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TABLE OF CONTENTS
1. INTRODUCTION.....................................................................................................3
1.1 Description of the company...............................................................................3
1.2 Divisions in the company...................................................................................3
1.2.1 Production..........................................................................................................3
1.2.2 Sales..................................................................................................................3
1.2.3 Human Resource...............................................................................................3
1.2.4 Bakery Manager.................................................................................................3
1.2.5 Transport............................................................................................................4
1.2.6 Maintenance.......................................................................................................4
1.2.7 Administration + Finance....................................................................................4
1.2.8 Food Safety........................................................................................................4
1.3 Job Title...............................................................................................................5
1.3.1 Job Description..................................................................................................5
1.4 Organizational structure.....................................................................................6
1.5 Products...............................................................................................................7
2. THE PRODUCTION PROCESS.............................................................................8
2.1 Purpose of each unit operation........................................................................9
2.1.1 Raw Material Receiving.....................................................................................9
2.1.2 Premix................................................................................................................9
2.1.3 Mixing...............................................................................................................10
2.1.4 Divider and Rounder........................................................................................12
2.1.5 Intermediate Proofer........................................................................................13
1
2.1.6 Moulder............................................................................................................14
2.1.7 Final Proofing...................................................................................................15
2.1.8 Oven Baking.....................................................................................................16
2.1.9 Depanning........................................................................................................19
2.1.10 Cooler.............................................................................................................19
2.1.11 Bagging, Slicing and Packaging.....................................................................21
2.1.12 Metal Detector................................................................................................22
2.1.13 Dispatch.........................................................................................................22
2.2 Critical factor that influence the safety and quality of final product......................22
3. DUTIES.................................................................................................................26
3.1 Routine duties...................................................................................................26
3.2 Administrative duties........................................................................................26
3.3 Ad hoc duties....................................................................................................26
4. ANALYTICAL TESTING.......................................................................................27
5. PRODUCTION......................................................................................................27
5.1 Materials and Methods........................................................................................27
6. EXTERNAL AND INTERNAL AUDITS.................................................................29
6.1 Internal Audits...................................................................................................29
6.2 External Audits..................................................................................................30
7. AD HOC DUTIES..................................................................................................30
7.1 Shelf life.............................................................................................................30
8. COMMENTS ON TUT TRAINING.........................................................................30
9. REFFERENCE......................................................................................................31
APPENDIX 1: TYPICAL NUTRITIONAL INFORMATION OF WHITE BREAD.........32
APPENDIX 2: TYPICAL NUTRITIONAL INFORMATION OF BROWN BREAD.......33
2
1. INTRODUCTION
1.1 Description of the companySUNBAKE is a baking division of Foodcorp consumer brands, now a division of
Rainbow Chicken Limited (RCL) and it distributes bread and confectionery to four
provinces in South Africa namely Limpopo, Gauteng, Mpumalanga, and North West.
Sunbake manufactures brown, white, and crushed wheat bread and white
hamburger buns, super hamburger buns, seeded mega hamburger buns, hot dog
rolls and mega hot dog rolls (confectionery). Sunbake products are available at
major retailers like Shoprite, Pick ‘n Pay, and Spar and also at informal markets.
1.2 Divisions in the companyThe company consist of eight divisions namely production, sales, human resource,
management (bakery manager), transport, maintenance, administration (finance)
and food safety.
1.2.1 Production
Production is responsible for the manufacturing of bread and ordering raw materials
from suppliers. The department is responsible for supplying personal protective
equipment as well as providing Health and safety measurements to its staff.
1.2.2 Sales
Sales division is responsible for selling bread and looking for new customers in order
to expand business. They are involved in the distribution of goods and services.
1.2.3 Human Resource
Human Resource (HR) is responsible for hiring employees and making sure that the
workers are working under good conditions. HR is also responsible for giving
training to staff.
1.2.4 Bakery Manager
Bakery manager is responsible for managing the bakery. The manager oversees all
the activities in the bakery and is responsible in making sure that the bakery is
operating efficiently. The manager is also responsible for effective planning,
delegating, coordinating, organizing, and decision making to attain desirable profit for
the company. The manager’s responsibility also includes running the bakery and
providing leadership to heads of departments, supervisors and workers, to create a
3
motivated working team which would improve productivity, save cost, deliver on time
and produce a quality service which will ensure long term employment for all.
