TABLE OF CONTENTS

1. INTRODUCTION.....................................................................................................3

1.1 Description of the company...............................................................................3

1.2 Divisions in the company...................................................................................3

1.2.1 Production..........................................................................................................3

1.2.2 Sales..................................................................................................................3

1.2.3 Human Resource...............................................................................................3

1.2.4 Bakery Manager.................................................................................................3

1.2.5 Transport............................................................................................................4

1.2.6 Maintenance.......................................................................................................4

1.2.7 Administration + Finance....................................................................................4

1.2.8 Food Safety........................................................................................................4

1.3 Job Title...............................................................................................................5

1.3.1 Job Description..................................................................................................5

1.4 Organizational structure.....................................................................................6

1.5 Products...............................................................................................................7

2. THE PRODUCTION PROCESS.............................................................................8

2.1 Purpose of each unit operation........................................................................9

2.1.1 Raw Material Receiving.....................................................................................9

2.1.2 Premix................................................................................................................9

2.1.3 Mixing...............................................................................................................10

2.1.4 Divider and Rounder........................................................................................12

2.1.5 Intermediate Proofer........................................................................................13

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2.1.6 Moulder............................................................................................................14

2.1.7 Final Proofing...................................................................................................15

2.1.8 Oven Baking.....................................................................................................16

2.1.9 Depanning........................................................................................................19

2.1.10 Cooler.............................................................................................................19

2.1.11 Bagging, Slicing and Packaging.....................................................................21

2.1.12 Metal Detector................................................................................................22

2.1.13 Dispatch.........................................................................................................22

2.2 Critical factor that influence the safety and quality of final product......................22

3. DUTIES.................................................................................................................26

3.1 Routine duties...................................................................................................26

3.2 Administrative duties........................................................................................26

3.3 Ad hoc duties....................................................................................................26

4. ANALYTICAL TESTING.......................................................................................27

5. PRODUCTION......................................................................................................27

5.1 Materials and Methods........................................................................................27

6. EXTERNAL AND INTERNAL AUDITS.................................................................29

6.1 Internal Audits...................................................................................................29

6.2 External Audits..................................................................................................30

7. AD HOC DUTIES..................................................................................................30

7.1 Shelf life.............................................................................................................30

8. COMMENTS ON TUT TRAINING.........................................................................30

9. REFFERENCE......................................................................................................31

APPENDIX 1: TYPICAL NUTRITIONAL INFORMATION OF WHITE BREAD.........32

APPENDIX 2: TYPICAL NUTRITIONAL INFORMATION OF BROWN BREAD.......33

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1. INTRODUCTION

1.1 Description of the companySUNBAKE is a baking division of Foodcorp consumer brands, now a division of

Rainbow Chicken Limited (RCL) and it distributes bread and confectionery to four

provinces in South Africa namely Limpopo, Gauteng, Mpumalanga, and North West.

Sunbake manufactures brown, white, and crushed wheat bread and white

hamburger buns, super hamburger buns, seeded mega hamburger buns, hot dog

rolls and mega hot dog rolls (confectionery). Sunbake products are available at

major retailers like Shoprite, Pick ‘n Pay, and Spar and also at informal markets.

1.2 Divisions in the companyThe company consist of eight divisions namely production, sales, human resource,

management (bakery manager), transport, maintenance, administration (finance)

and food safety.

1.2.1 Production

Production is responsible for the manufacturing of bread and ordering raw materials

from suppliers. The department is responsible for supplying personal protective

equipment as well as providing Health and safety measurements to its staff.

1.2.2 Sales

Sales division is responsible for selling bread and looking for new customers in order

to expand business. They are involved in the distribution of goods and services.

1.2.3 Human Resource

Human Resource (HR) is responsible for hiring employees and making sure that the

workers are working under good conditions. HR is also responsible for giving

training to staff.

1.2.4 Bakery Manager

Bakery manager is responsible for managing the bakery. The manager oversees all

the activities in the bakery and is responsible in making sure that the bakery is

operating efficiently. The manager is also responsible for effective planning,

delegating, coordinating, organizing, and decision making to attain desirable profit for

the company. The manager’s responsibility also includes running the bakery and

providing leadership to heads of departments, supervisors and workers, to create a

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motivated working team which would improve productivity, save cost, deliver on time

and produce a quality service which will ensure long term employment for all.

