BAKED, LEAVENED BREADS
Prepared By
Richard J. Bess
Reviewed By
William Carman
Ron Wirtz
INDUSTRY PROFILE #19
(1991)
VITA
Published By
VOLUNTEERS IN TECHNICAL
ASSISTANCE
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Suite 500
Arlington, Virginia 22209 USA
Telephone: (703)
276-1800
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INDUSTRIAL PROFILES
THIS INDUSTRY
PROFILE IS...
one of a
series briefly describing small or medium-sized industries. The Profile
provides basic
information
for persons wishing to start manufacturing plants in developing countries.
Specifically,
the Profile
contains general plant descriptions, financial and technical factors for plant
operation,
and sources of information and expertise. The series is intended to be useful
in determining
whether the
industries described warrant further inquiry, either to rule out or to decide
upon
investment. The underlying assumption of the profiles is that the individual
making use of
them already
has some knowledge and experience in industrial development.
Dollar values
are listed only for machinery and equipment costs, and are primarily based on
equipment in
the United States. The prices do not include shipping costs, duty, or taxes,
which
must be
considered and will vary greatly from country to country and with the type of
equipment.
Requirements,
but not costs, are given for land, labor, materials, fuel, etc., to provide
potential
investors
with a general checklist of considerations for setting up a business.
THIS INDUSTRY
PROFILE IS NOT...
a substitute
for a feasibility study. Before any investment is made in a plant, a thorough
feasibility
study should
be conducted. This may require skilled economic and engineering expertise. The
following
questions illustrate the range of answers that may be required:
*
Is there a market for the product? What is the extent of the present
demand for the product,
and how is it being satisfied?
*
Will the estimated price and quality of the product make it competitive?
*
How will the plant be financed?
*
Has a realistic time table been developed for construction, equipment
delivery, obtaining
materials and supplies, training, and
start up?
*
How are needed materials and supplies to be procured? How will machinery
and equipment
be maintained and repaired?
*
Are trained personnel available? Is training available?
*
Are there adequate facilities for transportation, storage, power/fuel,
communication, water,
etc.?
*
What management controls for design, production, quality control, and
other factors have
been considered?
*
Will the industry complement or interfere with development plans for the
area?
*
What social, cultural, and technological considerations must be
addressed regarding the
manufacture and use of this product?
*
What will be the environmental impact of the manufacture and use of the
product?
Fully
documented information responding to these and many other questions should be
compiled
before
proceeding with implementation of an industrial project.
Professional
engineers who specialize in industrial design can be found through their
national
associations
or by referring to the published cards in many engineering journals. The services
of a
professional
engineer are desirable in the design of even small industrial plants. An
experienced
engineer can
design a plant that provides the greatest economy in the investment of funds
and
which will be
capable of expansion without extensive alteration.
Manufacturers
of industrial equipment employ engineers familiar with the design and
installation
of their
specialized products. These manufacturers are usually willing to give
prospective customers
the benefit
of engineering advice to help determine the suitability of their equipment in
any
proposed
project.
ABOUT VITA
Volunteers in
Technical Assistance (VITA) is a private, nonprofit, international development
organization.
It make
available to individuals and groups in developing countries a variety of
information
and technical
resources aimed at fostering self sufficiency. VITA provides assistance in
needs
assessment and program development support, by-mail and on-site consulting
services, information
systems training,
and management of long-term field projects. Special emphasis is
placed on the
areas of agriculture and food processing, renewable energy applications, water
supply
and
sanitation, housing and construction, and small business development--areas in
which self
sufficiency
in the community is an essential step toward the well-being of the country.
On industrial
development projects, VITA provides a range of assistance on a fee-for-service
basis. VITA
keeps its costs low because of the extensive participation of skilled VITA
Volunteer
industrial
and process engineers.
The author
and reviewers of this industry profile are VITA Volunteers, specialists in the
field,
who have
donated their time to the preparation and review of this profile.
Volunteers in Technical
Assistance (VITA)
1815 North Lynn Street,
Suite 200
Arlington, Virginia 22209
USA
Telephone 703-276-1800
Telex 440192 VITAUI
Fax 703-243-1865
BITNET: VITA @ GMUVAX
BAKED, LEAVENED BREADS
Prepared
by: Richard J. Bess
Reviewed
by: William Carman
Ron Wirtz
PRODUCT
DESCRIPTION
The Product
The product
is a baked, leavened food whose basic ingredient is flour or meal, to which
water is
added, and
often fat and salt, and sometimes sugar. The principal leavening agent is
usually yeast.
