Tech 03 Grain Corp IAOM Jordan 2011 PDF

Step by Step
Wheat Farming, Milling &

Quality Requirements
By
Dr. Irfan Hashmi
Wheat Farm
Cultivation
Irrigation
Plant
Seed
Grain
Ready to Harvest
Harvesting
Country Elevator
Rail Car
Barge Loading
Barge Unloading
Shipping
Wheat Kinds
• Wheat is grown in 2 color shades:
Red White
Wheat Types
Wheat comes in 3 types:
1.Hard 2.Medium 3.Soft

Wheat Types
Durum wheat is used for pasta products & special

milling is required
Major Wheat Exporters
•Australia
•Canada
•CIS
•EU
•USA
•Others
Wheat Structure
Bran 15%
<3%
Germ
<82% Endosperm
Wheat Composition
• Carbohydrate 70%
• Protein 9-15%
• Fat 2-2.2%
• Fiber 2-2.5
• Ash 1.8 %
• Moisture 9-13%
Wheat Milling Process
Finished
Cleaning
Tempering Product
Storage &
Blending
Wheat Grinding
Storage
Siffting
Cleaning
• The first milling steps involve equipment that

separates wheat from seeds and other grains,
eliminates foreign materials such as metal, sticks,
stones and straw; and scours each kernel of wheat.
It can take as many as six steps
Dark Sort Defects
deceased grain
immature grain
foreign seeds
spot colored
defects
foreign grains
(e.g. oats)
1.Magnetic Separator
• The wheat first passes

thru magnet that
removes iron and
metal particles
2.Separator
• Vibrating screens
remove bits of wood
and straw and almost
anything bigger or
smaller than wheat
3.Aspirator
• Air currents act as a

kind of vacuum to
remove dust and
lighter impurities
4.De-Stoner
• Using gravity, the

machine separates
the heavy material
from the light to
remove stones that
may be the same
size as wheat
kernels
5.Cockle Cylinder
• Wheat passes
through a separator
that identifies the
size of the kernels
even more closely. It
rejects anything
longer, shorter,
more round, more
angular or in any
way a different
shape
6.Scourer
• The scourer
removes outer
husks, crease dirt
and polish the
outer surface with
an intense scouring
action. Currents of
air pull all the
loosened material
away.
Conditioning/Tempering
• Wheat is conditioned for

milling. Moisture is added in
certain amounts to toughen
the bran and mellow the inner
endosperm. This help the parts
of the kernel to be separated
easily and cleanly
• Tempered wheat is stored in
bins from 8-24 hours,
depending on the type of
wheat - soft, medium or hard
Scanner
•Wheat is scanned &

discolored kernel are
separated
Grinding (Milling)
• Milling process is a gradual
reduction of the wheat
kernels to produce particles
of endosperm which are
then graded & separated
from the bran by sieves &
purifiers
• Each size returns to
corresponding rollers & the
same process is repeated
until the desired flour is
obtained
Grinding (Milling)
• The rolls are paired &

rotate inward against each
other, moving at different
speeds
• Just one pass through the
corrugated "first break"
rolls begins the separation
of bran, endosperm and
germ
Sifting
• The broken particles of

wheat are introduced into
huge, rotating, box-like
sifters where they are
shaken through a series of
bolting cloths or screens to
segregate the larger from
the smaller particles
Sifting
• Up to 6 different sizes of
particles may come from a
single sifter, including some
flour with each sifting. Larger
particles are shaken off from
the top, or "scalped," leaving
the finer flour to sift to the
bottom
• These fractions are sent to
other roll passages and
particles of endosperm are
graded by size and carried to
separate purifiers
Purifiers
• In a purifier, a
controlled flow of air
lifts off bran particles
while at the same time
a bolting cloth
separates and grades
coarser fractions by
size and quality
Reduction Rolls
• Reduction of
particle size of
semolina into fine
flour by passing it
through a pair of
smooth rolls
Final Product
• The process is
repeated over and
over again, sifters to
purifiers to reducing
rolls, until the
maximum amount of
flour is separated,
consisting of close to
75 percent of the
wheat
Miller’s Job
• “The job of the miller is to produce the best flour from

the cheapest grist for the maximum number of days per
year, at the lowest conversion cost”
Wheat Milling & Flour
Why should a baker care about the wheat?

