Bakery Associate

Description

Lamination:

Start of Shift
1. PRE - OPERATIONAL PRODUCTION CHECK LIST, and get Q.A. approval before you start your line.
2. Inform a truck loader and/or your supervisor as to any ingredients that will be needed for the dough mixing and lamination production.
3. Properly receiving Ingredients:

• Inspect all ingredient containers and bags for tears, punctures or broken seals.
• Reject any ingredient if the bag is torn or the seal is broken or leaking.
• Return the bag to the loader and request replacement ingredient.
• Record waste on designated sheet.
• Always clean the outside of all ingredient containers BEFORE opening.
• Use a BLUE FOOD USE brush to clean off the bag or container completely.
• Look for any foreign material that may have been brushed off the bag such as pallet wood and remove it from the area.
• Clean away any materials that could contaminate the ingredient or mix before opening the bag or container.

• Do not cut near and/or on the seal of the bag when cutting ingredient bags.
• Avoid using dull knives to cut bags. Replace knife as needed to ensure clean cuts and reduce potential contaminates produced by jagged or torn bags.
• Diagram below illustrates how to open a bag properly:
• When bag is open, inspect the INSIDE of bag for foreign material.

Inspect the inside of mixer bowl and containers for foreign material/contamination and cleanliness BEFORE SCALING INGREDIENTS into the bowl or container.

1. Pre-scale ingredients in containers using digital scales, according to dough type to be mixed first. (see Dough Mixing Schedule / Dough Formulas)

2. Lot numbers are recorded on designated forms for each dough type.

3. Ingredient containers are placed on racks near dough mixers.

4. Liquid eggs are measured in buckets and brought out of walk-in cooler. (40 degrees or less)

5. Record temperature of eggs on space provided. (see Dough Mixing Schedule / Dough Formulas)

6. Remix dough barrel(s) brought out of walk-in cooler.

7. Required amount of flour is entered and drawn from flour silo.

8. Required water amount is entered on water meter.

9. Ingredients are loaded into dough mixer (i.e. Danish concentrate, pre-scaled ingredients including sugar and yeast, liquid eggs, ice (if needed) and remix dough.

10. Inspect ingredients for contaminates as they are added to the mix.

11. Water and flour is added.

12. Mix time is set and the dough mixer is started. (see Dough Mixing Schedule / Dough Formulas)

13. When mixing is completed the dough is deposited into the dough hopper.

14. For sponge doughs (i.e. V3, V4) sponges are mixed in the small mixer and allowed to ferment in troughs, then added to other ingredients and mixed in the big mixer (see Dough Formulas). Always inspect trough dough for foreign material before adding to a mix.

1. During Dough mixing steps A thru L the lamination operator completes pre-operational form.

2. Record lot numbers for fats and dusting flour.

3. Fill flour barrels and flour dusters.

4. Open fat boxes, place fat cubes on fat pump conveyor. (3 cubes at a time)

5. Enter dough lamination recipe in computer and prepares rack tags.

6. The lamination assistants bring out dough racks with pans, set up catch pans and help open fat boxes.

7. When dough is in dough hopper lamination operator starts the chunker and conveyor belts to bring the dough to the lamination hopper.

8. Start the lamination line, along with the first flour duster.

9. When the flour reaches the dough extruder (six roller) press the start button and the dough will come out onto the belt.

10. For most dough types the bottom roller is set at 50.0, but for Bimbo dough it should be opened to 11.

11. When the dough is under the fat extruder, press the start button, and the fat will be extruded on top of the dough.

12. Start the overhead flour duster as the dough is guided through the folding unit.

13. Start the first flour duster for section two. At the end of the first section the dough must be guided into the center of the lamination rollers. Start the top flour duster.

14. As fat is used the fat pump will automatically bring in fat cubes which must be replaced by the operator.

15. When the dough reaches the multi-roller on section 2 turn on the first flour duster on section 3.

16. Start the next flour dusters in order as the dough reaches them.

17. When the dough has gone through the cutter the first piece can be removed and put back in the hopper and then the panning system is started.

18. One lamination assistant feeds pans onto the panning conveyor while the other picks them up and loads them on a dough rack.

19. The operator (or other person) writes the time on a tag, attaches it to the rack and takes the rack into the walk-in cooler (retarder).

20. The operator must keep the flour dusters filled and fat unboxed and ready to place on fat conveyor.

21. Operator must watch for changes in the dough (i.e. tighter or looser) and make necessary…