Project Report Day/Date : Thursday/ 16th September 2021

Industrial Machinery and Lecturer : Dr. Ir. Meika Syahbana Rusli

Equipment (TIN 326) Class : P5

Assistants :

1. Fabian Akbar Putranto (F34180058)

2. Nada Safira (F34180021)

3. Aulia Lubbi Luthfan (F34188001)

WHITE BREAD INDUSTRY AND PROCESSES

Arranged by:

Diaswan Rafi Fauzan (F34198008)

Iwang Benaya (F34198016)

M. Rasyiid Fajri R (F34198019)

Michellia cempaka S (F34198020)

DEPARTMENT OF AGROINDUSTRIAL ENGINEERING

FACULTY OF AGRICULTURAL TECHNOLOGY

IPB UNIVERSITY

BOGOR

2021
 PREFACE

Praise and Gratitude must be prayed to Almighty God, Allah SWT, for all the graces and
blessings that provide health and wisdom to the author so the writer can finish this thesis well.
The title of this thesis is” white Bread Industry and Processes” so that we can complete the
research that started on 16th September until 29th November 2021. is a prerequisite for the
Industrial Machinery and Equipment 2021 course. Hopefully, this scientific effort will be
valuable and will serve as a source of ideas for operating agroindustry.On this occasion, the
author also conveys respect and gratitude to Dr. Ir. Meika Syahbana Rusli, MSc, Agr as the
coordinators and also other lectures who has provided guidance and suggestions to the author
since the beginning of the study until the completion in writing this Project

Bogor, 29th November 2021

Michellia Cempaka Saraswaty

 CHAPTER 1
INTRODUCTION

1.1. Background

Bread has been a staple food for many civilizations. Even today, bread and cereal-based
products constitute the base of the food pyramid, and its consumption is recommended in all
dietary guidelines. Bread has a fundamental role in nutrition due to the adequate balance of
macronutrients in its composition; in addition, it provides some micronutrients and minerals
(Rosell 2019). Bread is an important part of the human diet providing energy, protein, dietary
fiber, and vitamins. Bread is commonly made from cereals such as wheat and rye along with
water, yeast and salt. The common use of wheat in bread is due to its gluten-forming proteins,
gliadins and glutenins (Barak et al. 2013).

Bread is one of the examples of familiar food choices among consumers. In line with
that statement, familiarity affects how consumers use the available information to form an
appreciation of the product quality, proposing that increasing consumers’ knowledge of the
products would increase their choice of high-quality products. Vegan products have been
gaining popularity with demand that increased over the past few years. The plant-based pieces
of bread need to be produced in the market because it has a lot of nutrients, as well as the
mouthfeel. Therefore, the present study was undertaken to develop gluten-free and vegan bread
and enrich it with a functional component such as flaxseeds and assess its overall acceptability
and nutritional value compared to plant-based bread available in the market (Rynk 2005).

1.2. Purpose

This paper is aimed to interpret the tools and industrial machines used. Besides that, it
also provides illustrations of industrial tools and machines. Furthermore, in this paper, will be
described the power source, capacity, and dimensions for each tool and machine.
 CHAPTER 2
PROCESSING LINE DESIGN

2.1 Material

Raw materials for the bread-making process can be classified into three groups, namely
basic ingredients or main ingredients such as wheat flour, yeast and water, flavor enhancers,
namely sugar, salt, fat in the form of shortening/butter/margarine, milk and eggs, and additional
ingredients. in the form of mineral yeast food (MYF), malt, emulsifier, ingredients to improve
dough quality (dough improver) and preservatives, especially for mushrooms.

