritz’ type snack cracker

FIG. 2.2 ‘Ritz’ type crackers.

2.1.1

Description

Snack crackers are successful in every market, savoury, light and crispy with oil spray.

Biscuit, Cookie and Cracker Process and Recipes. https://doi.org/10.1016/B978-0-12-820598-3.00002-0 © 2020 Elsevier Inc. All rights reserved.

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34 Biscuit, cookie and cracker process and recipes

2.1.2 Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: pH: Moisture:

48.0 mm diameter 4.9 mm 3.0 g Evenly blistered Golden Light and crispy 5.5 1.3–2.0%

Ingredient list Wheat flour, palm oil, sugar, raising agents (ammonium hydrogen carbonate, monocalcium phosphate, potassium hydrogen carbonate), salt, barley malt flour, glucose–fructose syrup, acidity regulators (potassium chloride, sodium gluconate). Formulation Recipe 2.1.1 Flour weak Sugar fine Vegetable fat at 45 °C Invert syrup at 45 °C Malt extract at 45 °C Salt Calcium acid phosphate Sodium bicarbonate Ammonium carbonate Enzyme Proteinase No.18 Water

100.000 6.000 10.000 3.000 2.000 0.900 1.100 1.050 1.000 0.200 20.000 145.250

Critical ingredients 1. Flour should be weak with a protein content of 8–9% 2. Proteolytic enzyme. Recommended source: Kerry – Biobake BSC and Profix 100P

FIG. 2.3 Process flow for ‘Ritz’ type crackers.

Snack crackers Chapter

2.1.3

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Mixing

An ‘all in’ mix on a horizontal mixer. Temperature of about 33 °C for enzyme doughs.

FIG. 2.4 Baker Perkins horizontal high speed mixer with shaft-less blade.

(1) (2) (3) (4) (5) (6) (7) (8)

Charge mixer with sugar, fat, invert syrup, malt extract, salt and water Mix at slow speed for 1.5 min Add ammonium bicarbonate dissolved in 2 L of water at 32 °C Mix at slow speed for 1.5 min Add enzyme dissolved in 2 L of water at 32 °C Mix at slow speed for 1.5 min Add flour, calcium acid phosphate, sodium bicarbonate Mix at slow speed for 2 min and at high speed for 1.5 min

Temperature of finished dough: 33 °C. pH 6.5–7.5. Note: Adjust temperatures of mixer water jacket and ingredients to achieve the finished dough temperature of 33 °C, which is important for maximum enzyme activity.

Standing time After mixing, the dough is stood to allow the enzyme to react with the gluten. The standing time is about 3.5–4 h at 32 °C and RH 70–80%. The time must be determined carefully depending on the amount of enzyme and the quality of the flour in order to achieve the soft, delicate eating texture of the cracker.

36 Biscuit, cookie and cracker process and recipes

2.1.4 Forming The dough is laminated with 4–6 laminations, approximately 3 mm thick. Gauge roll reductions on the forming line 2:1.

FIG. 2.5 Baker Perkins forming line: (from right to left) laminator, 3 gauge roll units, relaxation conveyor, rotary cutter, scrap lift and return conveyors.

2.1.5 Baking Direct Gas Fired (DGF) oven or Hybrid DGF/Indirect Radiant or DGF/ Convection.

FIG. 2.6 Baker Pacific Hybrid DGF/Indirect Radiant oven.

Baking time: Temperatures: Band pre-heated to: Oven band:

3.5–4.0 min 220/230/240/240/220 °C 180–200 °C Z47 type wire-mesh band or Compound Balanced Weave band

2.1.6 Oil spray Crackers are oil sprayed immediately after baking with coconut oil at 60 °C.

Snack crackers Chapter

2.1.7

Formulations for ‘Ritz’ type crackers

Recipe 2.1.2 Flour (weak) Barley flour Granulated sugar High fructose corn syrup Vegetable oil (soya bean) Lecithin Ammonium bicarbonate Sodium bicarbonate ACP Salt Profix 100P enzyme Biobake BSC enzyme Water

100.000 1.269 8.016 2.845 11.658 0.196 1.839 1.077 1.077 0.770 0.004 0.005 29.466 158.222

Flour Sugar High fructose corn syrup Vegetable oil (soya bean) Lecithin Ammonium bicarbonate Sodium bicarbonate ACP Salt Enzyme Water

100.000 8.020 2.850 11.660 0.200 1.840 1.080 1.080 0.770 0.010 29.470 156.980

Recipe 2.1.3

Recipe 2.1.4 Flour Soybean oil Sugar Salt Sodium bicarbonate Yeast Enzyme Water

100.000 10.000 1.800 1.800 0.600 0.200 0.002 25.000 139.402

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38 Biscuit, cookie and cracker process and recipes

Recipe 2.1.5 Flour Fat Sugar Corn syrup Ammonium bicarbonate Sodium bicarbonate Salt Monocalcium phosphate Sodium acid pyrophosphate Sodium metabisulphite Enzyme

100.000 10.000 7.500 2.500 1.000 0.800 1.000 0.400 0.400 0.019 0.020 123.639

Recipe 2.1.6 ‘Ritz’ chips Flour Modified starch Native potato starch Sugar Invert syrup Soya bean oil Salt Sodium bicarbonate Acid calcium phosphate Monoglyceride Water

100.000 30.275 1.523 6.055 3.633 7.578 1.211 1.651 1.523 0.606 41.284 195.339

2.2 ‘TUC’ type cracker

FIG. 2.7 ‘TUC’ type crackers.

2.2.1 Description A crisp, very light bite with salt and savoury flavours.

Snack crackers Chapter

2.2.2

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Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Moisture:

64  67 mm 5.8 mm 5.0 g Evenly blistered Golden Light and crispy 1.5%

66  51 mm 6.0 mm 5.5 g

Ingredient list Wheat flour, vegetable oil, barley malt extract, glucose syrup, raising agents (ammonium bicarbonate, sodium bicarbonate), sugar, flavouring, dried whole egg, dried whey, salt.

2.2.3

Mixing

‘All in one’ mix on a horizontal high speed mixer. Mix on low speed for 3 min and high speed for 5–6 min. Dough temperature 28 °C.

Standing time 30–60 min.

2.2.4

Forming

Biscuit cutting machine:

▪ ▪ ▪ ▪ ▪

3 roll sheeter 2/3 pairs of gauge rolls Relaxation web Rotary cutter Salt sprinkler

2.2.5

Baking Baking time: Zone temperatures: Baking band:

4.5–5.0 min 290/270/230/200/200/150 °C Z47 type wire-mesh band. Pre-heat is required

40 Biscuit, cookie and cracker process and recipes

2.2.6 Oil spray Crackers are sprayed immediately after baking with coconut oil at 60 °C. Oil content up to 17% of biscuit weight.

2.2.7 Formulations for ‘TUC’ type crackers Recipe 2.2.2 Flour, soft Vegetable fat Coconut oil Liquid malt Whole egg Glucose Ammonium bicarbonate Sodium bicarbonate Salt Water

100.000 11.071 7.143 8.000 7.857 11.893 3.679 0.557 3.325 16.429 169.954

Flour Vegetable fat Glucose Malt Liquid egg Ammonium bicarbonate Sodium bicarbonate SMS Water

100.000 10.000 10.000 10.000 8.000 2.500 0.500 0.086 20.840 161.926

Flour Palm oil Glucose Malt extract Egg Ammonium bicarbonate Sodium bicarbonate Salt SMS Water

100.000 12.800 8.000 6.667 7.467 3.333 0.507 0.933 0.053 16.800 156.560

Recipe 2.2.3

Recipe 2.2.4

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Recipe 2.2.5 Flour Fat Glucose Malt Liquid egg Ammonium bicarbonate Sodium bicarbonate Salt Water Biscuit crumb

100.00 11.072 10.938 7.991 7.991 2.932 0.569 0.787 19.048 3.500 164.828

2.3 Three layer crackers

FIG. 2.8 Three layer crackers.

2.3.1

Description

A light, crispy cracker texture with three separate layers. The centre dough is coloured.

2.3.2

Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: pH: Moisture:

2.3.3

47  47 mm 5.6 mm 4.0 g Evenly blistered Pale creamy Light and crispy Added flavours 5.5 2.5%

Formulations for three layer crackers

Recipe 2.3.1 Alternative recipes Recipe (1) is an enzyme cracker suitable for sheeting. Recipe (2) is fermented for 18 h and should be laminated (see forming with a cut sheet laminator below).

42 Biscuit, cookie and cracker process and recipes

Recipe for outer dough 2.3.1 Flour Powdered sugar Invert syrup 70% Malt extract 80% Fat Ammonium bicarbonate Sodium bicarbonate Acid calcium phosphate Salt Proteolytic enzyme Yeast Cream of tartar Butter essence Water

(1)

(2)

100.000 3.000 3.000 2.000 12.000 1.000 1.050 1.100 0.900 0.200 – – – 20.000 144.250

100.000 0.400 – 1.000 17.500 – 0.620 – 1.700 0.020 0.500 0.620 0.170 22.500 145.030

Recipe for outer dough 2.3.2 Flour Glucose Shortening Malt extract Liquid whole egg Salt Sodium bicarbonate Ammonium bicarbonate Sodium metabisulphite Water

100.000 13.350 11.716 6.665 7.570 1.000 0.500 4.000 0.050 18.800 163.651

Recipe for inner dough The dough uses the same recipe, but has added colour. Some suitable food colour additives are: Tartrazine Riboflavin β-carotene

Yellow Yellow Orange

E102 E101 E160a

Critical ingredients (1) Flour should be weak with a protein content of 8–9% for outer dough for recipe 1. (2) Recipe 2 for outer dough uses a strong flour. (3) Proteolytic enzyme (proteinase).

2.3.4 Mixing An ‘all in’ mix on a horizontal mixer. Temperature of about 33 °C for enzyme doughs. Two doughs are required of similar consistency, but contrasting colour.

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Standing time After mixing the dough is stood to allow the enzyme to react with the gluten. The standing time is about 3 h at 35 °C. The time must be determined carefully depending on the amount of enzyme and the quality of the flour in order to achieve the soft, delicate eating texture of the cracker. 2.3.5

Forming

The dough is sheeted, gauged and cut (laminating is not required for recipe (1)). Three sheets are required. Each sheeter to produce a sheet of minimum thickness (not exceeding 10 mm). Gauge roll Gauge roll Gauge roll Gauge roll

1: 2: 3: 4:

15.0 8.0 4.0 2.0

The process is not ideal as the three sheets will produce a combined thickness of around 30 mm. Three gauge roll units are not sufficient to reduce this dough sheet to the cutting thickness of 2.0 mm without excessive reductions. This will reduce the spring and open texture of the cracker. An alternative forming method, which is now favoured is described below.

2.3.6

Forming with the cut sheet laminator

Three layer crackers may be laminated on a cut sheet laminator. The hopper is divided into three sections. The two outside sections contain the outer dough and the centre section contains the inner dough. A single dough sheet is produced by the 3 roll sheeter with the outer and inner doughs. The cut sheets are laid so that the inner dough is covered at the top and bottom by the outer dough. The laminated dough is fed to the cutting machine at right angles.

FIG. 2.9 Laminated dough sheet for three layer crackers.

The resulting laminated sheet is gauged and cut in the same way as other cracker doughs. This system gives a good cracker texture and appearance with the contrasting colour in the centre.

2.3.7

Baking Baking time: Temperatures:

5.0 min 220/220/210/180 °C

High bottom heat in Zones 1 and 2 is required. Baking band: Z47 wire-mesh band. Pre-heat is required.

44 Biscuit, cookie and cracker process and recipes

FIG. 2.10 Packaging tray for three layer crackers.

2.4 Cheese crackers

FIG. 2.11 Cheese crackers.

2.4.1 Description Cheese crackers are one of the most popular categories of snack crackers, savoury, light and crispy with oil spray.

2.4.2 Product specification Dimensions: Thickness: Weight: Colour: Texture: Moisture:

55 mm diam. 4.0 mm 3.6 g Pale creamy to golden Light and crispy 1.4–2.0%

Ingredient list Wheat flour, vegetable oils, dried cheese, sugar, dried onion, flavouring, ammonium bicarbonate, sodium bicarbonate, salt.

Snack crackers Chapter

2.4.3

Formulations for cheese crackers

Recipe 2.4.1 Flour Fat Glucose syrup Cheese powder Yeast Peppers Ammonium bicarbonate Sodium bicarbonate Salt Lactic acid SMS 10% solution Water

100.000 18.000 5.240 16.600 3.490 0.065 2.440 0.349 0.872 0.698 0.190 147.944

Recipe 2.4.2 Flour Sugar Glucose Malt Vegetable oil Cheese powder (fat free) Skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate Lactic acid Nuclin flavour MSG Buttabelle flavour Cheese flavour White pepper Water

100.000 2.500 3.055 2.778 11.110 8.333 2.778 1.000 0.333 3.194 0.694 3.055 0.333 0.100 0.278 0.042 32.000 171.583

Recipe 2.4.3 Sponge Flour, weak Water at 29.5 °C Yeast, dissolved in water Cheese Shortening Dough Flour, weak Salt Sodium bicarbonate Water at 29.5 °C

50.000 26.000 0.094 10.000 10.000 50.000 1.250 0.500 7.500

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46 Biscuit, cookie and cracker process and recipes

Recipe 2.4.4 Flour Shortening Cheddar cheese Sugar Salt Paprika Red pepper Celery seed (ground) Yeast Ammonium bicarbonate Water

100.000 6.500 10.000 0.500 1.000 1.200 0.025 0.100 1.000 1.500 22.500 144.325

FIG. 2.12 Cheese straws.

Recipe 2.4.5 cheese straws Flour Cheddar cheese Butter Margarine Egg Salt Ammonium bicarbonate Baking powder Worcester sauce Cayenne pepper MSG Water Topping (sprinkler) Flour Cheddar cheese Salt White pepper Egg wash Milk Egg Golden syrup Water

100.000 30.170 12.333 40.333 5.000 4.533 0.800 1.867 0.633 0.187 0.400 5.333 201.589 10.000 10.000 1.250 0.600 5.000 3.750 1.250 0.315

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2.5 Vegetable and herb crackers

FIG. 2.13 Vegetable crackers.

2.5.1

Description

Savoury crackers with vegetable and herb inclusions in the dough. The production process may follow ‘Ritz’ type or ‘TUC’ type crackers.

2.5.2

Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: pH: Moisture:

Ingredient list

FIG. 2.14 Chive cracker.

50  50 mm 4.6 mm 4.16 g Evenly blistered, made in pairs Pale creamy Light and crispy Added flavours 5.5 2.5%

48 Biscuit, cookie and cracker process and recipes

Wheat flour, palm oil glucose syrup, malted barley extract, salt, ammonium bicarbonate, sodium bicarbonate, dried egg, chive.

Formulation for vegetable and herb crackers Recipe 2.5.1 Flour (weak) Cornflour Sugar Invert syrup 70% Malt extract 80% Dough fat Lecithin Ammonium bicarbonate Sodium bicarbonate Acid calcium phosphate Salt SMS Proteolytic enzyme Dehydrated vegetable flakes Water

(1) With enzyme

(2) With SMS

100.000 – – 1.040 2.080 13.540 – 2.600 0.440 0.050 1.230 – 0.180 2.000 25.000 148.160

90.000 10.000 3.000 16.000 – 14.000 0.280 3.000 1.000 – 1.000 0.050 – 2.000 25.000 165.330

Critical ingredients (1) Flour should be weak with a protein content of 8–9%. (2) Proteolytic enzyme (proteinase). (3) Oil for spraying: coconut oil or palm kernel oil are suitable and have a good resistance to rancidity. Alternative formulations Savoury crackers are mixed on horizontal mixers and the dough is stood to allow the action of the proteolytic enzyme on the gluten. Forming is by sheeting and cutting. Similar products can be made using SMS (sodium metabisulphite) in place of the proteolytic enzyme. The SMS increases the extensibility of the gluten and does not require the 3 h standing time. This type of product can also be made using the soda cracker recipe. This will give an open texture and very crisp bite. 2.5.3 Mixing An ‘all in’ mix on a horizontal mixer. Temperature of about 33 °C for enzyme doughs. Temperature of about 40 °C for SMS doughs. The vegetable flakes may be mixed into the dough.

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Standing time After mixing the dough is stood to allow the enzyme to react with the gluten. The standing time is about 3 h at 35 °C. The time must be determined carefully depending on the amount of enzyme and the quality of the flour in order to achieve the soft, delicate eating texture of the cracker. Doughs made with SMS do not require a standing time. 2.5.4

Forming

The dough is sheeted, gauged and cut (laminating is not required). Typical roll gap settings are: Sheeter: Gauge roll 1: Gauge roll 2: Gauge roll 3:

12 mm 6 mm 3 mm 1.5 mm

If the vegetable flakes are to be sprinkled, a suitable sprinkler unit before the final gauge roll is required.

2.5.5

Baking Baking time: Temperatures:

4.0–5.0 min 220/220/210/180 °C

High bottom heat in Zones 1 and 2 is required. Baking band: Z47 wire-mesh band. Pre-heat is required.

2.5.6

Oil spray

The oil spray should be located immediately after the oven. An application of 10–16% of coconut oil is recommended.

2.5.7

Formulations for vegetable and herb crackers

Recipe 2.5.2 Flour Rye flour Meal Golden syrup Sugar Glucose Malt Milk powder Butter

67.700 20.300 12.000 4.060 1.617 1.353 1.222 1.880 10.526

50 Biscuit, cookie and cracker process and recipes Lecithin Sodium bicarbonate Ammonium bicarbonate SMS Enzyme protease MSG Salt Buttabelle flavour Gluten powder Roasted sesame seed Water

0.376 0.226 3.383 0.022 0.037 0.376 0.752 0.135 0.338 6.770 31.500 164.573

Recipe 2.5.3 Flour Caster sugar Malt Groundnut oil Whey powder Lecithin Sodium acid pyrophosphate Salt Sodium bicarbonate Ammonium bicarbonate Enzyme protease Buttabelle flavour Roasted nut essence Water

100.000 5.000 1.538 20.000 3.461 0.256 0.344 0.769 0.749 1.282 0.025 0.026 0.077 28.200 161.727

Recipe 2.5.4 Flour, strong Flour, weak Vegetable shortening Onion oil Chives Sesame Corn syrup Sugar Skimmed milk powder Salt Amylase Water

50.000 50.000 4.500 10.000 18.000 7.000 2.200 2.000 1.750 1.875 0.003 13.000 160.328

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2.6 Sesame crackers

FIG. 2.15 Sesame crackers.

FIG. 2.16 Multigrain sesame crackers and poppy seed and sesame crackers.

2.6.1

Description

A light, crispy cracker texture with sesame seeds deposited on top of the biscuit.

2.6.2

Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: pH: Moisture:

64  47 mm 5.8 mm 5.00 g Evenly blistered Golden Light and crispy Sesame 5.5 2.5%

Ingredient list: Poppy seed and sesame crackers Wheat flour, palm oil, poppy seeds (4%), sesame seeds (4%), salt, ammonium bicarbonate, yeast, sugar.

52 Biscuit, cookie and cracker process and recipes

Ingredient list: Poppy snack Wheat flour, palm oil, glucose syrup, poppy seeds (4.5%), malted barley extract, ammonium bicarbonate, sodium bicarbonate, dried egg, salt. Formulations for sesame crackers Recipe 2.6.1 Flour Powdered sugar Invert syrup 70% Malt extract 80% Fat Ammonium bicarbonate Sodium bicarbonate Acid calcium phosphate Salt Proteolytic enzyme Yeast Sesame Water

(1)

(2)

100.000 3.000 3.000 2.000 12.000 1.000 1.050 1.100 0.900 0.200 – 0.370 20.000 144.620

100.000 0.090 – 0.090 11.700 – 0.430 – 1.330 – 0.300 0.370 30.000 144.310

Critical ingredients (1) Flour should be weak with a protein content of 8–9% for recipe 1. (2) Recipe 2 uses a strong flour. (3) Proteolytic enzyme (proteinase). Alternative recipes Recipe 1 is a ‘Ritz’ type recipe. Recipe 2 is a soda cracker type recipe with a 12 h fermentation time (not sponge and dough). Process: Recipe (1) See Recipe 2.6.1 (1) above. 2.6.3 Mixing An ‘all in’ mix on a horizontal mixer. Temperature of about 33 °C for enzyme doughs.

Standing time After mixing the dough is stood to allow the enzyme to react with the gluten. The standing time is about 3 h at 35 °C. The time must be determined carefully depending on the amount of enzyme and the quality of the flour in order to achieve the soft, delicate eating texture of the cracker.

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2.6.4

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Forming

The dough is sheeted, gauged and cut (laminating is not required). Typical roll gap settings are: Sheeter: Gauge roll 1: Gauge roll 2: Gauge roll 3:

2.6.5

12 mm 6 mm 3 mm 1.5 mm

Sesame seed application

Two alternative methods can be used. The seeds can be sprinkled before the final gauge roll, which will press them into the dough sheet. Alternatively the wash-over unit is used to apply water to the dough pieces and then the seeds are sprinkled before transfer to the oven.

2.6.6

Baking Baking time Temperatures:

5.0 min 220/220/220/180 °C

High bottom heat in Zones 1 and 2 is required. Baking band: Z47 wire-mesh band. Pre-heat is required.

2.6.7

Formulation for sesame cracker

Recipe 2.6.2 Flour, soft Flour, strong Soya flour Vegetable fat Granulated sugar Ammonium bicarbonate Yeast Salt Sesame seeds Water

2.7 Wheat crackers

FIG. 2.17 Wheat crackers.

