2. Internship Report :Dawn Bread
Sana Mehboob
Roll No. 06 (Regular)
B.Sc. (Hons.) Food Science & Technology
Institute of Food Science & Nutrition.
University of Sargodha, Sargodha.

3. INTERNSHIP REPORT
DAWN BREAD

4. Internship Report Outline
Introduction to industry
Functions of departments
Vision and mission
Objective and quality statement
Swot analysis of dawn bread
Baking ingredients and their functions
Cake Hal
Burger hall
Bread section
Friction factor
Bread baking problems
Suggestions

5. Products Of Dawn Bread

6. Introduction Dawn bread establishment of plant City Year Karachi 1981
Islamabad
1985
Hyderabad
1987
Lahore
Multan
1989
Faisalabad
1992

7. Vision and Mission Statement
Dawn Bread with a vision to exceed the expectations of consumers
With great taste products that delivers convenience, quality, safety and value
Dawn bread is undoubtedly market leader in fresh baked bakery products
“To provide quality products to customer and explore new markets to expand sales of the company through good Governance and dynamic team
So as to achieve Optimum price of products of the company for sustainable and equitable Growth and prosperity of the company”

8. Objectives and Quality Policy
Dawn Bread’s longstanding commitment toward consumer satisfaction is evident and initiation of bringing Pakistan the world’s most technologically advanced baking units and processes
Quality Policy
We work together as a team for implementation and continual improvement of total quality system in order to achieve satisfaction of our internal and external customers

9. Continue… ISO 9001: 1994 certified in 2000
Established yeast plant at Lahore
Halal certified
Supplier of McDonald’s hamburger
KFC (Kentaccy fried chickens)
Hardees
Avari Lahore
Subway
Dunkin donuts
Pearl continental
Hot dog

10. Continue… Comprises of Group of private limited companies
Group members based on food products
Bread and beyond
Dawn mayo
Dawn foods
Dawn bread
Dawn maizban

11. Nature of Organization Continue…
Dawn bread
Breads
Burgers
Buns
Rusks
Cakes
Biscuits
Dawn foods
Ready to eat
Zinger
Koofta
Aloo Paratha
Wings
Chicken Patties
Chicken rolls

12. Nature of Organization Continue…
Dawn mayo
Chili and soya sauce
Chicken spread
Mayonnaise
Tomato ketchup
Chili garlic
Sauce vinegar
Tomato sauce
Ginger & garlic paste
Dawn maizban
Chicken chapli kebabs
Chicken mallei boti
Chicken samosa
Chicken spring roll
Chicken seekh kabab
Chicken shami kabab
Vegetable spring roll .

13. Bread and Beyond Dawn foods has various brands
Bread and beyond one of them
Daughter company of dawn bread
Have more than 200 products
Acutely aware of the needs for appealing products (confectionery and bakery products)
Satisfying customer
Backbone of dawn bread

14. Continue… Competitors Gourmet Bunny’s Cakes and bakes Bake parlors
City bread
Mary gold
Morgan bread
Wonder bread

15. Swot Analysis of Dawn Bread
Strength
Holding 35% shares of bread in Pakistan
Largest distribution network
Advance production units
Effective on time delivery
Vast range of quality
Vast range of products with variety of flavors
Stability of production

16. Swot Analysis (Continue…)
Weakness
No quality control labs
No proper medical facilities
Hygiene and sanitation issues
No proper research laboratories
Over work burdens on employers
Large product range lacking proper planning

17. Swot Analysis (Continue…)
Opportunities
Innovation in product
Product quality
Growing varieties in RTE food
To create the awareness among customers about new products
To increase the skilled labor
Use motivational techniques regarding employees

18. Swot Analysis (Continue…)
Threats
More manual work
Trade discounts offered by competitors
Lack of implementation of quality standards
Lacking bench marking and re-engineering
High affinity to better/new image brands
Some products loose focus, due to new brands

19. Baking ingredients and their functions
Flour
Largest single component of bread
Reduced form of endosperm (particle size 140 mµ)
Powdery substance produced by finely grinding grain through milling
Patent (white) flour is used
Gelatinizing capacity
Contain essential amino acids except lysine