a. Flour, The elastic and swellable physical properties of gluten allow the dough to
withstand rising gases. This allows the bread product to have a smooth and uniform
hollow structure as well as a soft and elastic texture. On the other hand, wheat flour
which has a small capacity to absorb water results in a dough that is less elastic,
resulting in dense bread and imperfect texture.
b. Water allows the formation of gluten, plays a role in controlling dough density,
dissolves salt, holds and spreads ingredients non-starch uniformly, moistens and
expands the starch as well as making it digestible. Water also functions as a solvents
for materials such as salt, sugar, milk and minerals so that these materials evenly
disperse in the dough. Amount of water used determines the quality of the resulting
bread.
c. Yeast, In bread, yeast is the main raw material. By fermenting sugar, yeast produces
carbon dioxide gas which is used to expand the dough. As a result of this fermentation,
Bread flavor-forming components arise, including acetic acid, aldehydes and esters.
Yeast for bread is made from the yeast cells Saccharomyces cerevisiae (Birhanu 2016).
d. Sugar, The main use of sugar is as a food source for yeast growth during the
fermentation process. The remaining sugar after the fermentation will give the crust
color and flavor to the bread. Sugar is also intended as the first carbon source of yeast
cells that promote active fermentation. The sweetener plays a role in improving roast
quality and crust color, and allows for a faster ripening process. With the short baking
time, it is affected that there is still a lot of moisture left in the dough, and this will
cause the bread to remain soft.
e. Soy Milk, The use of milk for bakery products has the function of forming flavor,
binding water, as a filler and forming a strong and porous structure due to the presence
of protein in the form of casein. Soy milk can easily be substituted for cow's milk in all
baking needs. While the flavor will not be exactly the same, it will be close, and you
should have a similar final product in terms of texture and consistency (Maduforo
2015).
f. Bread Improver, making bread using flour other than wheat (e.g. soy or tapioca flour)
requires the addition of several ingredients related to the unavailability of protein in the
form of gluten as contained in wheat flour. As we know, gluten functions to maintain
the air that enters the dough during the mixing process and the gas produced by the
yeast during fermentation, so that the dough expands. Making bread from cassava flour
 requires the addition of starch grain binding agents. Materials that can be used include
xanthan gum, and other materials such as CMC, alginate, glyceryl monostearate and so
on. These ingredients will increase the attraction between the starch grains, so that most
of the gas contained in the dough can be retained. Thus, a fairly fluffy dough will be
produced and in the end bread with a relatively large volume, fine crumbs, and a soft
texture (Sutriyono 2016).
g. Margarine, Different saturated fat content margarines have been created. The material
is tailored to the application. Tub-based margarines, for example, are low in saturated
fatty acids, whereas industrial puff pastry margarines were created to minimize the need
to stop manufacturing to cool the pastry. Butter cream margarine, cake, croissant, puff
pastry, and hard puff margarines are examples of commercial baking margarines.
Tempering puff pastry margarine, for example, improves plasticity. Margarine adds
texture, mouthfeel, and other sensory qualities to baked foods as a fat. Its other
functions include prolonging the shelf life of a product.

2.2. Product Description

White bread typically refers to breads made from wheat flour from which the bran and the
germ layers have been removed from the whole wheat berry as part of the flour grinding or
milling process, producing a light-colored flour. A type of bread made with white wheat flour
that has a fine texture and is one of the most popular varieties of bread. It is often baked
commercially, sliced, and packaged to be sold as sandwich bread. Fresh bread usually presents
an appealing brownish and crunchy crust, a pleasant roasty aroma, fine slicing characteristics,
a soft and elastic crumb texture, and a moist mouthfeel.

2.3. Product processing

Start

250Kg
White Flour

3 L Soy milk
0,5 Kg Yeast
15,5 Kg Sugar 331,5 Kg
50 L Water Mixing
Dough
750g bread improver
12,5 Kg Margarine

Fermentation I in 1 331,5 Kg
331,5 Kg
Smooth Dough
Dough hour T 90⁰C RH 85%
CO2

1000 White
331,5 Kg
Dividing bread dough
Smooth Dough
@331 gram
500g dough sticks in the machine
 1000 White 1000 White
Dough weighing bread dough in
bread dough
@331 gram and shaping pan @331 gram