75.000 25.000 1.361 8.845 0.907 1.361 2.000 0.709 5.607 32.000 152.790

54 Biscuit, cookie and cracker process and recipes

2.7.1 Description Crackers made with wholemeal wheat and rye flours.

Ingredient lists (1) Wholemeal wheat flour, butter, wheat flour, sugar, salt, barley malt flour, sodium bicarbonate, glucose syrup, dextrose. (2) Wheat flour, sunflower oil, wheatgerm, sugar, whey powder, ammonium bicarbonate, sodium bicarbonate, salt, bran. Yeast extract, hydrolysed wheat protein, flavouring. (3) Wheat flour, palm oil, water, wheat bran, salt, sodium bicarbonate, malted barley extract, yeast. 2.7.2 Formulations for wheat crackers Recipe 2.7.1 Flour Whole wheat flour Soya oil Granulated sugar Sodium bicarbonate Ammonium bicarbonate Salt Yeast Enzyme SMS Water

60.000 40.000 10.000 1.800 0.800 0.500 1.800 0.030 0.006 0.019 16.400 131.355

Recipe 2.7.2 Flour Whole wheat flour Wheat germ (toasted) Granulated sugar Malt Glucose Vegetable fat (soya bean oil) Salt Ammonium bicarbonate Sodium bicarbonate SMS SAPP Antioxidant Water

100.000 21.413 17.772 12.206 6.000 2.141 21.413 0.900 2.847 1.071 0.900 0.621 0.028 45.000 232.312

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2.8 Oyster crackers

FIG. 2.18 Oyster crackers.

2.8.1

Description

Very light crackers, rotary cut often without dockers or print so that the cracker expands in the oven with a hollow centre. Oyster crackers originated in the United States where they were eaten with soup, often clam chowder.

2.8.2

Formulations for oyster crackers

Recipe 2.8.1 Flour, soft Flour, strong Butter Fat Hydrogenated vegetable oil Malt extract Salt Yeast Powdered sugar Flavour Water

50.000 50.000 3.571 3.571 8.929 3.571 1.786 1.429 1.071 0.022 29.000 152.950

Recipe 2.8.2 Sponge Flour Enzyme Yeast Additive Water/ice

60.000 1.000 0.100 0.800 30.500

56 Biscuit, cookie and cracker process and recipes Dough Flour Malt syrup Salt Sodium bicarbonate Water Sponge

40.000 3.600 1.300 0.800 2.000

Mix 5 min. Temperature: 25 °C Ferment: 18 h. pH 4.0–5.0 Dough Mix 9 min. Temperature: 32 °C Ferment: 6 h pH of baked cracker 7.0–8.0 Moisture: 3.0%

2.9 Fish type snack crackers

FIG. 2.19 Fish type snack crackers.

2.9.1 Description Very light thin, small, hollow, crispy snacks, with many shapes.

Ingredient list Wheat flour, corn powder, vegetable fat, potato starch, sugar, tomato seasoning, tomato powder, caramel colour, lecithin, corn starch, salt, vegetable flavour, sodium bicarbonate, rosemary extract.

Snack crackers Chapter

2.9.2

Formulation for fish type snack crackers

Recipe 2.9.1 Flour Fat Cheddar cheese Sugar Yeast extract Activated dried yeast Inactive dried yeast Sodium bicarbonate Cream of tartar Salt Spice Colour Water

100.000 5.757 21.011 0.810 1.611 1.000 1.000 0.135 0.089 0.890 0.354 0.377 28.700 161.734

2.10 Bacon snacks

FIG. 2.20 Bacon snacks.

2.10.1 Description Light ‘Ritz’ type crackers with bacon flavour.

2.10.2 Formulation for bacon snacks Recipe 2.10.1 Flour Ground nut oil Castor sugar Malt Milk powder Lecithin

100.000 20.000 1.806 1.250 3.472 0.250

2

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58 Biscuit, cookie and cracker process and recipes MSG Sodium acid pyrophosphate Salt Sodium bicarbonate Ammonium bicarbonate Flavours (boiled ham, Buttabelle) Water

0.405 0.189 0.500 0.500 1.667 1.220 26.100 157.359

Oil spray Oil Bacon flavour Smoked ham flavour

100.000 1.5.00 0.066

2.11 Potato chips (baked and fried)

FIG. 2.21 Potato chips.

2.11.1 Description A variety of snacks based on potato flakes and modified starch.

Ingredient list Potato flakes, starch, rapeseed oil, sugar. Sunflower lecithin, sea salt, sunflower oil, colour (annatto). Formulation: Recipe 2.11.1 (baked) Potato flakes Modified starch Granulated sugar Fat/oil Lecithin Sodium bicarbonate Calcium phosphate Water

100.000 18.861 7.037 3.019 0.313 0.758 0.564 82.500 213.052

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2.11.2 Mixing (1) Pre-blend at low speed: calcium phosphate, starch, sugar, fat/oil, lecithin, 25% of the potato flakes, (2) Add 60% of the water at 50 °C and mix. (3) Add 33% of the potato flakes and the remaining water and mix. (4) Add remaining potato flakes and the soda and mix.

2.11.3 Forming The dough is sheeted very thin and rotary cut.

2.11.4 Baking Direct Gas Fired oven with a pre-heated Compound Balanced Weave band. Baking time: 3 min.

2.11.5 Formulations for potato snacks Recipe 2.11.2 (baked and fried) Potato flakes Potato starch Salt Emulsifier Water

100.000 67.773 7.500 2.500 100.000 277.773

Dry blend: 2 min Add water, mix: 2 min Biscuit cutting machine: sheet to final dough thickness 0.7 mm Bake at 150 °C for 2 min. Fry in vegetable oil at 190 °C

Recipe 2.11.3 (baked and fried) Potato flakes milled Potato starch Salt Blend of glyceryl monooleate/sunflower oil Water Bake: 3 min Fry in vegetable oil at 170 °C

100.000 5.307 0.514 1.541 63.700 171.062

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Recipe 2.11.4 (baked and fried) Flour Masa flour Modified starch Rice flour Salt Emulsifier Water

100.000 38.461 7.308 15.385 3.077 1.538 67.307 233.076

Dry blend for 2 min Add water, mix 2 min slow, 1.5 min fast Sheet dough to 1.0 mm thick and gauge to 0.6 mm Bake for 2 min at 100 °C Fry in vegetable oil at 190 °C

Recipe 2.11.5 Ingredients by mixing stages Stage 1 Calcium acid phosphate Corn starch Granulated sugar Potato flakes Vegetable oil Lecithin Mix 1 min at low speed Stage 2 Water at 60 °C

0.566 18.865 7.040 23.700 3.021 0.313

47.400

Mix 1 min at low speed Mix 1 min at high speed Stage 3 Potato flakes 33.654 Water at 60 °C 35.076 Mix 1 min low speed and 0.5 min at high speed Stage 4 Potato flakes 42.660 Sodium bicarbonate 0.758 Mix 8 min (approx.) at low speed Dough temperature 40–44 °C Rest dough for 50 min 213.053

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2.12 Munchies potato snacks 2.12.1 Description Small snack size biscuits with potato powder, oil sprayed and topped with salt and vinegar.

2.12.2 Formulation for munchies Recipe 2.12.1 Flour Potato powder Dried gluten powder Sugar Fat Skimmed milk powder Salt Glycerol monostearate White pepper Meat flavour Baking powder Lactic acid Water

100.000 23.080 3.077 0.923 19.230 3.462 3.077 2.770 0.058 0.385 0.038 0.135 46.000 202.235

2.12.3 Mixing (1) All ingredients except potato powder, lactic acid, baking powder and water. Blend for 1 min. (2) Add lactic acid and 75% of water. Mix for 5 min. (3) Add baking powder dissolved in water. Mix for 2 min. (4) Add potato powder. Mix 3 min. (5) Add remaining water. Mix 15 min.

Standing time 15 min. 2.12.4 Forming Laminator and cutting machine.

62 Biscuit, cookie and cracker process and recipes

2.12.5 Baking Baking time: Temperatures:

3.45 min 225/240/200/175 °C

2.13 Vanilla snacks

FIG. 2.22 Vanilla snack crackers.

2.13.1 Description Snack crackers with vanilla flavour.

2.13.2 Product specification Dimensions: Thickness: Weight: Colour: Texture: Moisture:

48.0 mm diameter 4.9 mm 3.0 g Golden Light and crispy 1.5–2.5%

2.13.3 Formulation for vanilla snack Recipe 2.13.1 Flour Sugar, granulated Shortening Sodium bicarbonate Ammonium bicarbonate Ethyl vanillin Sodium metabisulphite Sodium acid pyrophosphate BHA/BHT Water

100.000 36.714 14.286 0.286 0.556 0.050 0.043 0.227 0.018 14.286 166.466

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2.14 Little Hearts 2.14.1 Description Light, multi-layered crackers.

2.14.2 Formulation for Little Hearts Recipe 2.14.1 Flour Fat Lecithin Sugar, fine caster Skimmed milk powder Enzyme Salt Sodium bicarbonate Ammonium bicarbonate Yeast (inactive) Water

100.000 15.748 0.252 5.984 2.992 0.002 1.024 0.354 3.543 1.024 27.600 158.523

2.14.3 Mixing (1) Mix all ingredients except the enzyme and ammonium bicarbonate to a cream. (2) Add flour, ammonium bicarbonate, enzyme dissolved in 200 mL of warm water and mix. (3) Rest the dough for 1–1.5 h.

2.14.4 Forming Laminate up to 11 layers, followed by 3 gauge rolls and single roll cutter. Add fine caster sugar up to 19% of dough piece weight.

2.14.5 Baking Temperatures: Baking time:

210/220/245/275/270/195 °C 6 min

Adjustment of extraction, turbulence (closed) and zone temperatures are required to avoid the sugar dropping onto the oven band.

Chapter 3

Semi-sweet biscuits 3.1 Semi-sweet biscuits

FIG. 3.1 Semi-sweet biscuits.

3.1.1

Description

Examples of semi-sweet biscuits are Marie, Petit Beurre, Rich Tea, Arrowroot, Breakfast biscuits. They are characterised by an even, attractive colour with smooth surface sheen, light texture and good volume. Doughs for semi-sweet biscuits have the following features: l

l l l

l

l

Doughs have strong, developed gluten which gives an elastic dough, which is sheeted and cut. It often shrinks in the first stage of baking Doughs have relatively low sugar and fat Doughs have water contents typically of around 12% Biscuits are normally baked on a wire-mesh band (except for Marie which is traditionally baked on a steel band) Humidity in the first part of the baking is important to achieve good volume and a smooth surface sheen Biscuits are baked to low moisture contents, around 1.5–2.0%

3.1.2 l

l

l

Critical ingredients

Medium protein flour which should not exceed 9.0% protein. Higher protein will result in a hard biscuit. Cornflour and maize flour are used to reduce the total gluten content and make a more tender eating biscuit. SMS will modify the protein to make a softer extensible dough

Biscuit, Cookie and Cracker Process and Recipes. https://doi.org/10.1016/B978-0-12-820598-3.00003-2 © 2020 Elsevier Inc. All rights reserved.

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66 Biscuit, cookie and cracker process and recipes

FIG. 3.2 Process flow for semi-sweet biscuits.

3.1.3 Mixing

FIG. 3.3 Baker Perkins Horizontal High Speed Mixer with shaft-less blade.

FIG. 3.4 Shaft-less mixing blade.

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Semi-sweet doughs are mixed with an ‘all in one mix’ on a horizontal mixer. Mixing is critical to developing the soft extensible dough. A mixing action which kneads the dough without too much tearing and extruding is ideal. Mixing time on a typical high speed mixer will be 20–25 min. Doughs such as ‘Marie’ are mixed until the required temperature is achieved. The dough should reach 40–42 °C. At this temperature it should be well kneaded and of correct consistency for machining. Higher dough temperatures result in unstable doughs. The dough is used straight away without standing and it is important to maintain the temperature.

3.1.4

Forming

The dough may be laminated, but doughs made with SMS are usually sheeted without lamination. Dough scrap incorporation is very important and should be very even and consistent. The temperature of the scrap dough should be as close as possible to the temperature of the new dough. Dough sheet reduction should be gentle and should not exceed the ratio of 2.5:1.

FIG. 3.5 Dingson Food Machinery rotary cutting line with 3 gauge roll units.

Typical roll gaps are: Forcing roll gap on sheeter: Gauging gap on sheeter: First gauge roll Second gauge roll Final gauge roll

18.0 mm 9.0 mm 5.0 mm 2.5 mm 1.1 mm (cutting thickness: 1.3 mm)

The doughs shrink and require good relaxation before cutting. Separate cutting and printing rolls on the rotary cutter are recommended to achieve good, clear printing and docker holes (pierced holes in the dough pieces).

68 Biscuit, cookie and cracker process and recipes

3.1.5 Baking Direct Gas Fired and Indirect Radiant ovens are both suitable for baking semisweet biscuits either as individual ovens or as a Direct Gas Fired/Indirect Radiant combination oven. Convection zones may be used in the final zones of the oven for drying and colouring the biscuits. Steam may be used at the oven entry to achieve a high humidity. This will improve the surface finish of the biscuit. Baking time: Temperatures: Moisture:

5.0–6.5 min 200/220/180 °C 1.5%

FIG. 3.6 Baker Pacific Direct Gas Fired multi-purpose oven with steam injection.

FIG. 3.7 Baker Pacific Indirect Radiant oven.

3.1.6 Cooling A ratio of cooling to baking time should be at least 1.5:1. This will help to avoid checking (cracking of the biscuits after packaging due to an internal moisture gradient).

Semi-sweet biscuits Chapter

FIG. 3.8 Two tier cooling system from Dingson Food Machinery.

FIG. 3.9 Biscuit stacking and packing table by Dingson Food Machinery.

3.2 Marie, Maria

FIG. 3.10 Marie biscuits.

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70 Biscuit, cookie and cracker process and recipes

3.2.1 Description The classic semi-sweet biscuit made around the world. The name is embossed and the intricate edge design is instantly recognisable. Marie was originally created by Peek Freans bakery in London in 1874 to commemorate the marriage of the Grand Duchess Maria Alexandrovna of Russia to Prince Albert, Duke of Edinburgh.

3.2.2 Product specification (1) Dimensions: Thickness: Weight: Appearance: Colour: Texture: Moisture:

(2)

66.0 mm diam. 59.0 mm diam. 6.0 mm 5.6 mm 8.3 g 6.25 g Smooth surface with sheen, clear printing Pale golden Crisp and light 1.0–1.5%

3.2.3 Formulations for Marie Critical ingredients l The flour quality is critical, the dry protein content should ideally be 7–8% and should not exceed 10%. If the flour is at the higher end of this protein range, SMS is used to make the dough more extensible (not too tough and elastic). l The fat should be semi-solid and plasticised. l Lecithin, as an emulsifier, improves the shortening property of the fat to give the required eating quality. Recipe 3.2.1 Flour (weak) Cornflour Sugar (granulated) Invert syrup Golden syrup Fat Full cream milk powder Salt Ammonium bicarbonate Sodium bicarbonate Sodium acid pyrophosphate SMS Water

100.000 3.428 28.571 4.984 2.540 13.968 0.825 0.857 0.635 0.013 0.182 0.254 21.900 178.157

Semi-sweet biscuits Chapter

Recipe 3.2.2 Flour (weak) Cornflour Syrup Invert syrup Butter Margarine Whey powder Salt Lecithin SMS Sodium acid pyrophosphate Ammonium bicarbonate Sodium bicarbonate Proteolytic enzyme Eggs Water

100.000 4.102 21.666 6.667 4.872 10.000 1.667 0.705 0.500 0.018 0.152 0.333 0.585 0.015 3.333 18.000 172.615

Recipe 3.2.3 Flour Maize starch Sugar, granulated Invert syrup Palm oil Natron Ammonium bicarbonate Sodium bicarbonate Salt Vanilla essence Butter flavour Water

100.000 7.143 23.214 5.357 21.429 0.134 0.446 0.535 0.714 0.045 0.067 20.000 179.084

Flour Sugar, pulverised Vegetable fat Sodium bicarbonate Ammonium bicarbonate Salt Soya lecithin Whey powder Sodium metabisulphite Water

100.000 21.400 21.400 0.450 0.850 1.250 0.390 0.890 0.039 20.000 166.669

Recipe 3.2.4

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Recipe 3.2.5 Flour Cornflour Maize flour Sugar, granulated Invert syrup 80% Shortening Lecithin Salt Sodium bicarbonate Ammonium bicarbonate Acid calcium phosphate Protease SMS 10% solution Water

100.000 4.411 14.705 25.588 7.941 11.029 0.574 0.882 0.671 0.735 0.076 0.018 0.025 26.470 193.125

Flour (weak) Cornflour Fat Sugar, granulated Golden syrup Invert syrup Ammonium bicarbonate Sodium bicarbonate Salt Full cream milk powder SMS Water

100.000 3.428 14.000 28.570 2.540 4.984 0.635 0.127 0.857 0.825 0.025 21.900 177.891

Recipe 3.2.6

3.3 Golden Maria

FIG. 3.11 Golden Maria biscuit.

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3.3.1

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Description

A semi-sweet biscuit, characterised by an attractive design and golden colour, crisp, slightly hard bite, light, open texture.

3.3.2

Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: Moisture:

3.3.3

59.0–60.0 mm diam. 6.2 mm 7.2 g Rich, golden, with distinctive design Golden biscuit colour Light and crispy, slightly hard bite Semi-sweet 1.0–1.5%

Formulations for Golden Maria

Recipe 3.3.1 Flour Sugar, granulated Shortening Glucose Sodium bicarbonate Ammonium bicarbonate Salt Lecithin SMS Water

100.000 24.200 11.970 6.740 0.490 0.270 0.630 0.130 0.090 17.300 161.820

Flour Cornflour Powdered sugar Shortening Glucose Invert syrup Sodium bicarbonate Ammonium bicarbonate Salt Lecithin SMS Vanilla flavour Condensed milk flavour Water

100.000 3.630 21.500 17.400 3.300 1.800 0.530 0.270 0.980 1.000 0.040 0.045 0.045 17.950 168.490

Recipe 3.3.2

74 Biscuit, cookie and cracker process and recipes

3.4 Rich Tea

FIG. 3.12 Rich Tea biscuits.

3.4.1 Description A favourite biscuit in England, often ‘dunked’ in a cup of tea.

3.4.2 Product specification Rich Tea Dimensions: Thickness: Weight: Colour: Texture: Moisture:

65 mm diam. 6.4 mm 8.3 g Pale golden Light 1.5%

Dimensions: Thickness: Weight: Colour: Texture: Moisture:

82  33 mm 4.6 mm 4.9 g Pale golden Light 1.5%

Rich Tea Finger

Ingredient list Flour, vegetable oil, glucose–fructose syrup, barley malt extract, sodium bicarbonate, ammonium bicarbonate, salt. 3.4.3 Formulations for Rich Tea Recipe 3.4.1 Flour Corn starch Sugar, granulated Sugar, pulverised Corn syrup

100.000 4.483 11.196 11.196 1.489

Semi-sweet biscuits Chapter

Shortening Liquid eggs Salt Full cream milk Sodium bicarbonate Ammonium bicarbonate Butter flavour Water

18.657 2.986 1.119 14.923 0.510 0.461 0.461 3.735 171.216

Flour Corn flour Vegetable oil Sugar, pulverised Syrup Golden syrup Malt extract Salt Sodium bicarbonate Ammonium bicarbonate Cream powder Sodium metabisulphite Condensed milk flavour Vanilla essence Water

100.000 1.667 22.000 20.334 3.333 0.533 0.667 1.067 0.500 0.333 0.233 0.043 0.090 0.090 21.181 172.071

Flour Sugar, pulverised Shortening Syrup Malt extract Salt Sodium bicarbonate Ammonium bicarbonate Sodium meta-bisulphite Biscuit dust Water

100.000 23.600 17.720 2.750 2.200 1.300 0.360 0.270 0.031 2.750 18.500 169.481

Flour (weak) Sugar, pulverised Syrup Butter Milk powder Salt Sodium bicarbonate

100.000 21.000 2.000 13.000 2.000 1.000 0.600

Recipe 3.4.2

Recipe 3.4.3

Recipe 3.4.4

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Ammonium bicarbonate Sodium meta-bisulphite Water

0.700 0.040 25.000 165.340

Flour Sugar, pulverised Margarine Condensed milk Invert syrup Salt Sodium bicarbonate Ammonium bicarbonate Cream powder Egg colour Buttabelle flavour Oil of lemon Vanilla Sodium meta-bisulphite Water

100.000 17.000 20.000 3.500 2.000 1.000 0.700 0.350 0.350 0.400 0.025 0.013 0.025 0.045 16.000 161.408

Flour Fat Liquid sugar Syrup Malt extract Ammonium bicarbonate Sodium bicarbonate Salt Biscuit dust Water

100.000 19.230 28.490 6.350 4.170 0.540 0.580 1.110 8.000 18.000 186.470

Recipe 3.4.5

Recipe 3.4.6

3.5 Le Veritable Petit-Beurre

FIG. 3.13 Lu Petit-Beurre Nantes.

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3.5.1

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Description

The Petit Beurre from Nantes is known throughout France and the Lu PetitBeurre has become successful world-wide. It was invented by Louis Lefe`vre in 1886 and later named Le Veritable Petit Beurre. The LU company is now part of the Mondelez Group.

3.5.2

Product specification

Traditionally Petit Beurre is 65 mm  54 mm and 6.5 mm thick with a weight of 8.33 g. It has 4 ‘ears’, 14 ‘teeth’ in length and 10 ‘teeth’ in width, a total of 52. Our samples were as follows: Dimensions: Thickness: Weight: Appearance: Colour: Texture: Moisture:

62  53 mm 5.8 mm 8.0 g Distinctive shape and emboss Rich golden Light, crisp 1.0–1.5%

Ingredient list Wheat flour 73.4%, sugar, butter 13.6%, skimmed milk powder 1.3%, salt, ammonium carbonate sodium carbonate, citric acid, flavour.

3.6 Petit Beurre type biscuits

FIG. 3.14 Petit Beurre type.

3.6.1

Description

Various versions of Petit Beurre have been made and marketed internationally.