20. Flour continue…. Classification based on amount of protein
Protein determines gluten strength of flour
Gluten gives the dough its shape and form
Bread flour (9-13% gluten content, used for bread making)
Cake flour or soft flour (< 7 % gluten content )
All purpose flour (medium gluten strength, suitable for any baking purpose)

21. Quantitative Analysis Of Flour
Component
%age
Protein
11-12%
Fat
0.3%
Fiber
0.6%
Minerals
0.5%
Sugar
2.5%
Starch
70%

22. Characteristics Of Flour
Water absorption
pH ( )
Color ( creamy white )
Uniformity ( uniform particle size )
Flour strength ( according to product)

23. Constituents of Flour Starch Important carbohydrate in flour
About 70% in bread making flour
Dilute gluten
Provide strong union with gluten
Become flexible by gelatinization
Moisture 14-16%

24. Flour constituents (Continue… )
Protein
8-10% in soft wheat flour
12-14% in hard wheat flour
>16% in extra hard wheat flour
4 types of protein in flour
Albumin
Globulin
Gliadin
Glutenin

25. Baking Ingredients (Continue…)
Others are
Water
Eggs
Leavening agent
Sugar
Fat
Shortening agents and emulsifiers

26. Baking Ingredients (Continue…)
Water
Basic ingredient
Solvent for the dispersion of salt, sugar and other ingredients
Hydration of protein to form gluten
Controls the consistency of dough
Controls the dough temperature
Make enzymes activities possible
Amount varies according to the product

27. Baking Ingredients (Continue…)
Sugar
Table sugar or sucrose
Major ingredient in baking
Amount varies according to the product
Serves as nutrient for yeast in fermentation
Retains moisture and prolong freshness
Improves flavor
Improves grain and texture of bread

28. Baking Ingredients (Continue…)
Shortening Agents and Emulsifiers
Type of solid fat, made from vegetable oils, such as soybean and cotton seed oil
It shortens gluten strands in wheat by adding fat
To obtain improved slicing properties as well as extra softness, tenderness
Example are butter and margarine
Increases the nutritive value
Assists in gas retention, thus giving better volume and crust.

29. Baking Ingredients (Continue…)
Leavening agents
Yeast and baking powder
Leavening dough by CO2 production
Types of yeast
Flavoring and fermentation purpose.
Give structure to the product
Acetic acid and lactic acid produced, give flavor to the product
The ideal temperature is 26-30°C
Living Yeast
Baker’s Yeast
Dead Yeast

30. Baking Ingredients (Continue…)
Salt
Used for taste and toughens the gluten
Effect on color and keeping quality
Controls the activity of yeast (fermentation)
Decreases the stickiness of dough
Salt should have the following characteristics.
Completely soluble in water.
Pure, give a clear solution.
Free from bitter/ bad taste and lumps

31. Baking Ingredients (Continue…)
Eggs
Binders, holding ingredients together
Whole eggs and yolks contain emulsifiers that distribute fat in the batter
Provide coagulated structure, color, flavor
Egg whites contribute aeration and leavening when beaten due to the presence of air cells that are filled with CO2
Egg proteins contribute to the structure
Play an important part in nutrition

32. Internship Areas Following areas: Cake hall Production hall
Burger section
Bread section

33. Cake Hall Products of Cake Hall Fruity buns Rusk Baqar khani Bread
Shawarma bread
Sheer mal
Muffins
Rusk
Bread
Biscuits
Fruit cake
Simple bun

34. Images of Cake Hall

35. Cake Hall (Continue…) Ingredients used in cake hall Salt Murabba Flour
Sugar
Improver
Calcium propionate
Exotic essence
Potassium sorbate
Murabba
Eggs
Oil
Ice and water
Leavening agents
Color
Flavor

36. Dividing, molding, Panning
Cake Hall (Continue…)
Fruit Bun
Mixing
Slow 3-4 min
Fast min
Dividing, molding, Panning
Proofing
35-37°C
min
Baking °C
14-16 min
Depanning
Cooling
Packaging
Figure 1. Process Flow Diagram of Fruit Bun Making