1000 White
1000 White
Fermentation II in 30 bread dough
bread dough @331 gram
@331 gram minutes T 40⁰C RH 85%
CO2

Steam
1000 White
bread dough in Baking in 30 Cooked 1000 White
pan @331gr minutes T 200⁰C bread @331gr

Cooked 1000 White Tempering in 5 1000 White bread

bread @331gr @331gr ready to slice
minutes T 27⁰C

1000 White bread Each 1000 white bread

@331gr ready to slice
Slicing into 10 slices @331gr

Each 1000 white bread

into 10 slices @331gr
Packaging

Packaged
White Bread

End
2.4 Machine Flow Chart

Start

Mixer
Baking Trolley

Fermentation Dough
Baking Trolley

Vacuum screw Dough

divider
Baking Trolley

Fermentation Dough
Belt Conveyor

Convection Oven
Belt Conveyor

Band Slicer
Belt Conveyor

Packing Machine

End
2.5. White Bread Processing

a. Mixing
Mixing machines are all designed to combine both the mixing and kneading
aspects of the manual operation. In essence, mixing is the homogeneity of the
ingredients, whereas kneading is the 'labor done' after the initial mixing to build the
dough (gluten) structure. This 'job' is now done in mixing machines in a variety of ways,
depending on the production capacity needed, the type of dough needed for the final
product specification, and its use in further processing.
b. Fermentation
Yeast activity starts to produce carbon dioxide gas during the first proof. The
duration and (most importantly) the temperature of the dough determine the extent of
the activity. The temperature of the intermediate prover has a little effect, but the need
to avoid peeling is more crucial. The gas bubbles in the dough begin to expand as a
result of the yeast activity, and the initial proof period can be used to impact the final
bread cell structure. If no degassing happens during final moulding, the more open the
bread cell structure will be.
c. Dividing
To get the shape and size of the product we want, we need to separate the bulk
dough from the mixer into individual sections and then shape them into the shape of
the final product we want after proving and baking. Dough is usually divided
volumetrically, which means it is cut into uniformly sized portions either by filling a
chamber with dough and cutting off the excess (piston dividing) or by pushing dough
through an orifice at a constant rate and cutting billets from the end at regular intervals
(extrusion dividing).
d. Dough Weighing and Shaping
The overall weight of the materials in our dough, including our sourdough
starter, is called dough weight. Shaping is a method of allowing gluten to develop while
also creating surface tension by generating a skin on the dough's surface. This skin aids
in the creation of a crispy, even exterior for the dough during baking, preventing it from
collapsing or splitting apart in the oven.
e. Baking
The moisture in the bread dough is transformed into steam by the heat of the
oven, causing the bread to rise quickly. The yeast in the dough continues to create
carbon dioxide gas, which helps the bread rise as it bakes. The temperature of the dough
has usually risen to a level that kills the active yeast cells, putting an end to the rising
action, usually within the first 10 minutes of baking. The bread's final shape and size
are determined, and the crust begins to form. This stage should not be completed before
the oven door is opened. Further baking causes the natural sugars in the dough to
caramelize, resulting in the golden brown hue associated with many types of bread.
f. Tempering
Tempering is a phrase used in cooking to describe the process of stabilizing an
ingredient so that its properties remain unchanged. Tempering gradually raises the
temperature of the cold ingredient, allowing it to become more compatible with the
 temperature of the hot ingredient (which essentially slowly cools down when it comes
in contact with the cold food). The shock of a cold substance abruptly becoming heated
might cause it to cook too quickly, curdle, seize, shatter, ball up, or split, and change
its composition.
g. Slicing
For consumers' convenience and portion control, bread slicing is cutting or slicing
loaves into separate pieces. After passing through metal or X-ray detection and cooling,
the process takes place.

