MUC LUC PHAN I: NGUYEN LIEU ............................................................................................................ 2 PHAN I: NGUYEN LIEU ............................................................................................................

2
1.1.Nguyen lieu chnh: .............................................................................................................................................. 3 1.1.1.BOT M ........................................................................................................................................................ 3 1.2.Nguyen lieu phu .................................................................................................................................................. 8 1.2.1.Nc ............................................................................................................................................................. 8 1.2.2.Chat tao ngot ................................................................................................................................................ 9 1.2.3.Bot sa gay ................................................................................................................................................. 10 1.2.4.Bot phomai ................................................................................................................................................. 11 1.2.5.Chat beo ..................................................................................................................................................... 12 1.2.6.Muoi ........................................................................................................................................................... 14 1.2.7.Nam men .................................................................................................................................................... 14 1.2.8.Cac nguyen lieu khac ................................................................................................................................ 15 1.3.Phu gia ................................................................................................................................................................15 1.3.1.Bot noi ........................................................................................................................................................ 15 1.3.2.Chat tao mau .............................................................................................................................................. 16 1.3.3.Chat tao mui ............................................................................................................................................... 16 1.3.4.Chat nhu hoa .............................................................................................................................................. 16 1.3.5.Chat chong oxy hoa .................................................................................................................................... 17 1.3.6.Chat bao quan (khang vi sinh vat) .............................................................................................................. 17

PHAN II: QUY TRNH CONG NGHE..................................................................................... 19 PHAN III: GIAI THCH QUY TRNH .................................................................................... 20
3.1.Qua trnh sang ...................................................................................................................................................20 3.3.Qua trnh nhao tron ..........................................................................................................................................23 3.4.Qua trnh u .........................................................................................................................................................33 3.5.Can, xep lp, nh hnh .....................................................................................................................................37 3.6.Nng .................................................................................................................................................................44 3.7.Phun dau.............................................................................................................................................................55 3.8.Lam nguoi ..........................................................................................................................................................56 3.9.Phun mui ............................................................................................................................................................57 3.10. Xep banh .........................................................................................................................................................58 3.11. Bao goi .............................................................................................................................................................59

PHAN 4: CH TIEU CHAT LNG SAN PHAM .................................................................. 61

San xuat banh cracker phomai

4.1.Ch tieu ly hoa ....................................................................................................................................................61 4.2.Ch tieu cam quan ..............................................................................................................................................61 4.3.Ch tieu vi sinh ...................................................................................................................................................61

PHAN 5: THANH TU CONG NGHE .................................................................................... 63

5.1.LO NNG RF (RADIO FREQUENCY) ........................................................................................................63 5.2.THAY OI NGUYEN LIEU .............................................................................................................................64

TAI LIEU THAM KHAO .......................................................................................................... 65

PHAN I: NGUYEN LIEU

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San xuat banh cracker phomai Savory hay Snack cracker (Ritz, Tuc, Cheddar ) - Pho bien, co nhieu hnh dang, kch thc. - Co the c xem nh snack man, la mon nham vi bia, hay biscuit an vi phomai. San xuat: - Bot nhao tot + SMS va/hay protease. - Co the tron them bot phomai. - Banh sau khi nng c trang tr tren be mat bang muoi. - Banh sau khi nng con nong se c phun dau thc vat am. Dau co tac dung lam tang be mat, cai thien mau va tang s ngon mieng. Ngoai ra dau con gi cho mui v banh khong b mat i sau qua trnh nng. - S dung dau da v no co t acid beo khong no, giam nguy c dau b oxy hoa. Ngoai ra dau da re hn, de kiem hn cac loai chat beo khac. 1.1.Nguyen lieu chnh: 1.1.1.BOT M Bot m la thanh phan nguyen lieu tao cau truc c ban cua banh cracker.Protein cua bot m se tao thanh mot khoi keo deo, an hoi, co the gi kh va tao thanh cau truc xop khi nng. ay la tnh chat rat ac biet cua bot m, cac loai ngu coc khac khong he co. e co c cau truc ac trng cua banh cracker, ngi ta da tren tnh chat ac biet o cua protein bot m, ket hp vi anh hng cua mot so nguyen lieu khac nh muo i, ng, shortening, chat nhu hoa, enzym...va mot che o nhao tron thch hp . 1.1.1.1.Thanh phan hoa hoc cua bot m: Bang 1: Hang bt Pentozan Thng hang Hang I Hang II 1,95 2,5 3,5 79,0 77,5 71,0 Thanh phan hoa hoc cua cac loai bot m Thanh phan hoa hoc trung bnh (tnh bang % trong lng chat kho) Tinh bot Protein 12,0 14,0 14,5 Chat beo 0,8 1,5 1,9 ng 1,8 2,0 2,8 Cellulose 0,1 0,3 0,8 Tro 0,55 0,75 1,25

Nhng nhn chung, bot m co thanh phan c ban sau :

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San xuat banh cracker phomai Chat vo c: chiem t 15 - 17%, chu yeu gom nc va muoi khoang. Chat hu c: chiem t 83 85%, gom lipid, glucid, protein, vitamin, sac to, enzyme a) Glucid bot m: Glucid la thanh phan chu yeu trong bot m, chiem ti 70 90% trong lng kho tuy theo loai bot m va giong lua m dung san xuat loai bot o. Glucid la thanh phan tao nen cau truc xop, tao o ngot, tao mau sac, va tao mui thm. Bang 2: Thanh phan cac loai glucid trong bot m Glucid T le (%) Tinh bot: Tinh bot la polysaccharide quan trong nhat trong bot m, trong cac bot cao cha ti 80%. Tinh bot lua m co cau truc hat tron, kch thc hat t 5 50 m, gom 2 cau t chnh la: Amilose va Amilopectin. Amilose c cau tao t cac goc glucose gan vi nhau bang lien ket -1, 4 glucoside. Amilose de hoa tan trong nc tao ra dung dch co o nht khong cao, ham lng amilose trong tinh bot bot m khoang 20%, khoi lng phan t cua amilose trong tinh bot m khoang 350.000 vC, mc o polimer hoa la khoang 2000 2200 goc glucose. Bot cha nhieu amilose th banh se gion hn va de v. Amilopectin c cau tao t cac goc glucose lien ket -1, 4 va -1,6 glucoside v vay ma amilopectin co cau truc mach nhanh, amilopectin ch hoa tan trong nc nong, tao dung dch co o nht cao, rat ben vng va chnh amilopectin tao cho san pham co tnh dai, an hoi. Khoi lng phan t amylopectin cua tinh bot lua m khoang 90.000.000 vC, trong o cac mach nhanh cha khoang 19 20 goc glucose. Nhiet o ho hoa cua tinh bot lua m bat au t 53 0 va ket thuc 650C. Dextrin: Dextrin la san pham tao thanh khi tinh bot b thuy phan di tac dung cua he enzyme amylase cua lua m. Tuy vao mc o thuy phan khac nhau ma cac dextrin co phan t lng khac nhau. ng 0,6 1,8 Dextrin 15 Tinh bot 80 Cellulose 0,1 2,3 Hemicellulose Pentozan 2-8 1,2 3,5

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San xuat banh cracker phomai Dextrin hut nc nhieu hn so vi tinh bot, neu ham lng dextrin cao, bot banh dnh, t dai, t an hoi, bot co khuynh hng chay long ra. Pentozan: Pentozan la cac polysaccharide cua ng co cha 5 Cacbon. Cac pentozan de keo hoa lam tang o nht va o dnh cho bot nhao do o anh hng xau en chat lng cua banh. Cellulose va hemicellulose: Cellulose chiem khoang 0.1 2.3%, hemicellulose chiem 2 8% thanh phan cua bot m. Cellulose khong co y ngha ve mat dinh dng v c the ngi khong the tieu hoa c do khong co enzyme cellulase. Tuy nhien, chung co vai tro quan trong oi vi khau phan an v cellulose co kha nang gi nc, giup tieu hoa tot. Cac loai ng: ng trong bot m gom cac loai nh glucose, fructose, maltose, saccharose. Cac loai ng n trong bot m chiem khoang 0.1 1%, chung tham gia phan ng Maillard tao mau cho san pham. oi vi banh len men th cac ng n nay la nguon thc an cho vi sinh vat. Bang 3: Thanh phan cac loai ng co trong bot m ng T le (%) b)Protein bot m: Protein ong vai tro chnh trong viec tao cau truc cho san pham. Protein cua bot m chiem ham lng khoang 8- 25%. Cau truc cua protein anh hng ti chat lng gluten, ma chat lng gluten lai anh hng quyet nh tnh chat cua banh. Phan t protein co 4 bac cau truc, neu t le cau truc bac 3 va bac 4 nhieu hn th gluten cua bot chat hn sc cang t ln hn th chat lng banh tot hn. Protein cua bot m gom bon nhom chnh: albumin, globulin, gliadin, glutenin. Trong o chu yeu la gliadin va glutenin, chiem ti 70 80%. Chnh hai nhom nay khi nhao vi nc tao thanh mang phan bo eu trong khoi bot nhao. Mang nay va dai va an hoi, co tac dung gi kh lam cho khoi bot nhao n va c goi la gluten. Glucose 0,01 -0,05 Fructose 0,015 0,05 Maltose 0,005 0,05 Saccharose 0,1 0,55 Pentozan 0,5 1,1

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San xuat banh cracker phomai Albumin : albumin cua bot m con goi la : leukosin. Khoi lng phan t 12.000 60.000 vC. Albumin tan c trong nc. B ket tua nong o muoi (NH4)2SO4 kha cao (70-100% o bao hoa) . Globulin: chiem khoang 5,7 10,8 % protein cua bot m. Globulin tan rat t trong nc, tan trong muoi trung hoa loang (NaCl, KCl, Na2SO4) Gliadin: (Prolamin) chiem khoang 40 50% protein cua bot m. Gliadin khong tan trong nc va dung dch muoi, ch tan trong dung dch ethanol hoac isopropanol 70 80%. Gliadin ac trng cho o co gian cua bot nhao. Gliadin co tnh a hnh rat ln Glutelin: chiem khoang 34 55% protein cua bot m, glutenin ch tan trong dung dch kiem hoac acid loang, co cau truc bac 4 phc tap. Glutenin co xu hng lien ket vi nhau bang cac tng tac a beo, bang lien ket hidro va bang cau disunfua ln hn so vi gliadin. Glutenin ac trng cho do an hoi cua bot nhao, khi ngam nc co kha nang tao khuon deo, dai, an hoi . Khi em bot m nhao vi nc s tao thanh bot nhao. Ra bot nhao cho tinh bot troi i con lai khoi deo goi la gluten t. e tang chat lng gluten khi nhao bot co the bo sung mot so cac chat oxy hoa nh: acid ascorbic, peroxide Gluten t la chat tao hnh, tao bo khung, tao hnh dang, trang thai cung vi o cng, o dai va o an hoi cho cac san pham thc pham. c) Lipid bot m: Ham lng chat beo trong bot m khoang t 2 3%, trong o 75% la chat beo trung tnh, con lai la phosphatide, cac sac to va vitamin tan trong chat beo. Trong bot m co khoang t 0,4 - 0,7 % phosphatide thuoc nhom lecithine, lecithine la chat beo hao nc, co hoat tnh be mat cao nhu hoa tot nen co tac dung lam tang chat lng banh. Trong o sac tot va vitamin eu co ham lng rat t. Trong qua trnh bao quan bot, chat beo de b phan huy, giai phong acid beo t do, anh hng en o acid va v cua bot, ong thi anh hng en v cua gluten. Bang 4: Ham lng chat khoang va vitamin trong cac loai bot m Vitamin (mg/kg) B1 Bot thng hang Bot loai I 0,5 1,0 B2 0,4 0,5 PP 10 20 Chat khoang (mg/kg) CaO 10 30 P2O5 70 200 FeO 1,0 4,0 Trang 6

