Bakery Industry: Production Targets, Requirements, Processes, And Schedule

Production Targets

Bakery industry is a highly specialized and diversified food manufacturing and marketing industry. The employees of the bakery industry are indulged in making different varieties of baked foods that include cakes, donuts, yeast bread products, pizza, cookies, pies and other delicious food items. The employees are proficient in preparing, mixing, identifying and applying the ingredients in a perfect proportion to deliver mouth watering dishes to the customers. The bakery industry is equipped with skilled employees who have added more flavors in the culinary sector (Abdel-Aal and Rabalski 2013).

Davies bakery is a 130 years old business owned by the family of John Davies. The owner of the company was a genuine hard- working man who had an affinity for super quality bread. They have turned out to be the fifth generation in the bakery industry and are regarded as one of the largest in the same. They are equipped with a modern plant which manufactures and produces premium quality frozen and fresh bakery products. They are concerned with baking flavored foods and continuously put their effort to provide good products to the customers. They are recognized for their fresh production and efficient distribution network which makes them trust- worthy and reliable. They excel in distributing frozen product throughout the world including some of the popular companies in Australia (Bilge et al. 2015).

The bakery collects information to identify the number of visitors in their online site. The copyright of all the information is owned and licensed by them. The legal policies of the company do not allow using the information in some other way without written permission.

The classic recipes which are used in the production process of Davies bakery make them outstanding. Their sales have experienced remarkable improvement with the introduction of their new packaging. They have made use of their design thinking and doing to get effective results. In 2015, the company was considered for the Hall of Fame in the Australian Society of Baking, which was something new acquired by only nine people in 35 years (Cauvain 2015).

Boulder brands in 2013, has acquired Davies bakery to produce superior quality and innovative gluten free products. They will utilize the retail relationships and the expertise opportunities to launch bakery products.

It is important to take delivery, store and prepare the raw materials, processing of the ingredients and then mixing and blending of the ingredients in the appropriate proportion to get the best quality products is the main criteria required for the workers employed in the bakery industry.  The required equipment in the bakery industry are ovens, fryers, mixers, proof boxes and bakery racks. The equipment remains same for the start- ups and well- established companies (Dagnas et al. 2017).

It does not require too many ingredients for a bakery company. The essentials are yeast, flour, water, milk, buttermilk, cream, juice, sweetener, salt, eggs and fat. The ingredients are required in different quantities for the different recipe. The proportion should be appropriate in order to bring the good taste.

Production Requirements

The bakery industry shares the most of publicly traded producers of the baked goods that are sold. The baking business is mostly regional for providing fresh foods and baked products to the customers. The award- winning bakery companies such as Davies bakery have adopted the strategy of selling their products on some routes along with the trucks and drivers thus creating a bunch of entrepreneurs and reducing the company costs at one go (Junyapoon 2016). With the rapid consolidation of the bakery industry, there is a constant selling of slightly weaker companies to their better counterparts. This is because bakery is a segmented industry and therefore the procurement provides the opportunity to gain the economies of scale.

Flawless interaction is crucial in the production process of the bakery industry and the combined automation gives the perfect answer. There is efficient bakery production process which delivers the best quality at a minimum cost.

The Davies bakery company utilizes the primitive method of long fermentation of bread and laminated pasties. It refers that although the dough is mixed it is provided with a pre- determined time at the regulated temperature for improvement in flavor and strength. The flavor comes out well from the wheat with constant fermentation. It is a lengthy procedure which can take up to hours and days.

The successful and gaining control of the frozen products require a normal standard of product quality and situation and appropriate methods for identifying the level of product performance with standards (Koy 2017). The bakery industry has improved at an extensive rate in the past two decades and there is serious concentration on the regulation of sufficient standards and the objective methods for measuring the required quality. These standards and methods must be kept on a consistent basis to get the official and legal status.

The processing of dough involves mixing as its primary step. The temperature has to be taken in consideration and the products must be kept under complete observation. All the ingredients have to be properly weighed and must not be forgotten to mix in the dough. The ingredients include100 kg of flour, 62 kg of water, 2 kg of yeast and 1.8 kg of salt which are mixed and baked at a temperature of 28 degree centigrade with the temperature of the flour at 35 degrees centigrade and the water at 6 degrees centigrade. The chemical change takes place with the mixture of acids which reduce the baking time 20%- 30% (McCarthy 2015).

The nutritional facts in the manufacturing of bakery products include biscuits made of composite flour, of different flavors, special vitamin biscuits with high fiber and low sugar and fat. Protein is considered as a vital nutrient in terms of quality and quantity. The wheat flour protein, 12%- 16% deficient in the essential amino acids- 80and the quality of bread in the bakery industry is controlled below mild and meat class. For getting 20% protein in bread by using the dry non- fat milk with a minimum of 19% should be added to 100 parts of flour. The basic bakery ingredients include flour, sugar, salt and fat. Changes cannot be brought in salt and sugar but only modification can be brought in flour with the addition of soya and amaranth and also isoflowones, high fiber and protein and solualve claims (Ponomaryova et al. 2015).

Production Processes

The bakery industry is looking forward to more efficient equipment that are well built and can reduce time. To increase the maximum bakery capacity the energy efficient equipment can be used which are for long term sustenance. The amazing methods of technology can be used as innovative methods in the food industry. Smarter the equipment will be, better will be the bakery industry with smooth operations.  