1.2.5 Transport

Transport is responsible for transporting bread to customers and two depots, namely

Mafikeng and Potchefstroom. The department takes care of all the services of the

vehicles in the company to make sure all vehicles can deliver breads without

mechanical failures. Transport makes sure all vehicles are cleaned after deliveries

and making sure all vehicles are road worthy in line with the South African Transport

Laws. The transport manager hires in consultation with the Human Resources

Manager all the drivers and provides additional training to all drivers to make sure

they are competent.

1.2.6 Maintenance

Maintenance makes sure all production machines and equipments are operating

effectively and if there is a breakdown they must solve the problem. Maintenance is

also responsible for repairs in the building. They do all the maintenance work like

changing light bulbs, replacing windows, and painting of the building.

1.2.7 Administration (Finance)

Finance is responsible for paying salaries to all employees and managing sales.

They manage all the accounts used by all departments and making sure all accounts

are up to date by paying them on time. Administration officers perform a range of

administrative tasks to ensure an organization functions efficiently. Administration

officers use computers, software packages, fax machines, telephone systems, filing

systems, salary and leave record systems, photocopiers and binding machines.

They take orders from customers and supply them to production.

1.2.8 Food Safety

Food Safety ensures that the products produced on site are safe for human

consumption and they are of acceptable quality to the customer and consumer. The

team makes sure all products distributed or marketed is of high quality and shall

meet the demands of customers. Food Safety makes sure the company is clean and

GMPs (Good Manufacturing Practices) are implanted and the company is certified

with certain certifying bodies like Pick ‘n Pay and government health department. I

am employed in the Food Safety division. Food safety takes responsibility on

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customers’ complaint, raw material inspection, bread quality checks, dough weight

checks, training of production workers and management, shelf life testing, microbial

testing, bread evaluation, verification and calibration of scales and thermometers,

hygiene of staff and the whole plant. Uniform implementation of the standards such

as ISO 22000 and other requirements as specified by procedure is done by food

safety department

1.3 Job TitleFood Safety Technician.

1.3.1 Job Description

Food safety technician is responsible for making sure that the bread manufactured

at the facility is safe and will not harm consumers when prepared for its intended use

by implementing and maintaining Good Manufacturing Practices, Prerequisite

programmes (PRPs), and providing training to staff. A food safety technician must

conduct HACCP analysis and check the quality of the bread.

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1.4 Organizational structure

Figure 1.1 Company Organogram

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- Bakery Manager

-Production Manager

Production Supervisors

Production Personnel

Transport Mnager

Transport Clerk -

Machanics

Maintenance Manager

Technicians

Human Resource Manager

Sales Manager

Driver

Van Assistant

Promoters

Financial Manager

Admin

Dispatch

Food Safety controller

Food Safety Tech-

Richard Sebola

Pest Control

Company

Cleaning Company

1.5 ProductsAt Sunbake Rustenburg we manufacture three types of products namely sliced and

unsliced 700g brown bread, sliced and unsliced 700g white bread, and sliced 700g

crushed wheat bread. The product range of Sunbake Rustenburg is shown in figure

1. Typical nutritional information of brown and white bread is shown in appendix 1

and 2.

Figure 1.2: Sunbake Product Range (www.sunbake.com)

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2. THE PRODUCTION PROCESS

Figure 2.1: Unit operations

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Raw material receiving

Premix

Mixing

Divider

Rounder

Intermediate Proofer (First proofing)

Moulder

Second proofer (Final proofing)

Oven Baking & Deppaner

Cooler

Bagging and Slicing

Packaging

Despatch

2.1 Purpose of each unit operation

2.1.1 Raw Material Receiving

All raw materials are received by the store man and are checked for quality and any

deviations. If any raw material is found to be out of spec it is returned to the supplier.

All the raw material must come with a certificate of analysis (COA).

2.1.2 Premix

During premixing ingredients are weighed and mixed together in to the mixer. The

premix contains a combination of Minor Ingredients like emulsifiers, sugars and fat.