San xuat banh cracker phomai Bot loai II d)Enzyme: Trong bot m cung co u he enzyme nh trong hat lua m nhng ham lng va hoat o khac nhau tuy theo loai bot, bot loai thap th co hoat o cao va ngc lai. Enzyme thuy phan protein gom protease va polipeptidase. Enzyme protease phan giai phan t protein cau truc bac 3 , do o gluten b vun nat lam giam chat lng cua bot nhao. Protease cua bot m hoat o manh 4547 0 C, pH= 4,55,6. Khi co s hien dien cua chat kh th hoat tnh protease tang nhng vi chat oxi hoa va muoi an th b kiem ham. Enzyme thuy phan tinh bot gom amylase thuy phan tinh bot thanh dextrin, amylase thuy phan tinh bot thanh glucose, maltose, dextrin. Dextrin tao o quanh cho bot, gay kho khan trong qua trnh nhao tron, nhng qua trnh thuy phan tinh bot tao ra cac ng n giup bot nhao len men nhanh hn. Ngoai 2 loai enzyme tren, trong bot m con co lipase, lipoxidase, tyrosinase cung anh hng en chat lng bot m. Lipase thuy phan lipid thanh glyxerin va acid beo con lipoxidase oxy hoa chat beo khong no thanh peroxyt, ay la mot chat oxy hoa manh co anh hng ti gluten va trang thai cua protease. anh gia chat lng bot m ngi ta da vao tnh chat nng banh cua bot. Tnh chat nng banh phu thuoc vao trang thai he protein protease va glucide amylase. He protein protease cua bot gom so lng va trang thai protein, trang thai enzyme thuy phan protein, lng chat hoat hoa va chat c che nam men. Trang thai protein protease ac trng cho o manh hay kha nang gi nc cua bot. Con he gluxit _ amylase ac trng cho kha nang sinh ng va tao kh CO2 1.1.1.2.Ch tieu chat lng cua bot m Bang 5: Ch tieu chat lng cua bot m: (TCVN4359:1996) Ch tieu Cam quan Ten tieu chuan Mau sac Mui Yeu cau Trang hoac trang nga ac trng Mui cua bot t nhien, khong co mui v la. Trang 7 2,8 0,8 60 60 400 0,9

San xuat banh cracker phomai V Tap chat vo c Vat ly o mn: Con tren ray 420 m Qua ray 118 m o am Ham lng gluten kho: Ham lng tro o chua Khong co v chua, Khong lan cat, at, sat Khong ln hn 20% Khong nh hn 80% Khong ln hn 13,5% 8-10% Khong ln hn 0,75% Khong ln hn 3,5 (so ml NaOH 1N e trung hoa cac acid co trong 100g bot) Tap chat Fe D lng hoa chat tr sau Vi sinh Nam oc Vi nam 1.2.Nguyen lieu phu 1.2.1.Nc: Nc dung trong tieu chuan nay la nc dung cho an uong, che bien thc pham, nc t cac nha may nc khu vc o th cap cho an uong va sinh hoat. Ch tieu cam quan la nhng ch tieu anh hng en tnh chat cam quan cua nc, khi vt qua ngng gii han gay kho chu cho ngi s dung nc. Bang 6: Bang tieu chuan ve sinh nc s trong cng nghip thc phm cua bo y te (QD1329-2002-BYT) STT 1 2 3 4 5 6 Mau sac (a) Mui v (a) o uc (a) pH
(a)

Hoa hoc

Khong ln hn 30 mg/kg Nam trong gii han cho phep Khong co Khong co

Ten ch tieu Ch tieu cam quan va thanh phan vo c

n v tnh TCU NTU mg/l

(a)

Gii han toi a 15 Khong co mui, V la 2 6,5-8,5 300 1000 Trang 8

o cng (a) Tong chat ran hoa tan (TDS)

mg/l

San xuat banh cracker phomai 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Ham lng nhom (a) Ham lng Amoni, tnh theo NH4 (a) Ham lng Antimon Ham lng Asen Ham lng Bari
+

mg/l mg/l mg/l mg/l mg/l

0,2 1,5 0,005 0,01 0,7 0,3 0,003 250 0,05 2 0,07 0,7 1,5 0,05 0,5 0,01 0,5 0,001 0,07 0,02 50 (b) 3 (b) 0,01 200 250 3 2

Ham lng Bo tnh chung cho ca Borat va Axit boric mg/l Ham lng Cadimi Ham lng Clorua (a) Ham lng Crom Ham lng ong (Cu) Ham lng Xianua Ham lng Florua Ham lng Hydro sunfua (a) Ham lng Sat (a) Ham lng Ch Ham lng Mangan Ham lng Thuy ngan. Ham lng Molybden Ham lng Niken Ham lng Nitrat Ham lng Nitrit Ham lng Selen Ham lng Natri Ham lng Sunphat (a) Ham lng kem (a) o oxy hoa
(a)

mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l mg/l

1.2.2.Chat tao ngot: ng saccharose: ng saccharose la mot disaccharide c cau tao t mot goc D glucose va mot goc - D fructose lien ket vi nhau bi lien ket 1,2 glycoside co nhieu trong cu cai ng, ma va la, than, re, qua cua nhieu loai thc vat. ng saccharose ton tai chu yeu dang tinh the, co the ton tai dang vo nh hnh nhng khong ben, co cac tnh chat sau:

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San xuat banh cracker phomai Khoi lng rieng d = 1,5879 g/cm3. Co hoat tnh quang hoc, hut am manh nhiet o cao. B thuy phan tao thanh ng nghch ao. Tan tot trong nc, o hoa tan 25 0C la 2,04 kg/kg nc. o ngot phu thuoc vao s co mat cua cac chat khac va ieu kien moi trng, pH, o nht Tnh chat cong nghe cua cac chat tao ngot: Tao v ngot, tao mau va mui cho san pham banh keo nh cac phan ng xay ra qua trnh nc: phan ng Maillard, phan ng caramel hoa. Bang 7: Ch tieu chat lng ng dung trong san xuat cac loai banh ngot (TCVN 6959:2001) STTn cCh tieu Te 1 Cam quan Mau sac 2 3 4 5 Mui V Trang thai Yeu cau RE Trang sang, vang anh Mui ng ac trng, khong co mui la Ngot thanh, khong lan v khac Tinh the ri, kho, tng oi mem 99,8 0,05 0,03 0,03 99,62 0,07 0,1 0,07 RS

Ham lng saccharose (%) o am (%) Ham lng ng kh (%) Ham lng tro (%)

1.2.3.Bot sa gay: La sa a c tach beo, trong sa gay ham lng chat beo chiem mot t le ra nho. Bang 8 : Ch tieu chat lng cua bot sa gay (TCVN 5538:2002) Ch tieu Hoa hoc (%) Hoa ly o am (%) 5 o o chua ( T) 20 Ham lng chat beo 1,5 34 Ham lng am (%) Ch so khong hoa tan 1ml Sa bot gay

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San xuat banh cracker phomai 50oC Cam quan Vi sinh o mn Mau sac Mui V Tap chat Hat mn, ket dnh tot. Vang nhat Mui thm ac trng V t beo, khong co v la. Khong co

Tong so vi sinh vat hieu kh, cfu/g sp 5.104 Nhom Colifom, vk/g sp E.coli, vk/g sp Salmonella, vk/g sp Nam men va nam moc, vk/g sp 10 0 0 10

1.2.4.Bot phomai:
INS no. Nam

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San xuat banh cracker phomai

e of additive Maximum level

1.2.5.Chat beo: a) Shortening: La dau thc vat a c tinh luyen va hydro hoa. Shortening co mot so tnh chat sau:

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San xuat banh cracker phomai Nhiet o nong chay cao khoang 40 420C. Dang ran, co mau trang uc, be mat bong, trn lang. Co tnh deo, kha nang tan chay tot, co o on nh cao. t b oi, tr mui, t b oxy hoa trong thi gian dai nhiet o cao. Cac san pham chien, nng dung dau shortening th tot hn cac dau khac ve nhieu mat nh gia tr cam quan, chat lng san pham va thi gian bao quan. Do shortening a c hydro hoa giup giam s oxy hoa cua khong kh len noi oi. Bang 9a: Tieu chuan ky thuat dau shortening cong ty Dau thc vat Tng An STT 1 2 3 4 5 6 7 8 Ten ch tieu Ch tieu cam quan Mau sac Mui v o am (%) Ham lng lipid (%) Ch so acid (ml NaOH 1N/g mau) Ch so peroxyt (ml Na2S2O3 0,002 N/ g mau) Ch so Iod Phan ng Kreiss Tap chat 0 < 95 Am tnh Khong co Mau trang hoac trang nga Thm ngon, khong co mui la <2 > 96 0,2 0,3 Yeu cau

b) Dau thc vat: Dau an at tieu chuan, an toan ve sinh thc pham phai qua che bien cong nghiep e loai bo cac chat co hai cho sc khoe, loai bo aflatoxin. Bang 9b: Tieu chuan ky thuat dau thc cua cong ty dau thc vat dau Tng An STT 1 2 Ten ch tieu Ch tieu cam quan Mau sac Mui v o trong o am (%) Yeu cau Co mau vang ac trng Khong mui Trong suot 0,05% Trang 13

San xuat banh cracker phomai 3 4 5 Ch so acid t do (% FFA) Ch so peroxyt Tap chat 0,25% 3 meq/kg 0,05%

c) Tnh chat cong nghe cua chat beo: Trong san xuat banh keo, ngi ta bo sung them cac chat beo ngoai muc ch lam tang gia tr dinh dng va gia tr cam quan, chat beo con ong vai tro quan trong ve mat cong nghe. Trong san xuat banh quy, chat beo giup bot nhao them deo, ti va giup banh tang o xop. Nguyen nhan la do chat beo tao mot lp mang mong bao trum va boi trn cac hat tinh bot, giup gi c lng khong kh trong khoi bot nhao. Tuy nhien anh hng cua chat beo con phu thuoc

thuoc nhieu vao kha nang phan tan cua chat beo vao trong khoi bot nhao.
1.2.6.Muoi: Muoi c s dung la muoi NaCl. Chc nang chnh cua muoi la tao hng v. Muoi khong nhng lam cho thc pham co mui v de chu nh v man ma no con lam thay oi cac hng v khac . Ngi ta thay rang, muoi NaCl co the lam tang v ngot cua ng va lam giam v chua cua acid. Muoi tac ong len bot nhao theo hai hng: +Tac ong len toc o len men: lam giam toc o sinh kh nen lam cho thi gian len men keo dai. +Tac ong en ac tnh lu bien cua bot nhao: lam thay oi tnh chat c ly cua mang gluten lam cho khoi bot nhao gan ket lai. ieu nay se lam tang thi gian anh tron e khoi bot nhao at c s phat trien thch hp. e khong phai keo dai thi gian anh tron, ngi ta anh tron khoi bot nhao khong co muoi en mot mc o thch hp nhat, sau o mi them muoi va tiep tuc anh tron. 1.2.7.Nam men: Nam men s dung ay la Saccharomyces cerevisiae. Trong nam men trung bnh cha: nc 68 75%, protein 13 14%, glicozen 6.8 8.0 %, xenlulose 1.8 %, chat beo 0.9 2.0%, tro 1.77 2.5%. Ngoai ra con co cac vitamin D,B1, B2, B6, PP, biotin, mot so chat khoang nh: Kali, Phospho, Magie, sat, Canxi, va mot so nguyen to vi lng khac..Trong qua trnh len men thng bo sung mot so chat dinh dng nh (NH4)2SO4, NH4Cl.. cung cap N cho nam men phat trien

