Biscuit And Cookies

Introduction
 Biscuit

• cereal based product and baked to a moisture

content of less than 5%.
• Delicate, crisp crust and peels apart in tender
layers
• Derived from the word biscocuts which is Latin
for twice cooked bread and refers to bread rusks
that were made for mariners (ships biscuits)
from as long as the Middle Ages.
What's the difference between biscuits &
cookies
• The word biscuit is used in Britain and several
other countries including crackers, Hard sweet
and semi –sweet biscuits, cookies and wafers.
• The name cookie was adopted in America.

Biscuits Cookies
Smooth surface Rather rough surface
Definite shape Irregular shape
Prepared from developed Short dough
dough
Low in sugar and fat Rich in sugar and fat
Crisper and thinner product Softer and thicker
Groupings based on:
• the name, e.g., biscuits, crackers and cookies,
which are based on the texture and hardness
• the method of forming of the dough and
dough piece, e.g., fermented, developed,
laminated, cut (simple or embossing),
moulded, extruded, deposited, wire cut,
coextruded, etc.
• the enrichment of the recipe with fat and
sugar.
 secondary classification
Based on secondary processing that the baked
biscuit has undergone.
• cream sandwiched
• chocolate coated
• iced (half coated with an icing that has been
dried)
• added jam or mallow (or both).
 Biscuits as per FSSAI
• Biscuits including wafer biscuits shall be made from maida, vanaspati or refined edible oil
or table butter or desi butter or margarine or ghee or their mixture containing any one or
more of the following ingredients:
 Edible common salt
 butter, milk powder
 cereals and their products
 Cocoa, coffee extract
 edible desiccated coconut
 fruit and fruits products, dry fruit and nuts
 Egg, milk and milk products
 edible vegetable products, ginger, gluten groundnut flour
 honey, liquid glucose, Dextrose
 malt products, edible oilseeds, flour and meals
 spices and condiments
 edible starches such as potato starch and edible flours
 sugar and sugar products, invert sugar, jaggery
 protein concentrates
 oligofructose (max 15%)
 vinegar and other nutrients and vitamins
• It may contain food additives specified in these regulations
including Appendix A.
• It may contain artificial sweetener as provided in regulation 3.1.3
of these regulations and label declaration as provided in
regulation 2.4.5 (24, 25, 26, 28 & 29) of Food Safety and
Standards (Packaging and Labeling) Regulations, 2011.

Provided also that it shall conform to following standards,

namely:—
 ash insoluble in dilute hydrochloric acid (on dry basis) – shall not
be more than 0.1 per cent
 acidity of extracted fat (as oleic acid) – not exceeding 1.5 per cent

• It may contain Oligofructose (dietary fibres) upto 15% maximum

subject to label declaration under Regulation (43) of Food Safety
and Standards (Packaging and Labeling) Regulations, 2011.
 Types Of Biscuit Dough

Biscuit

Hard soft
 Soft/ Short Dough
• Sweet biscuits are made
• Soft dough does not show any elastic and extensible
properties
• Dough is not cohessive but show cohesiveness only
when pressure is applied
• Gluten development is minimized by-
1. Mixing for short period
2. Adding low amount of water
3. Adding high amount of sugar (30-40%) and fat (20-
30%)
4. Using soft flour
 Methods of Dough piece Formation

1. sheeting, gauging and cutting

2. rotary moulding
3. wire cutting
4. extrusion, including co extrusion
 Hard dough
• High gluten content about 9-10%
• Mixing for a long time
• Adding lower amount of sugar (15-25%) and fat (5-20%)
• Higher amount of water for dough development
• Lamination is done
• Between the layers, a fat+ flour mixture is spreaded
Types
• 1. semi sweet biscuit: marie type
• 2. salted biscuit: cream crackers, soda crackers
Method of dough piece formation
Lamination
Sheeting and cutting method
 Batter and Foam Based Cookies
• Sponge drops
• Meringues
 Wafer Biscuits
• thin crisp type of biscuit.
• The sheets formed by baking between pairs
of heated metal plates hinged at one side,
typically thin and usually bear intricate
surface patterns
• usually formed as large flat sheets
• sandwiched with cream or caramel
• Or chocolate enrobbed
 Preparation
• baked from a simple batter containing little or no
sugar
• Batter mixing
• Deposition on plates
• Baking
• Sandwiching
• Book building
• Cutting
• Enrobbing
 Ingredient Of Biscuit