37. Cake Hall (Continue…) Shawarma bread
Mixing (slow 2 min, fast min)
Moulding
Dividing
Sheeting (Sheeter machine) and loading
Proofing
40-50 min
Baking °C
7-8min
Depanning
Cooling
Packaging
Figure 2. Process Flow Diagram of Shawarma Bread Making

38. Cream filling(Apply Puff on The dough) Cutting , Rolling and pressing
Cake Hall (Continue…)
Baqar khaani
Mixing
10-12 min
Weighing
Dough wt. 3kg
Margarine puff wt. 1kg
Molding and Sheeting
(Sheeter machine)
Cream filling(Apply Puff on The dough)
Folding and pressing
Sheeting
Rolling and folding
(Pressing)
Cutting , Rolling and pressing
Baking
210°C
45min
Figure 3. Flow Diagram of Baqar Khaani Making

39. Cake Hall (Continue…) Sheer maal Mixing Slow 3min Fast 28 min
Molding and dividing
Proofing
Molding
(Manually)
Second proofing
Baking
180°C
16 min
DE panning
Cooling
Packaging
Figure 4. Process Flow Diagram of Sheer Mal

40. (pouring mixed fluid into cups)
Cake Hall (Continue…)
Muffins
Mixing
15 min
Filling
(pouring mixed fluid into cups)
Baking
220°C
13-17 min
Cooling
De panning
Packaging
Figure 5. Flow Diagram of Muffins Making

41. Burger Hall Followings are the type of burgers
Followings are the regular customer of dawn burger
KFC
OPTP
Hardees
Fri chicks
FAT restaurant
Johnny Rocket
Local market
Followings are the type of burgers
Burger bun
Junior bun
Minni hoggi
Hot dog bun
Hoggi roll
Bran bun
Macroil

42. Images of Burger Hall

43. Ingredients used in Burger hall
Flour
Yeast ( AB Maury )
Water / ice
SSL ( sodium sterol lactilate)
Sugar (powder form)
Improver (wheat flour, soy flour,
enzymes, flour treatment agent E-300)
Oil
Gluten
Till (sesame)
Ascorbic acid
Burger softener
Salt
Calcium propionate

44. Procedure For Manufacturing of Burger
Fist spongue is made (7min)
Stay time half hour
Mixing
( min
20-21°C )
dividing,
Molding, dusting
Initial proofing
(3-4 min)
Sheeting and loading
Dedusting by vacuum sucker
Final proofing (45 min, Humidity 95% 35◦C temp)
Seeding by seeding machine
Baking
10min, °C
Depaning and cooling
Slicing
Packaging

45. Bread Section Flour, water, yeast, sugar and salt are the
four basic ingredients of bread
Shortening, mineral, vinegar, soya flour, milk powder, preservatives and fruits are optional
The different types of breads are
White bread
Atta bread

46. Bread Section (Continue…)
Bran bread
Milky bread
Mini bread
Sandwich bread.
It is largest bread
Called as extra-large bread.
It is close top bread

47. Bread Section (Continue…)
Kinds of mixing
Straight dough method
Mixing of all the ingredients at a time to make dough
Less fermentation time
Less labor cost
Time saving
Less bread flavor and volume
2. Sponge and dough method
Take 1/3 of ingredients and mix them to make spongue
Leave the spongue for 2-3 hours
After that 2/3 of ingredients are added and mixed
Then fermentation time is given minutes

48. Purposes of Dough Mixing
Intimate and uniform mixture of the necessary ingredients
To properly form the smooth glutinous mass called dough
Complete wetting of the starch
Insure complete hydration of the gluten
Promoting its extensibility and palatability which is later perfected by yeast action
Completely and uniformly distribute the yeast cells throughout the dough mass
Bringing them into intimate contact with the rest of the dough from which the yeast secures its nutrition

49. Four Stages of Dough Mixing
Initial Stage:
Uniform Blending of the Ingredients
Dough Wet and Sticky
Pick up Stage:
Gluten Structure develop
Clean up stage:
Dough Become dry and Elastic
Cohesive Mass is produce which avoid stickiness from the wall
Development Stage:
Critical Stage
Smooth, Dry and Silky Appearance
Form Smooth and Long Structure