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San xuat banh cracker phomai Nam men hoat ong nhiet o toi u la 2830 0 C, pH=4 6. Thi gian sinh san hnh thanh te bao mi thng la: 30 40 phut, nhng trong moi trng bot can 2 3h. Toc o sinh san phu thuoc vao thanh phan va nong o chat dinh dng cua bot, nhiet o, pH, mc o suc kh. oi vi mot so loai banh cracker khac nhau thi gian len men khac nhau, vi mot banh man thi gian len men cham hn thng la 24h, vi mot so banh craker khac thong thng thi gian len men ch 18h. Nam men s dung co the dung nam men dang ep, kho, hoac long. Thng nam men ep va kho co nha may hoac phan xng san xuat rieng, con nam men long do nha may t san xuat. 1.2.8.Cac nguyen lieu khac: Vitamin D, canxi cacbonat, rautao gia tr cam quan cung cap them chat dinh dng cho san pham. 1.3.Phu gia 1.3.1.Bot noi La cac chat co kha nang sinh ra kh trong qua trnh nng, hnh thanh cac lo hong kh ben trong banh, tao cau truc cho banh va lam banh xop. Trong san xuat banh Cracker, s dung chat tao noi sau: Natri bicacbonat (NaHCO3) (soda): Khi nng, soda phan huy tao kh lam tang the tch va o xop cua banh Ch so quoc te: E500ii ADI: Cha xac nh Gii han toi a cho phep trong thc pham: 30g/kg 2NaHCO3 Na2CO3 + CO2 + H2O

Kh CO2 sinh ra khong mau, khong mui nen khong anh hng xau en chat lng banh. ay cung la thuoc noi s dung rong rai ben canh bot khai. Bang 10: Tieu chuan ky thuat cua Sodium bicarbonate (Tham khao t cac cong ty hoa chat) Tieu chuan Trang thai Yeu cau Tieu chuan Dang bot mn, khong von cuc Trang 15

San xuat banh cracker phomai Mau sac Mui v Tap chat o tinh khiet (%) pH (dd 10%) 1.3.2.Chat tao mau: Cac chat tao mau s dung: Trang Khong mui v la Khong lan tap chat thay bang mat thng 99 100 7,9 8,4

Chat tao mau Riboflavin (mau vang) Amaranth, erythrosine (mau o) cam) (E110) Tartrazine (E102) (mau vang

ML banh nng (mg/kg) Theo GMP 300

ADI (mg/kg) 0 0,5 0 0,5 0 2,5 0 7,5

Sunset yellow FCF (mau vang 300 chanh) 300

1.3.3.Chat tao mui: Hng lieu t nhien la cac loai tinh dau c trch ly t thc vat nh hng cam, chanh, da, ca phe, da Hng tong hp la cac chat tong hp hoa hoc, cung co mui nh nhom hng t nhien. Hng lieu c cho vao nham bo sung hng thm b mat mat trong qua trnh che bien, ong thi lam tang gia tr cam quan cho san pham, giup san pham phong phu, a dang hn. Hng lieu thng hay s dung: hng chanh, hng ca phe, hng khoai mon, hng vani, hng phomai, hng dau 1.3.4.Chat nhu hoa Lecithine: dang long, quanh, mau vang nau, khong tan trong nc, la chat nhu hoa va chat hoat ong be mat co hieu qua cao. ong thi, no la chat chong oxi hoa, tr hoan qua trnh oi hoa san pham, la chat on nh, chat tao noi. +ML banh nng: 0,5 2% chat beo +Monoglycerides (E471):

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San xuat banh cracker phomai ADI: Cha xac nh Dang long hoac ran, mau vang en vang nga, mui v de chu. Monoglycerides la chat nhu hoa, chat hoat ong be mat, giup phan tan tot cac thanh phan chat beo trong bot nhao, lam giam sc cang be mat, tang lc nhao, tnh tao bot on nh hn, giam thi gian nhao bot, tang kha nang gi kn kh trong qua trnh che bien. Hieu qua lam banh xop, gion. Ngoai ra con lam tang the tch khoi banh va keo dai thi gian ton tr banh. ML banh nng: 0,5 1% trong lng bot. 1.3.5.Chat chong oxy hoa: Acid ascorbic (vitamin C): la tinh the mau trang, tan trong nc, khong tan trong dung moi beo. ay la chat chong oxy hoa hoat ong nhanh nhng yeu neu s dung rieng le. LD 50: 518 mg/kg. ADI: cha xac nh Butylate hydroxy anisol (BHA): chat long ac, mau trang, tan trong nc, la chat chong oxy hoa va bao quan hieu qua cao, c s dung rong rai nhat trong cac san pham giau chat beo. ML banh nng: 200 mg/kg LD 50: 2000 mg/kg ADI: 0 0,5 mg/kg Butylate hydroxy toluen (BHT): la chat ran khong tan trong nc, dang tinh the, mau trang. BHT la chat bao quan thc pham, chat on nh, nhu hoa cho shortening, ngan nga s hong, oi khet cua chat beo. ay cung la chat chong oxy hoa hieu qua va c s dung rat rong rai trong cac san pham giau chat beo. ML banh nng : 200 mg/kg LD 50: 890 mg/kg ADI: 0 0,3 mg/kg 1.3.6.Chat bao quan (khang vi sinh vat): Acid sorbic, Kali sorbate, Natri sorbate, Canxi sorbate: dang bot hoac hat mau trang, mui kho chu, v chua, rat ben vi cac tac nhan oxy hoa, co the s dung ket hp vi muoi sorbate, benzoate, acid benzoic. Acid sorbic chong hieu qua cac loai vi khuan hieu kh va khong anh

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San xuat banh cracker phomai hng en nam men. Acid sorbic la chat bao quan c u tien s dung do kha nang gay hai en sc khoe con ngi la rat thap. ML banh nng: 2000 mg/kg LD 50: 8700 mg/kg ADI: 0 25 mg/kg Acid benzoic, Natri benzoate: dang bot hay tinh the mau trang. Dang acid t tan trong nc, dang muoi th hoa tan tot. Acid benzoic va Natri benzoate la chat bao quan co tac dung ac hieu oi vi nam men, nam moc va t co tac dung oi vi vi khuan. ML banh nng (acid): 40 ppm ML banh nng (dng mui): dung dch 0,1% LD 50 (acid): 1700 3700 mg/kg ADI: 0 5 mg/kg.

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San xuat banh cracker phomai

PHAN II: QUY TRNH CONG NGHE

Bot m Sang va Tach kim loai Nam men, nc Nhao tron Lan 1 bang may truc ngang U bot lan 1 Nhao tron lan 2 bang may truc ngang U bot lan 2 Can Ra banh nh hnh Nng banh Dau thc vat Phun dau Lam nguoi Dch mui Phun mui ong goi Chat beo, muoi, phu gia, ng, bot sa gay, sa whey Tap chat

Phoi tron

San pham
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San xuat banh cracker phomai

PHAN III: GIAI THCH QUY TRNH

3.1.Qua trnh sang 3.1.1. Muc ch: chuan b cho qua trnh u bot: tach tap chat va lam cho bot mn tranh b von cuc khi nhao tron 3.1.2.Cac bien oi: Bot khong con tap chat, mn hn 3.1.3. Thiet b:

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San xuat banh cracker phomai Hnh 1: Thiet b sang bot Cau tao va thong so thiet b: +Nang suat: 1kg-1 tan /gi +Kch thc lo sang: 20 micromet en 20 mm +Thi gian ray : 180-280 phut +o dao ong : ngang 60-80 mm, doc 5-40mm Nguyen tac hoat ong: May hoat ong nh ong c rung, bot chuyen ong qua lai xuong ray thu bot, tao chat nam tren ray c lay ra. Thong so cong nghe: +Nang suat sang 500kg/h +Kch thc hat sau khi sang 2mm +Thi gian sang : 180-280 phut 3.2.Qua trnh phoi tron nguyen lieu phu va phu gia 3.2.1.Muc ch : Chuan b cho qua trnh nhao tron nhanh hn va hieu qua hnNguyen lieu phu thc hien phoi tron gom nam men, nc, ng, bot sa gay , bot sa Whey, chat beo, muoi, phu gia (Chat tao mau (E102, E110) ; Chat tao mui, chat nhu hoa(E471); Chat chong oxy hoa 3.2.2.Cach thc hien: Shortening, sa, ng, muoi, phu gia c tron trc vi nc trong 5 phut 3.2.3.Thiet b phoi tron:

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San xuat banh cracker phomai

Hnh 2: Thiet b phoi tron a. Cau tao va thong so thiet b +Nang suat: 100 kg/me +Toc o tron co the thay oi: 60 120 vong/phut + Coi tron lam bang thep khong g +Cau tao cua canh khuay b. Nguyen tac hoat ong: La loai thiet b anh tron co coi tron co the thao ri. Thiet b ch co mot canh khuay. Canh khuay c treo thang ng. Khi thiet b hoat ong, canh khuay quay tron quanh mot v tr co nh, ong thi, coi tron cung xoay. Thiet b hoat ong theo tng me. Bang ieu khien c gan tren than may, bao gom: Nut khi ong: dung e khi ong may Can gat toc o: ieu chnh toc o nhanh, cham. Co 3 v tr tng ng vi 3 mc toc o: cham, nhanh 1, nhanh 2. Nut nang, ha coi tron: ieu khien e nang hoac ha coi anh tron. Cac thanh phan se lan lt cho vao coi tron. Canh khuay quay vi toc o cao se tao thanh mot hon hp kem. Hon hp kem nay se c nhao tron chung vi bot m. c. Thong so cong nghe: Trang 22

San xuat banh cracker phomai toc o quay cua truc, thi gian tron : tuy thuoc vao yeu cau khac nhau cua tng loai nguyen lieu 3.3.Qua trnh nhao tron 3.3.1.Muc ch Chuan b: cho qua trnh qua trnh u, do phan phoi eu nam men vao nc, nguyen lieu phu, bot m, tao nen khoi bot nhao ong nhat thuan li cho qua trnh len men.ong thi, chuan b cho qua trnh tao hnh, do nhao tron tao thanh mang gluten. Hoan thien: cac ch tieu chat lng cho san pham nh o dai,o gion, o xop do mang gluten c tao thanh, khoi bot nhao co o dai va co kha nang gi kh. 3.3.2.Phng phap: Hien nay trong san xuat banh cracker co nhieu phng pha p nhao bot khac nhau, nhng pho bien hn ca la phng phap bot au va phng phap khong bot au +S dung phng phap bot au,chia lam giai oan bot au va giai oan bot bat +e chuan b bot au gom: 65% bot m vi nc, toan bo lng nam men . Muc ch la tao ieu kien cho nam men phat trien nhanh hn, o am cua bot au cao hn bot bat va khong cho them cac chat han che s sinh san cua nam men nh: shoterning, dau thc vat, muoi an +Bot hat: khoi bot sau khi nhao tron lan 1 vi lng ng sa, shortening con lai, muoi, vitamin D, canxicacbonat, phu gia.