3.6.2

Formulations for Petit Beurre type

Recipe 3.6.1 Flour Sugar, granulated Corn syrup

100.000 17.860 5.355

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Shortening Full cream condensed milk Egg yolks Salt Butter flavour Sodium bicarbonate Ammonium bicarbonate Cream of tartar Water

14.284 5.000 1.788 0.882 0.087 0.528 0.528 0.087 16.000 162.399

Flour Sugar, granulated Corn syrup Shortening Full cream condensed milk Egg yolks Salt Butter flavour Sodium bicarbonate Ammonium bicarbonate Cream of tartar Water

100.000 17.860 5.355 14.284 5.000 1.788 0.882 0.087 0.528 0.528 0.087 16.000 162.399

Recipe 3.6.2

3.7 Tostada

FIG. 3.15 Tostada.

3.7.1 Description Semi-sweet biscuit similar to Petit Beurre produced in Spain and Portugal.

3.7.2 Product specification Dimensions: Thickness: Weight: Colour: Texture: Moisture:

60  47 mm 5.2 mm 5.6 g Pale golden Light 1.5%

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Ingredient list Flour, sugar, glucose–fructose syrup, vegetable oils (high oleic sunflower and palm), colours, plain caramel and E150d (sulphites), salt, sodium bicarbonate, ammonium bicarbonate, lecithin, flavourings, sodium metabisulphite.

3.7.3

Formulations for Tostada type

Recipe 3.7.1 Flour Cornflour Shortening Sugar, granulated Glucose Milk powder Dextrose powder Salt Sodium bicarbonate Ammonium bicarbonate Cream of tartar Lecithin Butter flavour Milk flavour Vanillin Cocoa powder Caramel colour Cinnamon Sodium meta-bisulphite Water

100.000 8.000 16.000 22.000 8.800 3.600 4.000 0.880 0.520 1.200 0.160 0.600 0.060 0.080 0.080 1.000 0.160 0.800 0.072 20.400 188.412

Flour Shortening Sugar, granulated Glucose Skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate Caramel syrup Sodium meta-bisulphite Biscuit dust Water

100.000 11.000 24.500 5.750 1.125 0.750 0.575 0.625 0.400 0.050 7.500 15.000 167.275

Recipe 3.7.2

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3.8 Nice

FIG. 3.16 Nice biscuits.

3.8.1 Description Classic biscuit with coconut, popular with tea in England.

3.8.2 Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: Moisture:

62  39 mm 6.9 mm 8.0 g Simple, plain with name Pale, even colour Short and tender Sweet, coconut 1.4–2.0%

Ingredient list Wheat flour, sugar, palm oil, desiccated coconut 7%, wheat starch, glucose syrup, ammonium bicarbonate, sodium bicarbonate, dried whole milk, salt, flavourings. 3.8.3 Formulations for Nice Recipe 3.8.1 Flour Shortening Sugar, granulated Glucose Skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate Caramel syrup Sodium meta-bisulphite Biscuit dust Water

100.000 11.000 24.500 5.750 1.125 0.750 0.575 0.625 0.400 0.050 7.500 15.000 167.275

Semi-sweet biscuits Chapter

Recipe 3.8.2 Flour, weak Flour Caster sugar Golden syrup Glucose Milk powder Butter Margarine Fat Lecithin NC powder Sodium acid pyrophosphate Salt Sodium bicarbonate Ammonium bicarbonate Egg yellow colour Buttabelle flavour Coconut essence Vanilla essence Coconut Water

50.000 50.000 27.500 7.083 2.500 0.972 5.000 12.500 5.000 0.555 0.022 0.155 0.500 0.750 0.694 0.125 0.033 0.033 0.017 10.000 5.000 178.439

Dough sheeted and cut Baking time 6.5 min

Recipe 3.8.3 Flour Granulated sugar Coconut flour Invert syrup Palm oil Ammonium bicarbonate Sodium bicarbonate Salt Vanilla essence Biscuit dust Water

3.9 Arrowroot

FIG. 3.17 Arrowroot.

100.000 33.929 9.821 5.357 25.000 0.179 0.357 0.893 0.089 8.929 6.000 190.554

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3.9.1 Description Arrowroot is a starch obtained from the rhizomes (rootstock) of several tropical plants, traditionally Maranta arundinacea, but also Florida arrowroot from Zamia integrifolia, and tapioca from cassava (Manihot esculenta). Arrowroot has been used for thousands of years for its health properties such as healing wounds and bites. It is now mainly used in food products as an alternative to corn starch. It is gluten free and a valuable ingredient in gluten free baked products and infant foods. Arrowroot is rich in several B vitamins including thiamine, niacin, pyridoxine and in minerals including iron.

3.9.2 Product specification Dimensions: Thickness: Weight: Colour: Texture:

63 mm diam. 5.7 mm 7.4 g Pale Light

Ingredient list Wheat flour, sugar, palm oil, arrowroot 2.5%, partially inverted sugar syrup, barley malt extract, salt, sodium bicarbonate, ammonium bicarbonate. 3.9.3 Formulation for arrowroot biscuits Recipe 3.9.1 Flour Corn flour Sugar Butter Fat Skimmed milk powder Malt extract Glucose Lecithin Ammonia bicarbonate Salt Natron (10%) Vitamin powder Flavour Water

91.500 8.500 21.250 9.490 9.490 2.060 2.060 2.060 0.190 2.090 0.690 0.040 0.030 0.020 22.390 171.860

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3.10 Garibaldi biscuits

FIG. 3.18 Garibaldi biscuits.

3.10.1 Description A semi-sweet biscuit containing currants. It is baked in strips and may be cut into individual biscuits after cooling. In Europe, it is known as ‘Garibaldi’. This biscuit presents various production problems, which must be overcome to produce a good product. (1) The quality of the currants is critical and they should be small and dry. Large fruit will be crushed by the gauge rolls and will cause sticky juice to be smeared onto the dough surface. (2) The cutting of the dough sheet requires high pressure with a sharp metal cutter to cut through the fruit. Usually reciprocating cutters are used. The dough sheet should be floured before cutting to reduce sticking. (3) A high fruit content biscuit such as a Garibaldi from United Kingdom contains 33% fruit. This is made by sprinkling the currants evenly between two sheets of dough of 3 mm thickness and then passing through one gauge roll unit before cutting. This produces a product with high fruit content and minimises the crushing of the fruit. (4) If the two dough sheets are thicker (produced directly from 3 roll sheeters), the percentage of currants in the biscuit will be substantially reduced. In addition the necessity to reduce the combined dough sheet thickness through three gauge roll units will cause some crushing of the fruit and some sticking to the rolls. Flouring of the dough sheet will be necessary. (5) The biscuits are cut into separate strips and baked in strips. Rotary cutting discs may be used to cut the individual biscuits after baking. (6) The product is made with minimum edge scrap only. This can be returned and incorporated in the bottom dough sheet at the sheeter or it can be returned to the mixer. (7) Small dry currants can be distributed in the mix, producing a product with low fruit content evenly spread throughout the dough. Currants may be added at 10% of the flour weight. This simplifies the production and produces a product with evenly spread fruit. An example is ‘fruit shortie’, which is a softer, sweet dough with currants.

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3.10.2 Product specification Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: Moisture:

70  37 mm 6.6 mm 5.3 g Rectangular biscuit with visible currants. Glazed surface Medium to dark colour Crisp semi-sweet biscuit with chewy currants Sweet plain biscuit with strong currant flavour 5.0–10.0%

3.10.3 Formulations Recipe 3.10.1 Flour (weak) Powdered sugar Cane syrup 80% Dough fat Lecithin Ammonium bicarbonate Sodium bicarbonate Salt SMS (soln.) Spicea Flavoura Water Fruitb

(1)

(2)

100.00 20.70 3.57 18.23 0.37 0.49 0.18 0.71 0.022 0.10 0.10 21.00 65.30 230.772

100.00 15.59 2.65 13.88 – 0.35 0.13 0.53 0.25 0.01 0.03 25.88 65.30 224.600

a

Approximate quantities only. This quantity of fruit gives a product with about 33% fruit content. The quantity can be reduced to suit the equipment available.

b

3.10.4 Critical ingredients Flour Should be 8.0–9.0% protein, not higher. Currants Currants are small black seedless tasty and nutritious grapes grown in Greece. They can be obtained as good quality fruit with strong flavour, which makes them useful in biscuit making. After the fruit is dried in the sun, it is separated from the stems and stalks and then stored. Before exporting, the fruit is again screened to remove any remaining stalks and foreign matter. Currants are graded in size. Small and medium size currants are used in biscuit making. Smalls have 920 currants per 100 g and mediums 500 currants per 100 g. Moisture content should be 16% (but is often up to 20%). Currants are packed in cartons, which may be polyethylene lined. The currants are fumigated

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after packing and before shipment with methyl bromide gas to avoid insect infestation. A typical specification for currants suitable for biscuit making is: l l l l l l l l

Number of stones not to exceed 3 per tonne Number of stalks not to exceed 25 per tonne Number of stems not to exceed 25 per tonne Cartons to be staple free Moisture content 16% Only black fruit Flavour to be free of off flavours from packaging or poor storage Currants to be fumigated before shipment

The fruit will require washing before use and is normally inspected on white tables before use to ensure that it is as clean as possible. It is recommended that small black currants are used. These are dry and easier to sprinkle evenly. Fruit which is too large and juicy will cause problems when it is crushed by the gauge rolls. Juice may be smeared on the surface of the dough and will cause sticking on the rolls and cutter. The amount of fruit will be adjusted to suit the equipment available.

Seedless raisins and sultanas Seedless raisins may be obtained from United States, Turkey, Chile, South Africa, Iran and India. Smyrna sultanas, which are similar, may be obtained from Greece, Turkey, Australia and Iran. Both seedless raisins and sultanas are larger and more juicy than currants and are therefore more difficult to use in biscuit making. Grading of US fruit is ‘small’, about 550 berries per 100 g and ‘select’, about 380 berries per 100 g. The quality is graded from A (best) to C. Maximum moisture content is 18%. Other countries have similar grading systems. 3.10.5 Mixing Normally an ‘all in’ mixing method is used. The chemicals may be dissolved in water before adding to the mix. Mixing requires adequate time for hydration of the flour, dissolving the sugar and the development of the extensible gluten. To achieve this, the dough may be mixed to a set temperature of 40 °C. The dough is used straight away without any standing time.

3.10.6 Forming If the product is made by producing the dough sheets on two 3 roll sheeters with a currant spreader between, the sheets must be as thin as possible. The gauging gap on the 3 roll sheeter should be set to a maximum of 12 mm.

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Flouring of the dough sheet will be required to avoid sticking to the rolls and the cutter. Usually sultana biscuits are cut by reciprocating cutters as it is very difficult to cut through the currants and to avoid sticking. Where a rotary cutter is to be used, it must have a very sharp, metal cutter to ensure clean and effective cut through for the currants. The dough sheet is cut into strips across the band. Edge scrap is removed by scrap wheels and may be returned to the sheeter for the bottom sheet or collected and used in a new mix.

3.10.7 Currant spreader The currants may be spread by a belt type unit or a roll with impressions. The first method uses a hopper with an adjustable gate. The currants are drawn out of the hopper by a synthetic textured belt and form an even carpet of currants on the belt. The gate controls the amount of currants. The currants are deposited from the belt onto the dough sheet in an even curtain. The second method uses a hopper with a roll which has impressions of similar size to the currants. As the roll rotates, the currants are taken from the hopper and then dropped onto the dough sheet.

3.10.8 Wash-over A solution of milk may be applied to the dough sheet before baking to give a dark shiny appearance. (Milk powder: 43, water: 100.)

3.10.9 Baking The strips are baked on a Z47 wire-mesh or steel band. Temperatures: Baking time:

220/220/220/180 °C 6.0 min

(Over baking will make the fruit tough and leathery).

3.10.10 Cutting After baking the strips pass through rotary cutting discs to be cut into separate biscuits. The discs are normally positioned over the steel oven band on an extended oven run out. If the biscuits are baked on a wire-mesh band, a separate cutting table is required.

3.10.11 Cooling The biscuits are cooled at ambient temperature. Cooling to baking ratio of 2:1 is required for high fruit content biscuits (33% fruit).

Semi-sweet biscuits Chapter

3.10.12 Formulations for Garibaldi Recipe 3.10.2 Flour (weak) Ground rice Invert syrup Glucose Fat Milk powder Salt Sodium bicarbonate Ammonium bicarbonate Cream powder Egg colour Buttabelle flavour Water Currants Wash-over Milk Egg

100.000 1.000 15.000 1.500 15.000 3.500 0.500 0.700 0.350 0.350 0.100 0.050 15.000 153.050 100.000 10.000 5.000

Recipe 3.10.3 Flour Maize starch Sugar, caster Invert syrup Palm oil Natron Sodium bicarbonate Salt Ground ginger Oil of lemon Butter flavour Water Wash-over Water Milk powder Sugar Invert syrup

100.000 33.333 28.571 8.333 30.952 0.238 0.714 1.429 0.119 0.089 0.200 26.200 230.178 10.000 3.000 1.700 2.800

Recipe 3.10.4 Flour Cornflour Palm oil Sugar, liquid Invert syrup Dextrose monohydrate Full cream milk powder

100.000 19.760 24.430 27.660 10.419 7.713 6.588

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Lactose Ammonium bicarbonate Sodium bicarbonate Salt Flavour Water Currants

1.078 0.090 0.584 0.348 0.348 20.000 219.018 140.500

3.11 Gala fruit cookies 3.11.1 Product specification Dimensions: Weight: pH Moisture:

62.0  62.0 mm 9.8 g 6.2 3.0%

3.11.2 Formulation Recipe 3.11.1 Flour Soya flour Sugar Syrup Fat Salt Sodium bicarbonate Ammonium bicarbonate Sodium acid pyrophosphate Currants Water

100.000 1.795 31.795 3.590 34.360 0.900 0.360 0.718 0.492 14.360 17.000 205.370

3.11.3 Mixing Stage 1: Mix sugar, syrup, fat, ice water. Stage 2: Add flour, soya flour, salt, Soda, SAP, ammonium bicarbonate (dissolved in water). Stage 3: Add currants. Final dough temperature: 22–25 °C.

3.11.4 Forming Biscuit cutting machine.

3.11.5 Baking Baking time: Temperatures:

7.0 min 220/215/195/175 °C

Semi-sweet biscuits Chapter

3.12 Harvest type

FIG. 3.19 Harvest, tomato, sesame and green tea flavours.

3.12.1 Description A thin, light crispy biscuit with attractive range of flavours.

3.12.2 Product specification Dimensions: Thickness: Weight: Appearance: Texture: Moisture:

60.0 mm diam. 2.8 mm 9.0 g Even colour, glazed and with sugar sprinkled Crisp and light 1.0–1.5%

3.12.3 Formulation Recipe 3.12.1 Flour Wheat germ Sesame seeds Desiccated coconut Fat Butter Sugar, granulated Salt Sodium bicarbonate Acid calcium phosphate Ammonium bicarbonate Condensed milk Water Milk wash Full cream milk powder Water

100.000 5.000 10.000 3.000 10.000 13.000 50.000 1.500 0.200 0.400 0.500 2.000 26.000 221.600 1.000 4.000

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3.12.4 Mixing Premix fats, sugar, salt, soda, condensed milk, ammonium (dissolved in water). Mix at high speed 1.0 min. Add the remaining ingredients, mix at low speed 1.0 min and at high speed 4 min. Rest dough for 10 min.

3.12.5 Forming Biscuit cutting machine. Final dough thickness 1.25 mm. Light milk wash. Light sugar sprinkle.

3.12.6 Baking Oven band: Z47 type. Baking time 4 min at up to 300 °C. Oil spray top and bottom.

3.13 Caf e Noir type

FIG. 3.20 Cafe Noir type biscuits.

3.13.1 Description Crisp, semi-sweet biscuit with coffee flavoured icing.

Ingredient list Wheat flour, sugar, coffee glaze (23%), [sugar, colour (E150c), coffee powder (0.3%), alpha-cyclodextrin, gum arabic, salt, flavourings] vegetable oils (palm, rapeseed), wheat starch, invert sugar syrup, salt, sodium bicarbonate, disodium diphosphate, coffee powder (0.3%), lactic acid, flavourings.

Semi-sweet biscuits Chapter

3.13.2 Product specification Dimensions: Thickness: Weight: Appearance: Texture:

43  32 mm 6.25 mm 5.0 g Even colour, dark icing Crisp

3.13.3 Formulation for Cafe Noir type Recipe 3.13.1 Flour (weak) Vegetable fat Sugar, pulverised Syrup Salt Sodium bicarbonate Ginger, ground Water Icing Icing sugar Gelatine Vanilla powder Glycerine Coffee essence Caramel colour Water

100.000 25.000 21.429 14.286 0.714 0.268 0.223 9.000 170.920 100.000 0.500 0.250 4.000 6.000 0.125 25.000 135.875

3.14 Morning Coffee

FIG. 3.21 Morning Coffee.

3.14.1 Description Plain, crisp biscuit, popular with coffee or tea.

3.14.2 Product specification Dimensions: Thickness: Weight: Appearance: Texture: Moisture:

60  45 mm 5.0 mm 4.8 g Even colour Crisp and light 1.0–1.5%

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Ingredient list Wheat flour, sugar, palm oil, barley malt extract, ammonium bicarbonate, sodium bicarbonate, salt, partially inverted sugar syrup, natural flavourings. 3.14.3 Formulation for Morning Coffee Recipe 3.14.1 Flour Maize starch Sugar, caster Invert syrup Palm oil Natron Ammonium bicarbonate Sodium bicarbonate Salt Butter flavour Water

100.000 33.333 28.571 8.333 30.950 0.238 0.238 0.714 1.428 0.120 20.240 224.165

3.15 Animals

FIG. 3.22 Animal biscuits.

3.15.1 Description Small plain snack biscuits made with butter and enjoyed by children. A wide variety of animal shapes.

3.15.2 Product specification Average weight: Thickness:

2.0 g 6 mm

Ingredient list Wheat flour, sugar, butter 12%, invert sugar syrup, sodium carbonates, diphosphates, whey products, whole milk powder, salt, soya acidulant, citric acid, flavouring (milk), whole egg powder.

Semi-sweet biscuits Chapter

3.16 Potato Biscuits

FIG. 3.23 Potato Biscuits.

3.16.1 Description A variety of crisp biscuits made with potato flakes and granules.

3.16.2 Formulation Recipe 3.16.1 Flour Potato flakes Potato granules Sugar, caster Biscuit oil Butter emulsion Onion powder Salt Sodium bicarbonate Ammonium bicarbonate Sodium meta-bisulphite Yeast extract Lecithin Potato flavour Cream flavour Water

100.000 20.835 8.334 4.167 25.000 0.233 0.833 1.583 0.792 1.583 0.029 0.625 0.417 0.500 0.233 54.000 219.164

3.16.3 Mixing Horizontal mixer, 1–2 min at low speed.

3.16.4 Forming Biscuit cutting machine: 3 roll sheeter, 3 gauge roll units, rotary cutter.

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3.16.5 Baking Baking time: Temperatures: Moisture content: Oven band:

4.5 min 245/210 1.6% open mesh

3.17 Cabin and Gem biscuits

FIG. 3.24 Cabin biscuits.

3.17.1 Description Cabin and Gem are popular biscuits in Nigeria and Sri Lanka. The biscuits have a long shelf life and are widely distributed.

3.17.2 Formulations Recipe 3.17.1 Cabin Flour Sugar Fat Margarine Glucose Ammonium bicarbonate Sodium bicarbonate Salt Lecithin Natron Butter essence Ethyl vanillin Biscuit dust Water

100.000 10.000 4.000 0.800 2.000 0.800 0.800 0.800 0.200 0.008 0.160 0.160 2.000 20.000 141.728

Semi-sweet biscuits Chapter

Recipe 3.17.2 Gem Flour Corn starch Sugar Fat Margarine Glucose Ammonium bicarbonate Sodium bicarbonate Salt Lecithin Natron Butter essence Ethyl vanillin Biscuit dust Water

100.000 6.000 18.000 10.000 2.800 4.000 0.400 0.800 0.800 0.200 0.008 0.320 0.320 2.000 20.000 165.648

Note: Recipes are from West Africa.

3.17.3 Iced gem

FIG. 3.25 Iced gem.

3.17.4 Description Iced gem are a popular children’s biscuit, particularly in England.

3.17.5 Formulation for iced gem Recipe 3.17.3 Flour Sugar, caster Palm oil Natron Ammonium bicarbonate

100.000 17.857 17.857 0.178 0.576

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Sodium bicarbonate Salt Citric acid Vanilla essence Coconut essence Biscuit dust Water

0.625 1.071 0.089 0.089 0.056 8.930 22.800 170.128

3.18 Hard tack biscuits, army biscuits

FIG. 3.26 Hard tack biscuits.

3.18.1 Description Hard tack biscuits have a long history, being produced mainly for seamen, armies and people living in remote communities. Original recipes were simple, providing an inexpensive biscuit with a long shelf life. More recently biscuits are formulated for military personnel and for expeditions to provide nutrition and fortification with vitamins in a simple biscuit with a long shelf life.

3.18.2 Formulation Recipe 3.18.1 Flour, brown Sugar, brown Lard Salt Sodium bicarbonate Ammonium bicarbonate Sodium meta-bisulphite Vanilla Skimmed milk powder Soya flour Dried yeast Water

100.000 27.800 21.800 0.960 0.340 0.600 0.044 0.600 3.000 3.000 3.000 20.000 181.144

Semi-sweet biscuits Chapter

Recipe 3.18.2 Flour Wholemeal flour Soya flour Brown sugar Fat Skimmed milk powder Dried yeast extract Salt Sodium bicarbonate Ammonium bicarbonate Sodium meta-bisulphite SMS Vanilla flavour Calcium propionate Niacin, riboflavin, thiamine Ferrous gluconate Water

85.000 15.000 3.040 27.800 21.700 3.040 3.040 0.960 0.330 0.540 0.040 0.020 0.030 0.010 0.010 18.300 178.860

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Chapter 4

Short dough biscuits

FIG. 4.1 Short doughs (moulded biscuits).