2.6. Source of Energy

Electricity

Source: Perusahaan Listrik Negara (PLN)

Category: I-3/TM

Total Electricity That needed in Industry: 23.578 kWh (just for the machinery)

Total Electricity Provided by PLN: for medium scale industrial use at low voltage, has a
power of 14 kVA to 200 kVA and the type is I-3/TM

Estimated daily electricity consumption (in watts): 168,686 watt

Power limit: 200 kVA -2000 kVA

Estimated price in month: Rp.5,241,648

Estimated price in year: Rp. 62,899,771

Generator Set

Type: TYG35
Engine: Yanmar 4 Cylinder 4TNV98-GGE (Made In Japan)

Fuel Consumption: 6 ltr/ hour

Rated power: 35kva (28kw)

Standby power: 38,5kva (20,8kw)

Alternator: Original Stamford PI144H1 (coo)

Dimension: 2,15m x 0,8m x 1,2m

Price: Rp70.000.000

Water

Source: Perusahaan Daerah Air Minum (PDAM)

Category: KELOMPOK IV.b: (K-4.b)

Price: Rp 12.550/ rate

Total Worker: 20 skilled trained workers who have been trained in their respective fields.

2.7. Specifications of tools and machines production

1. Belt conveyor

Specification

Capacity : 30-300kg
Speed : 0.1-10m/min
Power : 30W (0.03) Kwh
Weight : 50 kg
 Price : Rp 12.000.000

2. Mixer (Spiral Mixer)

Specification

Capacity : 100kg flour/hr

Dimension : 1300 x 880 x 1380 mm
Voltage : 380V / 50 HZ (0.38) Kwh
Weight : 350 kg
Price : Rp 5.000.000

3. Fermentation Dough Machine

Specification

Pan Capacity : 32 Pan

Pan Dimension : 60 x 100 cm
Dimension : 102 x 80 x 170 cm
Voltage : 240V / 50HZ (0.24) Kwh
Weight : 85 kg
Price : Rp 6.600.000
4. Vacuum Screw Dough Divider

Specification:
Dough weight range: 30g-1500g
Ouput(pcs/h): 3000-5000 pc/h
Voltage (v): 400 v (0.40) Kwh
Hopper capacity: 160L
Power: 7.5
Price: 35.000.000

5. Convection Oven

Dimension : 905x1250x1280cm
Trays : 10 pan
Pan size : 60x100cm
Power : 14KW
Voltage : 3 phase 380V
Temperature range : 30-400 degree
Price : Rp. 35.000.000
6. Band Slicer

Specification
Capacity : max 3600 per hour, dependings on product
Product range : 160 – 370 mm ,80 – 200 mm, 70 – 160 mm
Electrical connection : 400v -50 hz, 4 Kw
Pneumatic connection : depending on options
Weight : approx. 810 kg
Price range : Rp. 28.000.000
7. Packing machine

Specification
Capacity : Max 3600 per hour depending on product
Product range : length 160 – 340 mm, width 80-200 mm
Width : 80 – 200 mm
Height : 70 -140 mm
Electrical connection : 400v -50hz ,4,5 Kw
Pneumatic connection : 6 bar, about 400 L/min depends on the speed
Weight : approx. 950 kg
Price range from : Rp 40.000.000
8. Baking Trolley

Type: Aluminum

Bakery Pan Size (Tok): 40x60 cm

Dimension: 47 x 62 x 175,3 cm

Weight: 24 Kg

Electricity: -

Price: Rp 2.000.000
9. Industrial Basket

Type: plastic

Capacity: 69 L

Quantity: 24 unit

Dimension: 64 x 43.5 x 31 cm

Weight: 2.330 gram

Electricity: -

Price: Rp 2.000.000 (2 dozen)