Fat gives dough a slightly softer, smoother feel. Without the fat, the bread will have

no oven sprig, will be lacking in colour and crumb softness, and will have a close

texture. Emulsifiers cause oil and water to mix. Emulsifiers are added to bread

dough for their bread softening properties and for the improvement of gas retention.

Sugars act as a source of food for yeast activity, a source of sweetness and

influences crust colour. In order to raise and condition a dough, yeast requires

energy food and the primary reason for the use of sugar in a bread dough is to

supply the yeast with a readily available source of energy. The yeast enzyme

(Saccharomyces Cerevisiae) acts on the sugar in the dough, thereby releasing

carbon dioxide gas which raises the dough and some alcohol which evaporates from

the dough during baking. The premix is then weighed according to specification in to

premix bins. The premix machine is shown figure 2.1

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Figure 2.2: Premix Machine

Each premix bucket must have a premix that has a specific weight. There are

several ingredients which make up a premix that goes in to a batch of bread. Other

ingredients include calcium which helps to preserve the bread, especially during

summer plus some health benefits. Salt has three main functions, it improves the

taste of bread, it affects the fermentation process and it toughens the gluten which

alters the texture and grain of the final product. Salt affects dough texture by making

it stronger and less sticky; it reduces oxidation of the dough during mixing. Oxidation

causes the degradation of carotenoid pigments in the flour that contribute to flavour

and crumb colour. Salt also regulates yeast activity, causing fermentation to

progress at a more consistent rate (Wildyeastblog). Bread made without salt will

have signs of excessive proof, an uneven surface, a poor colour and be on the verge

of collapse. If salt is increased to more than 2% the loaf will become smaller and

have little volume.

2.1.3 Mixing

The premix bin is the poured into the spiral mixer (Figure 2.2), were water, flour and

yeast are added. Water is an important ingredient for giving dough its consistency

and for controlling dough temperature. Water hydrates the flour proteins to produce

the visco-elastic substance known as gluten. It is the gluten that is largely

responsible for the ability of the dough to retain the gas that is produced by the

yeast. Water makes possible the pliable and extensible properties of the dough so

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that it can be raised by the carbon dioxide gas resulting from yeast activity. Water

also provides yeast with moisture for fermentation as yeast needs moisture to

ferment. When the dough is mixed, some of the water is absorbed by the flower

proteins, and some by the carbohydrates (starch and bran). The rest of the water

stays as free water and forms the so-called “water phase” of the dough in which

other ingredients such as salt and sugar are dissolved. Table 2.1 shows how each

flour component absorbs water.

Table 1.1: Flour water absorption

Components of flour % Water absorption %

Protein 12 30

Undamaged Starch 64 25

Damaged Starch 11 4

Yeast is responsible for raising or leavening the dough during proofing. Yeast is a

single-celled microscopic organism which reproduces by budding. Yeast requires

four basic factors in order to produce carbon dioxide, namely food, moisture, warmth

and time. S Cerevisiae has three principal functions in dough. It produces carbon

dioxide gas which expands the dough to the required volume and gives the light

sponge-like texture necessary for the production of bread with good eating

properties. It makes or develops the dough through the action of fermentation on the

gluten. Yeast also provides flavor through the production of complex chemical

compounds as by-products of the fermentation process. Cream yeast is used at our

bakery.

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Figure 2.3: Spiral Mixer

2.1.4 Divider and Rounder

After mixing then the dough is transferred to a divider (Figure 2.3) using a high lift.

The divider then divides dough into required loaf sizes. It is important the divider

operator makes sure that the weight of the dough piece is correct for the weight that

is required, and that the machine runs at a speed that is appropriate for the speed of

the plant. After the dough piece has been cut by the divider it passes through a

process of rounding or first moulding, which provides the dough piece with a regular

shape before it enters the intermediate proofer. The rounder (Figure 2.4) does two

important things, it squeezes out surface bubbles; and it gives a round shape which

helps with the machining of the dough. The dough pieces that emerge from the

divider are also sticky, warm air is used during rounding to give the dough pieces a

smooth surface which is non-sticky.