1.2.5 Transport
Transport is responsible for transporting bread to customers and two depots, namely
Mafikeng and Potchefstroom. The department takes care of all the services of the
vehicles in the company to make sure all vehicles can deliver breads without
mechanical failures. Transport makes sure all vehicles are cleaned after deliveries
and making sure all vehicles are road worthy in line with the South African Transport
Laws. The transport manager hires in consultation with the Human Resources
Manager all the drivers and provides additional training to all drivers to make sure
they are competent.
1.2.6 Maintenance
Maintenance makes sure all production machines and equipments are operating
effectively and if there is a breakdown they must solve the problem. Maintenance is
also responsible for repairs in the building. They do all the maintenance work like
changing light bulbs, replacing windows, and painting of the building.
1.2.7 Administration (Finance)
Finance is responsible for paying salaries to all employees and managing sales.
They manage all the accounts used by all departments and making sure all accounts
are up to date by paying them on time. Administration officers perform a range of
administrative tasks to ensure an organization functions efficiently. Administration
officers use computers, software packages, fax machines, telephone systems, filing
systems, salary and leave record systems, photocopiers and binding machines.
They take orders from customers and supply them to production.
1.2.8 Food Safety
Food Safety ensures that the products produced on site are safe for human
consumption and they are of acceptable quality to the customer and consumer. The
team makes sure all products distributed or marketed is of high quality and shall
meet the demands of customers. Food Safety makes sure the company is clean and
GMPs (Good Manufacturing Practices) are implanted and the company is certified
with certain certifying bodies like Pick ‘n Pay and government health department. I
am employed in the Food Safety division. Food safety takes responsibility on
4
customers’ complaint, raw material inspection, bread quality checks, dough weight
checks, training of production workers and management, shelf life testing, microbial
testing, bread evaluation, verification and calibration of scales and thermometers,
hygiene of staff and the whole plant. Uniform implementation of the standards such
as ISO 22000 and other requirements as specified by procedure is done by food
safety department
1.3 Job TitleFood Safety Technician.
1.3.1 Job Description
Food safety technician is responsible for making sure that the bread manufactured
at the facility is safe and will not harm consumers when prepared for its intended use
by implementing and maintaining Good Manufacturing Practices, Prerequisite
programmes (PRPs), and providing training to staff. A food safety technician must
conduct HACCP analysis and check the quality of the bread.
5
1.4 Organizational structure
Figure 1.1 Company Organogram
6
- Bakery Manager
-Production Manager
Production Supervisors
Production Personnel
Transport Mnager
Transport Clerk -
Machanics
Maintenance Manager
Technicians
Human Resource Manager
Sales Manager
Driver
Van Assistant
Promoters
Financial Manager
Admin
Dispatch
Food Safety controller
Food Safety Tech-
Richard Sebola
Pest Control
Company
Cleaning Company
1.5 ProductsAt Sunbake Rustenburg we manufacture three types of products namely sliced and
unsliced 700g brown bread, sliced and unsliced 700g white bread, and sliced 700g
crushed wheat bread. The product range of Sunbake Rustenburg is shown in figure
1. Typical nutritional information of brown and white bread is shown in appendix 1
and 2.
Figure 1.2: Sunbake Product Range (www.sunbake.com)
7
2. THE PRODUCTION PROCESS
Figure 2.1: Unit operations
8
Raw material receiving
Premix
Mixing
Divider
Rounder
Intermediate Proofer (First proofing)
Moulder
Second proofer (Final proofing)
Oven Baking & Deppaner
Cooler
Bagging and Slicing
Packaging
Despatch
2.1 Purpose of each unit operation
2.1.1 Raw Material Receiving
All raw materials are received by the store man and are checked for quality and any
deviations. If any raw material is found to be out of spec it is returned to the supplier.
All the raw material must come with a certificate of analysis (COA).
2.1.2 Premix
During premixing ingredients are weighed and mixed together in to the mixer. The
premix contains a combination of Minor Ingredients like emulsifiers, sugars and fat.