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San xuat banh cracker phomai

Bot

Nc

nam men t=24h

Bot au

to=28-300C

Bot

Nc

Nguyen lieu con lai: shoterknin

Bot hat Thong thng, qua trnh nhao tron co hai giai oan: giai oan au co toc o cham, muc ch la e tron eu cac nguyen lieu vi nhau; giai oan sau toc o anh tron c tang len, ay la giai oan tao cho hon hp co o deo, o dai theo yeu cau. Bang 11: Thong so qua trnh anh tron cua cac loai banh cracker Loai banh Cheese cracker Cream cracker Marie Thong so Khoi lng coi tron (kg/coi) Thi gian anh tron (phut) Khoi lng coi tron (kg/coi) Thi gian anh tron (phut) Khoi lng coi tron (kg/coi) Thi gian anh tron (phut) Nhao tron lan 1 350 Cham: 3; nhanh: 4 300 Cham: 4; nhanh: 4 850 Cham: 2; nhanh: 12 Nhao tron lan 2 390 Cham: 3; nhanh:8 300 Cham: 3; nhanh: 7

3.3.3.Cac bien oi dien ra trong qua trnh nhao tron: a.Bien oi vat ly: Trong khoi bot nhao ong thi vi pha long gom: nc t do, protein hoa tan, ng va cac chat khac con co pha kh c tao nen do s tch luy khong kh khi nhao co s tang nhe the tch

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San xuat banh cracker phomai Co s tang nhe ve nhiet o do ma sat gia canh nhao va bot nhao. Co s thay oi ve khoi lng so vi ban au do mot phan bot dnh len canh nhao, do o ay la qua trnh quyet nh hieu suat cua cong nghe lam banh crackers Tang tnh ong nhat, deo, dai va an hoi cua khoi bot nhao, ieu nay phu thuoc vao thi gian nhao va toc o nhao. b.Bien oi hoa ly: Nhng cau t ri rac lien ket vi nhau tao khoi ong nhat, khoi lng rieng, o nht thay oi T 2 pha ran (bot m)-long(nguyen lieu phu dang dung dch) chuyen thanh 1 pha nhao bot nhao dang paste. Hai protein gliadins va glutenins khong tan trong nc se hap thu nc, duoi mach, nh hng sap xep lai thanh hang va lam phat sinh cac tng tac a beo va hnh thanh cac cau disulfur mi, ket qua hnh thanh mang protein 3 chieu co tnh nht, deo, dnh, an hoi, bao xung quanh cac hat tinh bot va nhng hp phan khac. Hon hp o goi la bot nhao. Tinh bot hap thu nc. Co hien tng nhu hoa chat beo vi nc nh chat nhu hoa . c.Bien oi hoa hoc: Co the xay ra s oxy hoa chat beo hoac bien tnh protein do tac ong c hoc neu thi gian nhao keo dai. Tao nen nhng lien ket hoa hoc mi nh lien ket hidro, lien ket disulfur, lien ket a beo gia cac gliadin va glutenin co trong bot m giup hnh thanh nen mang li gluten. d.Bien oi hoa sinh: Qua trnh nay hnh thanh di tac dung cu a cac enzyme Protease, Amylase va Lipase. Cac enzyme nay pha v cac lien ket trong khoi bot, Protease thuy phan protein lam anh hng en cau truc mang gluten cua khoi bot. Amylase thuy phan tinh bot thanh cac dextrin, lipase thuy phan lipit thanh cac acid beo tang o chua cho khoi bot nhao Cac enzyme thuy phan protein anh hng nhieu hn so vi cac enzyme thuy phan tinh bot. e.Bien oi sinh hoc: Trang 25

San xuat banh cracker phomai S tong hp, trao oi chat cua nam men e tao ca c thanh phan can thiet cho khoi bot nhao nh CO2, mot so san pham phu cua qua trnh len men gop phan tao mui v cho khoi bot nhao. 3.3.4.Cac yeu to anh hng qua trnh nhao tron a. Anh hng cua nguyen lieu Bot m +Protein va gluten: Ham lng va chat lng gluten cua bot co anh hng ln en tnh chat bot nhao va chat lng san pham. Bang 12: Quan he chat lng gluten Tnh cht bt m Protein (% cht kh) Gluten t % Kha nang hut nc % o gian (mm) +Glucid: Tinh bot: Hat nho th de hp vi nc Dextrin: Dextrin t lien ket vi nc do o khi bot nhao co ham lng cao cac dextrin th banh se t va kem an hoi. Pentozan: Cang nhieu pentozan th bot cang hut c nhieu nc, do o khi nhao ta cam thay nht, ac o am: o am cua bot cang thap th kha nang hut nc cua bot cang cao. o mn: Bot cang tho th kha nang hut nc cang thap v dien tch be mat rieng cua no be nen lng nc lien ket vi bot thap. Bot tho co toc o trng n protein cham hn so vi bot mn. Do o, e thu c bot nhao lam t bot tho vi yeu cau thch hp ta can tang o am hoac giam lng ng. ng ng anh hng ti tnh chat ly hoc cua bot nhao. ng lam cho bot nhao tr nen mem nht. Trang 26 Gluten mnh 13.2 35.1 59.2 170 Gluten yu 11.6 24.7 54.8 92 Gluten trung bnh 11.8 34.3 59.8 100

San xuat banh cracker phomai Phan t ng lai co kch thc nho hn nhieu so vi bot, cho nen ng rat hao nc. Khi cho ng vao bot, ng se hut nc trc, lam cho kha nang hut nc cua bot cung nh cua gluten giam. V the, lng nc lien ket vi bot nhao giam, con lng nc t do co trong bot nhao dang dung dch ng tang. Do o, neu co nhieu ng, bot nhao se b nhao, de dnh vao truc can, vao khuon. Cang nhieu ng th bot cang chay. o hut am cua ng cang ln th bot nhao cang nhao. Cac loai ng khac nhau co kha nang hut nc khac nhau. Do o, thanh phan cac loai ng co trong bot nhao cung gay anh hng khac nhau en chat lng bot nhao. ng lam giam s trng n cua protein, tuy theo nong o ng ma toc o trng n cua protein khac nhau: V ng co kha nang hut nc nen khi lng ng bo sung cang ln, ham lng gluten t co trong bot nhao cang giam. Lng ng gay anh hng cua en kha nang hut nc cua bot: Kha nang hut nc cua bot giam khi tang lng ng saccarose. Khi tang lng ng len 1% th kha nang hut nc cua bot giam 0,6%. ng giup phan phoi ong eu nc trong bot nhao Kch thc cua tinh the ng: se anh hng en chat lng san pham. oi vi bot nhao banh crackers, nen dung ng co kch thc tinh the be. Neu kch thc tinh the ln se anh hng en chat lng banh v ng con ong lai tren be mat banh. oi vi bot nhao banh biscuit dai co the dung ng co kch thc tinh the ln hn, v trong bot nhao dai lng nc dung nhieu hn, nhiet o cao hn va thi gian nhao lau hn, do o co u ieu kien e hoa tan ng hoan toan. Chat beo Tang ham lng chat beo se lam giam nang lng nhao tron. Giup bot nhao ti va deo: ham lng chat beo cang cao th bot nhao cang ti va deo, co ngha la co s giam s ket dnh trong cau truc banh crackers Ham lng chat beo cang ln, banh crackers thu c sau khi nng cang b. Chat beo co tac dung nh la mot chat boi trn. Khi co mat vi so lng ln, tac dung boi trn cua no rat ro rang va v the ta can rat t nc e tao nen mot cau truc ac va mem.

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San xuat banh cracker phomai Lam cham s tham nc vao ben trong protein: v khi cho chat beo vao trong bot nhao, chat beo se tao mang tren be mat protein va do o se can tr qua trnh khuech tan cua nc vao trong protein. Giup cho san pham crackers: v chat beo co trong bot nhao se tao mo t mang mong co tac dung bao trum va boi trn cac hat bot, nh o gi c lng khong kh trong bot nhao. Nh co chat beo, cac lo kh se mn va ong nhat hn. Lam giam tnh an hoi cua gluten: v no tao ra mot mang mong tren be mat cac micell, t o lam yeu lien ket gia cac micell vi nhau. Tuy thuoc vao mc o phan tan cua chat beo trong bot nhao, no co the anh hng tot hay xau en chat lng san pham. e phan tan chat beo vao trong bot nhao, phng phap tot nhat la dung chat nhu hoa. Phan t cac chat nhu hoa co au phan cc va au khong phan cc. Do o chat nhu hoa co tac dung lam giam sc cang be mat gia hai pha (pha nc va pha beo), lam cho cac chat phan bo vao nhau ong eu hn. Cac chat nhu hoa se co tac dung giam o nht va tang o deo cua bot nhao. Muoi an Muoi an c che enzym protease, giup gluten hnh thanh tot hn. V vay, muoi an c dung nhieu trong banh cracker e lam tang o dai cua banh. Ngoai ra, - amilase cung co the b c che bi muoi. Nc Nhiet o cua nc cung gay anh hng en chat lng bot nhao: do kha nang hut nc cua cac chat hut nc trong bot nhao nhiet o khac nhau la khac nhau. V du: oi vi protein: kha nang hut nc tot nhat la trong khoang 25 40oC. oi vi tinh bot: kha nang hut nc tot nhat la nhiet o khoang 60 oC. b. Anh hng cua che o nhao bot: o am cua bot nhao Nc la mot thanh phan quan trong trong viec hnh thanh bot nhao: no rat can thiet cho viec hoa tan cac thanh phan khac, cho viec hydrat hoa protein va cacbohydrate va cho viec phat trien mang gluten. Nc co mot vai tro phc tap bi v no quyet nh trang thai cau tao cua polymer sinh hoc, anh hng en moi quan he gia cac thanh phan khac nhau trong bot nhao va Trang 28

San xuat banh cracker phomai gop phan vao cau truc cua khoi bot nhao. No cung la mot yeu to quan trong anh hng en tnh chat lu bien cua bot nhao. o am qua cao se co anh hng xau en cac giai oan gia cong tiep: De dnh khuon trong tao hnh, lam cho nang suat cua thiet b tao hnh giam i ro ret. Trong qua trnh nng, o am cao th qua trnh nng keo dai, lng hi va kh tao ra nhieu lam thay oi cau truc cua banh. o am cao th cng o trao oi nhiet cao, de dang tao nen cac phan ng gay anh hng xau en chat lng san pham. Trong trng hp o am qua cao, bot nhao co the khong a vao cac khau san xuat tiep theo ma phai c nhao lai. Nc gop phan vao viec lam giam tnh an hoi cua bot nha o. o am thap kho khan trong khau tao hnh. Nhiet o bot nhao Nhiet o tang lam tang kha nang hut nc cua bot va tang cac lien ket ngang gia cac chuoi protein Nhiet o anh hng ti trng n va tnh chat vat ly cua bot nhao, 40oC gluten trng n triet e nhat. S hydrat hoa bot trong cac ieu kien khac nhau phu thuoc vao trang thai cua gluten va tinh bot theo nhiet o. trong khoang nhiet o t 25-400 C th s hydrat hoa xay do s hydrat hoa gluten, s hydrat hoa tinh bot trong khoang noi tren hau nh khong oi. Neu tang nhiet o en 600 C th s hydrat hoa tinh bot tang nhng s hydrat hoa gluten lai giam. Nh vay s trng n cua bot nhiet o thap ( 25-400C) phan ln la nh s trng n cua protein con nhiet o cao hn ( 600C) la nh s trng n cua tinh bot S tang nhiet o cung anh hng en ty trong, do co s chay cua cac chat beo. Khi nhiet o > 35oC th hau nh khong con tinh the beo nao con ton tai. Cac tinh the beo trong bot nhao co tac dung on nh be mat cac bong bong kh. Khi ta tang toc o nhao tron se gop phan tot hn cho viec phan bo cua cac tinh the beo , va do o no se giup on nh cac bong bong kh va giam ty trong bot nhao. Trai lai, viec lam chay chat beo nhiet o >35 oC se lam cho cac bong bong kh v ra, lam cho ty trong bot nhao tang len. Thi gian nhao