Major

Whe Leave
at
Sug Short Wa ning
ar ening ter
flour agent
 Flour

• primary raw material

• provides a matrix around which other ingredients in varying
proportions are mixed to form batter or dough systems.
• Most biscuits can be prepared from flour having low
quantity of protein and has a gluten content that is weak
and extensible.
• less than 9% is best and levels of more than 9.5% often
create processing problems.
• The exceptions are fermented cracker doughs and puffs:
protein value of 10.5%or more.
• High protein in the flour leads to hardness of texture and
coarseness of internal grain and surface appearance.
• Flour should be sifted to aerate it for easy mixing operation.
 Sweetener
• Imparts sweet taste, improves texture, crust colour and extends shelf-life.
• Selection of the proper sweetener mostly is determined by the desired
functions the sweetener is to provide.
• The principal sweetener used is sucrose (granulated sugar).
• Corn syrup, high fructose com syrup, invert sugar, honey, glucose syrups and
molasses are used to a lesser extent except in soft cookies.
• Granulation of sugar is very important.
• Coarse grain of sugar will cause more spread of cookie affecting its texture,
eating quality etc.
• Very fine granulation will not incorporate enough aeration resulting in dense
texture, toughness and poor eating quality.
• Coarsely powdered or a fine granulated sugar should be used.
• Some cookies are moist in eating in which case part of sugar is replaced with
liquid sugar such as invert sugar, honey or com syrup.
• Dextrose sugar will have reduced sweetness and will impart darker colour to
the cookie.
 Fat/shortening
• lubricates the structure of a baked product. It has tenderizing effect on
flour proteins and makes the product tender.
• Fat improves the eating quality for prolonged period.
• Generally smooth, plastic hydrogenated shortenings are used for cookie
making.
• Granular shortenings are unsuitable as they do not aerate sufficiently
and distribution of fat in the cookie remains uneven.
• The fat should be able to cream and incorporate aeration
• Fats used as surface coatings applied as a spray of warm oil, for savory
crackers are best if they have limited absorption into the cookie and
remain as a glossy film.
• Addition of part butter improves the taste and flavor of the cookie
and also does not affect the creaming quality.
• Butter should be softened before blending with hydrogenated fat
otherwise it will break into lumps which will be difficult to homogenize.
 Eggs
• perform as emulsifying, tenderizing and binding functions.
• also contribute colour, nutritional value, and desirable flavor.
• essential for obtaining characteristic organoleptic qualities of
products.
• Eggs whites are a toughener and structure builder and the
high fat contents of yolk function as a tenderizer.
• Eggs must be fresh. Stale eggs may give bad odour and spoil
the overall flavour of cookie.
• Whole eggs are best used at room temperature while egg
white whip better when it is cooled.
• Egg yolk alone or in combination with whole egg produces a
cookie with excellent eating quality with a bit inferior grain or
internal structure compared to that from whole egg.
 Milk
• Milk is generally used in the form of dry milk non-fat.
• It imparts good colour, flavor and a very creamy
eating quality.
• One or two percent of milk solids achieve very
desirable results.
• Dry milk is best used after dissolving in water if, water
is an ingredient of the formula.
• Milk powder should be mixed with equal quantity of
sugar in dry state and then small quantity of water
should be added to make lump free slurry.
• It can also be sifted along with other dry ingredients
 Flavours
• Generally use of butter and milk as the ingredients of the
formula perform the function of flavoring agents, which is
further fortified with vanilla, which is used within limits of 0.5
to 1 percent based on flour.
• Some spices like cinnamon, nutmeg, ginger, zeera are also
used as flavours.
• Flavours should be used with utmost care as even slightly
enhanced quantity may impart very strong and unacceptable
flavor to the product.
• The introduction of aromatic ingredients in three principal
ways:
1. By including the flavor in the dough or batter before baking
2. By dusting or spraying the flavor after baking
3. By flavoring a non -baked portion, such as cream filling, icing,
jam or mallow, which is applied later
 Other ingredients
• Ingredients that play a texture-modifying role
include raising agents and emulsifiers.
• Raising agents lighten the structure of a baked
product during, baking by releasing tiny bubbles
of gas in the dough or batter, which expand as
the temperature rises, opening up the products
structure and thereby lightening the texture.
• Baking powder, bicarbonates of soda and
ammonia are commonly used raising agents.
 Baking powder
• Baking powder is combination of sodium bicarbonate and an acid salt
(phosphates, tartrates, sulphates) when moistened and heated, will evolve gas,
which leaven the product giving it volume and making light and easy to digest.
• Baking powder must yield not less than 12% available carbon dioxide.
• The reactivity of baking powder is determined by their neutralization value (NY),
which is defined as the numbers of grams of soda that 100 g of acidic salt will
neutralize.
• Baking powders are classified as 'fast acting' 'slow acting' and 'double acting'.
• Fast acting powders release most of their gas at room temperature.
• Slow acting powders release a portion of the available carbon dioxide during
mixing but generate most of it by reactions occurring at elevated temperatures.
• Double acting powders are version of the slow acting type that has somewhat
more gas producing potential during mixing. This type of baking powder is most
widely used by bakers.
Baking soda
• It is chemically known as sodium bicarbonate. It will liberate CO2 gas, a
leavening gas, when heated.
• It also liberates the same gas when mixed with an acid, either hot or
cold.
• The popularity of sodium bicarbonate as a gas source is based on its
low cost, lack of toxicity, ease of handling very small contribution to the
taste of the end product.
Ammonium bicarbonate
• When ammonium carbonate or bicarbonate is heated CO 2 and NH3 is
produced. No solid is left behind in this reaction.
• However, the ammonia imparts a detectable odour unless it is
completely removed.
• It is used in biscuits and crackers as they have large surface to mass
ratio and ammonia escapes when baked at high temperature.
• It can be used in products that are to be baked at low moisture.
 emulsifiers
• Soy lecithin, Glycerol Mono Stearate (GMS),
polyoxy ethylenes, poly glycerol esters,
sorbitan monostearates, diacetyle tartaric acid
esters of mono glyceroids, sucrose esters etc.
• 0.5 to 1.0% level by dissolving in fat and using
in creaming step
 Antioxidants
• Ethyl/ propyl gallate or mixture: 0.01%
• Octyle/dodecyl gallate: 0.01%
• Ascorbyl palmitate: 0.02%
• TBHQ: 0.02%
• Citric / tartaric acid (synergists): 0.02%
 Salt
• For flavour
• 1-1.5%
• Toughens the gluten and reduces stickiness
• Should be free flowing
General Steps In Biscuit Manufacturing