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Figure 2.4: Divider dividing dough Figure 2.5: Rounder

2.1.5 Intermediate Proofer

The dough is then rested for about 5 minutes, this way the dough will not be sticky

and rubbery and it will easily go through the moulder rollers without tearing. The

intermediate proofer allows the gluten in the dough piece to relax and reform after all

the cutting and tearing that it has gone through. There is an Ultra Violet (UV) light at

the top of the proofer which inhibits the growth of mould on the pockets which hold

the dough pieces. The intermediate proofer is shown in figure 2.5

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Figure 2.6: Intermediate Proofer (Sunbake, 2015)

2.1.6 Moulder

After leaving the intermediate proofer, the dough piece is shaped by the final

moulder (Figure 2.7) into a “Swiss roll” shape. It then passes under a sealing board

which tightens up the shape and determines the correct length of the dough piece.

The moulder is responsible for shaping the dough piece into a cylindrical or sausage

loaf prior to being deposited in the pan. The moulding process will also squeeze and

subdivide any large gas bubbles that may have formed to produce a finer and more

regular cell structure. After moulding, the dough piece is then automatically

transferred to the baking pan.

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Figure 2.7: Moulder

2.1.7 Final Proofing

The purpose of the final proofer is to control the time it takes for the dough to rise to

a particular height by providing a controlled environment of warmth and humidity.

The warmth causes the yeast to produce the carbon dioxide gas at the required rate

and the humidity prevents a skin forming on the surface and therefore allows the

surface to be flexible to expansion without cracking (SA Chamber of Baking, 2010).

Final proofing gives yeast time to ferment, which allows the moulded dough to relax

and expand (rise to pan level). The proofer is maintained at a temperature of 40-

45C and a relative humidity of 65-80%. During proofing starch is converted into

sugars via enzyme alpha-amylase action. The sugars feed the yeast and yeast uses

the carbohydrates in the absence of oxygen to produce carbon dioxide and alcohol.

The carbon dioxide then causes the dough to rise as it is retained in the cells formed

in the protein matrix. The proofer takes about one hour to raise the dough to a

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desired level. The proofer capacity is 4116 dough in pans and the throughput Figure

2.7 shows the proofer outside and figure 2.8 shows the proofer inside.

Figure 2.7: Outside view of the proofer Figure 2.8: Inside view of the proofer

2.1.8 Oven Baking

The oven (Figure 2.14) is used to bake the bread at a temperature of 230-260 ̊C. In

the oven there are four baking chambers; chamber one, chamber two, chamber

three and chamber four to allow the bread to be exposed to controlled heat at

different stages in the travelling Oven. Development chamber (Chamber one) is kept

slightly at 230°C - 250°C to allow the initial setting of the bread to occur as quickly as

possible. To provide moist conditions to permit elasticity in the dough skin, this

chamber is injected with moisture through the steam valves. Steam is used to keep

the crumb soft, thus allowing the bread to expand freely. The steam that has settled

on top of the bread dissolves sugars in the dough, as the bread stops expanding and

the steam begins to evaporate, the sugars are left behind to caramelize and create a

glossy crust (Steam is important in the first five to 10 min of baking). Baking

chamber (chamber one & two) is kept at 240°C - 260°C and is the main body of the

oven, where heat is transferred into the core of the bread. This is to attain stability of

the starch structure through gelatinisation, because proteins originally responsible for

the dough structure and gas retention become denatured. In the baking chamber,

maximum air circulation is required to aid heat transfer. Finishing chamber (chamber

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four) is kept at 210°C - 230°C and it is responsible for the development of the crust

colour and bread flavour. Bread core temperature must reach 95°C to complete the

gelatinisation of the starch and to destroy most bacteria that may otherwise cause

pot-baking spoilage to the product. The bread changes physically, chemically and

biochemically. Caramelization and the Maillard reaction are two major thermal

chemical reactions that occur during baking, contributing to the browning of the crust

and the flavour and aroma of the bread. During baking, starch gelatinization occurs

at about 60C and completes at 90°C. The starch granules absorb any free water in

the dough, causing an increase in viscosity of the dough. This causes the bread

crumb structure to stabilize. The activity of fungal alpha-amylase is deactivated at