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San xuat banh cracker phomai Trong thi gian nhao phai tao ieu kien e cac nguyen lieu dang tinh the hoa tan hoan toan va cac qua trnh keo xay ra bnh thng a en tao ra bot nhao co cac tnh chat ly hoc nhat nh.Thi gian nhao ket thuc khi khoi bot nhao at cac yeu cau ve s ong eu va kha nang tao mang gluten Nhao cang lau th kha nang gi nc cua gluten se giam, v protein b bien tnh di tac dung c hoc. Trong thi gian nhao, bot hoan toan c tron lan vi nc va bot nhao tr thanh dnh. o dnh nay giam xuong khi nhao en mot thi gian xac nh. o la do protein va cac chat khac trong bot a lien ket vi nc va lng nc t do trong bot nhao giam xuong. Tang thi gian nhao tron se lam mem khoi bot nhao, va lam giam ca o nht va tnh an hoi. No cung lam tang o dai va giam khoi lng cua banh crackers. Khi ta nhao tron qua mc, mot vai lien ket gia nc va cac thanh phan khac b pha v, dan ti tang ham lng nc t do. Thi gian nhao phu thuoc chu yeu vao cac yeu to sau: +Loai bot nhao: bot nhao dai can thi gian nhao tron lau hn bot nhao xop. Ham lng gluten trong bot: Khi ham lng gluten tang th thi gian nhao cua bot nhao giam. Nhiet o cua hon hp nguyen lieu: Nhiet o ban au cua hon hp nguyen lieu cung co anh hng en thi gian nhao do nhiet o co anh hng en s trng n protein cua bot. Khi nhiet o ban au cua hon hp nguyen lieu tang th thi gian nhao giam. o am bot nhao: o am ln th gluten trng n nhanh. Do o, neu tang o am bot nhao khi cac ieu kien khac giong nhau th thi gian nhao rut ngan lai. Cng o khuay tron: Tang so vong cua canh khuay trong may nhao th thi gian se rut ngan. Cng o khuay tron Cng o nhao tuy thuoc vao chat lng bot va loai banh. Cng o nhao nhanh th khoi bot nhao se mau eu, nhng ong thi no cung de t, de nong. V the, neu muon hnh thanh khung gluten oi vi banh cracker th nen nhao cham. Con oi vi banh cookie, nen nhao tron nhanh e cat t mach, han che hnh thanh khung gluten.

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San xuat banh cracker phomai 3.3.5.THIET B NHAO TRON:

Hnh 4: May nhao tron truc ngang

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San xuat banh cracker phomai a.Cau tao: Co hai canh khuay dang sigma Phu hp vi tat ca cac khoi bot nhao xop va cng. Canh khuay va thung tron lam bang thep khong g e tranh nhiem tap chat va vi sinh vat. May co lp vo ao lam lanh e kiem soat nhiet o khoi bot nhao Chong ro r nc bang chat lieu Teflon

Hnh 5: Canh khuay sigma b.Thong so cua may:

Model Motor chnh Motor tao o nghieng Khoi lng may Toc o canh khuay c.Nguyen tac hoat ong: ay la may hoat ong gian oan

PTR 4 50 HP 5 HP 5700 Kg 30 60 vong/phut

Khoi lng bot nhao tao c 700 kg

Kch thc (Dai x rong x cao) 3182 x 1372 x 2743 mm

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San xuat banh cracker phomai Bot m va hon hp cac nguyen lieu phu se c cho vao pheu nhap lieu ben tren may. Khi hoat ong, hai canh khuay dang sigma se quay tron, nh o khoi bot se c keo dan va nhao tron. Sau mot thi gian nhao tron, ta quay coi tron e khoi bot nhao lay ra de dang. 3.4.Qua trnh u 3.4.1.Muc ch: Hoan thien: Tao kh CO2 lam n bot nhao tao o xop cho banh. Lam cho banh co mui v thm ngon. Trong qua trnh len men, ngoai ru va kh CO2 con tao thanh nhieu san pham phu nh: acid lactic, acid axetic, cac ester, cac andehyt chnh nhng chat nay lam cho banh co nhng mui v thm ngon. Tang o tieu hoa cua banh oi vi c the ngi v khi len men bot nhao th cau truc cac chat phc tap trong bot b bien oi thanh nhng chat n gian hn. 3.4.2.Nhng bien oi xay ra trong qua trnh len men: a. Bien oi hoa sinh: Len men ru: C6H12O6 2CO2 + 2C2H5OH

Trong qua trnh len men bot nhao, enzyme amylase co san trong bot m va do nam men tiet ra thuy phan tinh bot thanh cac ng n gian (glucose, fructose, sucrose va maltose). Nam men chuyen hoa cac ng nay thanh ru, kh CO2 va cac san pham phu khac. Nam men tieu thu cac loai ng nay khong ong thi, au tien no s dung monosaccharide va sucrose co san trong bot nhao luc nay kh CO2 bat au xuat hien sau o nam men tiep tuc s dung ti maltose c hnh thanh trong qua trnh thuy phan tinh bot, lng kh CO 2 sinh ra nhieu hn, ham lng ethanol tang len. Nh vay lng ng trong bot ch co tac dung trong giai oan len men au tien cua bot nhao. Len men lactic: Qua trnh len men chu yeu trong bot nhao la len men ru, nhng thng kem theo s len men lactic. Trong qua trnh nhao bot he vi khuan lactic t khong kh nhiem vao bot va cac nguyen

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San xuat banh cracker phomai lieu khac. Qua trnh len men lactic co the do vi khuan lactic ong hnh va vi khuan lactic d hnh. Vi khuan lactic ong hnh phan huy ng thanh acid lactic theo phng trnh: C6H12O6 2 CH3CHOHCOOH

Vi khuan lactic d hnh ngoai viec tao ra acid lactic con tao ra cac acid khac: acid acetic, acid malic, acid succinicViec tao ra cac acid lam cho pH cua khoi bot giam xuong. Trong qua trnh len men CO2, vi ham lng nho hoa tan trong nc cung co tac dung lam giam nhe pH. o pH cua bot nhao trong thi gian len men giam t 6.0 en 4.0.

Hnh 6: S thay oi pH theo thi gian len men Acid lactic sinh ra lam cho banh co mui v de chu trai vi acid acetic va mot so acid khac lam cho banh co mui v kho chu. Nhng trong qua trnh nng lng acid nay eu b bay hi nen khong anh hng nhieu ti mui v cua san pham. b. Bien oi hoa ly: Cac chat keo co trong bot nhao trng n manh, hp chat protein cu ng trng n. S trng n cua protein co the tien hanh vi cng o khac nhau, toc o khac nhau tuy theo lc n cua bot. Trong bot nhao lc n ln th qua trnh trng n xay ra cham, oi vi bot nhao lc n yeu th protein trng n nhanh . c. Bien oi vat ly: Qua trnh len men co toa nhiet lam nong khoi bot, nhiet o tang lam mot phan bot noi phan huy tao kh CO2, NH3 tao noi cho khoi bot. Lng kh CO2 tch tu trong khoi bot nhao tao nen nhng tui kh. Khung gluten co tac dung gi tui kh o, do o khoi bot tr len xop hn va the tch bot tang len. Khoi bot tr nen mong hn, mn hn. Trang 34

San xuat banh cracker phomai d.Bien oi sinh hoc: Co s sinh trng va phat trien cua te bao nam men,thi gian sinh san hnh thanh te bao mi khoang 30- 40 phut nhng trong moi trng bot can t 2.5 3h. Toc o sinh san phu thuoc vao thanh phan va nong o chat dinh dng cua moi trng, nhiet o, pH va mc o suc khong kh. Nhiet o thch hp cho nam men phat trien la 2931 0C, o pH thch hp t 55.8. nong o chat dinh dng cua moi trng cao hay thap eu han che toc o sinh san, con trong san xuat men, mc o suc kh cang nhieu cang tot 3.4.3.Nhng yeu to anh hng ti qua trnh len men: Nhiet o: Nhiet o thch hp cho qua trnh len la 28 32 0C.Toc o len men tang khi nhiet o tang len 38 400C. Khi nhiet o tang qua 400C kha nang tao kh giam, 540 C nam men b vo hoat nhiet o 300 C kha nang sinh kh gap 3 lan so vi nhiet o 20 0 C Kha nang tao kh con phu thuoc vao so lng nam men,so lng nam men cang nhieu, nhiet o toi u cho nam men phat trien la 320C th kha nang sinh kh CO2 cang cao va thi gian len men cung se ngan lai Tren ay la o th bieu dien s phu thuoc cua t le kh CO 2 sinh ra vi nhiet o va so lng nam men cho vao.

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San xuat banh cracker phomai Hnh 7: Anh hng so lng nam men va nhiet o len men ti kha nang sinh kh CO 2 pH: o pH: e duy tr hoat ong bnh thng cua nam men, pH cua moi trng len men dao ong t 4 6. pH toi u cho qua trnh tao kh cua nam men la 5.5, khi pH dao on g trong khoang 3.7 8 kha nang tao kh cua nam men ch bang 80% lng kh tao c gia tr pH toi u. Khi pH = 3.5, kha nang len men cua nam men giam 50%. Mot so nam men co kha nang song pH 3 trong khoang 1h nhiet o 30 0C. Nam men len men ng maltose pH thap tot hn so vi cac dextrose khac. Kha nang tao kh cua nam men chu yeu phu thuoc vao nhiet o va pH cua khoi bot. o am: o am cua khoi bot cang cao, kha nang len men cua nam men cang nhanh Cac yeu to khac: Lng muoi them vao cang nhieu, kha nang len men giam. Lng chat beo shorterning, dau thc vat nhieu cung anh hng ti kha nang len men, lam giam kha nang len men. 3.4.4.Thiet b len men:

