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AIB International

Troubleshooting Bread Products

AIB International

Troubleshooting Bread Products

Troubleshooting—What Does It Mean?

• Who is a Troubleshooter?

• What exactly is a Troubleshooter?

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Troubleshooting Bread Products

Troubleshooting

Definition

• Webster defines ‘‘trouble shooter’’ as “a skilled workman employed to locate trouble and make repairs in machinery and technical equipment”.

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Troubleshooting Bread Products

Troubleshooting

Definition of a “Bakery Troubleshooter”

• In a bakery environment, a “trouble shooter” is a skilled baker who is able to determine the cause of why a product fails to meet the expected quality standards. Not only is the baker able to determine the contributing factors, but she or he is able to make the necessary formulation and/or processing adjustments to get the product quality back to where it should be.

AIB International

Troubleshooting Bread Products

Does the thing work ?

Did you mess with it ?

Don’t mess with it

Does anyone know ?

You Dummy

Hide it Will you be in trouble ?

Can you blame someone else?

You poor man / woman

Forget it

NO PROBLEMYES

NO

YES

YES

YES

NO

NO

NO

NO

Problem Solving Flowchart

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Troubleshooting Bread Products

The Premise Behind Troubleshooting

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Troubleshooting Bread Products

Root CauseAnalysis• Define problem• Review

•Documentation•Ingredients•Process

Decision Making• Assess risk• Form hypothesis• Assess cost/benefit• Testing

Implementation• Execute plan• Make changes

Communication

Cross-departmental Interviewing Facilitation Change Management

Listening Training

Troubleshooting Model

Problem Discovery• Scoring• Self-Inspection• Customer

complaints

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Troubleshooting Bread Products

The Four Buckets• People

– Are your people well trained?– Do they have the tools and

staff they need?• Ingredients

– Are the ingredients correct, fresh, and known to the staff?

• Process– Are correct procedures being followed by staff?– Is the machinery running correctly?

• Product– What is causing product faults?

AIB International

Troubleshooting Bread Products

AIB International

Troubleshooting Bread Products

AIB International

Troubleshooting Bread Products

Troubleshooting Ingredients

• Know and understand the ingredients

• Poor ingredients will give you a poor product even if all other steps are followed correctly

• The correct ingredients are the foundation to baking!

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Troubleshooting Bread Products

Troubleshooting Ingredients

• Quality factors in supplier network

– Quality of ingredients depend on supplier

– Supplier process affects ingredient quality

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Troubleshooting Bread Products

Troubleshooting Ingredients

• Quality factors in supplier network

– Establish clear ingredient specifications

– Have a good working relationship with supplier

– Price not only consideration, also value service from supplier

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Troubleshooting Bread Products

Troubleshooting Ingredients

• Quality factors in distribution channels

– Storage temperature important for ingredients

– Once received, use proper rotation

• Use FIFO stock rotation

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Troubleshooting Bread Products

Troubleshooting Ingredients

• Quality changes over time

– Ingredients can change in storage as they age

– Ingredients can change each crop year

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Troubleshooting Bread Products

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Troubleshooting Bread Products

Troubleshooting the Process

Quality Factors in Production

• Define standards

• Monitor variations

• Give feedback

• Monitor results

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Troubleshooting Bread Products

Troubleshooting the Process

Production Standards

• Mixing times, temperatures, water absorption

• Accuracy of ingredient scaling

• Cleanliness

• Fermentation times, temperatures, pH, TTA

• Equipment maintenance

• Equipment adjustments

• Proofing and baking times, temperatures, relative humidity

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Troubleshooting Bread Products

Troubleshooting the Process

Production Variables

• People/human errors

• Ingredient variations

• Mechanical failure/ malfunction

• Atmospheric variation

• Pan variation

• Differences in judgment

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Troubleshooting Bread Products

Troubleshooting Tools

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Troubleshooting Bread Products

Troubleshooting Tools:

