Baking & Snack - August 2022 - 96

CRACKER PROCESSING
Any issues that
may have occurred
in the sheeting or
laminating won't be
revealed until after
the product is baked,
so controls become
increasingly critical
for real-time quality
checks.
Reading Bakery Systems
" We are working with companies now to help automate
the ingredient handling, proofing, mixing and trough
transportation process so that these timing issues become
irrelevant, " Mr. Smith explained. " We offer automated
trough handling, which completely automates the laborintensive
process of moving troughs around the plant. In
a process like yeast-leavened crackers, where the dough is
mixed more than once, this is especially helpful. "
In a tight labor market where experience is dwindling,
an easier-on-the-body production process is priceless.
Make it up as you go
Once dough is fermented, it's sent through the makeup
equipment to be sheeted and laminated and cut into
its final shape. At this stage, the dough must be treated
gently to ensure that the gluten isn't damaged while also
reducing the dough sheet enough to get the proper, even
bake in the oven.
A properly mixed and fermented dough goes a long
way to ensuring the sheeting and laminating process goes
well. Any issues that occur between these gauge rollers
won't show up until the product is baked and cooled, so
it's imperative that the sheeting line is designed properly
to get the right amount of reduction at each stage in the
process while not harming the dough sheet. Otherwise,
bakers will lose entire batches of finished product before
realizing a change needs to be made.
Mr. Christie has noticed two trends in makeup line
design to address these issues and prevent waste. Both
result in a longer production line but improve accessibility
and reduce stress on the dough.
" I've noticed a lot of bakers are taking the four-roll
sheeter off from the laminators and putting it on the
ground level, " he said. " This takes up more floorspace,
but it provides a better visual to see that the sheet is
good. It also makes the equipment more accessible.
Operators can see what's going on, see that they're getting
a good product and make corrections accordingly. "
After this initial dough reduction, the dough will typiPYLER
SAYS:
Fermentation impacts dough extensibility
According to Baking Science and Technology by E.J. Pyler and Laurie Gorton,
one of the biggest impacts of fermentation on cracker production is the
cracker dough's extensibility. As fermentation progresses, the cracker dough
loses some of its extensibility, most likely because of the increase in acidity
during this process.
Mr. Pyler and Ms. Gorton reference research by Doescher and Hoseney
cally go through three gauge rollers to reduce the sheet
to its final thickness. Each gauge roller puts more work
and stress into the dough to help it achieve that final required
thickness, which increases the likelihood of damage
being imparted to the dough sheet. This can negatively
impact the final product characteristics.
To relieve some of that tension, Mr. Christie is seeing
more bakers add a fourth gauge roller.
While this also extends the length
of the production line, it takes some
of the pressure off that final gauge
roller to carry the dough sheet to the
finish line.
" After laminating, the gauge rollers
(1985) that revealed that resistance to extension decreased over time during
fermentation. This is important because unlike bread doughs, cracker doughs
do not become fully developed in the mixer but when they are sheeted.
Research also shows that the addition of soda to cracker dough increases
the dough's extensibility, while adding salt strengthens the dough and
increases its resistance to extensibility.
96 Baking & Snack August 2022 / www.bakingbusiness.com
will reduce the dough sheet's thickness
by about 50% at each roller, " Mr.
Christie explained. " When you get to
the tail end of the rollers, there's more
work to do, and there's a lot of work on
the final gauge roller to meet that final
reduction without product damage.
By adding the fourth gauge roller, you
can put less stress on the dough and
ensure the quality is consistent. "
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