Tien hanh len men trong thiet b nhao tron hoac c a vao tu u

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San xuat banh cracker phomai Hnh 8: Tu u a. Cau tao: Khoi hnh ch nhat, ben trong c chia thanh nhieu ngan . Co he thong ieu khien nhiet o trong tu u. b. Thong so cong nghe: Nhiet o: 28-32oC Thi gian len men phu thuoc vao loai bot, cac nguyen lieu phu, lng nam men cho vao, nhiet o, pH cua moi trng len men.Thi gian u tuy thuoc vao tng loai banh: banh cream cracker thi gian u khoang 18gi, banh cheese co thi gian u tng oi dai hn, khoang 22 24gi . c. Cach tien hanh: Khoi bot sau khi anh tron c cho vao cac tu u, tren be mat co phu mot tam vai e ngan bui hoac cac vat la co the ri vao. Tren moi da bot eu co gan nhan ghi ay u cac thong tin nh ten san pham, thi gian bat au u, so th t cua khoi bot Khoi bot sau khi u c anh gia bang cam quan bang cach anh gia o nhao xem o dnh cua khoi bot. 3.5.Can, xep lp, nh hnh 3.5.1.Qua trnh can,xep lp: a.Muc ch: Hoan thien: Phan bo eu lc tac dung len ca hai phng doc va ngang bang cach can va gap mieng bot, sau o tiep tuc can. Cai thien cau truc khung gluten do qua trnh can, xep lp, can tao nhieu lc tac dung len khung gluten. Hnh thanh cac lp ben trong mieng bot, bo sung bot va chat beo (cracker dust) vao gia cac lp giup cac lp tach ri nhau trong qua trnh nng tao cau truc gion, de bong cho banh. b.Bien oi: Vat ly: nh tang o dai, o an hoi cua khung gluten. Trang 37

San xuat banh cracker phomai Thong so ky thuat: So lp: 6 8 lp Thiet b:

Hnh 9: May can xep lp Cau tao: Gom cac bo phan: Cac truc can. Khu vc tao lp. Pheu nhap lieu cua cracker dust. Bo phan rai eu cracker dust len cac lp bot. Nguyen tac hoat ong Khoi bot nhao c ep thanh dang tam va se c a len mot bang chuyen nam ngang e giam lc cang trc khi c a qua 2 cap truc can e a tam bot en o day can thiet. Sau o tam bot c tiep tuc a len bang chuyen ngh. ngay ban g chuyen nay lp bot ao se c phu len be mat tam bot e bot khong b dnh vao bang chuyen, v tam bot se b lat ngc lai khi i vao bo phan tao lp. Qua trnh tao lp lien tuc c thc hien bi mot c cau chuyen ong qua lai theo hng vuong goc vi tam bot khi tam bot i xuong theo mot bang chuyen cham. Chuyen ong phoi hp cua bang tai va c cau chuyen ong qua lai a mieng bot ti lui tren bang chuyen va tao ra mot c cau hnh zig-zag. So lp tao thanh co the len en 6 8 lp. Toc o di chuyen cua bang chuyen

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San xuat banh cracker phomai nay cang cham so vi toc o chuyen ong cua c cau qua lai, so lp tao c se cang nhieu. C cau nay ong thi cung giup rai bot cracker vao gia cac lp.

Hnh10: C cau hnh zig-zag. CAN LAN 2: S DUNG MAY CAN 2 TRUC (GAUGE ROLL)

Hnh 11: May can 2 truc Cau tao: Gom 2 truc co ng knh: 250 400 mm Thong so cua may: Nang suat: 500 kg/me Toc o: 3m/phut Trang 39

San xuat banh cracker phomai Nguyen tac hoat ong: Khoi bot nhao se b can thanh nhng tam bot nhao. May can 2 truc nay thng c s dung thanh 2 3 may noi tiep nhau. Khoang cach gia hai truc cua tng may cung khac nhau. May au co khoang cach ln nhat va may cuoi co khoang cach nho nhat. Thong so cong nghe: May can th nhat: Tam bot nhao co kch thc 8 mm May can th hai: Tam bot nhao co kch thc 6 mm May can th hai: Tam bot nhao co kch thc 4 mm Cau truc banh sau qua trnh can:

Cac dang xep lp ien hnh cua cream cracker 3.5.2.Qua trnh tao hnh: a. Muc ch cua qua trnh Chuan b: cho qua trnh nng: qua trnh tao hnh nham tao nhng san pham co kch thc, khoi lng nhat nh e ap ng yeu cau cong nghe, ong thi con tao ieu kien thuan li cho qua trnh nng dien ra. Hoan thien: ch tieu vat ly cua banh nh kch thc hnh dang b. Cac bien oi xay ra khi thc hien qua trnh.

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San xuat banh cracker phomai Do qua trnh tao hnh la qua trnh c ly nen khong gay ra nhng bien oi sau sac tnh chat nguyen lieu ma bien oi chu yeu cua nguyen lieu se la bien oi vat ly: s giam the tch, tang khoi lng rieng cua san pham do tac ong cua lc nen truc.

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San xuat banh cracker phomai c. May moc thiet b:

Hnh 12:Thit b to hnh Cau tao: Gom 2 co ng knh giong nhau. Truc th nhat co nhiem vu tao hnh, truc con lai co nhiem vu cat banh. ng knh truc khoang 260 300 mm. Pha di hai truc thng co 1 truc hoac 2 truc . ng knh ln hn: 400 450 mm. Nguyen tac hoat ong: S dung phng phap dap khuon: dung ap lc e nen ep nguyen lieu thanh hnh dang nhat nh bang truc uc.

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San xuat banh cracker phomai

Hnh 13: Nguyn tc hot ng ca my to hnh quay 2 trc v 3 trc Tam bot nam trong khu vc cat c gi chat gia nhng truc co khac (c khac hang loat) va mot hay nhieu truc e c phu cao su.Truc au tien an bot, in hoa van len be mat va sau o gi chat bot len khu vc cat.Truc th hai ch c cham khac nhng ng net ben ngoai cua cracker va cat e lai mot mang li cac phan ra (se khong c gi lai) tng t nh oi vi loai may cat di chuyen qua lai. d. Thong so cong nghe: Tuy vao tng nha may ma banh co nhieu hnh dang khac nhau. Yeu cau ky thuat: Banh song khong b ro mat, be mat bong lang, banh co hnh dang nguyen ven. Cac s co trong tao hnh: Hien tng Bot dnh truc khuon Bot can de gay nt, san sui Bot can dung khong eu Banh tao hnh khong nguyen ven Banh tao hnh b ria Nguyen nhan o am bot nhao cao o am bot nhao thap Truc can khong tru b r Bot nhao xuong khong eu Khac phuc Rac tinh bot khoai m len bot can em nhao lai ieu chnh lai no ieu chnh lai

Khuon tao hnh khong sac Thay khuon canh Trang 43

San xuat banh cracker phomai Banh tao hnh khong ra Bang tai khau tao hnh Lam t bang tai khuon qua kho Thu hoi ra banh:

Hnh 15: Thu bot ra banh Khi banh c tao hnh th phan ra banh se c lay ra va c 1 bang tai khac a ve may can e tiep tuc qua trnh can bot. Khi bot d sau cat c nhap tr lai pheu nhap lieu th co mot so van e nay sinh. Neu nhap bot mi lien tuc vao may tao tam th can phai a bot d vao pha sau hoac pha trc cua may tao tam e ket hp chung lai. Khi bot ti c nhap khong lien tuc vi so lng ln th can nhap bot d cung vi bot ti. ieu nay c thc hien vi s giup cua mot khe h hoac mot truc nho 3.6.Nng 3.6.1.Ban chat: Nng la qua trnh x ly nhiet, ma nhiet lng truyen vao san pham chu yeu bang bc xa. o la mot trong nhng qua trnh cong nghe phc tap, trong o xay ra nhng bien oi hoa hoc, ly hoc, hoa ly (bien oi he keo) lam cho san pham at ti chat lng theo yeu cau. Theo quan iem nhiet - ly th nng la qua trnh am - nhiet c ac trng bang s truyen nhiet va am trong he mao - xop - keo cua vat lieu di anh hng cua nhiet o cao. 3.6.2.Muc ich: Nng la cong oan quan trong nhat trong cong nghe san xuat banh noi chung. Qua trnh nng c thc hien nham cac muc ch cong nghe sau:

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San xuat banh cracker phomai a Che bien: ay la muc ch chu yeu cua qua trnh : di tac dung cua nhiet o cao san pham tr nen chn giup banh t cho khong an c tr thanh an c, thch hp cho muc ch s dung , ong thi qua trnh nng con tao cho banh co mau sac, mui v hap dan, cau truc ac trng. b. Bao quan: Nhiet o nng thng tren 2000C, vi nhiet o cao nh vay he enzyme phan huy se nhanh chong mat hoat tnh, ngan chan s tao thanh cua mot so thanh phan hoa hoc co the gay anh hng xau ti chat lng cua san pham. Tuy nhien vi mot nhiet o nng cao cung anh hng bat li ti san pham, ng b mat i do b caramel hoa, cac vitamin giam do b phan huy, nhng thay vao o hnh thanh lp vo cng, va tao mau caramel giup cho san pham them nhieu gia tr cam quan. Qua trnh nng con giup tieu diet vi sinh vat va tao mot moi trng bat li cho vi sinh vat do nhiet o cao pha huy cac enzyme trong te bao vi sinh vat cac qua trnh trao oi chat trong c the vi sinh vat b ngng lai. Mat khac san pham sau khi nng o am giam nhanh chong, san pham tr nen kho hn cung tao moi trng bat li cho s phat trien cua vi sinh vat. V vay, banh cracker sau khi nng co the c bao quan rat lau. c. Hoan thien: Giong nh oi vi cac loai banh biscuit khac, oi vi banh cracker, qua trnh nng lam bay hi nc va tao nen cau truc ac trng cho san pham, ong thi, tao mau sac tren be mat. Qua trnh nng giup banh tr nen chn, an c, co cau truc, mau sac, mui v hap dan, ac trng. 3.6.3.Bien oi cua bot nhao trong qua trnh nng: a.Bien oi vat ly: Bien oi ve nhiet o: nhiet o cua banh tang len do qua trnh truyen nhiet t lo nng vao banh, nhng s truyen nhiet xay ra khong ong eu trong san pham. Toc o tang nhiet tng lp giam dan theo chieu day cua khoi bot: lp ngoai cung tang nhanh, trung tam th cham, v vay no se tao ra mot gradient nhiet o gia vung tam va be ngoai cua banh. VD: ch trong vong thi gian vai phut nhiet o lp ngoai banh cracker tang len 100 0C trong khi o nhiet o trung tam banh mi ch at 70 0C.

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San xuat banh cracker phomai Khi nng banh cracker gradient nhiet o gia vung tam va lp ngoai cung tang giai oan au, sau o giam dan va tien ti thi k khong oi. Vao giai oan cuoi cua qua trnh gradient o co the tang vot len. giai oan au, nhiet o cua lp ngoai tang nhanh trong luc trung tam tang len cham chap. Giai oan 2: Khi nhiet o lp ngoai tien en gia tr khong oi ( en giai oan boc hi) th nhiet o trung tam tang dan, do vay gradient nhiet o giam i. giai oan cuoi, nhiet o ben ngoai tang do qua trnh boc hi ket thuc trong khi nhiet o trung tam th tien ti khong oi, ieu o dan en s tang vot gradient nhiet o.

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San xuat banh cracker phomai

Hnh 15: Nhng bien oi xay ra trong qua trnh nng. Hnh tren bieu dien s thay oi nhiet o trong suot qua trnh nng, vi moi s thay oi nhiet o mot thi iem nao o se xay ra nhng bien oi khac nh : + Nhiet o 400C se lam mem cau truc gluten. + 600C la nhiet o toi u cho cac enzyme hoat ong. + 780C mach gluten se b ong lai.

