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INDUSTRIAL VISIT

REPORT

CHINMAI.T.R

BBA S - III
MODERN BREAD

Modern, launched in 1965 is an iconic brand that pioneered the concept of bread,
and literally created the bread category in India. Modern Foods was the first
company to be privatised by the Government of India in 2000, and it was sold
to Hindustan Unilever Ltd. (HUL).

Modern Foods has been crafted with intensive efforts with significant investments
in manufacturing, and research and development at Modern’s new innovation hub
as well as thorough efforts on consumer insights, strategy and design.

Modern has a completely new portfolio with superior products such as milk plus
bread enriched with calcium high-fibre brown bread reinforced with premium
wheat fibre 100% whole-wheat bread and new innovations such as multigrain
super seed bread which not only has super seed sprinkles on top but even the flour
is made of seven grains and contains omega 3.

Modern wants its customers to ‘Thrive, and savour life to the fullest’ by helping
them make smarter choices from its expanded range of healthy, nutritious and tasty
bread and bakery products. Modern bread is available nationally in close to
100,000 stores and manufactured in 40 factories across India.
MANUFACTURING BREAD

INGREDIENTS
The basic ingredients are flour, yeast, salt and water. flour treatment
agents, usually Vitamin C (ascorbic acid), are used in commercial production.

FLOUR
Wheat flour is the key ingredient in most breads. Flour quality is particularly
important in bread making as the quality of the flour will have a significant impact
on the finished product. When flour is moistened and stirred, gluten develops to
give dough the 'stretch'. The elastic framework of gluten holds the gas produced by
the fermentation of yeast.

YEAST
Yeast requires moisture, food and warmth for growth. When these requirements
are satisfied, the yeast grows. Its function is to produce carbon dioxide gas to
enable the dough to rise, form the cellular network found in bread crumb resulting
in the significant texture and gives bread its characteristic aroma.

SALT
Salt is an essential ingredient in bread. It is used in very small amounts to give
bread flavor. It also helps to control fermentation to produce bread of good volume
WATER
Water is used to produce the dough. It should be used in a specific temperature and
quantity when making bread, because it affects the dispersal of the other
ingredients.

FAT
Vegetable fat is used in very small quantities; it helps to keep the bread soft and
also helps the dough pass more easily through the production process.

FLOUR TREATMENT AGENTS


Vitamin C (ascorbic acid) is used to strengthen the dough and help it rise. It has a
beneficial effect on the volume, crumb structure and softness of the bread.

PRESERVATIVES
Preservatives, such as acetic acid (vinegar), are often used in commercial baking to
ensure the freshness of the product and prevent staling.
METHOD

All ingredients are pumped from large storage bins into the dough mixers
automatically. The dough is mixed intensely for about three minutes in a high
speed mixer in batches. The temperature of the dough has to be carefully
controlled at so that the yeast can grow and the dough become elastic.

When mixing is complete the large mass of dough is tipped into a divider. It is then
divided into individual pieces and shaped into a ball. The weight of each piece
of dough is very important to ensure the quality of the finished product.

The dough pieces are allowed to recover for a few minutes in a conveyor prover.
Each piece of dough is then shaped and molded and placed in a tin. The texture and
size of the dough piece is automatically controlled. The dough then travels through
the final prover which allows the dough to rise gently for about one hour in strictly
controlled temperature and humidity conditions. It is then ready for baking.

The bread is baked for about 20 minutes, the loaves then go into a cooler.
Cooling is usually done under carefully controlled conditions to ensure correct
temperature, humidity and time. This is very important for quality. The cooling
stage lasts for about two hours which enables the loaves to be sliced easily. The
bread is then wrapped and ready for dispatch.

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