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Cereal and bakery technology

Food Science and Technology (B.Sc) · Food processing · free study notes for exams, placements and interviews

In short

Cereal and bakery technology covers how wheat, rice, maize and millets are cleaned, conditioned, milled and converted into flour, semolina, bread, biscuits, cakes and breakfast cereals. It is the largest branch of Indian food processing by volume — wheat flour milling, the organised bakery sector (bread, biscuits, rusk) and rice milling together handle well over a hundred million tonnes of grain a year. Examined in B.Sc/B.Tech Food Science papers on cereal technology and bakery science, and in competitive exams (GATE Food Technology / XL, ICAR-NET, FCI and NABARD technical papers). Employers who test it directly include Britannia, Parle, ITC Foods, Mondelez, Bakers Circle, Modern Foods, Hindustan Unilever, Adani Wilmar, ITC's Aashirvaad atta chakkis, Cargill, Bühler India and the Food Corporation of India.

Explained

Cereal grain structure and composition

Wheat milling — roller flour milling

  1. Cleaning (screen room): magnetic separator → sieve/separator (size) → aspirator (light chaff) → destoner (density) → disc/indented cylinder separator (shape — removes barley, oats) → scourer/brush (surface dirt) → optional colour sorter.
  2. Conditioning/tempering: water added to raise moisture to ~15.5-16.5% for hard wheat, ~14.5-15.5% for soft wheat, rested 8-24 h. Purpose: toughen the bran so it peels in flakes, and mellow the endosperm so it powders easily.
  3. Break system: 4-5 pairs of corrugated rolls running at a differential of about 2.5:1, with the corrugations usually dull-to-dull or sharp-to-sharp depending on the break. They scrape endosperm off the bran as semolina and middlings, deliberately avoiding flour production.
  4. Purification: purifiers use a sieve plus upward air current to separate pure endosperm particles from bran-attached ones by density and size.
  5. Reduction system: 8-12 pairs of smooth rolls (differential ~1.25:1) grind the purified semolina to flour; sifters (plansifters) classify after every passage; bran finishers and detachers recover the last endosperm.
  6. Streams and extraction: patent flour (first reduction streams, lowest ash), clear flour, low-grade flour; by-products bran, germ, and atta-type feeds.
Extraction rate = (flour produced / clean wheat fed) × 100 — typically 72-76% for white maida from roller mills; atta is ~95-100% extraction (whole-wheat).

Rice, maize and millet processing

Dough rheology and flour quality tests

Bread making — ingredients, methods, process

Biscuits, cookies, cakes and other bakery products

Indian standards, regulations and institutions

Key points

Formulas and examples

Extraction rate (%) = (mass of flour / mass of clean wheat milled) × 100
Flour yield balance: wheat in = flour + bran + germ + shorts + process loss (all on the same moisture basis)
Moisture balance for conditioning: W = M × (m₂ − m₁) / (100 − m₂) — W = water to add (kg), M = wheat mass (kg), m₁ = initial moisture %, m₂ = target moisture % (wet basis)
Baker's percentage: ingredient % = (ingredient mass / total flour mass) × 100 — flour is always 100%
Baking loss (%) = (dough piece mass − baked mass) / dough piece mass × 100
Specific loaf volume = loaf volume (cm³) / loaf mass (g); good pan bread ≈ 5-6 cm³/g
Dough temperature (straight dough, 3-factor): required water temp = 3 × (desired dough temp) − (flour temp + room temp + friction factor)
Dry basis ↔ wet basis moisture: M_db = M_wb / (100 − M_wb) × 100
Yield of head rice (%) = (mass of whole kernels / mass of paddy) × 100
Water activity shelf-life rule: biscuits a_w < 0.3 — spoilage is rancidity and moisture pickup, not microbial growth

Example 1 — Conditioning water. 5,000 kg of wheat at 11.5% moisture must be tempered to 16.0%.

Example 2 — Extraction rate and by-product balance. A mill feeds 10,000 kg clean wheat and gets 7,400 kg maida, 1,900 kg bran, 250 kg germ, 380 kg shorts.

Example 3 — Baker's percentage recipe and baking loss. Bread formula per 100 kg flour: water 62, yeast 2.0, salt 1.8, sugar 4.0, fat 2.0, SMP 2.0, improver 0.2.

Example 4 — Dough water temperature. Desired dough temperature 28 °C, flour 31 °C, bakery room 33 °C, friction factor 9 °C (spiral mixer).

Example 5 — Rice milling yield. 1,000 kg paddy at 14% moisture gives 200 kg husk, 85 kg bran, 640 kg head rice and 60 kg brokens.

Flour typeWheatProteinDough characterMain use
Strong (bread) flourHard aestivum11-13%Elastic, high absorptionBread, pav, pizza base
Weak (biscuit) flourSoft aestivum8-9.5%Extensible, low absorptionBiscuits, cookies
Cake flourSoft, chlorinated/heat-treated7-8.5%Very weak, fineHigh-ratio cakes
Semolina (suji/rava)Durum11-13%Coarse, strongPasta, upma, halwa
Atta (chakki)Hard/medium aestivum11-12%Whole grain, very high absorptionChapati, roti, paratha
FeatureBreadBiscuitCake
LeaveningYeast (biological)Chemical, mostlyChemical + air/steam
Flour strengthStrongWeakVery weak
Fat + sugar levelLow (1-5%)High (20-40% combined)Very high
Water in formula58-64%10-20%High (as milk/egg/syrup)
Final moisture35-40%1.5-3%18-28%
Spoilage limitMould, rope (days)Rancidity, moisture (months)Mould, staling (weeks)
ProcessBulk ferment timeYeast levelFlour strength neededNotes
Straight dough1.5-3 h~2%Medium-strongGood flavour, long cycle
Sponge and dough3-5 h (sponge)2-2.5%MediumFlexible, tolerant, strong flavour
CBPNil (~3-5 min dev.)2.5-3.5%Weaker acceptableNeeds oxidant, high work input, fine crumb
No-time (ADD)NilHighMediumReducing + oxidising agents

Where it is used

Interview questions

Common mistakes

Related topics

Food preservation methods · Food packaging · Food chemistry: carbohydrates and proteins · Food microbiology and spoilage · Food engineering: heat and mass transfer · Food analysis and quality control

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