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San xuat banh cracker phomai + 800C enzyme b c che. + 1000C the tch khoi bot at cc ai, ng bao hoa. + 1100C be mat banh vang + 1300C phan ng caramel bat au xuat hien. + 1600C be mat banh hoa nau. Bien oi ve khoi lng: khoi lng cua banh giam ang ke do s thoat hi nc. o am cua banh trc khi nng khoang 2030%, sau khi nng ch con khoang 10%. Bien oi ve the tch va khoi lng rieng: qua trnh nng lam cho the tch banh tang len do cac chat tao noi b phan huy va qua trnh len men sinh ra kh CO 2. The tch tang len ma khoi lng giam do o khoi lng rieng giam. Di ay la o th bieu dien s tang the tch trong qua trnh nng. nhiet o 90 0 the tch tang khoang 27%. Khi nhiet o tang len 100 0C la nhiet o hi nc bat au boc hi khi o the tch tang len rat nhieu do the hi chiem nhieu the tch hn so vi the long

Hnh 16: S tang the tch khi tang nhiet o.

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San xuat banh cracker phomai b. Bien oi hoa ly: Bien oi am: song song vi s bien oi nhiet o, o am cua banh cung bien oi do qua trnh trao oi am vi moi trng. ac trng cua qua trnh trao oi am la s boc hi nc, tien ti can bang am vi moi trng. Qua trnh boc hi am cua banh dien ra qua 3 giai oan. Giai oan 1: nhiet trong banh cha tang at en nhiet o boc hi, nen cha xay ra hien tng boc hi nc, o am cua khoi bot khong oi Giai oan 2: khi nhiet o cua banh tang cao, co s boc hi nc manh liet theo hng t trong ra ngoai. Giai oan 3: s boc hi am giam dan do luc nay, lng am t do trong banh a boc hi gan het, ch con lai am dang lien ket. Bien oi he keo: khi nng cac loai banh, s tac dung tng ho gia protein, tinh bot vi nc lam cho bot nhao tien ti trang thai mem, deo. Protein trng n nhiet o 30 0C, t0 cao hn th o trng n giam dan , tren 50 0C protein ong tu va tach nc. Nc o se c tinh bot thu hut trong qua trnh trng n cua no. Nhiet o trng n tot nhat cua tinh bot la 40 - 600C, ong thi qua trnh trng n la s ho hoa. Qua trnh ho hoa cua tinh bot xay ra trong suot qua trnh nng, thu hut mot lng nc ang ke lam cho san pham kho hn. Bien oi trang thai: di tac dung cua nhiet o cao, trang thai cua san pham bien oi ang ke. nhiet o khoang 50 70oC, protein ong tu va giai phong nc, con tinh bot th b ho hoa mot phan, tao thanh khung xop va cung vi cac thanh phan khac nh ng, chat beo, tao thanh cau truc ac trng cho banh. Cac acid acetic, ethanol, acid lactic nhiet o cao chuyen t dang long thanh dang hi c. Bien oi hoa hoc: Tinh bot: Ham lng tinh bot giam v mot phan b phan huy trong qua trnh nng banh tao ra cac dextrin va ng. Trong qua trnh nng, tinh bot b ho hoa nhng s ho hoa nay khong hoan toan v lng nc nay qua t khong u e ho hoa het tinh bot. ng: Lng ng trong banh giam do tham gia phan ng caramen va Maillard, tuy vay lng ng nay giam khong ang ke. Protein: Ham lng protein tong nhn chung khong thay oi. Khi ot nong en giai oan 6070oC protein b bien tnh, giai phong ra lng nc khi trng n a hut vao. Trang 49

San xuat banh cracker phomai Chat beo: Ham lng chat beo giam khong ang ke. Phan ng Maillard: gia ng kh va cac nhom amin. Phan ng Caramel: phan ng dehydrat hoa ng nhiet o cao. Tang toc o cua cac phan ng hoa hoc. d. Bien oi sinh hoc: Nhiet o cao lam vo hoat cac enzyme co trong bot m, tai nhng iem ma nhiet o tang nhanh cac loai enzyme hau nh b vo hoat ngay. Con nhiet o nhng phan ben trong tang cham hn, thi gian enzyme c duy tr nhiet o toi thch cho hoat ong cua chung keo dai hn, do vay chung hoat ong manh hn. o la nguyen nhan dan ti s bien oi chat lng cua mot so san pham. Nhiet o cao con tieu diet vi sinh vat, trong giai oan au nhiet do con thap cac loai vi sinh vat van con hoat ong. Khi nhiet o tang 60 0C , protein bat au bien tnh vi sinh vat b tieu diet dan en gan nh hoan toan e. Bien oi cam quan: nh cac bien oi sinh ly hoa neu tren, gia tr cam quan cua banh c tang len ang ke. Nh qua trnh nng, san pham tr nen chn, an c, co mau sac, mui v hap dan. 3.6.4.Cac yeu to anh hng qua trnh nng: Che o nng banh c ac trng bi cac thong so: nhiet o cac vung trong buong nng va thi gian nng banh: a.Nhiet o vung nng: Do qua trnh nng xay ra nhiet o rat cao thng tren 2000 C, v vay lng nhiet truyen vao cho banh thng la bc xa nhiet, dan nhiet,oi lu nhiet. Nhiet c truyen t lp ngoai cua banh vao trong banh. Noi chung nhiet o anh hng ti qua trnh nng, khi nhiet o tang len cac phan ng Maillard cho mau khong tot. Ngi ta thng khong che phan ng melanoidin 160 0C v nhiet o tren 1600C melanoidin tao thanh se khong hoa tan trong nc do o lam giam kha nang tao mau. Neu nhiet o thap qua se khong u ieu kien e qua trnh nng xay ra.

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San xuat banh cracker phomai

Hnh 17 : ng cong nhiet o va thi gian nng ly tng

Ta thay rang nhiet o cc ai la 257 0 C sau khi nng khoang 5 phut va giam t t sau khi nng 400 C ( ay ch la ng cong ly tng cho banh lam t 1 kg bot m) Ta phai tien hanh chon nhiet o tng vung sao cho phu hp gom co 4 vung: vung lam am, vung nhiet o cao, vung nhiet o trung bnh, vung nhiet o thap b.Thi gian nng: Thi gian nng oi vi nhieu loai banh m khac nhau phai c anh gia da tren hnh dang va khoi lng banh. Thi gian nng phu thuoc vao cac yeu to sau: Tnh chat mieng bot, loai bot s dung, khoi lng va hnh dang mieng bot, trang thai cua mieng bot. Neu bot vi gluten yeu can nng nhiet o cao e protein bien tnh nhanh gi nguyen khung va khong b xep lai Khoi lng moi banh, banh nho nhiet o buong nng cao va thi gian nng ngan, banh to phai ha nhiet o xuong va keo dai thi gian nng banh Che o nng, nhiet o, o am va toc o dong kh oi lu cng bc. Khoang cach gia mieng bot va be mat nng. Trang 51

San xuat banh cracker phomai Tuy nhien, chat lng cua banh phu thuoc rat nhieu vao thi gian nng toi u. Khong nhng mui, v cua banh m ma con cac tnh chat khac cua banh nh o an hoi cua ruot, ket cau va tnh chat khi nhai cung phu thuoc vao yeu to thi gian nng toi u va co kha nang kch thch s ham muon cua ngi tieu dung. moi s la chon che o nhiet o va cach thc truyen nhiet trong cac lo khac nhau eu co thi gian lu e banh at chat lng tot nhat. Trong thc te, nhng che o toi u c ch ra khong c tuan theo tuyet oi, va loi thong thng, tong quat nhat oi vi banh m la nng trong thi gian qua ngan. Ket qua la se lam cho banh co vo day va a nh hng en mui v cua banh. Trng hp qua trnh len men on nh ket thuc cha at th nen ha nhiet o nng va keo dai thi gian e qua trnh len men tiep tuc lau hn tao cho banh n to hn. 3.6.5.Thiet b:

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San xuat banh cracker phomai

Hnh 18: Lo nng a.Cau tao va nguyen tac hoat ong: Nguon nang lng: bang kh gas Cach truyen nhiet: gia nhiet gian tiep . Vat mang banh e nng: bang tai bang thep (bang tai dang mat li co nhieu day kim loai an lai vi nhau. Hnh dang buong nng: tang ham (tunnel) Cau tao: + Khoang nng c chia thanh nhieu vung (zone) doc theo chieu dai cua lo nng, co 5 zone, co 4 ong thai kh moi zone tr zone 1. Cac zone c bo tr cac au ot gian tiep bang gas tai mat tren va mat di cua bang tai i qua. + au ot trc tiep la mot ong hnh tru co uc lo pha ngoai e kh co the thoat ra ngoai, moi au ot co the ieu chnh oc lap. e tao ra la ta gi kh gas ap suat khong oi roi thoi qua au ot. Tai moi au ot se c bo tr cac bo phan anh la bang ien, co nhiem vu sinh tia la ien ot chay hon hp kh gas. +Nhiet o tai cac au ot co the ieu chnh ta ng giam va tat m thong qua man hnh at ben ngoai. Co cac thiet b cai at nhiet o cho tng au ot. Trang 53

San xuat banh cracker phomai b. Cac thong so ky thuat: Thiet b KL 1000 ( s dung kh ot ) Khoang nng +Be rong 0.8m +Chieu dai 15m +Chieu rong bang tai 0.65m . Nang lng s dung 22 Kw. Nhiet o at c 360 0C. Nang suat 1000 kg/h. 3.6.6. Thong so cong nghe: Qua trnh nng banh cracker c thc hien trong lo nng ot bang gas, c ieu khien t ong bang may vi tnh. Banh sau khi nh hnh xong tiep tuc theo bang tai i vao buong nng. Buong nng c chia thanh 5 khu vc (zone), moi khu vc c cai at mot nhiet o khac nhau tuy muc ch cua tng zone. Bang 3.23 cho biet nhiet o tai tng zone oi vi moi loai banh cracker. Bang 13: Thong so nhiet o lo nng cua cac loai banh cracker Nhiet o (oC) Vung 1 218 12oC Vung 2 247 12oC Vung 3 250 12oC Vung 4 257 12oC Vung 5 260 12oC Tong thi gian nng (phut) 3,54

Muc ch cua tng zone nh sau: Zone 1 co tac ong lam n banh. Sau khi qua zone 1 va zone 2, banh hau nh a at en o n va kch thc cua san pham sau cung. Zone 2, Zone 3, Zone 4 va Zone 5 co tac ong lam chn banh, tao cau truc, mau sac ac trng cho san pham va lam bay hi am cua banh en con khoang 23%. e lam tang hieu qua trao oi nhiet, bang tai lo nng c lam t si kim loai rat nhe. Ngoai ra, khi khi ong lo, phai ot nong lo en nhiet o cai at trong khoang 4 5 giay trc khi banh c bang tai a vao buong nng

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San xuat banh cracker phomai 3.7.Phun dau 3.7.1.Muc ch: Hoan thien san pham lam tang gia tr cam quan cua san pham, tao be mat banh lang mn, tang o bong, mau sac. 3.7.2.Cac bien oi: Bien oi vat ly: Tang the tch banh. S khuech tan cua dau vao banh va cac hp chat hng hoa tan vao dau. Bien oi hoa hoc: Co the xay ra oxi hoa chat beo khi phun nhiet o qua cao. Cam quan: Cai thien mau mui cho san pham, tao s bong lang cho be mat banh, tang s ngon mieng. 3.7.3.Thiet b: Cau tao: Thiet b phun dau gom bon cha dau, bm ap suat, mang hng dau. Hai ong phun dau vi cac au phun c bo tr tren va di bang tai. Thiet b gia nhiet dau co the gia nhiet dau en 170 oC. Thong so ky thuat: Cong suat cua thiet b gia nhiet dau 2 kW . Nguyen ly hoat ong: Dau c phun len khi banh ang con nong. Banh sau khi ra khoi lo nng c chay tren bang tai i vao he thong phun dau. Dau c gia nhiet va bm ap suat se hut dau t bon roi phun trc tiep len banh qua mot day cac au phun. Dau tha se chay khoi bang tai va c hng bang mang inox at ben di. Trang 55

