Manley’s technology of biscuits, crackers and cookies © Woodhead Publishing Limited, 2011 Related titles: Biscuit, cracker and cookie recipes for the food industry (ISBN 978-1-85573-543-9) This book provides a comprehensive collection of over 150 standard commercial biscuit recipes and provides the ideal companion to the fourth edition of Duncan Manley’s Technology of biscuits, crackers and cookies. It is designed for the biscuit product developer as an aid in the task of creating and perfecting a biscuit product. Biscuit, cookie and cracker manufacturing manuals (Volumes 1–6) ‘For anyone involved in the complex field of biscuit technology, the name of Duncan Manley will be well known. These manuals take the reader through the entire process from basic ingredients to packaging, wrapping and storage, looking at such issues as quality, safety, maintenance and troubleshooting.
All in all they are a useful set of guides full of practical tips for both expert and novice alike.’ Biscuit World Volume 1: Ingredients (ISBN 978-1-85573-292-6) Volume 2: Biscuit doughs (ISBN 978-1-85573-293-3) Volume 3: Biscuit dough piece forming (ISBN 978-1-85573-294-0) Volume 4: Baking and cooling of biscuits (ISBN 978-1-85573-295-7) Volume 5: Secondary processing in biscuit manufacturing (ISBN 978-1-85573-296-4) Volume 6: Biscuit packaging and storage (ISBN 978-1-85573-297-1) Details of these books and a complete list of Woodhead’s titles can be obtained by: • visiting our web site at www.com • contacting Customer Services (e-mail: sales@woodheadpublishing.com; fax: +44 (0) 1223 832819; tel. 130; address: Woodhead Publishing Limited, 80 High Street, Sawston, Cambridge CB22 3HJ, UK) • contacting our US office (e-mail: usmarketing@woodheadpublishing.: (215) 928 9112; address: Woodhead Publishing, 1518 Walnut Street, Suite 1100, Philadelphia, PA 19102-3406, USA) If you would like to receive information on forthcoming titles, please send your address details to: Francis Dodds (address, tel. and fax as above; e-mail: francis. Please confirm which subject areas you are interested in.
© Woodhead Publishing Limited, 2011 Woodhead Publishing Series in Food Science, Technology and Nutrition: Number 217 Manley’s technology of biscuits, crackers and cookies Fourth edition Edited by Duncan Manley Consultant, Duncan Manley Limited, Stamford Email: dmanley@duncanmanley.com Oxford Cambridge Philadelphia New Delhi © Woodhead Publishing Limited, 2011 Published by Woodhead Publishing Limited, 80 High Street, Sawston, Cambridge CB22 3HJ, UK www.com Woodhead Publishing, 1518 Walnut Street, Suite 1100, Philadelphia, PA 19102-3406, USA Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road, Daryaganj, New Delhi – 110002, India www.com First edition 1982, Ellis Horwood Limited Second edition 1991, Ellis Horwood Limited Third edition 2000, Woodhead Publishing Limited and CRC Press LLC Fourth edition 2011, Woodhead Publishing Limited © Duncan Manley, 2011 except: Chapter 5 © Duncan Manley and Malcolm Wilkes, 2011; Chapters 9 and 28 © Duncan Manley, Bram Pareyt and Jan Delcour, 2011; Chapters 7, 12, 20, 31 © Woodhead Publishing Limited, 2011 The authors have asserted their moral rights. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the authors and the publisher cannot assume responsibility for the validity of all materials.
Neither the authors nor the publisher, nor anyone else associated with this publication, shall be liable for any loss, damage or liability directly or indirectly caused or alleged to be caused by this book. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming and recording, or by any information storage or retrieval system, without permission in writing from Woodhead Publishing Limited. The consent of Woodhead Publishing Limited does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from Woodhead Publishing Limited for such copying.
Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Library of Congress Control Number: 2011935504 ISBN 978-1-84569-770-9 (print) ISBN 978-0-85709-364-6 (online) ISSN 2042-8049 Woodhead Publishing Series in Food Science, Technology and Nutrition (print) ISSN 2042-8057 Woodhead Publishing Series in Food Science, Technology and Nutrition (online) The publisher’s policy is to use permanent paper from mills that operate a sustainable forestry policy, and which has been manufactured from pulp which is processed using acid-free and elemental chlorine-free practices. Furthermore, the publisher ensures that the text paper and cover board used have met acceptable environmental accreditation standards.