4.1 Short dough biscuits This is a wide biscuit category with many designs. The doughs are short with higher fat and sugar contents than semi-sweet biscuits. This is the simplest category for the dough piece forming process (rotary moulding) and so these products are very widely produced, often in high volumes. The list of typical products would be very extensive and contains many local or regional specialities: Malted milk, Lincoln, Digestive, Nice, Shortcake, Shortbread, Custard Cream from Britain, Italian frollini, Dutch speculaas, Glucose from India…

▪ Doughs have a low water content, but more fat and sugar than the semisweet biscuits ▪ High humidity in the first part of the baking process allows the biscuit structure to form ▪ Relatively slow baking at comparatively low temperatures 4.1.1

Process for a moulded short dough biscuit: Glucose

FIG. 4.2 Glucose biscuits. Biscuit, Cookie and Cracker Process and Recipes. https://doi.org/10.1016/B978-0-12-820598-3.00004-4 © 2020 Elsevier Inc. All rights reserved.

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4.1.2 Description A rotary moulded biscuit derived from ‘Glucose’, a highly popular biscuit in India. One maker in India, Parle Products sells approximately 13 billion of their Parle G Glucose biscuits every month. Glucose biscuits were successfully introduced into Malaysia and Indonesia. In Indonesia it quickly became one of the biggest selling biscuits. The biscuit is a short, sweet, rotary moulded product, similar to the English ‘Malted Milk’ biscuit. It is cheap, nutritious and satisfying. It is often fortified with vitamins and minerals, particularly calcium and iron.

4.1.3 Product specification (1) Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: Moisture:

(2)

58  37 mm 55  34 mm 6.7 mm 5.4 mm 5.2 g 4.7 g Bold design Golden Short and tender Sweet 1.4–2.0%

Formulation Recipe 4.1.1 Flour (weak) Powdered sugar Palm oil Lecithin Glucose 42DE Fructose Skimmed milk powder Calcium carbonate Salt Sodium acid phosphate Ammonium bicarbonate Sodium bicarbonate Vitamin mix Flavours Water

100.00 29.50 19.50 0.62 2.50 1.25 2.35 0.55 1.10 0.30 0.58 0.49 0.11 0.21 13.33 172.39

Critical ingredients (1) Flour should not exceed 8.0–9.0% protein. Higher protein will result in a tough biscuit, particularly if it is overmixed. (2) The vitamin mix should be developed to suit the local requirement.

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FIG. 4.3 Process for short moulded biscuits.

4.1.4

Mixing

The mixing process must not develop the gluten in the flour as this will result in a tough biscuit. Mixing is therefore done in two stages. In the first stage all the ingredients are mixed except the flour and soda. The mixing continues until a consistent, homogenous cream is produced. It is important to keep the temperature of the dough low and chilled water is required for the mixer jacket. For the second stage, the flour and soda are added and mixed for 1 min at slow speed and 1–2 min at high speed. The final dough temperature should be 18–22 °C.

FIG. 4.4 Tonelli TR Series horizontal mixers TONELLI GROUP SpA—© all rights reserved.

Standing time The dough will be sticky when discharged from the mixer as the flour has not fully absorbed the water. The dough should be stood in a cool area for 20– 30 min before forming. It will then be less sticky and will release from the rotary moulding roll more easily.

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4.1.5 Rotary moulding The dough should be fed very evenly and consistently to the hopper of the rotary moulder, maintaining an even level across the width of the machine during the production. Adjustments will be made to the gap between the forcing roll and the moulding roll, knife position and pressure roll to achieve a good release and good product shape.

FIG. 4.5 Rotary moulder.

FIG. 4.6 Rotary moulder arrangement drawing.

Short dough biscuits Chapter

4.1.6

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Baking

An Indirect Radiant oven, Direct Gas Fired or hybrid DGF/Indirect Radiant oven are recommended. An open wire mesh baking band Z47 type is used.

FIG. 4.7 Baker Pacific Indirect Radiant oven.

Steam may be used at the oven entry to achieve a high humidity. This will allow the biscuit to expand in the first zone and achieve good volume. Baking time: Temperatures: Moisture:

4.1.7

5.0–5.5 min 180/200/220/200/180 °C Less than 3.0%

Cooling

Sufficient cooling is required to set the biscuit, which will be soft as it leaves the oven, usually 1:1.5 baking to cooling time. The oven requires an adequate extension and adjustable stripping knife to obtain good release and transfer.

4.1.8

Formulations for glucose biscuits

Recipe 4.1.2 Flour Cornflour Icing sugar Invert syrup Vegetable fat Butter Milk powder Lecithin Baking powder Ammonium bicarbonate

100.000 2.000 30.800 1.600 25.600 4.800 2.000 0.080 0.200 1.000

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Sodium bicarbonate Salt Butter essence Milk essence Vanillin Vitamin mix Water

0.400 0.600 0.060 0.120 0.024 0.050 12.000 181.334

Recipe 4.1.3 Flour Palm oil Icing sugar Glucose Fructose Semi-skimmed milk powder Lecithin Calcium carbonate Ammonium bicarbonate Sodium bicarbonate Salt Sodium acid pyrophosphate Vitamin pre-mix Flavour Dough scrap Biscuit dust Water

100.000 19.500 29.500 2.500 1.250 2.350 0.625 0.550 0.583 0.492 1.100 0.300 0.110 0.213 5.000 5.000 13.300 182.373

4.2 Digestive

FIG. 4.8 Digestive biscuits.

4.2.1 Description Rich wholemeal biscuits, widely made and consumed, particularly in United Kingdom and Asia.

Short dough biscuits Chapter

4.2.2

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Product specification Dimensions: Thickness: Weight: Colour: Texture: Flavour: Moisture:

73 mm diameter 6.9 mm 13.6 g Rich wholemeal Short and tender Sweet, wholemeal 1.4–2.0%

Ingredient list (1) Wheat flour, wholemeal wheat flour, sugar, dried skimmed milk, sodium bicarbonate, ammonium bicarbonate, invert sugar syrup, salt. (2) Wheat flour, palm oil, sugar, wheat germ, sodium bicarbonate, ammonium bicarbonate, salt, whey powder, flavouring. 4.2.3

Formulations for digestive

Recipe digestive 4.2.1 Flour Wholemeal Vegetable fat blend Demerara sugar Granulated sugar Cane syrup Sodium bicarbonate Ammonium bicarbonate Salt Tartaric acid Water

81.400 18.600 30.673 17.169 5.361 2.307 1.900 0.136 1.221 0.814 9.500 169.081

Recipe digestive 4.2.2 Flour Whole wheat flour Granulated sugar Molasses Malt extract Shortening Milk powder Salt Ammonium bicarbonate Sodium bicarbonate Water

78.000 22.000 21.667 2.167 1.667 30.500 1.667 1.000 0.808 0.750 9.170 169.396

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Recipe digestive 4.2.3 Flour Wheat meal Icing sugar Granulated sugar Demerara sugar Fat blend Cane syrup Dried malt Salt Sodium bicarbonate Ammonium bicarbonate Acid calcium phosphate Cornflour Ice Water

83.300 16.700 16.700 8.333 3.896 35.931 2.165 0.974 1.136 0.920 0.433 0.209 0.135 2.165 3.788 176.785

Recipe digestive 4.2.4 Flour Wheat meal Margarine Granulated sugar Demerara Syrup Salt Sodium bicarbonate Tartaric acid Water

81.400 18.600 34.043 5.375 18.087 2.300 1.217 1.893 0.811 9.200 172.926

Flour Wholemeal flour Fat Sugar Golden syrup Salt Sodium bicarbonate Tartaric acid Water

81.400 18.600 28.866 18.557 5.979 1.031 1.856 2.000 7.400 165.689

Recipe digestive 4.2.5

Recipe digestive 4.2.6 Flour Wholemeal flour Oatmeal Vegetable oil Sugar

66.700 33.300 5.833 35.274 19.442

Short dough biscuits Chapter

Icing sugar Whey powder Sodium bicarbonate Salt Water

12.499 2.944 2.155 1.378 9.440 188.965

Recipe digestive 4.2.7 Flour Wholemeal flour Vegetable oil Sugar Icing sugar Syrup Sodium bicarbonate Ammonium bicarbonate Salt Tartaric acid Water

82.000 18.000 26.471 18.382 6.127 3.431 1.961 0.245 1.211 0.471 9.560 167.859

Recipe digestive 4.2.8 Flour Wholemeal flour Fat blend Caster sugar Icing sugar Granulated sugar Cane syrup Salt Sodium bicarbonate Tartaric acid Water

81.500 18.500 34.150 8.598 7.508 5.450 3.149 1.211 1.889 0.823 6.782 169.560

Recipe digestive 4.2.9 Flour Wholemeal flour Bran Butter Granulated sugar Invert dark Sodium bicarbonate Ammonium bicarbonate Salt Tartaric acid Water

81.000 9.500 9.500 34.020 22.601 2.804 1.892 0.338 1.216 0.811 7.770 171.452

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Recipe digestive 4.2.10 Flour Meal, coarse Maize starch Caster sugar Invert syrup Malt Palm oil Ammonium bicarbonate Sodium bicarbonate Salt Butter flavour Sodium acid pyrophosphate Biscuit dust Water

100.000 50.000 7.142 32.142 10.714 3.571 39.286 0.714 0.982 1.786 0.268 0.089 35.714 16.000 298.408

Recipe low fat digestive 4.2.11 Flour Wholemeal flour Vegetable fat Icing sugar Caster sugar Granulated sugar Syrup Emulsifier Salt Sodium bicarbonate Tartaric acid Water

81.500 18.500 22.807 6.774 7.742 4.839 5.979 0.452 1.212 1.890 2.014 7.397 161.106

Recipe homewheat type 4.2.12 Flour Granular flour Crushed wheat Wholemeal Sugar Golden syrup Margarine Vegetable fat Lecithin NC powder Salt Sodium bicarbonate Ammonium bicarbonate Tartaric acid Water

40.900 27.300 9.100 22.700 23.400 2.273 15.909 15.909 0.077 0.018 1.182 1.943 1.068 0.818 16.400 178.997

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Chocolate digestive

FIG. 4.9 Chocolate digestive.

4.2.5

Product specification Dimensions: Thickness: Weight:

66 mm diam. 7.5 mm 16.6 g

Ingredient list Wheat flour 39%, plain chocolate 30%, palm oil, wholemeal wheat flour 9%, sugar, glucose–fructose syrup, sodium bicarbonate, malic acid, ammonium bicarbonate, salt.

4.3 Shortcake

FIG. 4.10 Shorties and shortcake.

4.3.1

Description

Rich sweet biscuits, widely made and consumed, particularly in United Kingdom.

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4.3.2 Product specification: Shortcake

FIG. 4.11 Shortcake. Dimensions: Thickness: Weight: Colour: Texture: Flavour: Moisture:

63 mm  39 mm 8.8 mm 10.5 g Rich Short and tender Sweet 1.2–1.4%

4.3.3 Formulations for shortcake Recipe 4.3.1 shortcake Flour Maize starch Icing sugar Invert syrup Palm oil Ammonium bicarbonate Sodium bicarbonate Salt Vanilla essence Butter flavour Biscuit dust Water

100.000 3.571 23.214 7.142 35.714 0.179 0.625 0.982 0.045 0.156 8.928 9.375 189.931

Recipe 4.3.2 butter shortcake Flour Maize starch Icing sugar Butter Palm oil Skimmed milk powder Sodium bicarbonate

100.000 5.357 25.000 25.000 18.750 5.000 0.625

Short dough biscuits Chapter

Citric acid Salt Butter flavour Water

0.045 0.714 0.089 9.000 189.580

Recipe 4.3.3 shortcake Flour Sugar, pulverised Icing sugar Margarine Vegetable fat Milk powder Salt Sodium bicarbonate Buttabelle flavour Egg colour Water

100.000 16.000 16.000 25.000 15.000 2.000 0.400 0.100 0.150 0.200 3.500 178.350

Recipe 4.3.4 shortcake Flour Palm oil Caster sugar Golden syrup Fresh eggs Full cream milk powder Ammonium bicarbonate Sodium bicarbonate Salt Vanillin Water

100.000 33.528 27.114 2.332 1.749 2.770 0.291 0.171 0.682 0.070 5.800 174.507

Recipe 4.3.5 shortcake Flour Dough fat Icing sugar Whey powder Salt Ammonium bicarbonate Sodium bicarbonate Water

100.000 36.920 28.650 1.430 0.980 0.920 0.540 13.460 182.900

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4.3.4 Product specification: Shorties

FIG. 4.12 Shorties. Dimensions: Thickness: Weight: Colour: Texture: Flavour: Moisture:

59.0 mm diam. 8.8 mm 12.0 g Rich golden Short and tender Sweet 1.2–1.4%

4.3.5 Formulations for shorties Recipe 4.3.6 shorties Flour Butter Margarine Icing sugar Granulated sugar Condensed milk Lecithin Ammonium bicarbonate Sodium bicarbonate Sodium acid pyrophosphate Buttabelle flavour Salt Water

100.000 24.038 24.038 43.750 23.077 3.365 0.433 0.720 0.240 0.240 0.013 0.923 11.058 231.895

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4.4 Fruit shortcake

FIG. 4.13 Fruit shortcake.

4.4.1

Description

Fruit biscuit, made with short dough and currants.

4.4.2

Product specification Dimensions: Thickness: Weight: Appearance Texture: Flavour:

56 mm diam. 6.6 mm 8.0 g Prominent dockers and sugar topping Short and tender Sweet with currants

Ingredients list Wheat flour, palm oil, sugar, currants (10%), sunflower oil, oatmeal, glucose syrup, ammonium bicarbonate, sodium bicarbonate, disodium diphosphate, partially inverted sugar syrup, salt, flavour, colour.

4.5 Shortbread

FIG. 4.14 Shortbread fingers and shortbread bites.

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4.5.1 Description Rich butter shortbread.

4.5.2 Specification: Shortbread fingers Dimensions: Thickness: Weight: Colour: Appearance Texture: Flavour:

72  27 mm 14.25 mm 19.0 g Light and even Prominent docker pin holes Short and tender Butter

4.5.3 Specification: Shortbread bites Dimensions: Thickness: Weight: Colour: Appearance Texture: Flavour:

30  27 mm 13.3 mm 6.9 g Light and even Rounded bite size Short and tender Butter

Ingredient list Wheat flour, rapeseed oil, sugar, butter, salt, natural flavouring, sodium carbonates. 4.5.4 Formulations for shortbread Recipe 4.5.1 Flour, soft Icing sugar Butter Margarine Salt Vanilla Buttabelle flavour Water

100.000 31.944 34.722 23.148 0.630 0.218 0.130 3.700 194.492

Flour, soft Icing sugar Butter Margarine Salt Vanilla Buttabelle flavour Water

100.000 31.944 34.722 23.148 0.630 0.218 0.130 3.700 194.492

Recipe 4.5.2

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4.6 Abernethy

FIG. 4.15 Abernethy biscuits.

4.6.1

Description

A short moulded biscuit invented by John Abernethy in Scotland in the 18th century. It was recommended for digestion and originally made with caraway seeds.

Ingredient list Wheat flour, sugar, palm oil, rapeseed oil, ammonium bicarbonate, sodium bicarbonate, sodium dihydrogen phosphate, partially inverted refiner’s syrup, Lyles Golden Syrup, salt, dextrose, natural flavouring (milk). 4.6.2

Product specification Dimensions: Thickness: Weight: Colour: Texture: Flavour:

4.6.3

69.0 mm diam. 6.6 mm 12.9 g Pale golden Short and tender Sweet

Formulation for Abernethy type biscuits

Recipe 4.6.1 Biscuit flour Sugar, pulverised Glucose syrup Dough fat Lard Margarine Milk powder Salt Sodium bicarbonate Ammonium bicarbonate

100.000 23.500 4.000 12.500 12.500 15.000 3.000 1.000 0.450 0.200

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Cream powder Egg colour Water

0.550 0.100 15.000 187.800

4.7 Malted Milk

FIG. 4.16 Malted Milk biscuits.

4.7.1 Description Classic English biscuit.

4.7.2 Product specification Dimensions: Thickness: Weight: Colour: Texture: Flavour: Moisture:

64 mm  40 mm 7.3 mm 8.7 g Highlighted design Short and tender Mild, milky 1.2–1.4%

Ingredient list Wheat flour, palm oil, sugar, barley malt extract, glucose syrup, dried whole milk, ammonium bicarbonate, sodium bicarbonate, salt, flavouring.

4.8 Frollini

FIG. 4.17 Frollini.

Short dough biscuits Chapter

4.8.1

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Description

Small short dough biscuits in a wide variety of shapes. An Italian speciality, often eaten at breakfast.

Ingredient list Wheat flour, sugar, margarine, palm oil, egg, glucose syrup, butter, raising agents (ammonium carbonate, sodium carbonate acid), salt, natural flavourings. 4.8.2

Formulation for Frollini

Recipe 4.8.1 Flour Sugar Caramelised sugar Glucose Maltose Caramel Margarine Skimmed milk powder Cocoa Soya lecithin Ammonium bicarbonate Sodium bicarbonate Vanilla flavour Salt Water +/

100.000 33.974 1.282 5.128 3.846 2.564 19.231 0.641 4.487 0.641 0.224 0.417 0.288 1.282 12.000 186.005

4.9 Ginger biscuits

FIG. 4.18 Ginger biscuits.

4.9.1

Description

Crisp bite, flavoured with ginger, cinnamon and other spices. Very popular in United Kingdom, Australia and New Zealand, Scandinavia.

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4.9.2 Product specification (1) Dimensions: Thickness: Weight: Colour: Flavour: Moisture:

(2)

(3)

58 mm diam. 54 mm diam. 6.53 mm 7.8 mm 11.35 g 10.0 g Rich Ginger and spice 2.5–3.5%

56 mm diam. 8.5 mm 11.5 g

Ingredient list 1 Wheat flour, sugar, palm oil, glucose–fructose syrup, molasses, sodium bicarbonate, disodium diphosphate, ground ginger, salt, lemon and ginger flavouring. Ingredient list 2 Wheat flour, sugar, glucose–fructose syrup, palm oil, semolina (wheat), ginger powder, sodium bicarbonate, disodium diphosphate, salt, lemon oil. 4.9.3 Process Ginger nuts may be baked on steel or Z47 bands. Water spray and steam in first zone of the oven will adjust cracking of the surface. Typical baking data: Baking time: Baking temperatures

6.25 min 300/320/290/270/210 °C

4.9.4 Formulations for ginger biscuits Recipe 4.9.1 Flour/brown bread meal Biscuit dust Sugar Vegetable fat Glucose Golden syrup Ginger Caramel Salt Sodium bicarbonate Ammonium bicarbonate Sodium acid pyrophosphate Baking powder Colour (Choc. Brown) Water

100.000 30.000 30.556 8.722 5.000 5.000 3.500 0.600 1.111 1.000 1.222 0.111 0.100 0.400 35.555 222.877

Short dough biscuits Chapter

Recipe 4.9.2 Flour (strong) Cornflour Sugar, powdered Liquid sugar Syrup Butter Lactose Liquid egg Cinnamon Ginger Cloves Nutmeg Allspice Salt Sodium bicarbonate Acid calcium phosphate Water

100.000 2.609 21.739 5.217 8.696 27.174 10.870 4.348 0.435 0.435 0.217 0.217 0.217 0.587 1.043 0.217 10.500 194.521

Flour Sugar, granulated Sugar, coarse granulated Syrup Glucose Fat Ground ginger Salt Sodium bicarbonate Ammonium bicarbonate Oil of lemon Egg colour Pink colour Water

100.000 30.000 6.000 34.000 8.500 17.000 1.700 1.200 0.800 0.200 0.150 0.250 0.100 4.500 204.400

Flour Sugar, granulated Golden syrup Fat Salt Sodium bicarbonate Ammonium bicarbonate Oil of lemon Ginger Biscuit dust Water (hot)

100.000 41.060 36.370 17.855 0.707 0.707 0.534 0.089 1.807 35.740 8.170 243.039

Recipe 4.9.3

Recipe 4.9.4

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Recipe 4.9.5 Flour Sugar Syrup Malt extract 100% Vegetable oil Salt Sodium bicarbonate Ammonium bicarbonate Oil of lemon Ginger flavour Ground ginger Water

100.000 41.890 10.360 5.990 22.930 0.507 1.126 0.225 0.315 0.315 0.811 9.210 193.679

Flour Sugar, granulated Golden syrup Fat Salt Ginger powder Sodium bicarbonate Ammonium bicarbonate Oil of lemon Water

100.000 41.683 27.368 25.789 1.428 2.105 1.053 0.632 0.085 5.000 205.143

Flour Invert syrup Sugar, caster Sugar, granulated Sugar, milled Fat Sodium bicarbonate Ammonium bicarbonate Salt Biscuit crumb Lecithin Ginger, ground Water

100.000 29.263 24.368 15.600 2.152 23.400 1.237 1.291 0.484 5.400 0.269 2.442 3.800 209.706

Recipe 4.9.6

Recipe 4.9.7

Short dough biscuits Chapter

4.10 Cinnamon Crisp

FIG. 4.19 Cinnamon Crisp cookie.

4.10.1 Description Crisp, moulded biscuit with cinnamon and sugar topping.

4.10.2 Formulation for Cinnamon Crisp Recipe 4.10.1 Flour Vegetable shortening Margarine Powdered sugar Eggs Whole milk powder Ammonium bicarbonate Sodium bicarbonate Salt Water

100.000 20.410 5.100 30.610 10.200 3.060 1.530 0.510 1.020 6.100 178.540

Topping: Cinnamon 1.0 Granulated sugar 10.0

4.11 Windmill biscuits

FIG. 4.20 Windmill biscuits.