San xuat banh cracker phomai Thong so cong nghe: Toc o bang tai i trong he thong phun dau 5-20m/phut Lng dau phun len banh chiem khoang1-5 Kg/phut

Hnh19: Thiet b phun dau

3.8.Lam nguoi 3.8.1.Muc ch Chuan b cho qua trnh bao goi. 3.8.2.Cac bien oi: Bien oi vat ly: Banh t nhiet o cao c lam nguoi en nhiet o moi trng, thuan li cho khau bao goi va tranh ngng tu am sau khi bao goi. Cac bien oi khac: khong ang ke. 3.8.3.Thiet b: lam nguoi bang bang tai. Cau tao:

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San xuat banh cracker phomai Chieu dai bang tai gap 1,5 lan chieu dai he thong nng, khoang 5-7m Co 4 quat gan pha tren, trong o gom 1 quat hut va 3 quat ay. So tang bang tai: 2, 4 hoac 6 tang. Khoang cach gia hai tang: 400 500 mm. Nguyen ly hoat ong: Banh c lam nguoi bang khong kh nh i mot quan g ng dai tren bang tai. Banh sau khi phun dau con rat nong, au tien qua quat hut, hut bt hi nong va hi dau tren banh. Sau o banh tiep tuc lam nguoi lan lt bang 3 quat ay. Thong so cong nghe:Toc o bang tai lam nguoi: 13,7 m/phut

Hnh 20: Thiet b lam nguoi bang tai 3.9.Phun mui 3.9.1.Muc ch: Hoan thien: tao mui ac trng. San pham ra khoi may nng hau nh t co mui hng do s ton that cua cac cau t de bay hi khi san pham n.Do o gia v thng bo sung vao san pham sau khi nng e lam tang mui v cho san pham. Gia v neu bo sung vao nguyen lieu trc khi vao thiet b nng se trai qua nhieu thay oi. Va hau het cac thay oi nay eu khong mong muon, nhng hng lieu de bay hi cung vi hi Trang 57

San xuat banh cracker phomai nc khi san pham n ngoai ra chung con b pha n huy hoac tng tac vi mt so thanh phan khac di tac dung cua nhiet o cao. Trong mot so trng hp, cac thanh phan gia v con gay tr ngai oi vi viec hnh thanh cau truc cua san pham, nhat la khi san pham cha nhieu chat beo.V vay phng phap thc te c s dung la phun gia v len san pham sau khi nng. 3.9.2.Chuan b: Nguyen lieu dung e tao dch mui bao gom dau an, shortening, mui, phomai.Hon hp tren c tron trong cac bon bang thep khong r trc khi c phun len san pham trong thiet b phun gia v. 3.9.3.Cach tien hanh: Qua trnh phun mui v c thc hien tng t qua trnh phun dau. 3.9.4.Cac bien oi Chu yeu xay ra cac bien oi ve hoa ly.Cac chat mau mui va cac chat tao v se hap phu tren be mat va tham thau mt phan vao ben trong ban thanh pham. 3.10. Xep banh 3.10.1.Muc ch: Chuan b cho qua trnh bao goi. 3.10.2.Thiet b Cau tao: May gom co nhieu ranh co o doc. Cuoi moi oan doc co 1 con quay hnh chong chong. Thong so ky thuat: ZW1000 Nang lng: 1,5 Kw. Toc o nhap banh: 5-20m/phut. Nang suat : 1000Kg/h. Khoi lng 1,9 T.

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San xuat banh cracker phomai Nguyen ly hoat ong: Banh sau khi c phun mui se nam ngang. Sau o banh se trt theo cac ranh cua may. Tai cuoi oan doc, con quay hnh chong chong se dng banh ng len. Sau khi ra khoi may, ta se co c 1 hang banh xep ng. Thong so cong nghe: Toc o nhap banh 20m/phut

Hnh 21: Thiet b xep banh 3.11. Bao goi 3.11.1.Muc ch: Bao quan: do biscuit la san pham de hut am nen can thiet ke bao b kn, chong am, khong hut mui. Hoan thien: Thuan tien trong van chuyen va phan phoi, tao gia tr thng pham. 3.11.2.Thiet b Cau tao:

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San xuat banh cracker phomai Gom 1 bo phan bao goi , mot bo phan ghep m, 1 ba ng tai. Thiet b lam bang vat lieu khong gay anh hng xau en san pham (ac biet la nhng bo phan tiep xuc nhieu vi san pham), khong b an mon, am bao ve sinh, lam viec vi s chnh xac cao. Thong so ky thuat: Toc o bao goi: 50 goi/phut. Chieu dai mot goi: 90 200mm. Chieu rong mot goi: 35 60mm. Nguyen ly hoat ong: Sau khi trai qua tat ca cac cong oan, banh c cho vao khay va a vao phong ong goi. au tien banh c bao goi trong bao b PE, co the hut chan khong hoac khong hut chan khong, sau o banh c bang tai a ti bo phan ghep m.

Hnh22: Thiet b bao goi

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San xuat banh cracker phomai

PHAN 4: CH TIEU CHAT LNG SAN PHAM

Theo TCVN 5909 1995. 4.1.Ch tieu ly hoa: Ten ch tieu o am, Ham lng protein Ham lng chat beo Ham lng ng toan phan (saccharose) Ham lng tro khong tan trong acid HCl 10% o kiem, o (o) 4.2.Ch tieu cam quan: Ten ch tieu Hnh dang ben ngoai Mui v Trang thai Mau sac Tao chat la 4.3.Ch tieu vi sinh: Loai VK hieu kh gay benh E.Coli Tong so VK hieu kh, con/g Nam moc sinh oc to Tong so nam men, con/g Bang 14: Thanh phan co trong 16g banh Ritz (1 goi) Thanh phan Chat beo tong Protein Khoi lng 3.7 g 1.2 g Yeu cau Khong c co Khong c co < 5.103 Khong c co < 100 Yeu cau Banh co hnh dang theo khuon mau. Banh khong b bien dang, dap nat, khong co banh song. Banh co mui thm ac trng cua tng loai. Don, xop, mn mat. Mau ac trng theo ten goi tng loai banh, khong co vet chay en. Khong co Mc < 4% > 3,7% > 20% > 15% < 0,1% < 2o

Cacbonhydrat tong 10.3 g

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San xuat banh cracker phomai Nc Tro Ca Fe Na 0.5 g 0.4 g 0.023 g 0.0006g 0.124 g

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San xuat banh cracker phomai

PHAN 5: THANH TU CONG NGHE

5.1.LO NNG RF (RADIO FREQUENCY) Lo nng RF lam viec rat hieu qua va tach am khong giong vi nhng loai lo nng khac ch dai 17 feet (5.2m) bi v nang lng cua RF co the gia nhiet san pham va tach am nhanh chong. Cong nghe song radio giong vi qua trnh x ly trong lo vi ba. Ca hai cong nghe eu sinh ra noi nhiet bi s va cham cua cac phan t ben trong san pham. Song vo tuyen cao tan la nguyen nhan cua s sap xep lai cua cac phan t nc trong banh cracker hoac cookies, truyen nhanh tao ra ma sat gia cac phan t va nhiet o c nang len cao 212 F (100oC). S boc am nay rat nhanh, eu nhau, va on nh t ngay qua ngay ngay ca nhng ngay am t nhat. RF cho c san pham co o am on nh eu nhau vi mc sai so la 0.2%. Ben canh tiet kiem dien tch va toc o nng nhanh con co nhng thuan li khac khi s dung thiet b song vo tuyen. RF mang lai cho chung ta s kiem soat tot hn ve ham lng am va s can bang am trong san pham, tang thi gian bao quan va khong can thong qua kiem tra v qua qua trnh kiem tra th banh phai b be gay, nt v. Lo RF nng 11,500 banh crackers va cookies trong 1.5 phut. Nang suat 900kg/me Banh cracker va cookie lo nng thong thng th ham am con lai sau khi nng la3.5-4.5%, con khi qua RF th ham am la 2.5-3.0% va chat lng san pham cung cao hn . Lo nng RF la buong c boc kn, ni ma nguyen lieu c at gia nhng ien cc va se c ot nong. Nhng ien cc va nguyen lieu tao ra tu ien au ra cua may phat RF. ay, nguyen lieu that s tr thanh ien moi trong mach cong hng. ay la ni ma nguyen lieu chuyen oi nang lng tan so cao c cung cap bi may phat thanh nhiet tc thi toan bo mat cat ngang cua nguyen lieu.

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San xuat banh cracker phomai

Hnh 23: Lo nng nguyen lieu 5.2.THAY OI NGUYEN LIEU: Ben canh s dung 100% bot m e lam banh Cracker th cac nha may thng s dung tinh bot khoai m vi 25 35% Muc ch: giam gia thanh va cai thien mot so tnh chat cua san pham V du nh giup be mat banh bong trong qua trnh nng banh v khi gia nhiet, nhiet o cao bien oi tinh bot, tao ra hp chat dextrin tren be mat san pham. trang thai thieu nc, dextrin lam cho be mat san pham bong.

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San xuat banh cracker phomai TAI LIEU THAM KHAO Duncan J.R Manley, Buiscuit, cookie and cracker manufacturing manuals Manual 3, Woodhead Publishing Limited, England, 1998 Duncan Manley, Technology of biscuits,crackers and cookies Samuel A.Mapz, Cookies and Cracker Technology, Van Nos Tranand Leinhold Publishing Limited, New Yorks, 1998. James G.speight, Chemical and process design handbook , Mc Graw- Hill companies. Le Bach Tuyet (Chu bien), Cac qua trnh cong nghe c ban trong san xuat thc pham, NXB GD, 1996. Tai lieu TCVN (Trung tam k thuat tieu chuan o lng va chat lng Viet Nam khu vc 3) TCVN 4359:1996 TCVN 5538:2002 TCVN 5539:2002 TCVN 6959:2001 TCVN 1874:1975 TCVN 6026:1995 TCVN 3974-84 TCVN 1858-86 TCVN 7400:2004 Tai lieu Web: http://www.apex-equip.com http://members.surfeu.de http://www.vuurslag.nl http://www.dijko.com/en/index.php http://www.hfmachine.com.cn http://www.huawei-machinery.com http://www.kbi.tw/biscuit.htm http://www.j4.cz/index.php?page=show&lang=en http://www.admir.com/biscuit-making.htm http://www.biscuitoven.net/ http://www.vdibiscuitplant.com/Rotary_Moulding_Machine.htm http://www.zhhp.com http://www.alibaba.com/catalog/11131026/Biscuit_Baking_Oven.html http://www.mechtechindia.com/files/virtual.htm http://www.vdibiscuitplant.com http://zqcoral.en.alibaba.com/product/50352246/200814654/Wafer_Baking_oven/Tunnel_Bakin g_Machine.html http://www.britannica.com/eb/subject?idxStructId=49594 http://www.fantasticsnacks.com.au/pdf/how_to_make_crackers.pdf http://www.allbusiness.com/business-finance/leasing-equipment-leasing/380173-1.html Trang 65

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7.