Step 1 ●
● Preparation of ingredients

Step 2 ●
Mixing of ingredients

Step3 Rotary molding/ wire cutting/ reciprocating

●
●

cutting
• Baking & cooling
Step 4

• Packaging
Step 5

• Storage & distribution

Step 6
 Preparation Of Ingredient
• Maida sifting - it passes through 30 Mesh screens to remove
foreign particle.
• Sugar grinding - after grinding the sugar, it is passed through
sieve size of about 0.7 mm.
• Flavour mix preparation
• SMP Sifting - The SMP is shifted through 20 meshes to
separate any foreign matters from the particle.
• Invert sugar syrup preparation
 Methods of mixing
Commonly used mixers:
1. Vertical mixers (planetary or spindle type)
2. Horizontal mixer (Z blade)
3. reciprocating arm mixer
4. Continuous mixer (barrel type)
Z blade Mixer
 Creaming Method
• May be done in 02 stages or 03 stages but principle is
same
• Shortening, sugar, sugar syrup, milk and other
ingredients are mixed together to form a smooth
cream. Then water is added and mixed well
• Suspension of salt, colour and flavour in remaining
quantity of water is mixed to cream
• Flour is added to get a desired consistency
• Used for soft doughs and it is processed generally by
rotary moulder or wire cut machine
 All in One method
• Salt+ leavening agent+ colour+flavour etc. are
dispersed in part of water and mixed with all
ingredients till the desired consistency is
achieved
• Used for hard dough
• Sufficiently developed to be sheeted between
rolls
• Should withstand cutting and removal of scrap
 Mixing methods for fermented dough
1. All in one mixing and fermentation-mixing with
yeast suspension and 3-8 hrs fermentation
2. Two stage mixing and fermentation
(a) sponge-70% flour+ sugar+ yeast+ suspension+
part of shortening+ whole of water are mixed
for 2-3 mins and fermented for 19 hrs
(b) Dough- sponge + rest of the ingredients and a
shorter fermentation
 Biscuit forming
(semi-sweet and fermented biscuit)
• Laminating-generally 4-6 layers sandwiched with fat and
flour dust layers
• Sheeting and cutting:
• Cutting:
1. Reciprocating cutter
2. Rotary cutter: 01 rolls forms impression and second cuts

Rotary moulding: used for soft dough or sweet biscuits

Wire cutting: softer dough or cookie dough

Rotary moulder
Dough in
Dough
Rotary Molding
hopper
batches

s
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Cutter
detector

D
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Forcing
Die roll
roll

R
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b ng
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Penning
Transfer

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knife
table

v Scrap
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v Hopper
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 Baking Section
•Cabinet ovens, reel ovens or tunnel ovens
•Conduction, convection and radiation all three types of heat
transfer
•Temp 180-250 depending on design
•Oven used for baking is divided into various zones
according to temp employed.
• There are 3 major sections:Colouri
Baking
Puffing section ng
(180-200 ˚C)
section
(230-280˚C)

section
 Cooling Of Biscuit
• After baking :
- M/C of biscuits 1.8%
- Temp of biscuits 90-100 ˚C.
• Cooling of biscuits to 45 ˚C.
• Flexible structure becomes
rigid and sugar and fat solidify
1. Atmospheric multi-tier
conveyor
2. Forced draft cooling conveyor
 Packing of biscuits
• Air tight containers
• Flexible package should be grease proof,
moisture proof , low gas permeability and
heat sealable

e.g. Wax paper, polypropylene, coated

cellophane etc.
 Parameters determining the quality of
biscuits
• Surface colour
• Spread or flow
• Raise/ thickness
• Crumb structure
• Hollow bottoms
• Checking (hairline cracks on the surface)
• Fat bloom
• Foreign materials