2.6 Cost Analysis

1. Material cost

Ingredients Price

White Flour Rp 10.000/kg

Soy milk Rp 20.000/ litre

Yeast Rp 45.000/ 500gr

Sugar Rp 10.000/ kg
 Water Rp 12.550/ 100 litre

Bread improver Rp 15.000/50gr

Margarine Rp 90.000/2kg

Plastic Rp 32.500/25pcs

2. Total cost per batch (331Kg)

Ingredients Price

White Flour Rp 2.500.000

Soy milk Rp 60.000

Yeast Rp 45.000

Sugar Rp 155.000

Water Rp 12.550

Bread improver Rp 225.000

Margarine Rp 562.500

Plastic Rp 1.300.000

Total Rp 4.860.050
3. Investment Cost

Tools Price

Belt Conveyor Rp 12.000.000

Spiral Mixer (2pcs) Rp 10.000.000

Fermentation Dough Rp 6.600.000

Vacuum screw Dough divider Rp 35.000.000

Convection Oven (2pcs) Rp 70.000.000

Band Slicer Rp 28.000.000

Packing machine Rp 40.000.000

Baking Trolley (4 pcs) Rp 8.000.000

Industrial Basket Rp 2.000.000

TOTAL Rp 211.600.000
Product capital/plastic=

= Rp 4.860
Selling Price = Rp 25.000/plastic
income/plastic = Selling Price – Product capital/plastic
= Rp 25.000 - Rp 4.860
= Rp 20.140
income/year = income/plastic x total plastic x 365 days
= Rp 20.140 x 1000 x 365
= Rp 7.351.100.000
2.7 Production Time
a. Production time

Process Time

Mixing (2 machine) 150 minutes

Fermentation I 60 minutes

Dividing 60 minutes

Fermentation II 30 minutes

Baking (2 machine) 75 minutes

Tempering 5 minutes

Slicing 20 minutes

Packaging 20 minutes

TOTAL 420 (7 hours)

b. Production Time Analysis

Bread production is carried out in one batch for a day. Batch will starts at 08:00
- 15:00. Each batch takes approximately 420 minutes to process. The process begins by
mixing all the ingredients for making bread in a spiral mixer for 150 minutes. Then the
dough is fermented for 60 minutes, followed by dividing the dough into 1000 pieces
for 60 minutes. Then the dough is brought to the fermentation machine and fermented
for 30 minutes. Then the baking process for 75 minutes in the convection oven. Bread
that has been baked will be carried using a conveyor belt to be cut into several pieces
while tempering for 5 minutes. The process of cutting bread into several pieces takes
20 minutes. Packaged bread will be checked first by the Quality Control (QC)
Department.
 CHAPTER 3
DISCUSSION

Our baking process and equipment engineered design conveyors for automation
challenges in handling baked goods. A conveyor belt works by using two motorized pulleys
that loop over a long stretch of thick, durable material. When motors in the pulleys operate at
the same speed and spin in the same direction, the belt moves between the two. This ergonomic
work station promotes better back health with a foot rest and minimized reaching.
The mixing machine has a spiral-shaped mixing tool that rotates on a vertical axis
against the inner circumference of a bowl that rotates on its vertical axis as well. Ingredients
are combined, and the dough is then kneaded by the spiral blade, which stretches the dough
against the bowl wall and folds it on itself repeatedly. A bread proofer machine is a device that
is used to develop bread dough prior to baking. Fermentation is a specific procedure that is
referred to as proofing. The process of making yeast in bread is known as fermentation. In the
process of baking bread in the oven, yeast is quite important. This yeast creates a coating of
bubbles to form on the bread, causing it to rise and give it the proper shape and flavor. The
hydraulic dough dividers are specialized pieces of equipment. Once the dough has been mixed
into a batch, the dividers take over. As the name implies, the machine separates it into portions.
Each one is of equal size and weight so that the results will be consistent. A convection oven
uses fans to circulate hot air around the product placed on racks in the baking chamber. This is
the convective component of heat transfer. Convection ovens are perfect for baking small-sized
goods such as pastry and other products that are baked free-standing on sheet pans or perforated
racks. Dough moisture typically evaporates faster in convection ovens. As a consequence, the
product bakes more quickly and more uniformly than conventional ovens. This reduces the
total baking time.
Fully automatic Band Slicer, for different types of bread to use in a semi or fully
automatic line. This bread slicer is manufactured for a company assured approach in the bakery.
Continuously rotating band blades, angled to pull the loaves through the blade to give the
highest quality slice. Effective enough for semi-automatic use, but also easy to connect with
every type of packaging machine such as the Bagloader HBS with the synchronization system.
Hardened steel blade guides ensure uniform slicing thickness and a wide range of different
slice thicknesses are possible. Generously proportioned doors and covers gives both good
access for cleaning and maintenance as well as quick change of the band blades. The machine
can be constructed for either left- or right-handed operation. Fully automatic packing machine
for loading sliced or unsliced bread and buns automatically into pre-made wicket bags. The
machine has been developed to high quality engineering standards using our knowledge of the
national and international bakery markets. The principle for the machine is standard, but the
version can be adapted with the optional features. Any slicer is simple to connect to the bagger
by using our synchronization system with flights which brings the product one by one to the
packaging machine. The bag loader can be connected with any type of closing machine to suit
the customers particular request, including: Clip band, Kwik-Lok, Twist Tie and Tape seal.
Heat sealing units can also be installed on the conveyors depending on material of bags and
type of closures.
 CHAPTER 4
CLOSING