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4.11.1 Description Windmill biscuits are based on the speculaas or speculoos specialities from Holland and Belgium. Traditional speculaas are moulded in a wide variety of shapes and made with butter, brown sugar and spices. Traditionally popular at Christmas time.

Ingredient list Enriched bleached wheat flour, sugar, vegetable oil, almonds, molasses, spices, sodium bicarbonate, Salt, whey, eggs, soy lecithin.

4.11.2 Formulations for windmill Recipe 4.11.1 Flour, cake Shortening Sugar Molasses Sodium bicarbonate Salt Almond flakes Allspice Cinnamon Nutmeg Cloves Water

100.000 26.304 53.804 6.630 2.206 0.756 10.000 0.604 1.210 0.604 0.151 13.475 215.744

Recipe 4.11.2 Flour Sugar Fat Milk powder Malt extract Salt Sodium bicarbonate Ammonium bicarbonate Citric acid Lecithin Acid calcium phosphate Baking powder Vanilla Water

100.000 25.000 25.000 3.400 1.640 1.040 0.600 0.500 0.120 0.240 0.240 0.280 0.100 11.000 169.160

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123

4.12 Chocolate fingers, finger biscuits

FIG. 4.21 Chocolate fingers.

4.12.1 Description Finger biscuits, chocolate enrobed.

4.12.2 Product specification Dimensions: Thickness coated: Weight:

75 mm long 10  10 mm 5.3 g

Ingredient list Milk, wheat flour, sugar, vegetable fats (palm, sal, shea in varying proportions), cocoa butter, cocoa mass, partially inverted sugar syrup, soya lecithin, salt, ammonium hydrogen carbonate, sodium hydrogen carbonate, flavourings. 4.12.3 Formulation for finger biscuits Recipe 4.12.1 Flour (weak) Sugar Golden syrup Fat Margarine Semi skimmed milk powder Salt Sodium bicarbonate Vanilla Sodium acid pyrophosphate Water

100.000 78.670 12.670 30.167 9.470 0.800 0.800 1.573 0.200 0.983 18.700 254.033

124 Biscuit, cookie and cracker process and recipes

4.13 Oaty biscuits

FIG. 4.22 Oatmeal biscuits.

4.13.1 Product specification Dimension: Thickness: Weight:

65 mm diam. 8.4 mm 15 g

Ingredient list 1 Rolled oats 38%, wholemeal wheat flour 23%, sugar, palm oil, partially inverted sugar syrup, sodium bicarbonate, ammonium bicarbonate, salt. Ingredient list 2 Oat flakes 41%, sugar, palm oil, wheat flour, whole wheat flour 6%, invert sugar syrup, sodium bicarbonate, ammonium bicarbonate, salt, flavouring. 4.13.2 Formulation for oat crisps Recipe 4.13.1 oat crisps Flour Rolled oats Sugar, caster Invert sugar syrup Fat Margarine Butter Malt extract Salt Sodium bicarbonate Ammonium bicarbonate Vanilla essence Water

50.000 50.000 43.000 3.500 21.500 3.500 2.000 3.500 0.400 0.700 0.700 0.025 15.000 193.825

Short dough biscuits Chapter

Recipe 4.13.2 for oatmeal biscuits Wholemeal flour Jumbo oats Rolled oats Sugar, icing Sugar, caster Sugar, granulated Cane syrup Fat Salt Sodium bicarbonate Ammonium bicarbonate Water

100.000 100.000 74.820 34.890 39.930 24.820 15.110 92.080 4.000 2.090 2.300 12.600 502.640

4.14 Vanilla cookie

FIG. 4.23 Vanilla cookies.

4.14.1 Description Light, soft cookies with vanilla flavour.

4.14.2 Formulation for vanilla cookie Recipe 4.14.1 Flour Shortening Icing sugar Glucose syrup Condensed milk Salt Lecithin Sodium bicarbonate Ammonium bicarbonate Butter flavour

100.000 28.300 27.500 1.667 5.500 1.000 0.333 0.500 0.167 0.011

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126 Biscuit, cookie and cracker process and recipes

Vanillin Sodium acid pyrophosphate Water

0.083 0.167 8.330 173.558

4.15 Little Hearts

FIG. 4.24 Little Hearts.

4.15.1 Description Sugar topped short dough snack biscuits.

4.15.2 Product specification Dimensions: Thickness: Weight: Colour: Texture: Flavour:

35–37 mm  32–34 mm 8.0 mm 2.7 g Rich golden with white sugar Crispy Sweet

Ingredient list Wheat flour, sugar, palm oil, ammonium bicarbonate, sodium bicarbonate, skimmed milk powder, salt, flavouring (inactive dried yeast), soya lecithin, enzymes (bacterial protease and amylase).

Chapter 5

Cookies

FIG. 5.1 Cookies.

5.1 Chocolate chip cookies

FIG. 5.2 Chocolate chip cookies.

5.1.1

Description

Popular throughout the world, originally invented by the American chefs Ruth Graves Wakefield and Sue Brides in 1938 at the Toll House Inn in Whitman, Massachusetts. There are many famous brands, Chips Ahoy, Maryland cookies, Keebler, Famous Amos, Cadbury’s, Mrs. Fields, Mother’s, Nestle Toll House…

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128 Biscuit, cookie and cracker process and recipes

5.1.2 Product specification (1) Dimensions: Thickness: Weight: Appearance: Colour: Texture: Flavour: Moisture:

(2)

(3)

55 mm diam. 50 mm diam. 2 60–66 mm diam. 12.0 mm 10.8 mm 14.6 mm 15.0 g 10.4 g 25 g Round, irregular shape with chips visible Golden brown Short Rich with chocolate or nut flavour 2.5–3.0%

Ingredient list Wheat flour, chocolate chips 22%, palm oil, sugar, whey powder, partially inverted sugar syrup, sodium bicarbonate, ammonium bicarbonate, salt, flavouring. Ingredient list Wheat flour, milk chocolate chunks 22%, vegetable fats, milk chocolate 16%, soya lecithin, palm oil, sugar, oatmeal, partially inverted refiner’s syrup, desiccated coconut, glucose syrup, molasses, ammonium bicarbonate, sodium bicarbonate, disodium diphosphate, salt, soya lecithin, flavouring. Formulation Recipe 5.1.1 Flour Shortening Granulated sugar Brown sugar Whole egg powder Vanillin Invert syrup Salt Ammonium bicarbonate Sodium bicarbonate Chocolate chips Water

FIG. 5.3 Process flow for cookies.

100.00 55.98 50.05 0.76 1.24 0.10 1.24 0.96 0.29 0.67 30.00 19.14 260.43

Cookies Chapter

5.1.3

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129

Mixing

The mixing is in two stages on a horizontal or a vertical mixer. Good dispersion of the fat over the flour particles is important and there must be a good proportion of solid fat.

FIG. 5.4 Peerless Food Equipment horizontal mixers for a wide variety of doughs www. peerlessfood.com.

FIG. 5.5 Tonelli Vertical Spindle Mixer: Carmen Bruno—TONELLI GROUP SpA—© all rights reserved.

130 Biscuit, cookie and cracker process and recipes

The following ingredients are mixed gently at the first stage: shortening, sugars, water, salt, egg powder, vanilla, invert syrup and ammonium bicarbonate. These ingredients are mixed to dissolve the sugar and achieve a creamy emulsion. The water should be cold and the mix kept as cool as possible. The flour and sodium bicarbonate are added for the second stage. The mixing is continued at low speed for no more than 1 min to obtain a homogenous mixture without hydration of the flour and formation of the gluten. The chocolate chips or nuts are added close to the end of the mix and given enough time to disperse evenly through the dough.

5.1.4 Forming The dough is fed to the hopper of a wire-cut machine. The dough may be fed from a bowl by gravity. The feed rolls of the depositor operate continuously and will extrude the dough through the dies. As the dough is extruded, it is cut by a horizontally reciprocating wire. The cut dough pieces drop directly on to the baking tray or oven baking band.

FIG. 5.6 Dough pieces being cut and deposited on to the oven band.

FIG. 5.7 Baker Perkins wire-cut machine.

Cookies Chapter

5.1.5

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131

Baking

Baking on an Indirect Radiant (cyclotherm) oven with a steel band is ideal to give good spread on the oven band, good texture and flavour. Baking time: Temperatures: Moisture:

7.0 min 180–220 °C 2.5–3.0%

Fat rich cookies will not stick to the oven band, but high sugar content may cause some sticking and the cookies must be stripped gently from the steel band. The band should be greased at the feed end of the oven.

FIG. 5.8 Baker Pacific Indirect Radiant Oven.

5.1.6

Cooling

A ratio of cooling to baking time should be 1.5:1.

5.1.7

Formulations

Recipe 5.1.2 Flour, pastry Flour, cake Shortening Sugar High fructose corn syrup Corn syrup Molasses Eggs, powdered Vanilla, powdered Butter flavour Sodium bicarbonate Salt Baking powder Ice Choc chips

68.000 32.000 29.607 37.160 26.435 7.563 0.755 2.719 0.273 0.325 1.597 1.373 1.092 6.949 22.659 238.507

132 Biscuit, cookie and cracker process and recipes

Recipe 5.1.3 Flour Sugar, granulated Corn syrup Molasses Shortening Dried eggs Salt Sodium bicarbonate Ammonium bicarbonate Vanilla flavour Chocolate chips Water

100.000 50.000 3.000 0.750 56.000 1.250 1.000 0.671 0.300 1.000 60.000 13.000 286.971

Recipe 5.1.4 Flour Sugar, granulated Shortening Butter Whole egg powder Egg white powder Whey powder Lecithin Salt Ethyl vanillin Sodium acid pyrophosphate Sodium bicarbonate Ammonium bicarbonate Chocolate chips Water, iced

100.000 65.000 45.000 5.000 3.000 1.767 1.767 0.100 1.000 0.367 0.250 1.000 0.600 48.000 23.000 295.851

Flour Sugar, granulated Glucose syrup Shortening Lecithin Whey Ethyl vanillin Sodium acid pyrophosphate Sodium bicarbonate Ammonium bicarbonate Chocolate chips Water, iced

100.000 53.500 4.750 50.000 0.125 4.250 0.015 0.187 1.000 0.800 25.000 10.000 249.627

Recipe 5.1.5

Cookies Chapter

Recipe 5.1.6 Flour Sugar Honey Butter Egg powder Whole milk powder Almond powder Lecithin Salt Sodium acid pyrophosphate Sodium bicarbonate Chocolate chips Water

100.000 44.550 3.000 34.375 1.600 2.530 14.340 0.555 1.280 0.900 0.900 38.000 19.000 261.030

Recipe 5.1.7 Flour Sugar, granulated Sugar, brown Golden syrup Fat Dried egg powder Vanilla Salt Ammonium bicarbonate Sodium bicarbonate Chocolate chips Water

100.000 50.000 0.744 3.012 56.000 1.250 0.492 1.000 1.000 0.674 60.000 13.000 287.172

Recipe 5.1.8 Flour Sugar, granulated Brown sugar Corn syrup Shortening Whey powder Dried egg white Emulsifier Salt Sodium acid pyrophosphate Sodium bicarbonate Ammonium bicarbonate Chocolate chips Water

100.000 33.839 10.000 2.502 13.763 1.000 0.493 1.010 1.250 0.493 1.882 0.246 37.700 19.600 223.778

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Recipe 5.1.9 Flour Sugar, granulated Invert syrup Shortening Malt syrup Dried eggs Whey powder Salt Sodium bicarbonate Ammonium bicarbonate Calcium acid phosphate Chocolate chips Water Ice

100.000 47.500 5.000 42.500 0.500 1.500 0.250 1.000 0.750 1.500 1.500 45.000 4.200 7.000 258.200

Recipe 5.1.10 chocolate chip with nuts Flour, soft Sugar, granulated Syrup Shortening Whey powder Hazel nut nibs Salt Acid calcium phosphate Vanilla Sodium bicarbonate Chocolate chips Water

100.000 45.000 3.281 45.625 6.094 3.906 1.023 1.023 0.758 0.758 27.813 15.000 250.281

Flour Sugar, fine granulated Sugar, brown Invert syrup Shortening Butter Whole egg powder Salt Sodium bicarbonate Baking powder Butter flavour Macadamia nuts White chocolate chunks Water

100.000 65.000 2.300 12.000 25.000 25.000 2.000 1.000 2.000 0.750 2.000 25.000 50.000 15.000 327.050

Recipe 5.1.11

Cookies Chapter

Recipe 5.1.12 mini chocolate chip Flour Sugar Invert syrup Shortening Butter Whey Salt Sodium bicarbonate Ammonium bicarbonate Chocolate chips Iced water

100.000 40.000 6.250 25.000 13.750 2.500 0.875 0.875 1.250 25.000 10.000 225.500

Recipe 5.1.13 mini chocolate chip Flour Sugar, granulated Invert syrup Shortening Butter Whey powder Ethyl vanillin Citric acid (50%) Salt Sodium bicarbonate Ammonium bicarbonate Chocolate flavour Chocolate chips Iced water

100.000 40.000 6.330 25.000 3.670 2.500 0.017 0.260 0.900 0.870 1.130 0.130 33.300 17.000 231.107

Recipe 5.1.14 Flour, soft Sugar, granulated Invert syrup Shortening Whole egg powder Salt Cinnamon powder Nutmeg powder Vanilla Rum butter flavour Sodium bicarbonate Ammonium bicarbonate Sodium acid pyrophosphate Desiccated coconut Raisins Chocolate chips Water, iced

100.000 47.500 1.750 37.500 1.000 0.875 0.550 0.075 0.050 1.255 1.125 0.750 0.312 1.250 17.500 25.000 15.000 251.492

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Recipe 5.1.15 Flour Whole wheat flour Granulated sugar Invert syrup Shortening Butter Skimmed milk powder Vanilla Salt Ammonium bicarbonate Sodium bicarbonate Walnuts Chocolate chips Ice (flaked)

66.670 33.330 56.600 10.000 33.330 18.315 1.765 0.826 1.000 1.100 0.832 20.000 33.300 10.000 287.068

5.2 Maryland type cookies

FIG. 5.9 Maryland cookies.

5.2.1 Description Maryland is a brand name of Burtons Biscuits, United Kingdom. The cookie was first made by Burtons in 1956 and remains a favourite cookie.

5.2.2 Product specification Dimensions: Thickness: Weight: Moisture content:

(1)

(2)

50.0 mm diam. 11.0 mm 10.5 g 2.5–4.0%

53.0 mm 10.8 mm 10.4 g

Ingredient list Wheat flour, chocolate chips 25%, sugar, palm oil, whey, partially inverted sugar syrup, sodium bicarbonate, ammonium bicarbonate, salt, flavourings.

Cookies Chapter

5.2.3

Formulations for Maryland type cookie

Recipe 5.2.1 Maryland type Flour Sugar, icing Sugar, granulated Syrup Fat Butter Milk powder Cream powder Salt Sodium bicarbonate Vanilla sugar Chocolate chips Roasted hazelnuts Water

100.000 30.000 20.000 3.500 42.000 7.500 6.500 1.100 1.000 0.800 0.800 30.000 13.500 17.000 273.700

Recipe 5.2.2 Maryland type Flour Sugar, icing Sugar, granulated Syrup Shortening Milk powder Vanilla sugar Salt Sodium bicarbonate Acid calcium phosphate Chocolate chips Hazel nuts, finely chopped Biscuit dust Water

100.000 30.160 19.740 3.580 48.420 6.470 0.790 1.050 0.790 1.050 26.320 12.100 4.200 22.000 276.670

Recipe 5.2.3 Maryland type Flour Sugar, granulated Syrup Shortening Whey powder Vanilla sugar Salt Sodium bicarbonate Acid calcium phosphate Chocolate chips Hazel nuts, finely chopped Biscuit dust Water

100.000 45.190 3.270 45.450 6.070 0.780 1.040 0.780 1.040 28.050 3.900 9.400 14.700 259.670

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5.3 Oatmeal cookies

FIG. 5.10 Oatmeal cookies.

5.3.1 Description Cookies made with oatmeal and other local flours. Dad’s is a very popular cookie in Canada since 1929, made by the Christie company. Dad’s is now a Mondelez International brand. It is made in a variety of flavours, some without oatmeal. Dad’s original ingredients: sugar, wheat flour, rolled oats, animal/vegetable shortening, ground raisins, salt, sodium bicarbonate, flavours, spices.

5.3.2 Product specification for oat cookies

FIG. 5.11 Oat cookies. Dimension: Thickness: Weight:

62–63 mm diam. 8.3 mm 13.6 g

Oat cookies ingredient list Oat flakes 41%, sugar, palm oil, wheat flour, whole wheat flour 6%, invert sugar syrup, sodium bicarbonate, ammonium bicarbonate, salt, flavouring.

Cookies Chapter

5.3.3

5

139

Oat and sultana cookies

FIG. 5.12 Oat and sultana cookies.

5.3.4

Product specification Dimension: Thickness: Weight:

65 mm diam. 12.0 mm 20 g

Ingredient list Rolled oats 23%, Sultanas 21% butter 18%, wheat flour, sugar, invert sugar syrup, desiccated coconut, sodium bicarbonate, disodium diphosphate, ammonium bicarbonate, molasses. 5.3.5

Formulations for oatmeal cookies

Recipe 5.3.1 Flour Oats Sugar Golden syrup Fat Butter Whey powder Sodium acid pyrophosphate Salt Sodium bicarbonate Vanillin Water

100.000 89.260 125.680 35.400 35.400 33.860 1.380 1.785 1.540 2.990 0.039 26.000 453.334

140 Biscuit, cookie and cracker process and recipes

Recipe 5.3.2 Flour Oats, ground Sugar, fine granulated Invert syrup Shortening Raisins Salt Sodium bicarbonate Water

100.000 65.000 80.000 5.000 50.000 20.000 2.500 3.000 12.000 337.500

Recipe 5.3.3 Flour Oatmeal Sugar, granulated Invert syrup Shortening Butter Raisins Salt Ammonium bicarbonate Sodium bicarbonate Sodium acid pyrophosphate Cinnamon Nutmeg Water

100.000 44.000 65.600 12.800 50.000 20.000 28.000 1.280 0.880 1.700 0.700 0.880 0.152 4.000 329.992

Recipe 5.3.4 (without oatmeal) Flour, weak Vegetable shortening Margarine Sugar, raw Granulated sugar Maple syrup Honey Glucose 42DE Salt Sodium bicarbonate Ammonium bicarbonate Cream of tartar Yellow colour Raisins, pulped Water

100.000 17.857 10.714 16.071 16.071 14.286 7.143 7.143 0.714 0.804 0.893 0.357 0.179 21.429 7.143 220.804 Mix: Vertical Spindle or Horizontal Forming: Rotary moulder or wire-cut Baking time: 9 min

Cookies Chapter

5.4 Coconut cookies

FIG. 5.13 Coconut cookies.

5.4.1

Formulations for coconut cookies

Recipe 5.4.1 Flour Oats Sugar, fine granulated Invert syrup Shortening Whole egg powder Whey powder Coconut Salt Sodium bicarbonate Calcium acid phosphate Water

100.000 10.000 52.500 24.000 40.000 1.000 2.500 40.000 1.250 1.250 0.250 4.200 276.950

Flour Sugar, granulated Invert syrup Palm oil Whey powder Salt Sodium bicarbonate Ammonium bicarbonate Baking powder Coconut, fine Coconut essence Water

100.000 52.678 10.357 33.393 2.500 1.451 0.625 1.250 0.167 19.642 0.234 18.200 240.497

Recipe 5.4.2

5

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Recipe 5.4.3 Flour, soft Cornflour Maize flour Sugar, fine granulated Invert syrup Dextrose Fat Full cream milk powder Salt Vanillin Butter flavour Sodium bicarbonate Desiccated coconut Water

100.000 1.670 8.000 78.650 2.330 4.000 74.650 2.000 1.583 0.023 0.167 1.583 29.330 20.000 323.986

Recipe 5.4.4 Flour Corn starch Granulated sugar Invert syrup Shortening Butter Desiccated coconut Whey powder Salt Sodium bicarbonate Ammonium bicarbonate Coconut flavour Sodium acid pyrophosphate Water

100.000 5.230 50.100 1.850 40.600 20.300 33.200 3.800 1.000 0.850 0.594 0.261 0.255 16.300 274.340

Recipe 5.4.5 Flour Fine sugar Granulated sugar Invert sugar Desiccated coconut Shortening Margarine Skimmed milk powder Ammonium bicarbonate Sodium bicarbonate Water

100.000 38.180 3.640 5.560 18.180 20.000 8.180 3.640 0.910 0.820 10.000 209.110

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Recipe 5.4.6 Flour Maize flour Cornflour Sugar, fine granulated Invert syrup Dextrose Fat Fine desiccated coconut Full cream milk powder Vanillin Salt Sodium bicarbonate Butter flavour Water

100.000 8.000 1.670 78.670 2.333 4.000 74.670 29.330 2.000 0.042 1.583 1.583 0.167 20.000 324.048

5.5 Cookie varieties 5.5.1

Description

There is a wide variety of wire-cut cookies with different flavours and inclusions.

5.5.2

Peanut cookies

FIG. 5.14 Peanut cookies.

5.5.3

Product specification Dimension: Thickness: Weight:

65–68 mm diam. 11.7 mm 16.7 g

Ingredient list Wheat flour, peanuts 25%, sugar, palm oil, rapeseed oil, egg, milk proteins, coconut oil, palm kernel oil, glucono-delta-lactone, sodium bicarbonate, salt, invert sugar syrup, dextrose, flavouring, sunflower oil.

