Analysis of Buns & Rolls
Quality Control Solutions for Bakers of Buns & Rolls
Most people wouldn't think much about the bread they buy at the grocery store, but for those who manufacture this staple food, quality control is of the utmost importance. Here, we will look at some of the methods that manufacturers of buns & rolls use to ensure their products are of the highest quality. We will also discuss some of the common defects that can occur during production and how these defects can be identified and rectified.
Moisture and Compositional Analysis
Flour selection is an important first step in the production of buns and rolls. In fact, differences in flour composition from batch to batch can greatly affect the baking process. KPM provides NIR instruments to analyze the protein, moisture, starch, and ash content; all of which can have a significant influence on the final product.
Parameters Measured
Parameters Measured
Flour
Specification compliance, quality control, cost control, recipe development, brand protection
Ash, gluten, moisture, starch, protein
Supplier's location, incoming ingredients, lab
Wheat flours, corn flour, spelt flour, buckwheat flour, rice flour, rye flour, gluten-free flours
Dry Yeast
Specification compliance, quality control, cost control, recipe development, brand protection
Moisture
Incoming ingredients, at-line, lab
All types
Fat/Oil
Specification compliance, quality control, cost control, recipe development, brand protection
Fat/oil
Supplier's location, incoming ingredients, lab, online
All types
NIR Analysis Solutions
Additional Reading
Functional & Rheological Analysis
When producing buns and rolls – either in small batch artisanal facilities or large commercial operations – the functional or rheological properties of incoming flour may lend itself better to produce one product over another. There are several measurable parameters that can directly affect final product quality. KPM offers solutions to assist in understanding the functional & rheological characteristics affecting the final product in each batch to be produced.
Water Absorption
For burger buns, as an example, the required level of hydration is high (around 60%). The amount of water that any flour can absorb increases with high levels of protein, damaged starch (particle size) or pentosans. It is very simple to measure water absorption directly using the KPM solutions outlined below.
Stickiness
This often occurs when starch damage or pentosan levels are too high and the protein levels are too low. Sticky dough causes process machine problems when dividing and pressing tortillas. Measure starch with the SDmatic 2, and protein levels with the SpectraStar XT-F NIR Analyzer.
Dough Consistency
Dough consistency depends on the amount of water added and the ability of the flour to absorb it. This consistency changes during mixing, reflecting the formation of the gluten network. For any given level of hydration, the consistency of the dough represents its firmness. This depends on the quantity and quality of the proteins, the level of starch damage, and the pentosans. Mixing consistency may be measured during mixing or after rolling. It is also possible to individually measure the factors responsible for consistency: proteins, damaged starch, and pentosans.
Mixing consistency may be measured by either the Mixolab 2 or, after rolling by the Alveolab or AlveoPC. It is also possible to individually measure the factors responsible for consistency: proteins (NIR) and damaged starch (SDmatic 2).
Extensibility
Extensibility is directly measured using the Alveolab or AlveoPC. During the deformation of the ball, it stretches to where it reaches its breaking point, mainly influenced by the quality of the protein network. This corresponds to the "L" or "G" value on the Alveograph. Read more about extensibility here.
Elasticity
It takes a certain level of elasticity for the dough to be machinable. If the elasticity is too low, the dough won’t hold shape; if it is too high, the dough will tend to retract, which impacts the appearance of the finished product. Elasticity is measured directly and exclusively with the Alveolab or AlveoPC.
Volume
The volume of baguette is primarily influenced by the volume of CO2 produced by the yeast during fermentation. This volume is measured directly by the Rheo F4. The amount of CO2 produced depends on the intrinsic activity of the yeast and also the amount of simple sugars available. The latter is directly influenced by the activity of the amylases present in or added to the flour, which degrade a portion of the starch into simple sugars, usable by the yeast. Damaged starch, measured by the SDmatic 2, is more easily attacked by amylases. It therefore positively impacts the volume.
The volume is also dependent on the quality of the gluten network, measured with the Alveolab, AlveoPC, and the Mixolab 2. This determines the ability of the dough to develop during fermentation, and to retain the CO2 produced, measured with the Rheo F4.
Color
Baguettes are judged more or less appetizing by consumers according to their color. This parameter is essentially governed by the Maillard reaction, occurring during baking, which relates to the action of sugars on proteins. The more free sugars, the darker the crust will be. The color, as with the volume, is related to amylase enzyme activity and indirectly with the level of damaged starch (SDmatic 2).
Retrogradation
After baking, the starch will tend to partially recrystallize. This phenomenon is called retrogradation and explains why the products become hard (stale). The beginning of retrogradation is very easily measured with the Mixolab 2. Damaged starch has the effect of reducing the speed of retrogradation, it is measured with the SDmatic 2.
Analysis Solutions
Additional Reading
Vision Inspection of Buns and Rolls
Vision inspection is transforming quality control for commercial bakers. The ability to inspect visual characteristics such as bake color, shape, topping coverage, and volume simultaneously and at full line speed allows for rapid improvement in quality, thereby reducing waste, improving throughput, and consumer complaints. KPM offers at-line, over-line, and in-line vision inspection systems to assist manufacturers of buns and rolls with their quality control program.
Product Types
- Single products (Round, Hot Dog, Rectangular/Oval)
- Clusters (Round, Hot Dog)
- Plain or with topping
Measurement Capability
- 2D/Shape&Size - diameter, roundness, length, width (accuracy: 0.2mm)
- 3D/Height - peak height, complete 3D profile, slope, surface texture (accuracy: 0.3mm)
- Top & Bottom Color - bake color, topping color (Lab and BCU coordinates, accuracy: 0.2 ΔE)
- Topping/Seeding - coverage, distribution, voids (accuracy: 0.5% of product surface)
- Scoring/Split/Imprint conformity check
Defects Detection Capability
- Misshapen products
- Out of specification products (e.g. too small, too tall, etc.)
- Spots (light, dark, foreign material on product surface)
- Blisters/Blotchy
- Topping defects (e.g. too little seeds, voids, etc.)
- Scoring/Split/Imprint defects
Vision Products
Additional Reading