4.1 Conclusion
Healthy, practical, safe and halal food is a necessity that cannot be separated from
people's daily lives, especially urban communities with active and dynamic lifestyles. One of
the healthy and practical food choices that are most in demand by many people is bread. Bread
is indeed the right choice, both for the breakfast menu in the morning and as a temporary
substitute for the main meal between busy schedules, apart from its practical preparation, bread
is also rich in carbohydrates as an energy source, no wonder bread is very popular with all
family members, especially children. Mainly because we make plant based white bread, where
eating a plant-based diet improves our gut health, so we are better able to absorb nutrients from
foods that support our immune system and reduce inflammation. To make plant-based bread,
especially for sale and purchase, professionalism is needed in the process. The general steps in
bread making are Mixing, Fermentation, Dividing, Dough weighing and shaping, Baking,
Tempering, Slicing, and Packaging. In order to have the best results, it is necessary to choose
the right type of machine to produce the best product.

4.2 Suggestion
The selection of quality raw materials needs to be considered in order to maintain the
quality of plant-based bread. for fermentation One of the best ways to add flavor to your bread
is by slowing down fermentation. This gives the enzymes present in the dough time to do their
work, breaking the starches into sugars and other flavor components. a great place to start is to
simply decrease the amount of yeast to maybe half of what you would normally use and then
place the shaped dough into the refrigerator to spend its final rest in a cold environment. In
addition, the cleanliness of the machines and production equipment needs to be improved
because the equipment is also one of the factors that affect the quality of bakery products.
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Barak S, Mudgil D, Khatkar BS. 2013. Relationship of glia-din and glutenin proteins with
dough rheology, flour pasting and bread making performance of wheat varieties.
LWT-Food Science and Technology. 51: 211–217.

Birhanu. 2016. Journal of Yeast and Fungal Research Isolation, identification and
characterization of yeast species from coffee waste collected from Sidama and Gedio
zone. 7: 47-53.

Cauvian SP, Young LS. 1999. Technology of Breadmaking. Gloucestershire (UK): Springer-
Science+Business Media.

Maduforo.2015. Nutrient and Sensory Quality of Soymilk Produced from Different Improved
Varieties of Soybean. Pakistan Journal of Nutrition.

Rosell CM. 2011. Flour and Breads and their Fortification in Health and Disease Prevention.
Massachusetts (US): Academic Press.

Sutriyono.2016. Karakteristik Adonan dan Roti Tawar dengan Penambahan Enzim dan Asam
Askorbat pada Tepung Terigu. Jurnal Mutu Pangan: Indonesian Journal of Food
Quality. 3(2): 103-110.
ATTACHMENT