144 Biscuit, cookie and cracker process and recipes

5.5.4 Formulations for cookies Recipe 5.5.1 cookies with orange flavour Flour Sugar, caster Sugar, granulated Sugar, milled Invert syrup Fat Lecithin Salt Sodium bicarbonate Ammonium bicarbonate Biscuit dust Orange flavour Water

100.000 24.176 15.385 5.220 28.846 24.176 0.275 0.538 1.203 1.396 5.500 1.610 3.900 212.225

Recipe 5.5.2 Flour Sugar, granulated Glucose syrup Shortening Whey Salt Sodium bicarbonate Sodium acid pyrophosphate Nutmeg Ethyl vanillin Water

100.000 40.000 1.750 25.000 1.750 1.312 0.937 0.220 0.500 0.007 14.250 185.726

Recipe 5.5.3 butter rings

FIG. 5.15 Butter rings. Flour, weak Butter Margarine Sugar, fine

100.000 50.000 15.000 40.000

Cookies Chapter

Whole egg, frozen Full cream milk Sodium bicarbonate Water

5.000 5.000 0.590 7.000 222.590

Recipe 5.5.4 chocolate cookie Flour Shortening Granulated sugar Invert syrup Cocoa 10–12% Whey Ethyl vanillin Ammonium bicarbonate (dissolved in 2.3 kg water) Sodium bicarbonate Salt Water

Recipe 5.5.5 shortbread rout press Flour Pulverised sugar Invert sugar Margarine Fat Salt Sodium bicarbonate Cream powder Vanilla essence Buttabelle flavour Egg Milk

Recipe 5.5.6 butter thins

FIG. 5.16 Butter thins.

100.000 23.500 5.000 3.500 1.550 0.700 0.200 0.400 0.200 0.200 5.000 10.000 150.250

100.000 58.333 73.333 5.000 12.500 1.000 0.040 0.917 0.500 1.000 20.000 272.623

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Flour Sugar, granulated Syrup Glucose 42DE Butter, salted Sodium bicarbonate Salt Water

100.000 44.271 4.600 11.600 35.000 1.089 0.726 10.000 207.286

Recipe 5.5.7 fruit cookie Flour Sugar, caster Sugar, icing Invert syrup Palm oil Salt Sodium bicarbonate Ammonium bicarbonate Baking powder Coconut flour Currants Caramel flavour Butter flavour Biscuit dust Water

Recipe 5.5.8 butter pecans

FIG. 5.17 Butter pecans.

100.000 16.670 16.670 17.140 23.810 0.595 0.714 0.268 0.179 11.900 11.900 0.179 0.268 23.800 12.000 236.093

Cookies Chapter

Flour Shortening Butter Sugar, granulated Skimmed milk Caramel Whole egg powder Pecan nuts Ethyl vanillin Salt Ammonium bicarbonate Sodium bicarbonate Sodium acid pyrophosphate Water

100.000 37.568 13.784 50.270 1.503 0.200 1.000 20.270 0.151 1.000 0.503 1.000 0.365 12.432 240.046

Recipe 5.5.9 fruit cookie Flour, soft Sugar, caster Sugar, granulated Golden syrup Fat Butter Margarine Currants Semi skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate Sodium acid pyrophosphate Mixed spice Lemon essence Egg yellow colour Eggs Water

5.6 Infant rusk

FIG. 5.18 Infant rusks.

100.000 30.000 27.500 3.533 25.000 10.000 7.500 15.000 1.000 0.373 0.627 0.500 0.933 0.250 0.667 0.127 10.000 7.330 240.340

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5.6.1 Description The infant rusk is widely used and popular infant food. It may be dissolved in milk or water or eaten as a biscuit. It is safe for young infants and delivers a measured amount of vitamins and minerals in each rusk. The vitamin and mineral supplements are developed to suit the particular needs of different populations.

5.6.2 Product specifications (1) Dimensions: Thickness: Weight: Appearance: Texture Taste Dissolving Moisture:

(2)

58–60 mm diam. 74 mm diam. 14–15 mm 15 mm 10 g 18 g Pale colour, slightly cracked Open and porous Sweet, mild, rapidly softening 20–30 s in warm water 5.7%

5.6.3 Formulations for infant rusks Recipe 5.6.1 Flour Sugar, liquid Sugar, milled Fat Ammonium carbonate Ammonium bicarbonate Calcium carbonate Ferric ammonium citrate Vitamin premix Water

100.000 73.520 3.280 11.800 1.200 1.200 7.000 0.280 11.800 24.000 234.080

Flour Sugar, milled Fat Ammonium carbonate Ammonium bicarbonate Calcium carbonate Ferric ammonium citrate Vitamin premix Water

100.000 51.800 11.800 1.200 1.200 7.000 0.280 1.720 25.000 200.000

Recipe 5.6.2

5.6.4 Mixing Horizontal mixer. Stage 1: All ingredients, except flour, fat and vitamin premix. Mix at slow speed for 3 min.

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Stage 2: Add flour, fat, vitamin premix. Mix at slow speed for 0.5 min and at high speed for 1.5 min. Dough temperature: 24 °C.

Standing time 15 min. 5.6.5

Forming

Dough pieces are wire-cut and dropped onto the steel oven band.

FIG. 5.19 Forming of infant rusks on the wire-cut machine.

5.6.6

Baking Oven types: Baking time: Baking temperatures:

Indirect Radiant, Re-Circ, electric 10.5–12 min 140/145/165/190

Steam application at the oven feed end is important. Gradual heat input in the first two zones of the oven.

5.6.7

Alternative shapes

FIG. 5.20 Alternative shapes for infant rusks.

Chapter 6

Danish butter cookies

FIG. 6.1 Danish butter cookies.

6.1 Description Danish butter cookies comprise five cookies, including deposited and rotary moulded cookies. They are made on dedicated lines with suitable forming, baking and packaging equipment.

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6.2 Product specifications and formulations 6.2.1 Swirl cookie

FIG. 6.2 Swirl cookie.

Dimensions: Thickness: Weight:

50  45 mm 10.25 mm 10 g

Recipe 6.2.1 swirl cookie Flour Corn starch Shortening Butter Sugar Invert syrup Milk powder Egg white Salt Sodium bicarbonate Vanilla flavour Butter flavour Water

6.2.2 Pretzel

FIG. 6.3 Pretzel.

100.000 7.352 58.820 7.352 41.174 4.411 5.147 1.470 0.735 0.184 0.184 0.184 14.700 241.713

Danish butter cookies Chapter

Dimensions: Thickness: Weight:

50  40 mm 9.75 mm 7.5 g

Recipe 6.2 pretzel Flour Butter fat Icing sugar Granulated sugar Soya flour Sodium bicarbonate Salt Water at 20 °C Egg wash Sugar topping

6.2.3

100.000 41.667 20.833 14.167 4.167 0.083 0.667 14.167 195.751 10.833 17.500

Vanilla cookie

FIG. 6.4 Vanilla cookie.

Dimensions: Thickness: Weight:

50  40 mm 10.25 mm 10 g

Recipe 6.3 vanilla cookies Flour, weak Butter fat Icing sugar Granulated sugar Soya flour Salt Vanilla flavour Water at 20 °C

100.000 47.619 23.809 14.286 1.428 0.762 0.219 17.143 205.266

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6.2.4 Coconut and currant cookies

FIG. 6.5 Coconut and currant cookies.

Dimensions: Thickness: Weight:

47 mm diam. 9.25 mm 8g

Recipe 6.4 coconut and currant cookies Flour Butter fat Icing sugar Granulated sugar Soya meal Desiccated coconut Currants Sodium bicarbonate Salt Water at 20 °C

100.000 43.478 30.435 21.739 1.300 10.435 4.000 0.348 0.696 19.130 231.561

6.2.5 Chocolate chip cookies

FIG. 6.6 Chocolate chip cookies.

Dimensions: Thickness: Weight:

50 mm diam. 9.25 mm 10 g

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155

Recipe 6.5 chocolate chip cookies Flour Shortening Sugar High fructose corn syrup Corn syrup Molasses Eggs, powdered Vanilla, powdered Butter flavour Sodium bicarbonate Salt Baking powder Ice Choc chips

100.000 29.607 37.160 26.435 7.563 0.755 2.719 0.273 0.325 1.597 1.373 1.092 6.949 22.659 238.507

6.3 Production The cookies are made on a single production line with typically a 1.0 m  30 m oven with a steel band. A major supplier is Haas-Meincke, part of the Haas Group, which is now a member of the B€ uhler Group.

6.3.1

Mixing

The doughs are mixed on a planetary mixer with a cream up process for 5 min followed by the addition of flour and eggs in two stages. The doughs are cold (16 °C).

6.3.2

Forming

The forming equipment has a rotary moulder, wire-cut and swirl depositor arranged in the line to deposit the cookies in a pre-arranged pattern for baking. The equipment is arranged as follows: (1) The rotary moulder produces the rectangular vanilla cookie and pretzel. (2) Wash-over unit with brush applying egg wash to dough pieces only. (3) Sugar topper applying sugar to the top of the dough pieces only, by a 100 mm diameter roll with holes approx. 8 mm diam. Pneumatic system can be employed to recover excess sugar. (4) Swirl depositor (5) Wire-cut depositor for coconut and currant cookies and chocolate chip. The forming machines are arranged to produce 20 rows on the oven band to give 4 sets of 5 products.

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6.3.3 Baking Baking time: 7.5 min Temperatures: 250–190 °C Steel baking band

6.3.4 Cooling Refrigerated cooling to 5 °C before packing.

6.3.5 Packaging

FIG. 6.7 Butter cookies.

Chapter 7

Sandwich biscuits

FIG. 7.1 Sandwich biscuits.

7.1 Cream sandwiches

FIG. 7.2 Jam and cream sandwiches.

7.1.1

Description

Sandwich biscuits with rotary moulded or deposited biscuit bases (or shells). The sandwiches may have jam or cream or a combination of fillings with sugar topping.

FIG. 7.3 Process flow. Biscuit, Cookie and Cracker Process and Recipes. https://doi.org/10.1016/B978-0-12-820598-3.00007-X © 2020 Elsevier Inc. All rights reserved.

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7.1.2 Product specification

FIG. 7.4 Jam and cream sandwich.

Dimensions: Thickness: Weight:

46 mm diam. 14.5 mm 15.0 g

Ingredient list Wheat flour, palm oil, sugar, raspberry jam 12%, glucose syrup, salt, dried skimmed milk, invert sugar syrup, soya lecithin, sodium bicarbonate, ammonium bicarbonate, flavourings. Raspberry jam contains: glucose–fructose syrup, invert sugar syrup, sugar, raspberry puree, pectin, sodium citrate, citric acid. Formulations Recipe 7.1.1 biscuit base 1 Flour Icing sugar Glucose Palm oil Sodium bicarbonate Ammonium bicarbonate Baking powder Whey powder Salt Biscuit dust Water

100.000 25.000 1.027 33.930 0.536 0.178 0.290 0.893 0.625 9.000 10.700 182.179

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Recipe 7.1.2 biscuit base 2 Flour, soft Soya flour Granulated sugar Shortening Sodium bicarbonate Ammonium bicarbonate Salt Vanilla sugar Biscuit dust Water

7.1.3

100.000 10.000 47.500 27.500 0.175 0.625 0.750 0.320 22.500 20.000 229.370

Cream processing

Sweet biscuit creams consist of fat, icing or powdered sugar with colour and flavour. For savoury creams, the sugar is replaced by whey powder, cheese powder, milk powder and starch. Cream density is typically 0.75–1.15 g/cm3. Fats are normally lauric fats, coconut and palm kernel and blends. For many applications the fat content of the cream is 30–35%. For high speed machines the average solid fat content of the lauric fats is around 15–20%. Sugar is generally milled to an average particle size of 40–60 μm. Mixing may be batch or continuous. Vertical spindle planetary machines may be used to supply a cream hopper from which the cream is continuously pumped to the cream stencils on the sandwiching machine. Continuous mixers are often used to feed high speed sandwiching lines and have advantages of good process control of temperature and consistency.

FIG. 7.5 Easy Industrial Planetary Mixer for soft doughs and creams from SIGMA, Italy. www.sigma.com.

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FIG. 7.6 Baker Perkins cream feed system with two pumps.

Recipe 7.1.3 raspberry cream filling Icing sugar Confectionery fat Cornflour Raspberry essence Salt Colour, red Water

50.000 38.000 2.500 0.125 0.130 0.095 0.625 91.475

7.1.4 Biscuit sandwiching process The biscuits are normally fed manually from the packing table to a set of vibratory conveyors. The vibratory conveyors ensure a ‘pressureless’ feed to the sandwiching machine. This avoids breakage of the biscuit shells. The biscuit shells are stripped one by one from the feed chutes by pegs on a chain conveyor. This carries the bottom biscuit shell under a stencil which

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deposits the cream. Subsequently the top biscuit shell is placed to form the sandwich. The cream is applied by rotary stencils with a wire cut off. Each stencil is fed by a cream pump from the cream reservoir tank. There is one cream pump for each lane of the sandwiching machine, each with its own variable speed drive and independently adjustable for accurate weight control of the cream deposit. Cream feed speed is set to follow the sandwiching machine.

FIG. 7.7 Baker Perkins cream stencils on a four lane machine.

FIG. 7.8 Biscuit sandwiching system.

FIG. 7.9 Co-depositing stencil for jam and cream.

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7.1.5 Biscuit cream sandwich machines The machines may have multi-lanes, usually from 2 up to 6 lanes. Each lane may produce 200–800 sandwiches per minute, depending on the product and machine characteristics. The sandwiching machine will generally be followed by a lane multiplier to increase the number of lanes of sandwiches to feed a cooling tunnel. The cooling will set the cream for the sandwiches to be delivered to packaging.

FIG. 7.10 Four lane sandwiching machine with lane multiplier from EverSmart Food Equipment, China.

FIG. 7.11 EverSmart two colour sandwiching machine. High speed sandwiching system for a variety of biscuit shapes and sizes.

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7.1.6

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Cookie capper machines

Cookie cappers are full width sandwiching systems. The cappers take the biscuit shells directly from the end of the cooling conveyor. The machines align the rows of biscuits, flip over the alternate rows, align and deposit the fillings on to alternate rows with bottom side up and then pick and place the top biscuits to form the sandwich. The systems are versatile and available with different depositing systems to handle cream, jam or mallow. Cappers may have several depositors to enable a variety of fillings to be applied.

FIG. 7.12 Procys cookie capper www.procys.eu.

7.1.7

Sandwich cooling

Sandwiches are cooled in refrigerated tunnel coolers to set the cream before packaging.

FIG. 7.13 Nielsen cooling tunnel www.aasted.eu.

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7.2 Biscuit sandwiches: Raspberry, orange, lemon, butter cream, vanilla cream 7.2.1 Formulations Recipe 7.2.1 raspberry biscuit base Flour Icing sugar Invert syrup Palm oil Condensed milk Sodium bicarbonate Salt Vanilla essence Butter flavour Biscuit dust Water

100.000 23.200 1.786 28.570 3.570 0.536 0.848 0.045 0.220 8.900 10.700 178.375

Recipe 7.2.2 raspberry biscuit base Flour Flour, weak Sugar, caster Invert syrup Shortening Margarine Semi skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate Vanillin Yellow colour Sodium acid pyrophosphate Eggs Water

67.000 33.000 28.000 5.000 14.000 12.000 1.000 1.000 0.627 0.280 0.047 0.127 0.230 7.500 1.300 171.111

Recipe 7.2.3 raspberry biscuit base Flour Flour, soft Cornflour Sugar Golden syrup Fat Butter Margarine Semi skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate

67.000 33.000 5.000 27.500 7.000 15.000 5.000 10.000 1.000 0.500 0.627 0.313

Sandwich biscuits Chapter

Sodium acid pyrophosphate Butterbelle flavour Egg yellow colour Vanilla Water

0.157 0.333 0.127 0.167 5.330 178.054

Recipe 7.2.4 raspberry cream filling Icing sugar Fat, coconut Cornflour Raspberry essence Citric acid Salt Red colour Water

50.000 38.000 2.500 0.125 0.125 0.125 0.950 0.625

Recipe 7.2.5 lemon cream base Flour Soft cake flour Cornflour Sugar Golden syrup White syrup Fat Margarine Semi skimmed milk powder Lecithin Sodium bicarbonate Ammonium bicarbonate Sodium metabisulphite Sodium acid pyrophosphate Yellow colour Water

67.000 33.000 8.330 26.670 4.750 2.170 10.000 6.670 1.670 0.500 0.670 0.750 0.017 0.157 0.147 23.300 185.801

Recipe 7.2.6 lemon cream filling Icing sugar Confectionery fat (coconut) Confectionery fat (palm kernel) Cornflour Malt Citric acid Lecithin Tartrazine yellow colour Liquid lemon yellow Oil of lemon Water

50.000 15.000 23.000 2.500 0.125 0.190 0.950 0.950 0.950 0.300 0.625 94.590

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Recipe 7.2.7 orange cream base Flour Sugar, granulated Sugar, liquid Glucose Fat Salt Sodium bicarbonate Ammonium bicarbonate Vanilla Biscuit dust

100.000 20.223 20.196 1.795 29.620 0.701 0.112 0.168 0.014 5.000 177.829

Recipe 7.2.8 orange cream base Flour Maize starch Sugar, icing Sugar, caster Invert syrup Palm oil Sodium bicarbonate Salt Vanilla essence Butter flavour Biscuit dust Water

100.000 5.357 17.860 8.930 3.570 28.570 0.536 0.848 0.045 0.223 8.900 10.700 185.539

Recipe 7.2.9 orange cream Sugar, granulated Cream fat Cornflour Orange oil Orange colour, natural

50.000 34.722 3.819 0.153 0.694 89.388

Recipe 7.2.10 orange cream Icing sugar Shortening Soy bean oil Skimmed milk powder Corn starch Orange flavour Yellow colour

50.000 22.900 2.076 3.086 2.755 0.121 0.106 81.044

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Recipe 7.2.11 orange cream Sugar, milled Cream fat Whey powder Skimmed milk powder Oil of orange

50.000 31.250 2.656 2.656 0.750 87.312

Recipe 7.2.12 butter cream base Flour, soft bread Cornflour Sugar Pura syrup Fat Margarine Butter Cocoa Caramel Semi skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate Lecithin Sodium acid pyrophosphate Ground cinnamon Butterbelle flavour Vanilla Pink colour Chocolate colour Water

100.000 5.000 35.000 7.125 20.000 10.000 5.000 5.000 1.750 1.000 0.500 0.500 0.562 0.500 0.187 0.250 0.325 0.150 0.500 2.750 12.500 208.599

Recipe 7.2.13 butter cream Icing sugar Coconut oil Corn flour Full cream milk powder Salt Vanilla Water

100.000 76.000 5.000 4.000 0.250 0.300 1.250 186.800

Recipe 7.2.14 vanilla cream Milled sugar Cream fat Butter oil Whey powder

50.000 20.830 13.330 3.330

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Skimmed milk powder Vanilla flavour

3.330 0.540 91.360

7.3 Bourbon

FIG. 7.14 Bourbon sandwiches.

7.3.1 Description Bourbon is a popular sandwich made with cocoa powder in the biscuit and the cream. Bourbon biscuits were originally introduced by Peek Frean in England in 1910.

7.3.2 Product specification Dimensions: Thickness: Weight:

60  30 mm 12.9 mm 13.5 g

Ingredient list Wheat flour, sugar, palm oil, fat reduced cocoa powder, glucose syrup, dextrose, wheat starch, ammonium bicarbonate, sodium bicarbonate, salt, flavouring. 7.3.3 Formulations for Bourbon Recipe 7.3.1 Bourbon base 1 Flour Sugar, pulverised Syrup Invert syrup Fat Cocoa powder Salt

100.000 19.000 5.000 8.500 25.000 1.500 0.500

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Sodium bicarbonate Ammonium bicarbonate Cream of tartar Vanilla flavour Water

0.200 0.300 0.300 0.100 14.000 174.400

Recipe 7.3.2 Bourbon cream 1 Icing sugar H.P.K.O. Bitter chocolate Glucose Brown colour Ethyl vanillin Milk powder

100.000 55.556 22.220 2.220 1.667 0.028 6.667 188.358

Recipe 7.3.3 Bourbon base 2 Flour Sugar, granulated Shortening Caramel Cocoa (10–12%) Salt Sodium bicarbonate Ammonium bicarbonate Sodium acid pyrophosphate Water

100.000 26.670 25.000 1.670 2.500 1.000 0.583 0.500 0.167 12.700 170.790

Recipe 7.3.4 Bourbon cream 2 Icing sugar Shortening Whey powder Cocoa (10–12%) Ethyl vanillin

100.000 50.000 6.833 6.333 0.041

Recipe 7.3.5 Bourbon base 3 Flour Sugar, icing Invert syrup Palm oil Cocoa, dark Salt Sodium bicarbonate Vanilla essence

100.000 25.890 3.571 31.250 1.518 0.848 0.446 0.045

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Biscuit dust Water

8.900 10.700 183.168

Recipe 7.3.6 Bourbon base 4 Flour Sugar, granulated Liquid sugar Syrup Fat Cocoa powder Salt Sodium bicarbonate Vanilla Biscuit dust Water

100.000 29.650 22.000 8.505 26.080 6.400 0.227 0.269 0.539 2.500 12.000 208.170

7.4 Cheese crackers

FIG. 7.15 Cheese crackers.

7.4.1 Description Light, crisp cracker with cheese filling.

7.4.2 Product specification Dimensions: Thickness: Weight:

45 mm diam. 14 mm 10.0 g

Ingredient list Wheat flour, vegetable oils (palm and sunflower), maltodextrin, cheese powder (6%), glucose–fructose syrup, sugar, barley malt extract, salt, sodium

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bicarbonate, ammonium bicarbonate, calcium phosphate, lecithin, yeast, flavouring, sodium metabisulphite.