-Flour comes from the wheat
-All wheat is not created equal
-Therefore all flour is not created equal
What is Flour
• Finely ground purified material from the wheat

kernel
• Purification of process depends up on wheat
source
• Usually remove the outer fibrous coating through a
gradual milling process
• Increased palatability but reduced nutritional value
• Wheat Flour Pass through 10 XX sieve
• Flour particle size range from 1µ to 200µ
What is the Best Flour?
• The best flour is one that corresponds exactly to the

needs of the customers
• Is the flour which gives the maximum extraction (flour
from wheat) in the mill
• History tells us that this is not necessarily the cheapest
flour
• History also tells us that bakers prefer consistent flour
quality above all other considerations
Basic Understanding of Flour
1. Types of Flour
2. Protein (Quantity vs Quality)
3. Ash
4. Extraction
5. Gluten
1.Types of Flour
Flour Types Usage

• Pan Breads, Roll & Buns (automated
• Bakers Flour bakeries)
• All Purpose Flour • Pizza, French Breads, Arabic breads
• High Extraction Flour • Tandoori Bread, Chapati & Puri
• Soft Flour • Cake & Biscuits
• Whole Meal Flour • Whole Meal & Brown Bread
• Semolina • Pasta & Sweets
• Pre-Mixes • Specialty Breads & Cakes
2.Protein: Quantity vs Quality
• Protein quality is best defined in terms of its intended

use
• Protein quality is more important than quantity
• There are no established industry standards for protein
quality
• Estimates with Gluten index
• Obtain some information from farinograph,
extensograph or alveograph
3.Ash
• Mineral residue remaining after incinerating a small
amount of flour
• Provides an estimate of the degree of separation of
bran and germ from the endosperm during the milling
process
• Most mineral matter of wheat is contained in the bran
and particularly in the aleurone
• An indication of the degree of extraction (flour grade)
• Soft wheat flours generally have lower ash than hard
wheat flours
• Ash is NOT a guide to flour’s baking quality
4.Extraction
• Weight of flour produced from given weight of

cleaned wheat
• Tons of flour per 100 tons of cleaned wheat
5.Gluten
• Protein complex that is

formed when wheat flour
is combined with water
• Energy (mixing) speeds
process
• Gluten quality = Protein
quality
• Provides:
– Extensibility
– Elasticity
– Gas retention
Choice of Flour
For quality baked products, a baker may define flour by the

following characteristics:
1-Colour (whiteness)
2-Strength: is the ability of the flour to be made into
large “well-piled” loaves, provided any deficiency in the
rate of gas production in the dough is adjusted in
suitable manner
3-Tolerance: ability to produce satisfactory results over
an extended fermentation period
4-Absorption:The ability of flour to carry maximum
amount of moisture in the dough
5-Uniformity” Shipment of the same type o flour from
the same mill are expected to be uniform in quality
The Judgments of Flour
• Two lots of flour are never
exactly alike, although the
miller strives, with the
help of the Q.A to produce
a uniform product from a
non uniform raw material
(wheat)
• A perfectly standardized
flour is impossible from
mill to mill and even still
less from crop year to crop
year
Difficulty of Standardizing Flour Quality
• What may be quality to one baker is not quality to

another
• Much depends upon the point of view, bakery
equipment, methods, customers and demand
• The baking characteristics of flour are not definitely
indicated by chemical tests
• Crops of wheat vary from season to season and
from section to section
• Wheat and flour change with age
• Milling techniques
Baker’s Most Common Complaints
• Variable Performance Bakers and biscuit

manufacturers accept to pay more for consistency –
this is proven
• Bakers Yield
• Weight loss in finished products.
• Unacceptable Bread Color, despite addition of sugar
• Lack of bread volume
• Bad Functionality of flour
• Lack of Choice (functional Flours)
High Resistance & Low Extensibility Flour
Short Curve
Weakens during fermentation & Collapses when

overfermented
Flattened bread
Pours in slice &

rough texture
Less Elastic & Highly Extensible Flour
Weak & Inelastic

Low fermentation without volume

& Lifeless dough
Low volume bread

No cohesiveness
Optimum Flour
Optimum Curve
Optimum Flour
Suitable for long fermentation

& Good in tolerance
Optimum Flour
Good in volume
Optimum Flour
Smooth texture,
Smooth structure
& High volume

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Step by Step

Wheat Farming, Milling &

Wheat comes in 3 types:

1.Hard 2.Medium 3.Soft

Durum wheat is used for pasta products & special

• The first milling steps involve equipment that

• The wheat first passes

• Air currents act as a

• Using gravity, the

• Wheat is conditioned for

•Wheat is scanned &

• The rolls are paired &

• The broken particles of

• “The job of the miller is to produce the best flour from

Why should a baker care about the wheat?

• Finely ground purified material from the wheat

• The best flour is one that corresponds exactly to the

Flour Types Usage

• Protein quality is best defined in terms of its intended

• Weight of flour produced from given weight of

• Protein complex that is

For quality baked products, a baker may define flour by the

• What may be quality to one baker is not quality to

• Variable Performance Bakers and biscuit

Weakens during fermentation & Collapses when

Pours in slice &

Weak & Inelastic

Low fermentation without volume

Low volume bread

Suitable for long fermentation

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