60C. The Maillard reaction is a chemical reaction of nitrogen compounds from the

denatured proteins and sugar. This results in the bread crust gaining its brownish

colour on the surface of the crust. Caramelization results from the browning that

occurs when sugar is heated to about 150°C. Sugar at the surface of the loaf is able

to reach this high temperature because of the evaporation of water. Oven ensures

food safety of the final product by killing any possible harmful microorganisms in the

dough and evaporates the alcohol produced by yeast. Oven baking also provides a

good quality final color of the bread. Figure 2.9 shows how the bread looks like after

three minutes. Figure 2.10 to 2.11 shows how the bread is developed before the

final stages of baking. After about 18 minutes the bread is done baking and is ready

for cooling. Figure 2.12 shows how the bread looks like after 18 minutes. All the

pictures from figure 2.10 to figure 2.12 are from South African chamber of baking.

The actual speed of the oven is 20 minutes 55.10 seconds (20.92 minutes) and the

theoretical speed is 20 minutes 51.30 seconds (20.85 minutes). The oven capacity

is 4245 loaves and the rows in the oven is 70.47 (rows of pans).

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Figure 2.9: Baking time: 3 Minutes Figure 2.10: Baking time: 6 Minutes

Figure 2.11: Baking time: 12 Minutes Figure 2.12: Baking time: 18 Minutes

Figure 2.14: Oven releasing pans after baking (Sunbake, 2015)

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2.1.9 Depanning

After the bread is baked, it is conveyed to the depanner (Figure 2.14) were it is

“depanned,” taken out of the baking pans. The depanner operates by suction cups,

which suck the bread out of the pans by means of compressed air.

Figure 2.15: Depanner removing bread from the baking pans (Sunbake, 2015)

2.1.10 Cooler

The bread is then conveyed to the cooler (Figure 2.15). Here the bread will be

cooled to a temperature above 23C before it is sliced and packaged otherwise the

crumb will be warm and gummy, causing a mechanical problem at the slicer. The

warm bread will also cause an undesirable moisture condensation inside the

package (Bakerpedia). During cooling, the baked bread loses moisture, dry out and

intensify in flavor. The starch in the loaf start retrogradating, helping setting the

crumb texture (Bakerpedia). Figure 2.16 shows the inside of the cooler with white

bread. This whole cooling process takes approximately one hour. Because the

cooler has 4 different sides in it, it has four different temperatures which are shown in

table 2.2

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Figure 2.16: Outside view of the cooler (Sunbake, 2015)

Figure 2.17: Cooler with white bread inside (Sunbake, 2015)

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Table 2.2: Different temperatures inside the cooler

Temperature (C)

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Position in the cooler

Down drum

12 Down drum for side

15 Up drum

14 Up drum far side

2.1.11 Bagging, Slicing and Packaging

After cooling, the bread is sliced into the slice width of 15mm (13-16mm acceptable).

The bread with the same slice thickness has a pleasing appearance and is easier to

use. If the bread is not evenly sliced it might indicate a broken blade or uneven

tension in the blade frame. Consumer trends have changed in the past years, now

consumers require sliced bread because they don’t have to cut it at home. After

slicing, the bread is packaged into a branded Sunbake plastic bag. The plastic bag

is then printed the best before (BB) date on its back. We print the best before date

for safety reason, letting our customers know when it is safe to consume the bread.

The BB date indicates the shelf life of the bread. The Julian Date, also printed on

the bag, indicates the day of the year which the bread was manufactured, i.e., if the

number says 113, it means the bread was produced in the 113 th day of the year.

Line number and time are also printed on the bag to help with traceability and recall.

The bread must not be packed too tightly or too loose. If the bread is packed too

tightly, the bread will feel hard and the slices will be damaged. The bread might also

be seen by a potential customer to be smaller than the competitor’s loaf. If the bread

is packed too loosely, the slices will fall around in the bag and look unappetizing.