7.4.3

Formulations

Recipe 7.4.1 Sponge Flour, weak Shortening Cheese Yeast Water

50.000 10.000 10.000 0.094 26.000 96.094 Mix on vertical spindle for 5 min Ferment for 18 h at 29 °C Dough Flour, weak 50.000 Salt 1.250 Sodium bicarbonate 0.500 Water 7.500 59.250 Add to sponge. Mix for 3 min Ferment for 4.5–5 h at 29 °C

Recipe 7.4.2 Sponge Flour, medium Yeast Cheese powder Water at 35 °C Mix on vertical spindle 7 min Ferment 18 h at 27 °C Dough Flour, weak Shortening Salt Sodium bicarbonate Water

50.000 0.375 10.000 22.500 82.875

50.000 10.000 1.250 0.550 7.500 69.300 Add to sponge. Mix for 5 min. Dough temp. 27 °C Ferment 4.5–5 h at 29 °C

Recipe 7.4.3 biscuit shells Flour Sugar, liquid Glucose 42DE Malt extract Fat Cheese powder Salt

100.000 1.500 5.000 2.000 20.000 7.000 2.125

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Sodium bicarbonate Ammonium bicarbonate Biscuit dust Water

0.170 0.920 5.000 16.000 159.715

Recipe 7.4.4 cheese cream filling Cheese powder Shortening Vegetable oil Skimmed milk powder Cracker dust

50.000 40.370 2.750 2.020 18.200 113.340

7.5 Chocolate alfajor

FIG. 7.16 Chocolate alfajor.

7.5.1 Description Afajor has ancient origins in Spain as an Arabic confection. In Spain it is called alauju´ and is still made with natural ingredients, flour, honey, almonds, sugar and spices. Recipes date back to 15th century and have been handed down from generation to generation. There are a wide variety of alfajores with different cookies and sweet fillings. Argentina is now the world’s largest consumer of alfajores and it is popular throughout Latin America. Popular brands are Jorgito, Suchard, Havanna, Cachafaz.

7.5.2 Specification and formulation The specification and formulation given are for a rotary moulded product.

Product specification Dimensions: Thickness: Diameter:

8.25 mm 6.0 mm 60 mm

Sandwich biscuits Chapter

Recipe 7.5.1 alfajor biscuit (rotary moulded) Flour, high extraction Sugar Shortening Sodium bicarbonate Ammonium bicarbonate Caramel colour Vanilla essence Water

100.000 31.750 26.000 1.200 1.000 1.000 0.170 8.500 169.620

Recipe 7.5.2. alfajor filling Sugar, pulverised Vegetable fat Cocoa liquor Skimmed milk powder Vanilla crystals Vanilla essence Lecithin Cocoa powder

39.000 29.000 18.000 6.000 0.060 0.010 0.400 0.500 92.970

Recipe 7.5.3 alfajor coating Sugar, milled Cocoa butter Cocoa liquor Full cream milk powder Vanilla crystals Vanilla essence Lecithin

7.6 Chocolate cookie sandwiches

FIG. 7.17 Chocolate cream cookie sandwich.

42.500 25.000 9.000 23.000 0.030 0.050 0.400 99.980

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7.6.1 Description A deposited cookie with chocolate filling. The cookie contains oats and coconut.

Ingredient list Sugar, wheat flour, palm oil, cocoa powder, whey derivatives, glucose syrup, partially inverted refiner’s syrup, chocolate powder, cocoa mass, sodium bicarbonate, disodium diphosphate, ammonium bicarbonate, salt, soya lecithin.

7.6.2 Product specification Dimensions: Thickness: Weight:

45–47 mm diam. 16.0 mm 14.0 g

7.6.3 Formulations Recipe 7.6.1 cookie Flour, soft bread Ground oats Fine coconut Sugar Golden syrup Margarine Vegetable fat Semi skimmed milk powder Salt Sodium bicarbonate Sodium acid pyrophosphate Vanilla Water

100.000 38.000 47.670 124.670 24.000 45.330 23.670 1.467 1.467 3.567 2.193 0.367 12.000 424.401

Recipe 7.6.2 chocolate cream Sugar, milled Cream fat Cocoa powder

100.000 83.330 27.750 211.080

Sandwich biscuits Chapter

7.7 Fudge and caramel cookies

FIG. 7.18 Cookie with caramel filling.

7.7.1

Product specification

A rotary moulded cookie with fudge filling. Dimensions: Thickness: Weight:

7.7.2

52–53 mm diam. 5.0 mm 14.4 g

Formulation

Recipe 7.7.1 fudge cookie Flour Flour, soft bread Cornflour Sugar, caster Golden syrup Fat Skimmed milk powder Cocoa powder Melted chocolate Chocolate brown colour Tartrazine Lecithin Salt Sodium bicarbonate Ammonium bicarbonate Fudge essence Water

50.000 50.000 13.889 38.889 5.555 50.000 5.555 6.667 13.889 0.694 0.500 0.250 1.389 0.833 0.333 0.200 7.200 245.843

Recipe 7.7.2 caramel cream Glucose syrup Invert syrup Sugar, granulated Cream fat Butter oil Condensed milk Toffee Salt Water

100.000 83.300 50.000 26.670 8.330 66.670 2.500 1.330 27.500 366.300

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7.8 Coconut sandwiches

FIG. 7.19 Coconut sandwich.

7.8.1 Formulations Recipe 7.8.1 coconut sandwich base 1 Cookie flour Corn starch Sugar, granulated Invert syrup Shortening Butter Desiccated coconut Whey powder Salt Sodium bicarbonate Ammonium bicarbonate Sodium acid pyrophosphate Toasted coconut flavour BHA/BHT Water

100.000 5.232 50.150 1.848 40.610 20.300 33.230 3.804 1.000 0.853 0.596 0.257 0.264 0.406 16.300 274.850

Recipe 7.8.2 coconut sandwich base 2 Flour Cornflour Icing sugar Invert syrup Palm oil Coconut Salt Sodium bicarbonate Baking powder Coconut essence Skimmed milk powder Biscuit dust Water

100.000 6.607 26.780 1.786 30.360 8.929 0.714 0.536 0.357 0.134 1.786 8.900 9.000 195.889

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Recipe 7.8.3 coconut rout press dough Flour Sugar, granulated Liquid sugar Glucose Fat Desiccated coconut Salt Sodium bicarbonate Ammonium bicarbonate Water

100.000 9.070 42.330 3.630 41.128 21.319 1.058 0.340 0.321 10.000 229.196

Recipe 7.8.4 coconut base Flour Sugar, granulated Sugar, liquid Syrup Desiccated coconut Fat Salt Sodium bicarbonate Ammonium bicarbonate Water

100.000 18.140 22.670 3.670 24.190 36.290 1.060 0.340 0.910 10.000 217.270

Recipe 7.8.5 coconut and oatmeal base Flour, soft Crushed wheat Oats, coarse Semolina Coconut Sugar Golden syrup Vegetable fat Whey powder Salt Sodium bicarbonate Ammonium bicarbonate Coconut essence Buttabelle Colours Egg yellow Cocoa powder Water

100.000 50.000 10.000 22.222 26.111 77.778 20.000 46.667 3.333 2.694 1.000 2.000 0.333 0.333 4.500 2.733 5.111 30.000 404.815

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7.9 Crunchy cookie creams

FIG. 7.20 Crunchie creams.

7.9.1 Description Rich, short cookies with thick cream filling.

7.9.2 Product specification Dimensions: Thickness: Weight:

48 mm diam. 16.3 mm 15.3 g

Ingredient list 1 Sugar, wheat flour, palm oil, partially inverted refiner’s syrup, dried whey, rolled oats, sodium bicarbonate, disodium diphosphate, ammonium bicarbonate, dried skimmed milk, salt, flavourings, soya lecithin, carotenes colour. Ingredient list 2 Wheat flour, palm oil, partially inverted refiner’s syrup, whey derivatives, sodium bicarbonate, disodium diphosphate, ammonium bicarbonate, ground ginger, salt, flavourings, lecithin, colour (carotenes). Ingredient list 3 Biscuit: Sugar, wheat flour, desiccated coconut, sodium metabisulphite, Unhydrogenated palm oil, oats, golden syrup, sodium acid pyrophosphate, Sodium bicarbonate, whey powder, salt, flavouring. Filling: Sugar, hydrogenated palm kernel oil, skimmed milk powder, cocoa powder, soya emulsifier, flavouring, salt.

Sandwich biscuits Chapter

7.9.3

Formulations

Recipe 7.9.1 ginger crunch base 1 Flour Invert syrup Sugar, caster Sugar, granulated Milled sugar Fat Sodium bicarbonate Ammonium bicarbonate Salt Biscuit dust Lecithin Ginger, ground Water

100.000 29.263 24.368 15.600 2.152 23.400 1.237 1.291 0.048 5.400 0.269 2.442 3.765 209.235

Recipe 7.9.2 ginger crunch base 2 Flour (weak) Rolled oats Sugar Fat Butter Golden syrup Glucose Semi-skimmed milk powder Salt Sodium bicarbonate Sodium acid pyrophosphate Vanillin Oil of ginger Lecithin Water

100.000 58.000 87.500 28.000 28.000 20.000 3.562 2.000 1.250 2.500 1.800 0.300 0.167 0.500 20.000 353.579

Recipe 7.9.3 ginger cream 1 Icing sugar Coconut fat Caramel Salt Oil of ginger Water

50.000 38.000 1.250 0.125 0.040 0.625 90.040

Recipe 7.9.4 crunch base 4 Flour Oats

100.000 10.000

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Sugar, granulated Sugar, caster Sugar, icing Glucose Syrup Fat Skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate Sodium acid phosphate Buttabelle flavour Water

18.000 21.500 17.500 7.500 7.000 40.000 2.500 1.285 0.950 1.085 0.330 0.285 10.000 237.935

Recipe 7.9.5 crunch base 5 Flour Rolled oats Sugar, granulated Sugar, liquid Syrup Fat Full cream milk powder Sodium bicarbonate Ammonium bicarbonate Salt

100.000 15.000 35.154 22.000 2.500 34.927 1.000 0.800 0.500 1.000 212.881

Recipe 7.9.6 cream 2 Icing sugar Fat Full cream milk powder Vanilla flavour Beta-carotene

7.10 Custard cream

FIG. 7.21 Custard cream sandwiches.

100.000 80.220 13.187 0.769 0.013 194.189

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7.10.1 Description Popular tea-time cream biscuit in England with soft texture and mild flavour. Distinctive traditional design.

7.10.2 Product specification Dimensions: Thickness: Weight:

45  37 mm 13.2 mm 11.1 g

Ingredient list Wheat flour, sugar, palm oil, whey powder, glucose syrup, wheat starch, ammonium bicarbonate, sodium bicarbonate, salt, flavouring, colour (carotenes). 7.10.3 Formulations Recipe 7.10.1 custard cream base 1 Flour Sugar Glucose Fat Whey powder Salt Sodium bicarbonate Ammonium bicarbonate Vanilla Water

100.000 24.267 1.916 30.000 2.747 0.678 0.170 0.288 0.254 13.400 173.720

Recipe 7.10.2 custard cream filling 1 Icing sugar Cornflour Fat Skimmed milk powder Vanilla Annatto colouring

50.000 4.458 29.256 7.793 0.183 0.110 91.800

Recipe 7.10.3 custard cream base 2 Flour Sugar Golden syrup Margarine Fat Semi skimmed milk powder

100.000 27.500 7.133 25.000 5.000 1.000

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Salt Ammonium bicarbonate Sodium bicarbonate Sodium acid pyrophosphate Buttabelle flavour Eggs Water

0.500 0.093 0.313 0.313 0.167 7.500 7.700 182.219

Recipe 7.10.4 custard cream filling 2 Icing sugar Coconut fat Full cream milk powder Cornflour Salt Vanilla Egg yellow colour Water

50.000 38.000 5.000 2.500 0.125 0.100 0.190 0.625 96.540

Recipe 7.10.5 custard cream base 3 Flour Icing sugar Invert syrup Palm oil Condensed milk Salt Sodium bicarbonate Biscuit dust Water

100.000 21.429 1.786 28.570 3.571 1.071 0.536 8.900 10.700 176.563

Recipe 7.10.6 custard cream base 4 Flour Sugar Liquid sugar Glucose Fat Whey powder Salt Ammonium bicarbonate Sodium bicarbonate Vanilla Water

100.000 11.790 17.460 2.040 29.940 2.835 0.709 0.450 0.170 0.014 10.000 175.408

Sandwich biscuits Chapter

Recipe 7.10.7 custard cream filling 3 Icing sugar Shortening Whey powder Corn starch Custard flavour Yellow colour

50.000 26.836 3.310 4.470 0.039 0.059 84.714

7.11 Fig bars

FIG. 7.22 Fig bars.

7.11.1 Description Rout press product filled with sweet fig jam.

7.11.2 Product specification Dimensions: Thickness: Weight:

43 mm long  33 mm wide 17 mm 18.2 g

7.11.3 Formulations Recipe 7.11.1 fig bar base 1 Flour Icing sugar Invert syrup Palm oil Skimmed milk powder Salt Sodium bicarbonate Ammonium bicarbonate Baking powder Yellow colour Vanilla essence

100.000 35.710 12.500 25.000 5.357 1.071 0.089 0.179 0.179 0.268 0.067

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Butter flavour Water

0.089 18.750 199.259

Recipe 7.11.2 fig bar base 2 Flour Icing sugar Cane syrup Palm oil Skimmed milk powder Salt Sodium bicarbonate Egg powder Egg colour Water

100.000 35.710 5.000 25.000 2.857 1.071 0.089 0.179 0.268 18.750 188.924

Recipe 7.11.3 fig jam 1 Fig paste Fig scrap Sugar, granulated Invert syrup Salt

100.000 6.760 9.875 8.316 0.312 125.263

Fig paste Fig bar scrap Sugar, granulated Invert syrup Salt Biscuit dust

100.000 6.313 21.464 16.414 0.379 19.000 163.570

Recipe 7.11.4 fig jam 2

Recipe 7.11.5 fig jam 3 Fig paste Fig scrap Sugar, caster Glucose Cane syrup Citric acid Salt Biscuit dust

100.000 7.550 37.760 15.100 12.690 0.208 0.735 15.100 189.143

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7.12 Jaffa type cake

FIG. 7.23 Jaffa cake.

7.12.1 Description Deposited cake with orange jam deposit and topped with dark chocolate.

7.12.2 Product specification (1)

(2)

Dimension: Thickness: Weight:

54–55 mm diam. 14.4 mm 11.25 g

49.0–56.0 mm 13.3–14.4 mm 10.4–13.6 g

Base weights: Jam weights: Chocolate weights:

3.9–5.2 g 4.8–5.2 g 2.2–2.4 g

Ingredient list Glucose–fructose syrup, plain chocolate 22%, sugar, wheat flour, egg, dextrose, glucose syrup, concentrated orange juice 1%, pectin, citric acid, glycerine, sunflower oil, ammonium bicarbonate, disodium diphosphate, sodium bicarbonate, sodium citrate, citric acid, flavouring, curcumin colour. 7.12.3 Process

FIG. 7.24 Jaffa cake base, jam and chocolate.

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Mixing for base cake Premix: Liquid egg (mixed with the glycerine, colour), water. Add chemicals, sugar and flour. Mix for 1.5 min and then pump to holding tank. Mix and aerate: feed batter to an Oakes type mixer with air. Rotor speed approximately 100 rpm and pump speed 45–50 rpm. Cake weight: Thickness: Moisture:

4.8 g  0.1 g 8.0 mm  0.2 mm 7.5%

Depositing The batter is deposited directly onto the steel oven band. Baking The steel band is well greased with flour, oil and lecithin. (Flour 10 kg, oil 6 kg, lecithin 0.33 kg.) Temperature of first zone and middle of the oven, approximately 200 °C. Temperature of final zones 160–175 °C. Steam is required in the first oven zone. Baking time: 6.5–8.5 min. Note: these temperatures and baking times may vary considerably depending on the oven specification. Cooling and jam depositing The cakes are cooled on a conveyor and then aligned before the jam depositor. The jam (pectin jelly) is boiled to 74% 1 solid, pH 4.2–4.4. The jam is stored at 33 °C. Jam is fed by gravity through a heat exchanger and deposited at about 55 °C. Citric acid is pumped through the jam line before depositing to increase the acid content of the jam to 0.9%. The jam is cooled in a tunnel before the cakes are transferred to the chocolate enrober. Chocolate weight: 2.4 g  0.1 g. 7.12.4 Formulations Recipe 7.12.1 cake base 1 Flour Sugar Glucose syrup Vegetable oil Salt Baking powder Glycerine Eggs Water

100.000 89.000 6.940 2.780 0.560 1.390 2.780 72.000 5.560 281.010

Sandwich biscuits Chapter

Recipe 7.12.2 cake base 2 Flour Sugar Glucose Sunflower oil Glycerine Sodium bicarbonate Sodium pyrophosphate Eggs Water

100.000 80.000 6.220 3.181 3.000 0.136 0.182 65.000 10.000 267.719

Recipe 7.12.3 jam Sucrose Glucose syrup Sodium citrate Citric acid Pectin Colour, yellow Flavour, orange

7.13 Lemon puff

FIG. 7.25 Lemon puff 1.

FIG. 7.26 Lemon puff 2.

100.000 60.000 0.500 0.250 1.600 0.010 0.162 162.522

7

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188 Biscuit, cookie and cracker process and recipes

7.13.1 Description Puff cracker with light lemon flavoured cream.

7.13.2 Product specification Dimensions: Thickness: Weight: Moisture

1

2

50 mm diam. 12.6 mm 14 g 2.0–3.0%

55  39.5 mm 6.3 mm (biscuit only) 5.3 g (biscuit only)

Ingredient list Wheat flour, palm fat, sugar, dextrose, ammonium bicarbonate, sodium bicarbonate, salt, yeast, natural lemon oil, citric acid, soya lecithin, sodium metabisulphite, rapeseed oil, colours. Process based on product specification 2 The following process data for mixing, forming, and baking is based on the rectangular lemon puff, product specification 2. 7.13.3 Mixing Horizontal 2 speed mixer. Dough temperature: Dough pH Standing time:

20 °C 6.1 20 min

(1) Flour (part), fat, whey powder, salt. Mix for 60 s on slow speed. (2) Add remaining flour and chilled water. Mix for 4.7 min on slow speed.

7.13.4 Forming Laminator: 7 layers with flour dusting, total thickness 43 mm. Gauge roll units: 5, dough sheet thickness at cutter 2.0 mm. Rotary cutter: Separate printing and cutting rolls. Sugar sprinkler.

7.13.5 Baking Convection oven. Baking temperatures:

160/270/330/330/310/280/110

Sandwich biscuits Chapter

7.13.6 Formulations Recipe 7.13.1 lemon puff Flour Soft cake flour Cornflour Sugar Golden syrup White syrup Fat Margarine Semi skimmed milk powder Lecithin Sodium bicarbonate Ammonium bicarbonate Sodium metabisulphite Sodium acid pyrophosphate Yellow colour Water

67.000 33.000 8.330 26.670 4.750 2.170 10.000 6.670 1.670 0.500 0.670 0.750 0.017 0.157 0.147 23.300 185.801

Recipe 7.13.2 lemon cream Icing sugar Confectionery fat (coconut) Confectionery fat (palm kernel) Cornflour Malt Citric acid Lecithin Tartrazine yellow colour Liquid lemon yellow Oil of lemon Water

50.000 15.000 23.000 2.500 0.125 0.190 0.950 0.950 0.950 0.300 0.625 94.590

7.14 Mint creams 7.14.1 Description Rotary moulded biscuits with mint cream filling.

7.14.2 Formulations Recipe 7.14.1 Sandwich base Flour Maize starch Sugar, icing Sugar, caster

100.000 5.357 17.857 8.929

7

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190 Biscuit, cookie and cracker process and recipes

Invert syrup Palm oil Salt Sodium bicarbonate Vanilla essence Butter flavour Biscuit dust Water

3.571 28.571 0.848 0.536 0.045 0.223 8.900 10.700 185.537

Recipe 7.14.2 mint cream 1 Sugar, granulated Cream fat Cornflour Peppermint oil

50.000 52.080 18.230 0.521 120.831

Recipe 7.14.3 mint cream 2 Sugar, milled Cream fat Whey powder Skimmed milk powder Peppermint oil

50.000 31.250 2.670 2.670 0.267 86.857

7.15 Oreo type sandwiches

FIG. 7.27 Oreo sandwiches.

7.15.1 Description Distinctive sandwich design produced world-wide by Mondelez. There are now many local variations by biscuit makers in most markets.

Sandwich biscuits Chapter

7.15.2 Product specification Diameter: Thickness: Weight:

44–45 mm diam. 15.6 mm 11.0 g

7.15.3 Formulations Recipe 7.15.1 Oreo type base 1 Flour Cornflour Sugar, pulverised Shortening Dark caramel colour Caramel colour Cocoa powder, black Salt Sodium bicarbonate Ammonium bicarbonate Vanilla flavour Acid calcium phosphate Water

100.000 2.500 24.300 25.000 20.000 4.500 8.800 0.660 1.000 0.200 0.084 0.190 6.200 193.434

Recipe 7.15.2 Oreo type base 2 Flour Meal Sugar Invert syrup Shortening Cocoa Whey Salt Sodium bicarbonate Water

100.000 8.250 37.500 6.750 22.500 19.250 1.000 1.500 0.917 22.000 219.667

Recipe 7.15.3 Oreo type cream Icing sugar HPKO Cornflour Salt Vanilla

100.000 49.100 4.464 0.096 0.312 153.972

7.15.4 Process Mix biscuit base on spindle mixer Stage 1. Sugar, cocoa, shortening, caramel colour. Mix time 10 min.

7

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Stage 2. Add water, salt, soda, ammonia, vanilla. Mix time 5 min. Stage 3. Add flour, cornflour, acid calcium phosphate. Mix time 17 min.

Forming Rotary moulding. Mix cream on spindle mixer All ingredients. Mix time 4 min.

7.16 Shortbread creams

FIG. 7.28 Shortbread creams.