Typeset by Toppan Best-set Premedia Limited Printed by TJI Digital, Padstow, Cornwall, UK © Woodhead Publishing Limited, 2011 Contents Contributor contact details. xvii Woodhead Publishing Series in Food Science, Technology and Nutrition. xix Preface to the fourth edition. xxvii Preface to the third edition.
xxix Preface to the second edition. xxxi Preface to the first edition. xxxiii 1 Setting the scene: A history and the position of biscuits. Manley, Consultant, Duncan Manley Ltd, UK 1.2 The beginnings of biscuit manufacturing .3 Ingredients and formulation development .5 References and useful reading.
9 Part I Management of technology in biscuit manufacture. 11 2 The role of the technical department in biscuit manufacture. Manley, Consultant, Duncan Manley Ltd, UK 2.2 The requirements of the technical (or technology) department .3 Selection of staff for the technical department .4 Facilities for the technical department .5 Liaison with other technical establishments .6 Support for purchasing .7 Support for training .8 Management of technical developments. 22 © Woodhead Publishing Limited, 2011 vi Contents 3 Quality management systems and hazard analysis critical control point (HACCP) in biscuit manufacture.
Manley, Consultant, Duncan Manley Ltd, UK 3.2 Management of product safety. 28 4 Quality control and good manufacturing practice (GMP) in the biscuit industry. Manley, Consultant, Duncan Manley Ltd, UK 4.1 Principles and management .2 Quality control tasks for finished product inspection .3 Quality control tasks for ingredient and packaging materials .4 Good manufacturing practice (GMP). 40 5 Process and efficiency control in biscuit manufacture.
Manley, Consultant, Duncan Manley Ltd, UK and M. Wilkes, MW Associates, UK 5.1 Process control and efficiency .3 Process control checks and records for plants with no continuous monitoring sensors .4 Making process control measurements .5 Action procedures as a result of product measurements .6 Instrumentation for monitoring .7 Efficiency and integrated plant control .8 Outline of the instrumentation that is available .12 Useful reading and suppliers of instruments. 67 6 Product development in the biscuit industry. Manley, Consultant, Duncan Manley Ltd, UK 6.3 Facilities for process and product development .5 Establishing the product specification .6 Management of product development.
92 7 Sustainability in the biscuit industry. Brightwell, United Biscuits, UK 7.2 Key drivers for sustainability in the biscuit industry. 94 © Woodhead Publishing Limited, 2011 Contents vii 7.3 Carbon emissions and energy use .4 Reducing water use .7 Other options for improving sustainability. 102 Part II Materials and ingredients for biscuit manufacture.
105 8 Choosing materials for biscuit production. Manley, Consultant, Duncan Manley Ltd, UK 8.2 Important technical aspects .3 Important commercial aspects .4 Programme for the meeting with a supplier. 108 9 Wheat flour and vital wheat gluten as biscuit ingredients. Manley, Consultant, Duncan Manley Ltd, UK and B.
Delcour, Katholieke Universiteit Leuven, Belgium 9.2 Flour from the viewpoint of the miller .3 Flour from the viewpoint of the biscuit manufacturer .4 Vital wheat gluten. 133 10 Meals, grits, flours and starches (other than wheat). Manley, Consultant, Duncan Manley Ltd, UK 10.2 Cereal-based materials .3 Non-cereal flours and starches .5 Useful reading and addresses. 141 11 Sugars and syrups as biscuit ingredients.
Manley, Consultant, Duncan Manley Ltd, UK 11.2 Common sugar, sucrose .4 Sugars and syrups from starches – glucose .5 Non-diastatic malt extract. 159 12 Fats and oils as biscuit ingredients. Atkinson, AarhusKarlshamn UK Ltd, UK 12.2 The role of fat in biscuits. 161 © Woodhead Publishing Limited, 2011 viii Contents 12.3 The chemistry and physical properties of fats .4 Quality and handling issues of fats .5 Key characteristics of fats for biscuits .6 Quality control of fats .7 General specification requirements for oils and fats .8 Challenges for the biscuit manufacturer.
