QUALITY CONTROL PROCEDURES.

Quality control is the process of controlling the quality of all the factors involved in production to ensure that the input and output of a process conform to specification. Controlling the quality of a product ranges from the inception of raw material, through in-process quality control to end product quality control. The raw material quality control determines the price and final use of the product. It is mainly done to know if the raw material suit demand, to check for defect and deformities and to know how to handle the material during processing. The In-process quality control is the quality control during production. Factors such as quantity, time, temperature, condition of the equipment, moisture content and so on are considered, while the end product quality control is the quality control done at the end product. This is normally done to ensure that, the end product conform to specification and standards, to check the wholesomeness of the product, and to ensure uniformity.

Raw materials quality control

The raw material quality control is the quality control done at the reception of the flour and other ingredients into the factory. The first critical control point during raw material reception is the acceptance point which include both the physical and chemical analysis. This point determines the price and final use of the product. The quality control parameters being analyzed at the point of reception include; Flour color, texture and feel, Absorption ability and moisture content.

1. Flour color: The flour should be of “perfectly regular consistency and not contain any specks”.

2. Texture and feel: A trained Q/A personnel examines the texture and feel of the flour manually before it can be accepted for production.

3. Absorption ability: Absorption measures the amount of water that can be absorbed by a given quantity of flour.

4. Moisture content: The level of moisture in flour is important mainly for the issues of storage. When the moisture level exceeds 16% the shelf life of the flour is greatly reduced. Generally, the moisture will be 14-15% (According to New Zealand flour millers association), which when stored in appropriate conditions (relatively cool, dry and aerated) improve the shelf life.

In- process quality control

These are the quality control check during production process. They include the following;

1) Dough consistency

2) Mixing time

3) Fermentation / standing time.

4) Temperature during mixing

5) Dough temperature

6) Dividing weights

7) Proving time

8) Baking time

9) Baking temperatures

10) Dimensions after baking

11) Upkeep of machinery

12) Audits for food safety management systems like HACCP, BRC, ISO etc.

1) Dough consistency: Dough consistency is sometimes confused with gluten development but they are two different things.

2) Mixing time: Mixing at different times affects both rheological and structural characteristics of dough. Excessively long mixing times leads to softer, less consistent, excessive pan flow and stickier dough than optimum mixed ones; while under mixed dough can lead to cold dough, stiff and too elastic, proofs slower, poor pan flow and Erratic scaling. The normal mixing time of dough is 12 minutes and is maintained for all the mixing to avoid inconsistency in the production.

3) Dough temperature: Dough temperature is monitored using a thermometer.

The temperature is usually at 24℃ to 26℃ because is one of the main contributors to vigorous fermentation, its key that we maintain a sufficiently high, and stable dough temperature through the entire baking process.

4) Dough temperature/ baking time: An oven thermometer is used to find out the true temperature of the oven. Baking is done usually at 180℃ for 45mins; Temperature plays an important role in baking more often than not controlling the temperature in an oven does more than just ensuring doneness. It can affect the flavor of the bread. Generally, a temperature that is too low makes it harder for the bread to be done.

5) Upkeep of machinery: Heavy machines such as the mixer, moulder, sheeter, divider and ovens etc are maintained by regular servicing, routine checks, repair works, and replacement of worn or non- functional parts. Maintenance of machinery is frequently handled reactively (eg: after a breakdown) though it may also be done proactively as with preventive and predictive maintenance.

End product quality control

The end product quality control is the quality control done on the Bread. This product ensures that the loaf (end product) conform to specification. The end product quality control check done at the factory includes;

i. Over-rised or under rised bread

ii. Sensory checks

iii. Under or excess Weights (Heaviness)

iv. Packaging details on labels

v. Sealing during packaging process

vi. Safe containers for transshipments

vii. Shelf-life

viii. Packaging defects

ix. Packaging materials

x. Deformation of bread.

xi. Pale crust

xii. Dark crumb

xiii. Small hard lumps in the bread slice

1) Over rised/ under rised loaf: After baking, the bread is being carried to the packaging section for quality checks and packaging. Over rised bread which is caused by high rising temperature, too much yeast, over proofed dough are sorted out from the good ones. They are taken back to the production section and re-mixed along with a new one. The same goes with under-rised loaf.

2) Packaging materials: Packaging of bread in a low density polyethylene plastic (LDPE) bags is an almost universal practice with either a wire twist tie or a plastic- clip closure. Care is taken to ensure that the packaging material is not contaminated by any form of organism during storage.

3) Deformation of bread: After unpanning the bread, it is handled gently and allowed to cool properly before packaging to avoid deformation. Any deformed loaf is sorted out from the good ones and taken back to the production section for re-mixing to form a new one.

4) Packaging details on label: There is a strict conformation to the details on the label, most especially the nutritional content of the product.

5) Small hard lumps in the bread slices: Any form of defects found in the bread leads to the rejection of the loaf although it can be re-mixed to form new bread. Small hard lumps in the bread slices can be caused when the dough is not mixed sufficiently or when the dough got too stiff to handle.

6) Pale crust: This occurs when there is too little sugar in the dough, high rising (so the yeast ate all the sugar before baking, not allowing enough for caramelization during the baking process), or when the oven temperature is too low.