QUALITY PARAMETERS Parameters Blend Processing Ingredients Taste XX XX Taste keepability XXX XX Homogenity X XXX Hardness XXX X Spreadability XXX X Heat stability XXX X XX Oral melt XXX X X Emulsion stability X XX XX Plasticity X XX X Baking performance X X XX shallow frying
FAT BLEND- Product characteristic defines N-line Spreadability from the refrigerator; N10 at ambient temperature; N20 Stability mainly N20 or N25 Heat stability at which temperature; N30? Oral melt and Taste mainly N35
FAT BLEND- Product characteristic defines N-line How to influence consumer requirements by the N-line Solids 40 30 20 Better spreadable More ambient stable Better oral melt and taste 10 10 20 30 35 Temperature
FAT BLEND- Product characteristic defines N-line 6,5 SFC at 20 C NMR 20 5.5 SFC at 35 C Control Chart: 35 derecedeki NMR 6,0 5.0 5,5 4.5 5,0 4.0 4,5 3.5 4,0 3,5 NMR 20 U Spec = 6,00 Average = 4,95 3.0 2.5 35 derecedeki NMR U Spec = 5 3,0 1 2 3 4 5 6 7 8 9 11 13 15 17 19 10 12 14 16 18 20 L Spec = 3,50 2.0 1.5 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 Average = 3.2 L Spec = 2 40 EN smp 38 36 34 EN 32 U Spec = 36 Average = 34,6 30 1 25 49 73 97 121 145 169 193 217 13 37 61 85 109 133 157 181 205 L Spec = 32
INGREDIENTS Almost all ingredients have an effect on the taste of the final product this can be positive / negative Ingredients like milkpowder, acids, salt and flavours (antioxidants) Specifying quality into ingredients but specify only what is relevant Buying the ingredients with analyses certificate from the approved suppliers Minimising stirring, pumping, storage time and temperature variations
INGREDIENTS - example Moisture,% ph Colour/appearance Total count Coliform Acid number Skimmed Milk Powder max.5 6.65±0.15 White, clean max. 100.000/g max.10 - Lecithin max.2 - Brown,viscous Max.5000/g - max.30 Peroxide - max.5
PROCESSING FAT FAT PHASE WATER PHASE EMULSION PREPERATION RESTING PACKAGING COOLING & CRISTALLISATION MIXING
PROCESSING FAT FAT PHASE WATER PHASE QC QC QC EMULSION PREPERATION QC QC RESTING QC PACKAGING COOLING & CRISTALLISATION MIXING
WATER PHASE MILK FAT TANK FAT PHASE FFA FFA IV SALT ph FFA ph TASTE COLOUR PHYSICAL PHYSICAL POV POV TASTE PHYSICAL SAMPLE AT FILLING EMULSION TANK COLOUR + MOISTURE WĐTH WATER WRAPPER & TUB FFA SALT ph MOISTURE COLOUR smp POV TASTE PHYSICAL WEIGHT SAMPLE AT FILLING BAKERY MARGARINES STORAGE ROOM TRANSPORT WITHOUT WATER SAMPLE AT FILLING INDUSTRIAL FATS FFA COLOUR smp POV IV TASTE PHYSICAL WEIGHT physıcal
31,00 30,50 30,00 29,50 29,00 28,50 28,00 27,50 WRAPPER MOISTURE CONTENT (%) 254 253 252 251 250 249 248 247 WRAPPER WEIGHT (gr) 27,00 1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 73 77 81 246 1 4 7 10 13 16 19 22 25 28 31 34 37 WRAPPER- SALT CONTENT (%) 4,9 PH 0,21 0,20 0,19 4,8 4,7 0,18 4,6 0,17 4,5 0,16 0,15 0,14 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 4,4 4,3 4,2 1 6 11 21 31 41 51 61 71 81 91 16 26 36 46 56 66 76 86 96 PH U Spec = 4,8 Average = 4,6
PRODUCT SPECIFICATIONS Criteria Wrapper & Tub Margarines Bakery Margarines Bakery & Industrial Fats * Fat, % 40-82 Min.82 Min.99 Water, % 16-60 max.16 max.1 * FFA,% max. 1 (0,5) max. 1 (0,5) max.0,2 * POV 0 0 0 ph (acidity) 4,4-4,7 2,5-4,5 - * smp max.36 max.45 max.45 Colour 3,5-5 R 3,5-5,5 R 5-6 R Salt, % 0,18-0,3 Max.0,2 - * TSE (Turkish Standarts Institute, Margarine Standart)