Fat gives dough a slightly softer, smoother feel. Without the fat, the bread will have
no oven sprig, will be lacking in colour and crumb softness, and will have a close
texture. Emulsifiers cause oil and water to mix. Emulsifiers are added to bread
dough for their bread softening properties and for the improvement of gas retention.
Sugars act as a source of food for yeast activity, a source of sweetness and
influences crust colour. In order to raise and condition a dough, yeast requires
energy food and the primary reason for the use of sugar in a bread dough is to
supply the yeast with a readily available source of energy. The yeast enzyme
(Saccharomyces Cerevisiae) acts on the sugar in the dough, thereby releasing
carbon dioxide gas which raises the dough and some alcohol which evaporates from
the dough during baking. The premix is then weighed according to specification in to
premix bins. The premix machine is shown figure 2.1
9
Figure 2.2: Premix Machine
Each premix bucket must have a premix that has a specific weight. There are
several ingredients which make up a premix that goes in to a batch of bread. Other
ingredients include calcium which helps to preserve the bread, especially during
summer plus some health benefits. Salt has three main functions, it improves the
taste of bread, it affects the fermentation process and it toughens the gluten which
alters the texture and grain of the final product. Salt affects dough texture by making
it stronger and less sticky; it reduces oxidation of the dough during mixing. Oxidation
causes the degradation of carotenoid pigments in the flour that contribute to flavour
and crumb colour. Salt also regulates yeast activity, causing fermentation to
progress at a more consistent rate (Wildyeastblog). Bread made without salt will
have signs of excessive proof, an uneven surface, a poor colour and be on the verge
of collapse. If salt is increased to more than 2% the loaf will become smaller and
have little volume.
2.1.3 Mixing
The premix bin is the poured into the spiral mixer (Figure 2.2), were water, flour and
yeast are added. Water is an important ingredient for giving dough its consistency
and for controlling dough temperature. Water hydrates the flour proteins to produce
the visco-elastic substance known as gluten. It is the gluten that is largely
responsible for the ability of the dough to retain the gas that is produced by the
yeast. Water makes possible the pliable and extensible properties of the dough so
10
that it can be raised by the carbon dioxide gas resulting from yeast activity. Water
also provides yeast with moisture for fermentation as yeast needs moisture to
ferment. When the dough is mixed, some of the water is absorbed by the flower
proteins, and some by the carbohydrates (starch and bran). The rest of the water
stays as free water and forms the so-called “water phase” of the dough in which
other ingredients such as salt and sugar are dissolved. Table 2.1 shows how each
flour component absorbs water.
Table 1.1: Flour water absorption
Components of flour % Water absorption %
Protein 12 30
Undamaged Starch 64 25
Damaged Starch 11 4
Yeast is responsible for raising or leavening the dough during proofing. Yeast is a
single-celled microscopic organism which reproduces by budding. Yeast requires
four basic factors in order to produce carbon dioxide, namely food, moisture, warmth
and time. S Cerevisiae has three principal functions in dough. It produces carbon
dioxide gas which expands the dough to the required volume and gives the light
sponge-like texture necessary for the production of bread with good eating
properties. It makes or develops the dough through the action of fermentation on the
gluten. Yeast also provides flavor through the production of complex chemical
compounds as by-products of the fermentation process. Cream yeast is used at our
bakery.
11
Figure 2.3: Spiral Mixer
2.1.4 Divider and Rounder
After mixing then the dough is transferred to a divider (Figure 2.3) using a high lift.
The divider then divides dough into required loaf sizes. It is important the divider
operator makes sure that the weight of the dough piece is correct for the weight that
is required, and that the machine runs at a speed that is appropriate for the speed of
the plant. After the dough piece has been cut by the divider it passes through a
process of rounding or first moulding, which provides the dough piece with a regular
shape before it enters the intermediate proofer. The rounder (Figure 2.4) does two
important things, it squeezes out surface bubbles; and it gives a round shape which
helps with the machining of the dough. The dough pieces that emerge from the
divider are also sticky, warm air is used during rounding to give the dough pieces a
smooth surface which is non-sticky.