180 13 Emulsifiers (surfactants) and antioxidants as biscuit ingredients. Manley, Consultant, Duncan Manley Ltd, UK 13.2 Function of emulsifiers in biscuits .3 Types of food emulsifiers .4 Reduced fat biscuits .5 General use of emulsifiers in biscuit doughs. 190 14 Milk products and egg as biscuit ingredients. Manley, Consultant, Duncan Manley Ltd, UK 14.2 Milk and milk products.
198 15 Dried fruits and nuts as biscuit ingredients. Manley, Consultant, Duncan Manley Ltd, UK 15.3 Other dried fruits used in biscuits .4 Fruit pastes and syrups .6 Peanuts, arachis or ground nut .7 Health problems associated with nuts. 208 16 Yeast and enzymes as biscuit ingredients. Manley, Consultant, Duncan Manley Ltd, UK 16.
215 © Woodhead Publishing Limited, 2011 Contents ix 17 Flavours, spices and flavour enhancers as biscuit ingredients. Manley, Consultant, Duncan Manley Ltd, UK 17.2 Sources and types of flavours .3 Suitability of a flavour material .4 Flavouring of biscuits.6 Storage of flavours and quality control. 222 18 Additives as biscuit ingredients. Manley, Consultant, Duncan Manley Ltd, UK 18.
234 19 Chocolate and cocoa as biscuit ingredients. Manley, Consultant, Duncan Manley Ltd, UK 19.2 The flavour of chocolate.4 Cocoa butter, cocoa butter equivalents and hard butters .5 Definitions of cocoa and chocolate products .6 Types of chocolate .7 Supply and storage of chocolate .8 Chocolate drops and chips .10 Handling of chocolate and chocolate chips. 245 20 Packaging materials for biscuits and their influence on shelf life. Robertson, Food•Packaging•Environment and University of Queensland, Australia 20.3 Packaging and shelf life .4 Indices of failure (IoFs).5 Package requirements to address indices of failure (IoFs).
267 © Woodhead Publishing Limited, 2011 x Contents Part III Types of biscuits. 269 21 Classification of biscuits. Manley, Consultant, Duncan Manley Ltd, UK 21.2 Classification based on enrichment of the formulation .3 Conversion of units. Manley, Consultant, Duncan Manley Ltd, UK 22.1 History and introduction to cream crackers .2 Mixing and fermentation of cream cracker doughs .3 Dough piece forming .4 Baking of cream crackers.5 Yields from fermented doughs.
Manley, Consultant, Duncan Manley Ltd, UK 23.3 Outline of typical soda cracker manufacturing techniques. 297 24 Savoury or snack crackers. Manley, Consultant, Duncan Manley Ltd, UK 24.3 Post-oven oil spraying. 302 25 Matzos and water biscuits.
Manley, Consultant, Duncan Manley Ltd, UK 25. Manley, Consultant, Duncan Manley Ltd, UK 26.2 Puff dough preparation .3 Baking of puff biscuits .4 Puff biscuit production techniques. 311 © Woodhead Publishing Limited, 2011 Contents xi 26. 311 27 Hard sweet, semi-sweet and Garibaldi fruit sandwich biscuits.
Manley, Consultant, Duncan Manley Ltd, UK 27.1 General description of this group of biscuits .2 Ingredients and recipes .5 Dough piece forming .6 Instrumentation of the forming machine .8 Flavouring of biscuits .9 Cooling and handling of biscuits .10 Continental semi-sweet biscuits .11 Garibaldi or fruit sandwich biscuits. 330 28 Short dough biscuits. Manley, Consultant, Duncan Manley Ltd, UK and B. Delcour, Katholieke Universiteit Leuven, Belgium 28.1 Description of the group .2 Recipes and ingredients .4 Dough piece forming .5 Instrumentation of the forming machine .7 Factors affecting dough piece spread during baking.
346 29 Deposited soft dough and sponge drop biscuits. Manley, Consultant, Duncan Manley Ltd, UK 29.1 Description of deposited biscuits .2 Description of sponge batter drops. Manley, Consultant, Duncan Manley Ltd, UK 30.2 The wafer oven or wafer baker .3 Wafer sheet production .6 Batter deposition and baking .7 Sheet handling, creaming and cutting .8 Process control of wafer production. 367 © Woodhead Publishing Limited, 2011 xii Contents 30.9 Hollow rolled wafer sticks .