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2.1.12 Metal Detector

Because most of the equipments used in the factory are metals, we are required to

have a metal detector in place. The metal detector (Figure 2.17) serves as a critical

control point. No bread which contains metal will pass the metal detector if it is

operating efficiently. The metal detector is able to detect three types of metals such

as ferrous, non-ferrous and Stainless steel

Figure 2.18: Bread passing through a metal detector

2.1.13 Dispatch

Dispatch cages are storage areas for finished product, to be loaded into trucks for

distribution. The cages are checked for pests and cleanness.

2.2 Critical factor that influence the safety and quality of final product.Metal Detector is one of the most important critical factors. It influences the safety of

the product. Without it, the metal inside the bread, if any, will pass undetected and

will harm the consumer. The oven is also a critical factor, as it ensures that all the

harmful microorganisms in the bread die because of the high baking temperatures.

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The cooler also affects the quality of the bread, it makes the bread soft and because

the starches in the loaf start retrogradating during cooling, the crumb texture sets.

Sieving and Inspection is done during premix, before the premix is poured into the

premix bins, the premix passes through the sieve, were all foreign objects are

sieved. Some of the bread faults are shown in table 2.2.

Bagging and slicing is also a major factor affecting quality. The loaf can be

squashed with dented sides (Figure 2.19), the packaging can be too lose (Figure

2.20) or too tight (Figure 2.21). If the tension is not set on the right parameter when

packaging the bread, it can be too loose or too tight. If the loaf is too tight it might

look smaller than the competitor’s loaf and if the loaf is too loose it will look

unappetizing. So it is very important to control the technical side of the machines to

make sure they are operating effectively.

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Figure 2.19: Bread dented on sides (Sunbake, 2015)

Figure 2.20: Packaging too loose (Sunbake, 2015)

Figure 2.21: Packaging too tight, bread appears smaller (Sunbake, 2015)

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Table 2.3: Bread faults

Mould and rope Cause Corrections

No anti-rope agent used

Unhygienic bakery added

Bread not cooled down

Add anti-rope agent

Clean bakery daily

Cool bread down rapidly

after baking

Collapsed bread Cause Corrections

Incorrect recipe

Too little yeast

Under mixed

Check recipe

Add more yeast

Increase mixing time

SIDES COLLAPSING Cause Corrections

Too much premix

Too much yeast

Too much malt flavour

Add correct premix level

Reduce yeast level

Reduce malt flavor

dosage

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3. DUTIES

3.1 Routine duties Bread quality checks

Bread quality retention( Shelf life Evaluation)

Bagging and slicing check

Dispatch bread weight checks

Weekly Good Manufacturing Practices (GMP) inspection

Weekly glass and brittle plastic inspection

Verification of scales and thermometers

Corrective action recordings and monitoring

Daily personal hygiene inspection

Approved jewellery checks

Sampling of microbial testing

Daily chlorine checks

Process control (Temperature monitoring)

Locker inspection

Ambient temperature monitoring

3.2 Administrative duties Photocopying and faxing

Distribution of food safety papers

Receiving calls

Receiving and filing food safety documents

3.3 Ad hoc duties Preparation of audits (External)

Helping in giving training to production staff

Shelf life testing

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4. ANALYTICAL TESTINGAt Sunbake we collect samples and send them to SWIFT laboratory. Product testing

is done every month and we rotate the products each month. Equipments are tested

every month. Air monitoring on the hand driers are done one in three months. All

other the ingredients are rotated each month. Water testing is done every month.

Bread shelf life is done twice a year. Total microbial activity (TMA), coliforms, E.coli,

Yeast and Mould, Salmonella and Staphylococcus are tested over a period of five

days compared to monthly testing which the mentioned microorganisms are tested

for one day only.

5. PRODUCTION

5.1 Materials and MethodsBread quality checks: Texture, taste, wrap, crust colour were checked and given a

score on a scale of one to three, were one = reject, two = standard and three =

excellent. Bread was weighed on a scale and the mass recorded. The bread weight

must be 700g but a defect weight of 610-710 was accepted and the resulting

variance was recorded in percentage. Correct packaging information was also

checked.

Bread quality retention: The bread was placed on a shelf for five days to see if it

retained its qualities. During these five days, texture, crust colour and shape of the

bread were inspected.