• Calibrated thermometer

• Oven temperature logger

• Hygrometer

• pH meter and buret for TTA

• Process or line audit checklist

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Troubleshooting Bread Products

Calibrated Thermometer

• Sponge set and return temperature

• Dough temperature out of the mixer

• Pan return temperature

• Dough temperature out of proofer

– < 95°F (35°C)

• Internal temperature of product out of oven

– > 200°F (93°C)

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Troubleshooting Bread Products

Oven Temperature Logger

• Use of recording thermometers (oven-rated)

– Check side to side variations

– Check temperature at each level or zone

– Used to monitor internal temperature of dough

– Check temperatures over time

– Such as M.O.L.E. or Scorpion

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Troubleshooting Bread Products

Temperature Profile of Oven

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Troubleshooting Bread Products

Hygrometer

• Two thermometers

– Dry bulb

• An ordinary thermometer

– Wet bulb

• Thermometer with a wick on it

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Troubleshooting Bread Products

pH Meter

• Check pH and TTA

– Fermentation

– Proofed dough

– Finished product

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Troubleshooting Bread Products

Process or Line Audit Checklist

• Record of:

– Times

– Temperatures

– Equipment settings

– Relative humidity

– Scaling weights

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Troubleshooting Bread Products

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Troubleshooting Bread Products

Troubleshooting a Fault (Product)

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Troubleshooting Bread Products

Evaluating Product

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Troubleshooting Bread Products

Score Sheet

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Troubleshooting Bread Products

External Characteristics

• Volume: too big or too small

• Crust color: too dark or too light

• Symmetry: uneven or even

• Evenness of bake: light or dark spots?

• Break and shred: bursting, wild

• Character of crust: tough or brittle

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Troubleshooting Bread Products

Objective Tool—Volume Meter

• Objective measure of finished product volume

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Troubleshooting Bread Products

Internal Characteristics

• Grain: appearance of cell structure

• Texture: feel of surface of slice

• Color of crumb: color of open slice

• Slicing: ragged or thick/thin?

• Aroma: off aroma or yeasty?

• Taste: off flavors

• Mouth feel: dryness or gumminess

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Troubleshooting Bread Products

Conducting a Bake Test

• Variables to consider testing:

– Mixing series

– Absorption series

– Fermentation series

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Troubleshooting Bread Products

Conducting Bake Test

• Mix Time Series

Under mixed- 2 minutes6 minutes

Control 8 minutes

Over mixed+ 2 minutes10 minutes

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Troubleshooting Bread Products

Wheat Bread Mixing Series

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Troubleshooting Bread Products

Conducting Bake Test

• Absorption Series

Under absorbed- 2% water

58%

Control 60%

Over absorbed+2% water

62%

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Troubleshooting Bread Products

Absorption Series

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Troubleshooting Bread Products

Wheat Bread Absorption Series

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Troubleshooting Bread Products

Conducting Bake Test

• Fermentation Series

Lessfermentation

3 hours

Control 4 hours

Morefermentation

5 hours

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Troubleshooting Bread Products

Wheat Bread Fermentation Series

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Troubleshooting Bread Products

Conducting Bake Test • Combinations of variables (9-point bake)

Mix time

Absorption

Control

+ 2%

- 2%

Control- 2 minutes + 2 minutes

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Troubleshooting Bread Products

Conducting Bake Test

• Combinations of variables (5-point bake)

Mix time

Absorption

Control

+ 2%

- 2%

Control- 2 minutes + 2 minutes

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Troubleshooting Bread Products

Conducting Bake Test

• Combinations of variables (3-point bake)

Mix time

Absorption

Control

+ 2%

- 2%

Control- 2 minutes + 2 minutes

AIB International

Troubleshooting Bread Products

Top 5 Troubleshooting Faults

• Mold or poor shelf-life

• Rounded corners/rough, ragged break and shred/open crumb structure

• Poor flavor

• Unattractive crust (spots and blotchiness)

• Grain (too open or too closed)

AIB International

Troubleshooting Bread Products

Thank You!!

Questions?????