12
Figure 2.4: Divider dividing dough Figure 2.5: Rounder
2.1.5 Intermediate Proofer
The dough is then rested for about 5 minutes, this way the dough will not be sticky
and rubbery and it will easily go through the moulder rollers without tearing. The
intermediate proofer allows the gluten in the dough piece to relax and reform after all
the cutting and tearing that it has gone through. There is an Ultra Violet (UV) light at
the top of the proofer which inhibits the growth of mould on the pockets which hold
the dough pieces. The intermediate proofer is shown in figure 2.5
13
Figure 2.6: Intermediate Proofer (Sunbake, 2015)
2.1.6 Moulder
After leaving the intermediate proofer, the dough piece is shaped by the final
moulder (Figure 2.7) into a “Swiss roll” shape. It then passes under a sealing board
which tightens up the shape and determines the correct length of the dough piece.
The moulder is responsible for shaping the dough piece into a cylindrical or sausage
loaf prior to being deposited in the pan. The moulding process will also squeeze and
subdivide any large gas bubbles that may have formed to produce a finer and more
regular cell structure. After moulding, the dough piece is then automatically
transferred to the baking pan.
14
Figure 2.7: Moulder
2.1.7 Final Proofing
The purpose of the final proofer is to control the time it takes for the dough to rise to
a particular height by providing a controlled environment of warmth and humidity.
The warmth causes the yeast to produce the carbon dioxide gas at the required rate
and the humidity prevents a skin forming on the surface and therefore allows the
surface to be flexible to expansion without cracking (SA Chamber of Baking, 2010).
Final proofing gives yeast time to ferment, which allows the moulded dough to relax
and expand (rise to pan level). The proofer is maintained at a temperature of 40-
45C and a relative humidity of 65-80%. During proofing starch is converted into
sugars via enzyme alpha-amylase action. The sugars feed the yeast and yeast uses
the carbohydrates in the absence of oxygen to produce carbon dioxide and alcohol.
The carbon dioxide then causes the dough to rise as it is retained in the cells formed
in the protein matrix. The proofer takes about one hour to raise the dough to a
15
desired level. The proofer capacity is 4116 dough in pans and the throughput Figure
2.7 shows the proofer outside and figure 2.8 shows the proofer inside.
Figure 2.7: Outside view of the proofer Figure 2.8: Inside view of the proofer
2.1.8 Oven Baking
The oven (Figure 2.14) is used to bake the bread at a temperature of 230-260 ̊C. In
the oven there are four baking chambers; chamber one, chamber two, chamber
three and chamber four to allow the bread to be exposed to controlled heat at
different stages in the travelling Oven. Development chamber (Chamber one) is kept
slightly at 230°C - 250°C to allow the initial setting of the bread to occur as quickly as
possible. To provide moist conditions to permit elasticity in the dough skin, this
chamber is injected with moisture through the steam valves. Steam is used to keep
the crumb soft, thus allowing the bread to expand freely. The steam that has settled
on top of the bread dissolves sugars in the dough, as the bread stops expanding and
the steam begins to evaporate, the sugars are left behind to caramelize and create a
glossy crust (Steam is important in the first five to 10 min of baking). Baking
chamber (chamber one & two) is kept at 240°C - 260°C and is the main body of the
oven, where heat is transferred into the core of the bread. This is to attain stability of
the starch structure through gelatinisation, because proteins originally responsible for
the dough structure and gas retention become denatured. In the baking chamber,
maximum air circulation is required to aid heat transfer. Finishing chamber (chamber
16
four) is kept at 210°C - 230°C and it is responsible for the development of the crust
colour and bread flavour. Bread core temperature must reach 95°C to complete the
gelatinisation of the starch and to destroy most bacteria that may otherwise cause
pot-baking spoilage to the product. The bread changes physically, chemically and
biochemically. Caramelization and the Maillard reaction are two major thermal
chemical reactions that occur during baking, contributing to the browning of the crust
and the flavour and aroma of the bread. During baking, starch gelatinization occurs
at about 60C and completes at 90°C. The starch granules absorb any free water in
the dough, causing an increase in viscosity of the dough. This causes the bread
crumb structure to stabilize. The activity of fungal alpha-amylase is deactivated at
60C. The Maillard reaction is a chemical reaction of nitrogen compounds from the
denatured proteins and sugar. This results in the bread crust gaining its brownish
colour on the surface of the crust. Caramelization results from the browning that
occurs when sugar is heated to about 150°C. Sugar at the surface of the loaf is able
to reach this high temperature because of the evaporation of water. Oven ensures
food safety of the final product by killing any possible harmful microorganisms in the
dough and evaporates the alcohol produced by yeast. Oven baking also provides a
good quality final color of the bread. Figure 2.9 shows how the bread looks like after
three minutes. Figure 2.10 to 2.11 shows how the bread is developed before the
final stages of baking. After about 18 minutes the bread is done baking and is ready
for cooling. Figure 2.12 shows how the bread looks like after 18 minutes. All the
pictures from figure 2.10 to figure 2.12 are from South African chamber of baking.