The product
is made in units (loaves or rolls) in a variety of sizes and shapes to suit
local laws,
customs, and
tastes. Spices, fruits, nuts, etc., may be added, depending on product and
locality.
The Facility
This profile
describes a small bakery operating with a single shift and producing 100 tons
of
baked
products a year. It also describes a medium-sized plant operating on the same
basis but
producing 250
tons of baked goods a year.
Dry materials
are received and water added to make dough, which is then blended and processed
in a sequence
of steps involving mixing the dough, allowing the dough to rise, then
portioning,
shaping,
baking, cooling, and wrapping the loaves to trade requirements.
GENERAL
EVALUATION
Outlook
Economic. The
economic prospect should be good because many countries throughout the world
consume baked
goods. Even in areas where rice is the staple food, the consumption of baked
goods made
from wheat flour is steadily increasing. And in times of economic downturn in
more
affluent
areas, many customers switch from more expensive foods to bakery products.
Technical.
Small, batch-process bakeries producing 200 to 500 kg daily, sold in one or a
few locations,
can maintain
satisfactory market shares.
Manufacturing
Equipment Flexibility
Flexibility
depends on the variety of special products made. This in turn depends on
production
volume and
market demands.
Knowledge
Base
Special
knowledge of food chemistry, mechanical engineering, and trade economics are
needed.
Commercial
baking experience is required. Specialized apprenticeship or formal training in
a technical
school is
highly advisable.
Quality
Control
Quality
control aims at freedom from adulteration of product, quality assurance of
ingredients and
products,
sanitary packaging practices, and proper storage. Quality control in production
involves
such
variables as density, porosity, appearance, weight, mixture properties, volume,
temperature
controls,
etc. These factors require instrumentation and laboratory testing in proportion
to plant
capacities.
Constraints
and Limitations
Traditionally,
continuous rather than batch mixing is needed for economic operation as
production
increases.
The production level above which continuous operation is needed depends largely
on
labor costs.
But if modern, high-speed mixing is used, energy costs may become important.
MARKET
ASPECTS
Users
Users are
individual consumers and institutions. Individuals may obtain a wrapped unit
either
directly on
the premises where baked goods are made, or transported from a large wholesale
bakery
in a distant
place. Institutions of ten obtain their bread from wholesalers. The degree of
integration,
including
transportation and labor costs, determines the cost-price relationship.
Suppliers
Suppliers
include millers who mix grain types and bulk ship through food brokers to
bakeries.
Construction
services originate or improve the plant. Machine erectors install
special-purpose
devices.
Public utilities provide water, sanitation, and electricity.
Sales
Channels and Methods
Sales
channels and methods depend on the origin of merchandise. Sales to consumers
may be made
at the bakery
site or at multiple sites integrated by centrally located dominant producers.
Advertising
may cost from
0.1 percent to 5 percent of sales.
Geographic
Extent of Market
The
geographic range of individual bakeries depends on their capacities,
transportation costs, and
competition.
For bread, the range is usually limited by the extent to which distant markets
can be
reached in a
day's time by surface transport. Improvements in technology have extended the
shelf
lives of some
other kinds of bakery goods from large bakeries.
Competition
In very
thinly populated areas, demand may be so low that many products are available
only
through
wholesale distributors. In sparsely populated areas, about 90 percent of the
market will be
controlled by
small producers. In large cities with large producers, the price structure may
be
dominated by
a few of them. However, small companies may also set prices if the industry
does
not quickly
pass on cost savings to consumers.
Market
Capacity
User income
level is a major determinant of baked goods acceptability. About 45 kg of the
product
per year per
capita is consumed in the United States. In low-income areas of the world 300
kg
would be
likely. Baked goods consumption in most high-income societies tends to decline
because
as income
goes up people's preferences shift from cereal-based food to meat. In the
United States,
the decline
is about 1 percent per capita annually.
PROCESS
DESCRIPTION
Sample Layout
of a Medium-Size Plant, about 250 square meters.