The survey and research on the buying pattern of the bakery customers described their characteristics. A qualitative approach was based on the interview of ten bakery managers and ten consumers. Again, a quantitative approach was aimed towards 465 bakery consumers. The outcome of the research showed that the consumers pay a visit at the bakery store to for purchasing perishable food or instant foods.

The production schedule of the Davies bakery as was discussed with the employees is given below-

Week	1	2	3	4	5	6
Bread	195	180	200	170	195	160
Biscuits	170	165	220	130	180	175
Pastries	180	170	200	190	160	185
Projected on- hand	6	700	420	250	70	600
Available to promise	35	50	48	65	28	40

                                                               Fig- Production schedule

                                                         Source- As created by the author

The professional implementation of the industrial line for baked goods production calls for detailed insight and a long term experience. Superior quality product, the best hygiene standards along with the cleaning and maintenance system of the Davies bakery are set as the prime requirements for modern plant concepts. Their concepts are the basis on which individual industrial lines are equipped with to form reliability.  

The Davies bakery produces a wide variety of bread, pastry and specialty products which is a large automated process (Soukoulis et al. 2014). The company has used the approach of formalizing management commitment to develop project targets. They provide training to all the staffs for assessing the production operation with respect to production target. They have a developed set of employees who are identified to implement successful options and evaluate their performance.

The variances require not to involve in low risk establishments that meet the criteria of selling raw, pre- packed, or hazardous foods; no preparation of hazardous foods; no cooling of the hazardous foods; processing limited to non- potential hazardous food; limited storage of non- potential hazardous food. The Davies bakery looks into the preparation of food done in a licensed kitchen under the supervision of a full- time certified manager.

Davies bakery is in constant search for ensuring superior quality standards in all their products. They stick to the standards of quality assurance and the safety of the personnel. They abide by the laws applicable in the food manufacturing facility (Sun 2016).

Davies bakery worked out on the tracking of waste and the cause behind waste generation. They were successful in identifying the main waste drivers and recognize the targeted actions for waste reduction.

Fermentation, the most critical part in baking is taken proper care in the Davies bakery. They have an improved characteristic of handling dough and the perfect fermentation conditions result in enhancing the texture of finished product (Varzakas and Tzia 2015).

Conclusion:

So it can be concluded from the assignment that Davies bakery has become successful in the bakery industry by supplying a variety of bakery products throughout the world and maintaining the quality standards. They have always focused on the superior quality food products for the customer and that is why they have adhered to the proper mixing and blending process in their factory. Their HACCP/SQF 2000 certification reflects their commitment of producing the premium quality bakery food products. The employees are properly trained on the basic skills of baking so that they can serve their customers well. These services have made them the popular provider of some of the largest Australian companies.  

Reference:

Abdel-Aal, E.S.M. and Rabalski, I., 2013. Effect of baking on free and bound phenolic acids in wholegrain bakery products. Journal of Cereal science, 57(3), pp.312-318.

Bilge, G., Boyac?, ?.H., Eseller, K.E., Tamer, U. and Çak?r, S., 2015. Analysis of bakery products by laser-induced breakdown spectroscopy. Food chemistry, 181, pp.186-190.

Cauvain, S., 2015. Process Control and Software Applications in Baking. In Technology of Breadmaking (pp. 213-227). Springer International Publishing.

Dagnas, S., Gougouli, M., Onno, B., Koutsoumanis, K.P. and Membré, J.M., 2017. Quantifying the effect of water activity and storage temperature on single spore lag times of three moulds isolated from spoiled bakery products. International journal of food microbiology, 240, pp.75-84.

Junyapoon, S., 2016. Biogas Production from Bakery Wastewater in Two-Stage Anaerobic Digestion System. KMITL SCIENCE AND TECHNOLOGY JOURNAL, 17(1).

Koy, R., 2017. Lactic acid bacteria as bio-preservatives in bakery–Role of sourdough systems in the quality, safety and shelf life of bread (Doctoral dissertation, University of Plymouth).

McCarthy, B.L., 2015. Trends in organic and green food consumption in China: Opportunities and challenges for regional Australian exporters. Journal of Economic and Social Policy, 17(1), p.0_1.

Ponomaryova, E.I., Lukina, S.I., Magomedov, M.G. and Roslyakova, K.E., 2015. Production technology of functional bakery products. European Journal of Natural History, (6), pp.59-59.

Safronova, T.N., Evtukhova, O.M. and Fedotova, I.Y., 2016. Production technology of bakery products containing processed artichoke and chokeberry products, with low yeast content. Baking in Russia.

Soukoulis, C., Yonekura, L., Gan, H.H., Behboudi-Jobbehdar, S., Parmenter, C. and Fisk, I., 2014. Probiotic edible films as a new strategy for developing functional bakery products: the case of pan bread. Food hydrocolloids, 39, pp.231-242.

Sun, D.W. ed., 2016. Handbook of frozen food processing and packaging. CRC Press.

Varzakas, T. and Tzia, C. eds., 2015. Handbook of food processing: food safety, quality, and manufacturing processes(Vol. 35). CRC Press.