Baking process

Soft baked goods, toast and sandwich bread should be baked in the shortest possible time to prevent the baked goods from drying out and to ensure they stay fresh for a long time. 

It has to be considered here that a core temperature of at least 95° C has to be reached in order to avoid key-holing and wrinkling.

The baking parameters have to be adjusted to the corresponding type of oven.

Addition of steam is not necessary for hamburger buns, as fermentation takes place at a high fermentation temperature and humidity and sufficient condensate forms during the baking process. If the dough pieces, e.g. for brioche buns, are sprayed with glaze before the baking process, there is no need to add steam, either.

Tin bread is usually baked with circulating air and steam to achieve the best possible heat transfer. Rack ovens for the artisan sector and special tunnel ovens in plant bakeries are primarily suitable for this purpose. A combination of radiant and convection heat as well as vertical air circulation is possible with both systems. The bread loaves must be decapsulated immediately after the baking process, otherwise there is a risk of key-holing.

Cooling should take place under the best possible hygienic conditions, ideally with clean room technology. The duration should not exceed 2 hours and a core temperature of 30 °C should be reached before the baked goods are sliced. Alternatively, vacuum conditioning can be used. Vacuum conditioning is used for rapid cooling and stabilization of baked goods directly after the baking process. The reduced baking time in combination with vacuum conditioning ensures improved freshkeeping, more stable sides, less crust colour and faster cooling of the baked goods, which can then be sliced and packaged immediately afterwards. (see chapter on Vacuum conditioning)

Slicing is a critical process step, as the baked goods crumb is the ideal breeding ground for microorganisms due to its moisture and composition. Regular cleaning and disinfection of the slicers, including the blades, is important in order to achieve the longest possible shelf life. In addition, disposable gloves should be used when cutting, but also for all other steps after baking, to minimise the risk of possible contamination with microorganisms.

After packaging the sliced toast and sandwich bread, pasteurization is one of several measures to extend shelf life. Toast and sandwich bread is not suitable for long pasteurization, otherwise the crumb will dry out and may become discoloured. 

The following parameters have proven effective for pasteurizing toast and sandwich bread in artisan bakeries:

• Rack oven temperature: 120° C
• Circulating air medium speed (approx. 70 % fan speed)
• Duration: 30 minutes

In plant bakeries, pasteurization takes place in special continuous ovens or in tunnel ovens at 
correspondingly low temperatures. (See chapter on Bread diseases as well as measures to preserve baked goods).