Bagging and slicing check: Slice thickness was checked using a ruler and the slice

thickness is within specification. The BB date was also checked behind the package

of the bread. If the printer was not printing, maintenance was informed to fix the

printer.

Dispatch bread weight checks: A crate containing eight loaves of bread was taken on

the conveyer belt and each bread loaf in the crate was weighed to check if the bread

was within the specification.

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Weekly Good Manufacturing Practices (GMP) inspection: Every week GMP

inspections were conducted and the facilities were inspected for good housekeeping

and insects were also inspected. For checklist see appendix 1.

Weekly glass and brittle plastic inspection: Glass and brittle plastic were inspected

once a week and checked if they are not broken. Lights, lights covers, equipment

screens and buttons, dispensers and camera lenses were some of the thing

inspected.

Verification of scales and thermometers: A 500g 0r one Kg weight was used to verify

the scales. The weight is put on top of a scale and the reading on the scales

recorded. The reading must be that of a weight (500g or 1 Kg)

Daily personal hygiene inspection: General hygiene of personnel was checked. Nails

were checked and must be short and clean. All personnel were inspected for strong

perfume which is not allowed in production. All personal protective equipment (PPE)

must be clean and no eating must be done in production.

Approved jewellery checks: All jewelleries on personnel was checked and recorded.

All jewelleries worn were either medical, traditional, spectacles or wedding bands.

Sampling of microbial testing: Every month, once a month, microbial samples were

collected and sent to SWIFT laboratory.

Scales were rubbed with a swab for testing of TMA and personnel hands were

rubbed between fingers for testing.

One ingredient was taken aseptically for testing for certain microorganisms

which are not allowed to be disclosed to the public.

Bread: Every month, bread (brown, white or crushed wheat) was sent for

normal microbial testing. TMA, Coliforms, E. coli, yeast and mold,

Staphylococcus aureus and Salmonella were tested.

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Water: Water sample were collected from the tap using sterile sampling

bottles ordered from swift laboratories for faecal Coliform, coliform bacteria, E.

coli and TMA testing.

Air testing was done on air that comes in contact with hands of personnel and

air that comes into contact with product. Air sample was taken from hand

drier and a depanner by exposing the petridish to the air.

Daily chlorine checks: Chorine test strip was placed inside the water and the reading

was recorded.

Process control (Temperature monitoring): A thermometer was used to check dough

temperature after mixing and after divider. After baking the core temperature of the

bread was checked to verify is it falls within specification. Water temperature at

mixer was also recorded. The bread temperature after cooling was checked and

recorded.

Locker inspection: All personnel lockers were inspected for cleanliness and pest

infestation.

Ambient temperature monitoring: A thermometer was placed in the air to check the

area temperature.

6. EXTERNAL AND INTERNAL AUDITS

6.1 Internal AuditsInternal audits are conducted every week, once a week, and the facilities, personnel,

and equipments were all audited. Audits are conducted and reported the relevant

department for auctioning. Find the criteria used in appendix one. The results of the

audit were satisfactory as the score would always be above 90%. The cleaning

company is good and always makes the place is clean and the staffs are given

training on food safety and GMPs, thus the audits are satisfactory every week.

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6.2 External AuditsThe Certification Audits are conducted by Certifying bodies (e.g. DQS) on a yearly

basis to assess the Food safety Status at the bakery. Customers (Pick n Pay) also

do audits. All head of departments are involved in the audit. Sunbake Rustenburg is

Currently ISO22000:2005 certified.

DQS (ISO 2200:2005) audit once a year (December).

Pick n’ Pay (Intertek) audit once a year (June). SANS 10049 requirements

prerequisite programs (PRPs), ISO/TS 22002 PRPs on food safety, Codex Hazard

Analysis Critical Control Point (HACCP), Food Safety Management System

requirement as guided by the Global Food Safety Initiative (GFSI) and applicable

laws, regulations and compulsory specifications are all audited.

7. AD HOC DUTIES

7.1 Shelf lifeThe purpose of the project is to check if the bread doesn’t expire within 5 days. A

loaf of bread is taken to SWIFT laboratory and the bread was tested for TMA,

coliforms, E.coli, Yeast and Mould, Salmonella and Staphylococcus. These

microorganisms are checked on second day after production until the last day of the

expiry date (BB) date to check if the product is safe to be consumed until expiry date.