The actual speed of the oven is 20 minutes 55.10 seconds (20.92 minutes) and the
theoretical speed is 20 minutes 51.30 seconds (20.85 minutes). The oven capacity
is 4245 loaves and the rows in the oven is 70.47 (rows of pans).
17
Figure 2.9: Baking time: 3 Minutes Figure 2.10: Baking time: 6 Minutes
Figure 2.11: Baking time: 12 Minutes Figure 2.12: Baking time: 18 Minutes
Figure 2.14: Oven releasing pans after baking (Sunbake, 2015)
18
2.1.9 Depanning
After the bread is baked, it is conveyed to the depanner (Figure 2.14) were it is
“depanned,” taken out of the baking pans. The depanner operates by suction cups,
which suck the bread out of the pans by means of compressed air.
Figure 2.15: Depanner removing bread from the baking pans (Sunbake, 2015)
2.1.10 Cooler
The bread is then conveyed to the cooler (Figure 2.15). Here the bread will be
cooled to a temperature above 23C before it is sliced and packaged otherwise the
crumb will be warm and gummy, causing a mechanical problem at the slicer. The
warm bread will also cause an undesirable moisture condensation inside the
package (Bakerpedia). During cooling, the baked bread loses moisture, dry out and
intensify in flavor. The starch in the loaf start retrogradating, helping setting the
crumb texture (Bakerpedia). Figure 2.16 shows the inside of the cooler with white
bread. This whole cooling process takes approximately one hour. Because the
cooler has 4 different sides in it, it has four different temperatures which are shown in
table 2.2
19
Figure 2.16: Outside view of the cooler (Sunbake, 2015)
Figure 2.17: Cooler with white bread inside (Sunbake, 2015)
20
Table 2.2: Different temperatures inside the cooler
Temperature (C)
14
Position in the cooler
Down drum
12 Down drum for side
15 Up drum
14 Up drum far side
2.1.11 Bagging, Slicing and Packaging
After cooling, the bread is sliced into the slice width of 15mm (13-16mm acceptable).
The bread with the same slice thickness has a pleasing appearance and is easier to
use. If the bread is not evenly sliced it might indicate a broken blade or uneven
tension in the blade frame. Consumer trends have changed in the past years, now
consumers require sliced bread because they don’t have to cut it at home. After
slicing, the bread is packaged into a branded Sunbake plastic bag. The plastic bag
is then printed the best before (BB) date on its back. We print the best before date
for safety reason, letting our customers know when it is safe to consume the bread.
The BB date indicates the shelf life of the bread. The Julian Date, also printed on
the bag, indicates the day of the year which the bread was manufactured, i.e., if the
number says 113, it means the bread was produced in the 113 th day of the year.
Line number and time are also printed on the bag to help with traceability and recall.
The bread must not be packed too tightly or too loose. If the bread is packed too
tightly, the bread will feel hard and the slices will be damaged. The bread might also
be seen by a potential customer to be smaller than the competitor’s loaf. If the bread
is packed too loosely, the slices will fall around in the bag and look unappetizing.