The space
required depends not only on the level of production and the kind of product,
but on
whether
production involves two or three shifts per day. <see plant layout>
PRODUCTION
AND PLANT REQUIREMENTS
Small
Plant Medium Plant
Annual
Output: 100
tons/yr 250 tons/yr
1.
Infrastructure, Utilities
Land
750 sq m
750 sq m
Building
150
sq m 200 sq m
Power
50 KW
100 KW
Fuel oil
4 KW
4 KW
Water
1 t/hr
2 t/hr
Other
2. Major
Equipment & Machinery (thousands of $US)
Tools & Machinery
ingredient handling-RR car
unload, pneumatics trucks,
conveyors, weigh and meter
300
500
dough-handling troughs,
mixers, proffers, dividers,
rounders, molders, and
homogenizers
400
900
baking and cooling ovens,
conveyors, and racks
200
400
bread-handling slicers,
wrappers, etc.
50
80
Support Equipment & Parts
Refrigerators, pan washers,
depanners, lab equipment
100
500
*TOTAL ESTIMATED COST
building and land
turnkey on stream
1,800
3,000
*Based on $US
1987 prices. The estimated costs provide a general idea of the investment
required
for
machinery. Actual costs will depend on just what is purchased, when, and where.
3. Materials
& Supplies, tons per year
Raw Materials
flour
55
140
water
200
500
salt
0.8
2.0
sugar
1.2
3.0
milk
1.2
3.0
fat
2.1
5.3
yeast
0.4
1.0
Supplies
Small Plant
Medium Plant
miscellaneous food items, shop,
office, and sanitation
Packaging
cartons, boxes, foils, and films
4. Labor
Skilled
supervisor
1
2
Semi-skilled
mixer, weigher, batcher
3
5
(3 for a three-shift operation)
Unskilled
machine operators
10
15
Indirect
warehouse, QC, office
2
4
5.
Distribution/Supply flow
Amount in per day
200 kg
500
Amount out per day
(loaves/units)
500
1,250
6. Market
Requirements
Retail outlets
1 or 2
2 to 5
7. Other
Requirements
REFERENCES
Technical
Manuals & Textbooks
Green, Don W.
(ed.), Perry's Chemical Engineers' Handbook. New York: McGraw-Hill, 1984.
Kutz, Myer
(ed.), Mechanical Engineers' Handbook. New York: McGraw-Hill, 1986.
Matz, Samuel
A., Bakery Technology: Nutrition, Packaging, Product Development. McAllen,
Texas:
Pan-Tech
International, 1989.
McGraw-Hill
Encyclopedia of Science and Technology, 20 v. New York: McGraw-Hill, 1987.
Pomeranz, Y.,
Modern Cereal Science and Technology, New York: VCH Publishers, 1987.
Pyler, Ernst
J., Baking Science and Technology. Kansas City, Missouri: Sosland Publishers,
1988.
Sultan, W.,
Practical Baking, 5th ed. Florence, Kentucky: Van Nostrand Reinhold.
Periodicals
Bakery
Production and Marketing. Chicago: Gorman Publishing Company, 8750 West Bryn
Mawr
Avenue,
Chicago, Illinois, 60631 USA. 13 issues per yr.
Bakery
Production and Marketing Buyer Guide, Chicago: Gorman Publishing Co.
Bakery
Production and Marketing Red Book, Chicago: Gorman Publishing Co.
Food
Processing. Chicago: Putnam Publishing Company, 301 East Erie Street, Chicago,
Illinois
60611 USA.
Trade and
Professional Organizations
American
Institute of Baking, 1213 Bakers Way, Manhattan, Kansas 66502 USA. This
not-for-profit
education and
research organization offers a large variety of training and certification
courses in
bakery technology. Some courses are offered by correspondence, and some course
brochures
are available
in Spanish.
American
Society of Bakery Engineers, 2 North Riverside Plaza, Room 1733, Chicago,
Illinois
60806 USA.
Retail Bakers
of America, 6525 Belcrest Road, Hyattsville, Maryland 20782 USA.
VITA
Resources
VITA has a
number of documents on file dealing with industrial processes. In addition,
VITA can
assist with
plant design, equipment acquisition, etc., on a fee-for-service basis.
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