PROCESSING
MARGARINE QUALITY SENSORY EVALUATION & PERFORMANCE TEST
SENSORY EVALUATION Linking the Consumer to the Margarine Producer Sensory Evaluation Methods FOR TUB MARGARINES; Spreading on the bread Tasting FOR WRAPPER MARGARINES; Cooking Performance Baking Performance
PERFORMANCE EVALUATION Linking the BAKER to the Margarine Producer Performance Evaluation Methods Physical Tests Baking Performance Tests
PUFF PASTRY FATS & MARGARINES During the baking, Fat between the layers melts Layers opened Dough wides Crispiness increase The FAT be: Not broken easily Homogenous structure in good plasticity Not be sticky Rheologhy of the dough be equal to rheology of fat SFC at 20 ºC : % 38-42, at 30 ºC : % 18-23, at 35 ºC : % 12-16 smp: max.42ºc
Puff Pastry Performance Trial Mixing of Flour, water, salt & citric acid 800 gr.dough pieces rounded Cutting the doughs and resting
350 gr fat OR 375 gr margarine Fat is packed with the dough Placed in the middle of dough.
Dough rested 10-15 min. Then lamination 90 º turned, Laminated till 8 mm 3 turn Rest in refrigerator 45 min. Lamination
4-5 turns final thickness 7-8 mm Special device, cutting 1 hour resting
Baking at 240-260ºC 20 min. QUALITY CHECK
CONSTRAINTS Neutral taste good sticking to biscuit CREAM FATS BY Good refining deodorisation not too hard not too soft good creaming properties well plasticised homogeneous rapid setting good cooling effect crystallisation rate steep N-line SFC at 20 ºC : % 22-26, at 30ºC : % 8-12 at 35ºC : % 4-8 smp: max.38ºc
Cream Fat Performance Trial Whipping Performance is measured by specific volume 600 gr. fat %30 water +% 70 crystal sugar= sol n 10 min. Mixing at high speed (SP1) 600 gr fat + 250 gr.sol n mix 10min.(SP2) Cup weight with sample empty cup weight = SPESIFIC VOLUME(gr/cm 3 )(SP) cup volume Ideal Performance: SP1 < 0,3 g/cm 3, SP2 < 0,4 g/cm 3
ALL PURPOSE FATS & MARGARINES Bakery margarines Consistency/hardness not too hard at 10-15 ºC not too soft at 30-35 ºC Plasticity, Worksoftening Creaming perormance (high air intake) Taste keepability, Taste after baking SFC at 20 ºC : % 22-28 at 30 ºC : % 10-15 at 35 ºC : % 5-8 smp: max.40ºc
All Purpose Margarine Performance Trial Plasticity Control by hand Penetration measurements at 20 C and 30 C no air cracks, not easily broken, Not sticky
Volume, shape, colour of the product
CAKE PERFORMANCE Air keepability Volume Crumb and crust structure
INDUSTRIAL FATS & MARGARINES Industrial fats Crystallisation rate Fatty acid composition Rancimat Stability Consistency Colour Foaming / Smokepoint
Voice of Customer Listen the customer Get the complains Physical & chemical & performance controls Find out the reason of the problem Share the result with staff Inform the customer about the result
QUALITY for the HOUSEWIFE for the BAKER Proud of herself with delicious products the way of showing his expertise
for the R&D MANAGER QUALITY for the PRODUCTION CHIEF the best formulation for the product Production according to the specs
QUALITY For the QC MANAGER product without defect
QUALITY FOR the MARKETING MANAGER Increasing sales
QUALITY Customer satisfaction