21
2.1.12 Metal Detector
Because most of the equipments used in the factory are metals, we are required to
have a metal detector in place. The metal detector (Figure 2.17) serves as a critical
control point. No bread which contains metal will pass the metal detector if it is
operating efficiently. The metal detector is able to detect three types of metals such
as ferrous, non-ferrous and Stainless steel
Figure 2.18: Bread passing through a metal detector
2.1.13 Dispatch
Dispatch cages are storage areas for finished product, to be loaded into trucks for
distribution. The cages are checked for pests and cleanness.
2.2 Critical factor that influence the safety and quality of final product.Metal Detector is one of the most important critical factors. It influences the safety of
the product. Without it, the metal inside the bread, if any, will pass undetected and
will harm the consumer. The oven is also a critical factor, as it ensures that all the
harmful microorganisms in the bread die because of the high baking temperatures.
22
The cooler also affects the quality of the bread, it makes the bread soft and because
the starches in the loaf start retrogradating during cooling, the crumb texture sets.
Sieving and Inspection is done during premix, before the premix is poured into the
premix bins, the premix passes through the sieve, were all foreign objects are
sieved. Some of the bread faults are shown in table 2.2.
Bagging and slicing is also a major factor affecting quality. The loaf can be
squashed with dented sides (Figure 2.19), the packaging can be too lose (Figure
2.20) or too tight (Figure 2.21). If the tension is not set on the right parameter when
packaging the bread, it can be too loose or too tight. If the loaf is too tight it might
look smaller than the competitor’s loaf and if the loaf is too loose it will look
unappetizing. So it is very important to control the technical side of the machines to
make sure they are operating effectively.
23
Figure 2.19: Bread dented on sides (Sunbake, 2015)
Figure 2.20: Packaging too loose (Sunbake, 2015)
Figure 2.21: Packaging too tight, bread appears smaller (Sunbake, 2015)
24
Table 2.3: Bread faults
Mould and rope Cause Corrections
No anti-rope agent used
Unhygienic bakery added
Bread not cooled down
Add anti-rope agent
Clean bakery daily
Cool bread down rapidly
after baking
Collapsed bread Cause Corrections
Incorrect recipe
Too little yeast
Under mixed
Check recipe
Add more yeast
Increase mixing time
SIDES COLLAPSING Cause Corrections
Too much premix
Too much yeast
Too much malt flavour
Add correct premix level
Reduce yeast level
Reduce malt flavor
dosage
25
3. DUTIES
3.1 Routine duties Bread quality checks
Bread quality retention( Shelf life Evaluation)
Bagging and slicing check
Dispatch bread weight checks
Weekly Good Manufacturing Practices (GMP) inspection
Weekly glass and brittle plastic inspection
Verification of scales and thermometers
Corrective action recordings and monitoring
Daily personal hygiene inspection
Approved jewellery checks
Sampling of microbial testing
Daily chlorine checks
Process control (Temperature monitoring)
Locker inspection
Ambient temperature monitoring
3.2 Administrative duties Photocopying and faxing
Distribution of food safety papers
Receiving calls
Receiving and filing food safety documents
3.3 Ad hoc duties Preparation of audits (External)
Helping in giving training to production staff
Shelf life testing
26
4. ANALYTICAL TESTINGAt Sunbake we collect samples and send them to SWIFT laboratory. Product testing
is done every month and we rotate the products each month. Equipments are tested
every month. Air monitoring on the hand driers are done one in three months. All
other the ingredients are rotated each month. Water testing is done every month.
Bread shelf life is done twice a year. Total microbial activity (TMA), coliforms, E.coli,
Yeast and Mould, Salmonella and Staphylococcus are tested over a period of five
days compared to monthly testing which the mentioned microorganisms are tested
for one day only.
5. PRODUCTION
5.1 Materials and MethodsBread quality checks: Texture, taste, wrap, crust colour were checked and given a
score on a scale of one to three, were one = reject, two = standard and three =
excellent. Bread was weighed on a scale and the mass recorded. The bread weight
must be 700g but a defect weight of 610-710 was accepted and the resulting
variance was recorded in percentage. Correct packaging information was also
checked.
Bread quality retention: The bread was placed on a shelf for five days to see if it
retained its qualities. During these five days, texture, crust colour and shape of the
bread were inspected.