7.16.1 Description Shortbread biscuits filled with a nut flavoured cream.

7.16.2 Formulations Recipe 7.16.1 shortbread base Flour Cornflour Icing sugar Butter Margarine Salt Sodium bicarbonate Ammonium bicarbonate Eggs Water

100.000 7.500 30.000 40.000 20.000 0.500 0.373 0.127 5.000 4.000 207.500

Sandwich biscuits Chapter

Recipe 7.16.2 shortbread cream Icing sugar Coconut based fat Cornflour Full cream milk powder Salt Almond essence Hazel nut essence Water

50.000 38.000 2.500 2.500 0.125 0.220 0.160 0.625 94.130

7

193

Appendix 1

Ingredients: An introduction The main ingredients for biscuits, cookies and crackers making are flours, sugars and fats. To these ingredients, various small ingredients may be added for leavening, flavour and texture.

A1.1 A1.1.1

Flour Wheat flour

The principle ingredient of biscuits is wheat flour. The grain consists of bran (12%), which is the outer husk, endosperm, which is the white centre (85.5%) and the tiny germ (2.5%). Typical biscuit flour is milled to a yield or extraction of 70–75%. Wholemeal flour is of 100% extraction and wheat meal flours in between these extraction rates, normally around 84% extraction. The flour will also contain moisture of between 13% and 15%. The wheat flour is composed of carbohydrate (as starch), protein and fat, together with some fibre, ash and trace minerals and vitamins. The protein is mainly gluten, composed of gliadin and glutenin. The percentage of protein determines the flour strength. A dough made from strong flour with a high protein content, is extensible and can be machined into a continuous sheet for crackers and hard biscuits. A weak flour with a low protein content produces a short dough which may be moulded or a soft, high fat dough which may deposited on the baking band and when baked, gives a soft, tender cookie. Wheat flour

Weak/medium flour

Strong flour

Starch Moisture Proteins (gluten forming) Proteins (soluble) Sugar Fat Total

74.5 14.0 7.0 1.0 2.0 1.0 100.0

71.5 13.5 10.0 1.0 2.5 1.0 100.0

Wheat flours are now frequently enriched with vitamins and minerals. Typically these may include: B vitamins, folic acid, riboflavin, niacin, thiamine and in some cases iron and calcium.

195

196 Appendix 1

A1.1.2 Wheat gluten The formation of the gluten, its strength and elasticity are largely determined by the flour specification, recipe and the mixing and forming processes. Wheat flour contains proteins including gliadin and glutenin. In the presence of water these proteins combine to form gluten. As the dough is mixed the protein molecules form long strands of gluten, which have strength and elasticity. The gluten forms an elastic web, which gives the dough strength and allows it to be machined into a thin sheet for crackers and hard sweet biscuits. These biscuits are made with ‘strong’ flour, which has a high protein content, typically 10–12%. The gluten web is also important in trapping air and gas bubbles formed by yeast fermentation or by leavening agents such as sodium bicarbonate (‘soda’) or ammonium bicarbonate (‘vol’). This leavening process, combined with the laminating of the dough, gives the characteristic open, flaky texture of crackers during baking. Soft or short biscuits are generally made with low protein flour (7–9%). A low protein flour makes a dough with a much weaker gluten web. In addition these doughs have higher fat contents. The fat coats the flour particles and this inhibits the hydration of the proteins and the formation of the gluten web. Shorter mixing times also result in less development of the gluten strands and hence the biscuits have a short texture.

A1.1.3 Starch Starch is the main component of wheat flour. It represents almost all of the carbohydrate content and around 80% of the total energy content of wheat flour. Starch is a polysaccharide (many sugars) made up of glucose units linked together to form long chains. The principle starch molecules in wheat flour are amylose, which typically comprises 28% of the total amount of starch. Amylose molecules contribute to gel formation. Their linear chains of molecules line up together and are able to bond to make a viscous gel. Starch is insoluble in water, however the starch granules do absorb a limited amount of water in the dough and swell. Above temperatures of 60–70 °C the swelling is irreversible and gelatinisation begins. The gelatinisation may continue until the starch granules are fully swollen, but it is normal in baked products that only partial gelatinisation occurs. The gelatinisation of the starch contributes to the rigidity and texture of the biscuit. As the starch gel is heated further, dextrinisation occurs. This contributes to the colouring of the biscuit. In soft dough products, the high sugar and fat content of the dough inhibits starch gelatinisation. The presence of sugars delays the gelatinisation of the starch, which may be due to the competition for water. The fat, composed of triglycerides and surfactants, also tends to inhibit gelatinisation. With high

Appendix 1

197

sugar and fat recipes, the dough has a low gel viscosity and strength and produces short and soft biscuits and cookies.

A1.1.4

Corn flour

Corn flour is a white free flowing powder produced by wet milling of maize, followed by washing, concentrating, centrifuging, drying, milling and sifting to give a natural maize starch. It has a short gel texture, relatively high viscosity and is easily dispersed in cold water. The protein in corn flour does not form gluten, and it can be used as an ingredient to produce a more tender biscuit with reduced gluten development.

A1.1.5

Oats

Oatmeal and oat flakes or rolled oats are used in various biscuits providing a distinctive flavour and texture. Oatmeal flour is a coarse flour used with wheat flour to produce short, friable biscuits. Oat flakes are a good addition to cookies and wire cut products.

A1.1.6

Soya

Soya flour is made from soya beans after the oil has been extracted. Soya flour is a source of protein and contains a small amount of the emulsifier lecithin. Soya flour is a valuable ingredient in some dietary and gluten free biscuits.

A1.2 A1.2.1

Sugars Sucrose

Common sugar (sucrose) is a carbohydrate derived from sugar cane or sugar beet. It is a disaccharide composed of two monosaccharides, a molecule of glucose joined to a molecule of fructose. Sugar is used in biscuit formulations in a granulated or powder form. Sugar gives sweetness, but it is also important in developing the texture of the biscuit. Dissolved sugar tends to inhibit starch gelatinisation and gluten formation and creates a biscuit with a more tender texture. Undissolved sugar crystals give a crunchy, crisp texture. Sugar crystals, which melt during baking, cool to a non-crystalline glass-like state which gives a crispy, crunchy texture, particularly on sugar topped biscuits. Dry sucrose melts at 160–186 °C. Biscuits with sugar toppings which are melted to a smooth, shiny surface require high intensity flash heat at the end of the oven to fully melt the sugar. Invert sugar syrup is a mixture of glucose and fructose. The sucrose is split into its’ component monosaccharides by hydrolysis. The sucrose in solution is heated with a small quantity of acid such as citric acid. After inversion the

198 Appendix 1

solution is neutralised by the addition of soda. The invert syrup is sweeter than sugar and it contributes to a moist, tender texture in the biscuit. Other reducing sugars are included in biscuit formulations in syrup form, for example glucose syrup, malt extracts, honey. The reducing sugars in the presence of amino acids produce the Maillard reaction which contributes to the colour of the biscuit.

Sugar specifications Moisture content: Ash content:

0.06% maximum 0.03% maximum

Particle size (average): Powdered sugar: Crystal sugar: Caster sugar: Granulated sugar:

60 μm 150 μm 150–450 μm 250–1050 μm

Brown sugar, a dry golden brown sugar with bold crystals. Particle size:

0.8–1.2 mm

A1.2.2 Glucose syrup Glucose syrup (C6H12O6) is a solution (up to 80%) of glucose (dextrose), maltose and malto-dextrins in water. It is normally obtained by enzymatic hydrolysis of starch. Starch from wheat, corn, potato, cassava or any other plant can be used for this purpose. Standard glucose syrup has a DE value (dextrose equivalent) of 42. The relative sweetness of 42DE glucose to sucrose is 40–45%.

A1.2.3 Cane syrup 80% Syrups with 80% solids derived from the refining of cane sugar. Used for their excellent flavour.

A1.2.4 Invert syrup 70% Syrup of 70% solids made by acid hydrolysis of sucrose. The result is a 50:50 mixture of dextrose and fructose which are both reducing sugars and contribute to the Maillard reaction in baking.

A1.2.5 Fructose syrup 80% Commercially, fructose is usually derived from sugar cane, sugar beets and corn. Crystalline fructose is a monosaccharide, dried and ground, and of high purity. High-fructose corn syrup (HFCS) is a mixture of glucose and fructose.

Appendix 1

199

High fructose syrup is a special type of glucose, formulated with a high fructose content. It is much sweeter than glucose.

A1.2.6

Malt extract 80%

A thick glutinous syrup of 80% solids usually non-diastatic and obtained by water extraction of malted wheat or barley. The heat treatment used to concentrate the solution destroys any enzymes. Used as an important flavour ingredient. Malt extract is rich in maltose, which is a reducing sugar.

A1.3 A1.3.1

Dough fats and oils Vegetable fats

Fats are a vitally important ingredient in achieving the texture, mouth feel, and the bite of the biscuit. The fats are produced from good quality crude oils by a process of refining, bleaching and deodorising. They are produced primarily from vegetable oils, but may contain hydrogenated fish oils. Typical blended vegetable dough fats are solid at ambient temperature and melt over a wide temperature range. Most fats used in biscuit making are melted below blood temperature (36.9 °C), and this avoids a waxy mouth feel. Fats are specified with a Solid Fat Index (SFI), which indicates the percentage of solid fat present in the total fat. A vegetable shortening typically has an SFI of around 21% at 25 °C and 17% at 30 °C.

FIG. A1 Graph showing melting profile (Solid Fat Index vs temperature) of a typical vegetable fat for biscuit dough.

Recipes with high fat contents require little water for producing a cohesive dough and produce soft, short doughs. During mixing, the fat coats the flour particles and this inhibits hydration and interrupts the formation of the gluten. Fats also tend to inhibit the leavening action of the carbon dioxide diffusion in the dough during baking and this produces a softer, finer texture. Where both fat

200 Appendix 1

and sugar amounts in the recipe are high, they combine to make a soft, syrupy, chewy texture. Typically crackers and hard sweet biscuit doughs, which are sheeted and cut, have fat contents of 10–22% of the flour by weight. Rotary moulded doughs may have 17–30% of fat and wire-cut and deposited cookie doughs 25–60%.

A1.3.2 Butter Butter is used for its shortening and flavour. The flavour of the butter is complemented by sugar and vanilla during baking and gives a distinctive flavour and aroma.

A1.3.3 Coconut oil Coconut oil is typically used for oil spraying. The oil is hydrogenated, neutralised, deodorised and bleached. Melting point: 32–34 °C.

A1.4 Other ingredients A1.4.1 Whole egg powder Whole egg powder is spray dried. Egg yolk is rich in fat and lecithin and it is these ingredients which enhance the flavour and eating quality of the cookie.

A1.4.2 Lecithin Lecithin is an emulsifier produced from soya beans and available in liquid or powder form. It may be added to the fat or directly into the dough mix.

A1.4.3 Yeast (fresh) A microscopic, unicellular organism. It breaks down sucrose and maltose into monosaccharides and glucose and fructose into alcohol and carbon dioxide. During fermentation, the gas production causes the dough to increase in volume and develop the characteristic flavour. Fresh yeast is available as a compressed block. Active dried yeast and instant active dried yeast are other forms.

A1.4.4 Ammonium bicarbonate (‘vol’) (NH4)HCO3 A volatile salt, which is an effective leavening agent. When heated it liberates carbon dioxide, ammonia gas and water.

Appendix 1

A1.4.5

201

Sodium bicarbonate (‘soda’) NaHCO3

The most important aerating agent. When heated, it reacts with acidic materials in the dough to release carbon dioxide and water.

A1.4.6

ACP—Acid calcium phosphate

Acid calcium phosphate is also known as monocalcium phosphate. It is used as a leavening agent in conjunction with sodium bicarbonate and ammonium bicarbonate.

A1.4.7

SAPP—Sodium acid pyrophosphate

Sodium acid pyrophosphate is commonly used in the baking industry as a leavening agent. It combines with sodium bicarbonate to release carbon dioxide.

A1.4.8

Salt (NaCl)

Sodium chloride, used as a flavour enhancer and also to control the rate and extent of fermentation.

A1.4.9

SMS—Sodium metabisulphite Na2S2O5

A reducing agent for the modification of the strength of the gluten in doughs. It causes the gluten to become more extensible and less elastic and so reduces shrinkage of the dough pieces during baking.

A1.4.10 Proteolytic enzyme Proteinases break down and modify the gluten in doughs, giving a softer, less elastic dough.

A1.4.11 MRP—Material recovered from production Many biscuits contain re-work such as damaged biscuits recovered from production. Hygiene in collection, storage and processing is essential. The biscuits are ground and may then be added to some recipes at up to 10% of the total.

Bibliography Baking Management, 2008. A Tropical Touch. Soy-Based Solutions. Penton Media Inc. http://www. baking-management.com/ingredients/brief_guide_functional_1028/index1.html. Benedict M. How Does Temperature Affect Yeast Activity? MadSci Network. http://www.madsci. org/posts/archives/jan2001/980908832.Gb.r.html. British Sugar plc, 2015. Screened White Sugars. www.britishsugar.co.uk.

202 Appendix 1 Buck, J.S., Walker, C.E., 2009. Sugar and sucrose ester effects on maize and wheat starch gelatinisation patterns. Starch. Wiley VCH Verlag GmbH. Dakota Yeast, 2010. Yeast Fermentation in Baked Goods. http://www.dakotayeast.com/helpfermentation.html. DTKFCPL, 2003. Examining the Role of Fats in Bakery, APR03. Eyre, C., 2008. AB Enzymes Launch Targets Improved Biscuit Baking. Decision News Media. www.bakeryandsnacks.com. Fineli®, National Institute for Health and Welfare, 2003–2010. Wheat Flour Whole Grain. Flour Specifications, 2015. www.flourmilling.co.uk. Food Resource, Oregon State University, 1990. Gel. Excerpts from Bender Arnold E. Dictionary of Nutrition and Food Technology. Butterworths, Boston. Food Resource, Oregon State University, 2010. Bread Dough. Starch. Ghiasi, K., Hoseney, R.C., Varriano-Marston, E., 1981. Effects of flour components and dough ingredients on starch gelatinisation. Cereal Chemistry 60 (1), 58–61. Gurney, A., 2008. Bakery Fats and Oils. Leading Edge. Lansbergen, G., 2002. Fats for Food Consultants. http://www.fatsforfoods.com/specifications.htm. Lowe, B., 2009. Experimental Cookery From the Chemical and Physical Standpoint. Gluten. Manley, D., 1996. Technology of Biscuits, Crackers and Cookies, second ed. Woodhead Publishing Ltd. Manley, D., 1998. Manual 1, Ingredients. Woodhead Publishing Ltd. Manley, D., 2001. Biscuit, Cracker and Cookie Recipes for the Food Industry. Woodhead Publishing Ltd. Moodie, P., 2001. Traditional baking enzymes—Proteases. In: Presented at American Institute of Baking, Manhattan, Kansas. Enzyme Development Corporation. Toufeili, I., Ismail, B., Shadarevian, S., Baalbaki, R., Khatar, B.S., Bell, A.E., Schofield, J.D., 1999. The role of gluten proteins in the baking of arabic bread. Journal of Cereal Science. Wade, P., 1988. Biscuits, Cookies and Crackers. vol. 1 Elsevier Applied Science Publishers Ltd.

Appendix 2

Biscuit, cookie and cracker manufacturers listed in Glyn Sykes notes provide a guide to his wide international experience in the biscuit industry Archway Cookies, United States Barilla Group, Italy Biscuits Delacre, Belgium Burton’s Biscuit Co., United Kingdom CIPA, Ivory Coast Continental Biscuits, Pakistan Danone Asia English Biscuit Manufacturers, Pakistan Ferrero, Italy General Mills, United States Shanghai GT Nissin Food Co., China I Mei Foods Co., Taiwan Irish Biscuits, Ireland Karl Fazer, Finland Lu General Biscuits, Belgie McVities UK Nabisco, United States Nestl e, Switzerland Orion Confectionery Co., Korea Pepperidge Farm, United States Premier Foods, United Kingdom Saiwa, Italy Sunshine Biscuits, United States Terrabusi, Argentina Tohato Inc., Japan United Foods Public Co., Thailand

Arnott’s Biscuits, Australia Bermudez Biscuit Company, Trinidad Britannia Industries, India Ceylon Biscuits, Sri Lanka Colombina SA, Colombia Cookie Man, Australia Dare Foods, Canada Fox’s Biscuits, United Kingdom Grupo Arcor, Argentine Gullo´n, Spain Interbake Foods LLC, United States Jacob’s, United Kingdom and Ireland Kelly’s Biscuits Maliban Biscuit Manufactories, Sri Lanka Morinaga & Company, Japan Nejati Industrial Group (ANATA), Iran Nongshim Co., Korea Oxford Biscuits A/S, Denmark, Plasmon Dietetici Alimentari s.r.l., Italy Quaker Latz GmbH, Germany Shoei Foods USA Symbol Biscuits, United Kingdom The Garden Company, Hong Kong United Food Ind. Corp., Saudi Arabia Verkade, Holland

203

Appendix 3

Galleries A3.1 A3.1.1

Photos of leading products Gallery 1 Crackers

205

206 Appendix 3

Appendix 3

207

208 Appendix 3

Appendix 3

209

210 Appendix 3

Appendix 3

211

212 Appendix 3

A3.1.2 Gallery 2 Semi-sweet biscuits

Appendix 3

213

214 Appendix 3

A3.1.3 Gallery 3 Short dough biscuits

Appendix 3

215

216 Appendix 3

Appendix 3

217

218 Appendix 3

A3.1.4 Gallery 4 Cookies

Appendix 3

219

220 Appendix 3

A3.1.5 Gallery 5 Danish butter cookies

Appendix 3

A3.1.6

Gallery 6 Sandwiches

221

222 Appendix 3

Appendix 3

223

224 Appendix 3

Index Note: Page numbers followed by f indicate figures.

A

D

Abernethy, 115–116, 115f Alfajor, 172–173, 172f Animals, 92, 92f Army biscuits, 96–97 Arrowroot, 65, 81–82, 81f

Danish butter cookies, 151–156, 220 Digestive, 99, 104–109, 104f

B Bacon snacks, 57–58, 57f ‘Bath Oliver’, 26, 26f Biscuit sandwiches, 164–168 Bourbon, 168–170, 168f Butter coconut, 19–21, 19f Butter pecans, 146–147, 146f Butter rings, 144–145, 144f Butter thins, 145–146, 145f

C Cabin and Gem, 94–96, 94–95f Cafe Noir type, 90–91 Cheese crackers, 44–46, 44f, 170–172, 170f Chocolate alfajor, 172–173, 172f Chocolate chip cookies, 127–136, 127f, 154–155, 154f Chocolate cookie, 145, 173–174 Chocolate cookie sandwiches, 173–174 Chocolate fingers, 123, 123f Cinnamon Crisp, 121, 121f Coconut and currant cookies, 154–155, 154f Coconut cookies, 141–143, 141f Coconut sandwiches, 176–177, 176f Cookies, 127–149 Cookie varieties, 143–147 Cornish wafer type crackers, 22–24, 22f Crackers, 1–31, 33–63, 170–172, 205–211 Cream crackers, 3f, 10–19, 10f, 18f Cream sandwiches, 157–163, 157–158f Crispbread, 29–31, 29f Crunchy cookie creams, 178–180 Custard cream, 99, 180–183, 180f

F Fig bars, 183–184, 183f Finger biscuits, 123 Fish type snack crackers, 56–57, 56f Frollini, 99, 116–117, 116f Fruit cookie, 88, 146–147 Fruit shortcake, 113, 113f Fudge and caramel cookies, 175

G Gala fruit cookies, 88 Garibaldi biscuits, 83–88, 83f Gem, 94–96 Ginger biscuits, 117–120, 117f Glucose, 99–100, 99f, 196–200 Golden Maria, 72–73, 72f

H Hard tack, 96–97, 96f Harvest type, 89–90

I Iced gem, 95–96, 95f Infant rusk, 147–149, 147f, 149f

J Jaffa type cake, 185–187, 185f

L Lemon puff, 187–189, 187f Le Veritable Petit Buerre, 76–77 Little Hearts, 63, 126, 126f

M Malaysian crackers, 18–19, 18f Malkist crackers, 18–19, 18f

225

226 Index Malted Milk, 99–100, 116, 116f Maria, 69–73, 72f Marie, 65, 67, 69–72, 69f Maryland type cookies, 136–137, 136f Mint creams, 189–190 Morning Coffee, 91–92, 91f Munchies potato snacks, 61–62

N Nice, 80–81, 80f, 99

O Oatmeal cookies, 138–140, 138f Oaty biscuits, 124–125 Oreo type sandwiches, 190–192 Oyster crackers, 55–56, 55f

P Peanut cookies, 143, 143f Petit Beurre type, 77–78, 77f Potato biscuits, 93–94, 93f Potato chips, 58–60, 58f Pretzel, 152–153, 152f, 155 Puff crackers, 21–22, 21f, 188

R Rich Tea, 65, 74–76, 74f ‘Ritz’ type snack cracker, 33–38, 33f

S Saltine, 1–10 Sandwiches, 157–193, 221–224 Semi-sweet biscuits, 65–97, 212–213 Sesame crackers, 51–53, 51f Shortbread, 99, 113–114, 113f Shortbread creams, 192–193, 192f Shortbread rout press, 145 Shortcake, 99, 109–113, 109–110f, 113f Short doughs, 99–104, 99f, 113, 117, 126, 195, 199, 214–217 Shorties, 109f, 112, 112f Snack crackers, 33–63 Soda crackers, 1f, 2, 3f, 4–7, 9–10, 48, 52 Swirl cookies, 152, 152f

T Three layer crackers, 41–44, 41f, 43–44f Tostada, 78–79, 78f ‘TUC’ type cracker, 38–41, 38f, 47

V Vanilla cookie, 125–126, 125f, 153, 153f, 155 Vanilla crackers, 62, 62f Vegetable and herb crackers, 47–50

W Water biscuits, 24–25, 24f Wheat crackers, 53–54, 53f Wholemeal crackers, 26–28, 26f Windmill biscuits, 121–122, 121f