This was done once a year.

8. COMMENTS ON TUT TRAININGTUT training was very important for me as some of the activities I did in the TUT

laboratory like taking swabs helped me to take swabs at the industry. The subject

Food Technology was important because it gave me and idea of GMPs. The subject

Food Quality Assurance has taught me many things like packaging information,

giving consumers a quality product which will in turn grow the business.

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9. REFFERENCEDr LATEGAN. 2011. Food safety manual, SABS Standards Division. Pretoria.

h t tp : / /www.sunbake .co .za

h t tp : / /www.bakerped ia .com/ in te rmed ia te_proo f ing /

http://www.wildyeastblog.com/worth-its-salt/

LEGRAS, J.L., MERDINOGLU, D. & CORNUET, J.M. 2007. Bread, beer and

wine: Saccharomyces cerevisiae diversity reflects human history. 16: 2091–2102. 

MONTVILLE, T.J., MATTEWS, K.R., & KNIEL, K.E. 2012. Food Microbiology: an

introduction 3rd Edition. Pages 283-284.

South African Chamber of Baking, 4th edition. 2010. Certificate in the theory of

Breadmaking.

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TYPICAL NUTRITIONAL INFORMATION

Per 100g Per single serving of 

150g (3-4 slices)

%N

RV1

Energy (kJ) 963 1444

Protein (g) 9.3 13.9 25Glycaemic carbohydrate (g)

of which total sugar (g)

41 62

7.1 10.7

Total fat (g)

of which Saturated fat (g)

1.7 2.6

0.5 0.8

               Trans fat (g) 0.0 0.0

               Monounsaturated fat (g) 0.3 0.5

               Polyunsaturated fat (g) 0.9 1.4

Cholesterol 0.0 0

Dietary fibre2 (g) 5.4 8.1

Total Sodium (mg) 400 600

Vitamin A (µg) 70 105 12Thiamine (mg) 0.3 0.4 32Riboflavin (mg) 0.1 0.2 16Niacin (mg) 4.2 6.2 39Pyridoxine (mg) 0.3 0.4 24Folic acid (µg) 74 111 28Vitamin D (I.U.) 215 323 54Calcium (mg) 324 486 37Iron (mg) 3.5 5.2 29Zinc (mg) 2 3 27

The nutritional information is based on the product as ready to eat.1 Nutrient Reference Value (NRV) for individuals 4 years and older2 The method used to determine dietary fibre is AOAC (Association of

analytical communities) 991.43

APPENDIX 1: TYPICAL NUTRITIONAL INFORMATION OF WHITE BREAD

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APPENDIX 2: TYPICAL NUTRITIONAL INFORMATION OF BROWN BREADTYPICAL NUTRITIONAL INFORMATION

Per 100g Per single serving of 

150g ( 3-4 slices)

%NRV1

Energy (kJ) 963 1444

Protein (g) 9.3 13.9 25Glycaemic carbohydrate (g)

of which total sugar (g)

41 62

7.1 10.7

Total fat (g)

of which Saturated fat (g)

1.7 2.6

0.5 0.8

               Trans fat (g) 0.0 0.0

               Monounsaturated fat (g) 0.3 0.5

               Polyunsaturated fat (g) 0.9 1.4

Cholesterol 0.0 0

Dietary fibre2 (g) 5.4 8.1

Total Sodium (mg) 400 600

Vitamin A (µg) 70 105 12Thiamine (mg) 0.3 0.4 32Riboflavin (mg) 0.1 0.2 16Niacin (mg) 4.2 6.2 39Pyridoxine (mg) 0.3 0.4 24Folic acid (µg) 74 111 28Vitamin D (I.U.) 215 323 54Calcium (mg) 324 486 37Iron (mg) 3.5 5.2 29Zinc (mg) 2 3 27

The nutritional information is based on the product as ready to eat.1 Nutrient Reference Value (NRV) for individuals 4 years and older2The method used to determine dietary fibre is AOAC 991.43 

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