Bagging and slicing check: Slice thickness was checked using a ruler and the slice
thickness is within specification. The BB date was also checked behind the package
of the bread. If the printer was not printing, maintenance was informed to fix the
printer.
Dispatch bread weight checks: A crate containing eight loaves of bread was taken on
the conveyer belt and each bread loaf in the crate was weighed to check if the bread
was within the specification.
27
Weekly Good Manufacturing Practices (GMP) inspection: Every week GMP
inspections were conducted and the facilities were inspected for good housekeeping
and insects were also inspected. For checklist see appendix 1.
Weekly glass and brittle plastic inspection: Glass and brittle plastic were inspected
once a week and checked if they are not broken. Lights, lights covers, equipment
screens and buttons, dispensers and camera lenses were some of the thing
inspected.
Verification of scales and thermometers: A 500g 0r one Kg weight was used to verify
the scales. The weight is put on top of a scale and the reading on the scales
recorded. The reading must be that of a weight (500g or 1 Kg)
Daily personal hygiene inspection: General hygiene of personnel was checked. Nails
were checked and must be short and clean. All personnel were inspected for strong
perfume which is not allowed in production. All personal protective equipment (PPE)
must be clean and no eating must be done in production.
Approved jewellery checks: All jewelleries on personnel was checked and recorded.
All jewelleries worn were either medical, traditional, spectacles or wedding bands.
Sampling of microbial testing: Every month, once a month, microbial samples were
collected and sent to SWIFT laboratory.
Scales were rubbed with a swab for testing of TMA and personnel hands were
rubbed between fingers for testing.
One ingredient was taken aseptically for testing for certain microorganisms
which are not allowed to be disclosed to the public.
Bread: Every month, bread (brown, white or crushed wheat) was sent for
normal microbial testing. TMA, Coliforms, E. coli, yeast and mold,
Staphylococcus aureus and Salmonella were tested.
28
Water: Water sample were collected from the tap using sterile sampling
bottles ordered from swift laboratories for faecal Coliform, coliform bacteria, E.
coli and TMA testing.
Air testing was done on air that comes in contact with hands of personnel and
air that comes into contact with product. Air sample was taken from hand
drier and a depanner by exposing the petridish to the air.
Daily chlorine checks: Chorine test strip was placed inside the water and the reading
was recorded.
Process control (Temperature monitoring): A thermometer was used to check dough
temperature after mixing and after divider. After baking the core temperature of the
bread was checked to verify is it falls within specification. Water temperature at
mixer was also recorded. The bread temperature after cooling was checked and
recorded.
Locker inspection: All personnel lockers were inspected for cleanliness and pest
infestation.
Ambient temperature monitoring: A thermometer was placed in the air to check the
area temperature.
6. EXTERNAL AND INTERNAL AUDITS
6.1 Internal AuditsInternal audits are conducted every week, once a week, and the facilities, personnel,
and equipments were all audited. Audits are conducted and reported the relevant
department for auctioning. Find the criteria used in appendix one. The results of the
audit were satisfactory as the score would always be above 90%. The cleaning
company is good and always makes the place is clean and the staffs are given
training on food safety and GMPs, thus the audits are satisfactory every week.
29
6.2 External AuditsThe Certification Audits are conducted by Certifying bodies (e.g. DQS) on a yearly
basis to assess the Food safety Status at the bakery. Customers (Pick n Pay) also
do audits. All head of departments are involved in the audit. Sunbake Rustenburg is
Currently ISO22000:2005 certified.
DQS (ISO 2200:2005) audit once a year (December).
Pick n’ Pay (Intertek) audit once a year (June). SANS 10049 requirements
prerequisite programs (PRPs), ISO/TS 22002 PRPs on food safety, Codex Hazard
Analysis Critical Control Point (HACCP), Food Safety Management System
requirement as guided by the Global Food Safety Initiative (GFSI) and applicable
laws, regulations and compulsory specifications are all audited.
7. AD HOC DUTIES
7.1 Shelf lifeThe purpose of the project is to check if the bread doesn’t expire within 5 days. A
loaf of bread is taken to SWIFT laboratory and the bread was tested for TMA,
coliforms, E.coli, Yeast and Mould, Salmonella and Staphylococcus. These
microorganisms are checked on second day after production until the last day of the
expiry date (BB) date to check if the product is safe to be consumed until expiry date.