50. Friction factor
Temperature resulting from the action of kneading or mixing, is friction factor
Friction factor refers to the amount of energy or heat generated during the dough making process
Friction varies according to whether the action is manual or mechanical,
How much time the action takes,
And the firmness of the dough.
If the action is mechanical, friction also depends upon the type of mixer used

51. Friction factor Continue…
The general procedure for calculation of friction is given below
Prior to making the dough, note the exact temperature of the room, flour, and water.
After the dough is made, note the dough’s temperature
FF = (FDT×3) – (RT+FT+WT)
FF = friction factor
FDT = finished dough temperature
RT = room temperature
FT = flour temperature
WT= water temperature

52. Friction factor Continue…
I calculated friction factors for various batches. Some examples are given below.
For large bread
RT = 28.5ºC
FT = 26.5ºC
WT = 5.5ºC
FDT= 26.5ºC
FF = (26.5×3) – ( )=79.5 – 60.5 = 19ºC

53. Friction factor Continue…
For medium bread
RT = 28ºC
FT = 26.5ºC
WT = 6ºC
FDT= 27ºC
FF = (27×3) – ( )
= 81 – 60.5
= 20.5ºC

54. Friction factor Continue…
For standard bread
RT = 29ºC
FT = 27ºC
WT = 6ºC
FDT= 25ºC
FF = (25×3) – ( )
= 75 – 62
= 13ºC

55. Friction factor Continue…
For mini bread
RT = 28.5ºC
FT = 25ºC
WT = 5ºC
FDT= 26ºC
FF = (26×3) – ( )
= 78 – 58.5
= 19.5ºC

56. Study the Indication of Completion of Mixing
Proper mixing is very important to obtain good quality end product
Under or over mixing will result in poor quality bread.
Completion of mixing is checked by using window test.
Procedure of checking the mixing indication is given below.
Pinch off a piece of dough
Using both hands, grasp opposite sides of the piece of dough with your fingertips
Slowly pull your hands apart and stretch the dough by approx cm
Dough should look like a window with a thin membrane in the center

57. Continue… Stop kneading Keep kneading
If the dough forms a window-like membrane and stretches without breaking.
Keep kneading
If the dough doesn't stretch easily and tears, continue kneading

58. Manufacturing process of Bread
weighing of ingredients
Shifting
Mixing
Loading of dough into divider/hopper
weighing of dough balls
shifted to the rounder
Dusting
Initial proofing
28-30°C
10min
Sheeting and molding
Cutting by cutters
Panning
(greased pans)
Loading into trays
Final proofing
75-85min
35-37°C
Baking °C
28-30min
Depaning and cooling
Packaging

59. Baking Report S.no Time (min) 36 225 200 40 203 202 34 204 196 195 198
Bread Type
RPM
Time (min)
Temperature
A-Zone B-Zone 1
Standard Milky 36
225
200 2
Simple Large 40
203
202 3
Simple O.T 34
204 4
Milky Small
196 5
Medium Bread
195
198 6
290
194 7
Bran Bread
380 25
206
211

60. Baking Report Continue…
S.#
Bread Type
RPM
Time (min)
Temperature
A-Zone B-Zone 8
Milky Standard
290 37
191
200 9
Simple Large
196 10
Sandwich Bread
203
201 11
Milky Large 38
202
207 13
Milky O.T
300
212 14 36
210 15
Small Rusk
450 25
208 16
198
216

61. Bread Baking Problems Too high and low oven temperature
Too low rise in loaf
Not enough yeast
Too much salt in the recipe
Too much sugar in dough
Under proofing or too short final rise of loaf
Over proofing or too long final rise time
Too high oven temperature

62. Bread Baking Problems Continue…
Too much expansion in dough
Loaves too large for pan
Under mixed or under developed dough
Over proofing
Too dark crust
Too pale crust
Not enough salt in the dough
Dough baked before it had finished proper proofing
Baking too long
Too much sugar in the recipe

63. Suggestions Hygiene of workers should be maintained
Sanitization of industry should be done
Industry should have its own ambulance and first aid facilities
Industry should develop research laboratories
Timely presence of workers and management persons
Appraisal must be done in different forms
Time wastage should be avoided
Keep an eye on every task and production line
Every one should be allowed to give innovative idea