This was done once a year.
8. COMMENTS ON TUT TRAININGTUT training was very important for me as some of the activities I did in the TUT
laboratory like taking swabs helped me to take swabs at the industry. The subject
Food Technology was important because it gave me and idea of GMPs. The subject
Food Quality Assurance has taught me many things like packaging information,
giving consumers a quality product which will in turn grow the business.
30
9. REFFERENCEDr LATEGAN. 2011. Food safety manual, SABS Standards Division. Pretoria.
h t tp : / /www.sunbake .co .za
h t tp : / /www.bakerped ia .com/ in te rmed ia te_proo f ing /
http://www.wildyeastblog.com/worth-its-salt/
LEGRAS, J.L., MERDINOGLU, D. & CORNUET, J.M. 2007. Bread, beer and
wine: Saccharomyces cerevisiae diversity reflects human history. 16: 2091–2102.
MONTVILLE, T.J., MATTEWS, K.R., & KNIEL, K.E. 2012. Food Microbiology: an
introduction 3rd Edition. Pages 283-284.
South African Chamber of Baking, 4th edition. 2010. Certificate in the theory of
Breadmaking.
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TYPICAL NUTRITIONAL INFORMATION
Per 100g Per single serving of
150g (3-4 slices)
%N
RV1
Energy (kJ) 963 1444
Protein (g) 9.3 13.9 25Glycaemic carbohydrate (g)
of which total sugar (g)
41 62
7.1 10.7
Total fat (g)
of which Saturated fat (g)
1.7 2.6
0.5 0.8
Trans fat (g) 0.0 0.0
Monounsaturated fat (g) 0.3 0.5
Polyunsaturated fat (g) 0.9 1.4
Cholesterol 0.0 0
Dietary fibre2 (g) 5.4 8.1
Total Sodium (mg) 400 600
Vitamin A (µg) 70 105 12Thiamine (mg) 0.3 0.4 32Riboflavin (mg) 0.1 0.2 16Niacin (mg) 4.2 6.2 39Pyridoxine (mg) 0.3 0.4 24Folic acid (µg) 74 111 28Vitamin D (I.U.) 215 323 54Calcium (mg) 324 486 37Iron (mg) 3.5 5.2 29Zinc (mg) 2 3 27
The nutritional information is based on the product as ready to eat.1 Nutrient Reference Value (NRV) for individuals 4 years and older2 The method used to determine dietary fibre is AOAC (Association of
analytical communities) 991.43
APPENDIX 1: TYPICAL NUTRITIONAL INFORMATION OF WHITE BREAD
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APPENDIX 2: TYPICAL NUTRITIONAL INFORMATION OF BROWN BREADTYPICAL NUTRITIONAL INFORMATION
Per 100g Per single serving of
150g ( 3-4 slices)
%NRV1
Energy (kJ) 963 1444
Protein (g) 9.3 13.9 25Glycaemic carbohydrate (g)
of which total sugar (g)
41 62
7.1 10.7
Total fat (g)
of which Saturated fat (g)
1.7 2.6
0.5 0.8
Trans fat (g) 0.0 0.0
Monounsaturated fat (g) 0.3 0.5
Polyunsaturated fat (g) 0.9 1.4
Cholesterol 0.0 0
Dietary fibre2 (g) 5.4 8.1
Total Sodium (mg) 400 600
Vitamin A (µg) 70 105 12Thiamine (mg) 0.3 0.4 32Riboflavin (mg) 0.1 0.2 16Niacin (mg) 4.2 6.2 39Pyridoxine (mg) 0.3 0.4 24Folic acid (µg) 74 111 28Vitamin D (I.U.) 215 323 54Calcium (mg) 324 486 37Iron (mg) 3.5 5.2 29Zinc (mg) 2 3 27
The nutritional information is based on the product as ready to eat.1 Nutrient Reference Value (NRV) for individuals 4 years and older2The method used to determine dietary fibre is AOAC 991.43
33