Process Manual for Vegetable Crackers

This article provides the complete information required to make vegetable crackers. The following notes introduce the main sections of the document.

Recipes 

In all cases at least two recipes have been given. The first is a standard proven recipe used in the industry, which can be developed to meet particular requirements in taste or texture for the target market. The second recipe is an actual recipe from a leading producer for a leading product brand.

Critical ingredients 

Following each recipe some notes have been added to identify any particularly important ingredients for the product.

Process 

The process descriptions are based on the best practice for producing a high quality product. The process may be modified to suit the equipment available. For each product, recommendations are made with regard to the type of equipment required for the mixing process, baking, in particular the power required and the recommended baking band. Modifications to the recipes and process recommendations may be required to suit the equipment available.

>Biscuit Baking Process

Ingredient specifications 

Some notes are given under this section of the report to identify the most important and special ingredients required.

Production machines: specifications 

This section lists the key features of the production machinery to achieve the optimum product quality and output. In some cases the specifications may vary from the actual equipment available. In these cases, discussions and development work during the trials will need to be carried out to achieve the best possible product quality.

VEGETABLE CRACKER

Description 

Very light and delicate texture snack crackers with vegetable flakes and oil sprayed to give an aromatic flavour. These crackers are usually modified with proteolytic enzyme and aerated with ammonium bicarbonate and sodium bicarbonate.

Product specification

Dimensions:                48 x 48mm
Thickness:                   4.4 mm
Weight:                         3.75 g
Appearance:                Evenly blistered
Colour:                         Golden with vegetable flakes
Texture:                        Light and delicate with soft mouth-feel
Flavour:                        Aromatic flavour
PH:                                5.5
Moisture:                     2.5%

Packaging

1. Flowpack with stack of 6 biscuits, packed in cartons.
2. Biscuits on edge in trays and wrapped in Flowpack.

Production output 

Oven cutting machine width 1250 mm
No. of crackers across the band: 21
Baking time: 5.0 mins
Biscuits per min. 21 x 965 = 20265/5 = 4053
Kg per hour: 4053 x 60 x 3.75/1000 = 912
Output at 90% efficiency: 820 kg/hr

Baking time: 4.0 min
Biscuits per min. 21 x 965 = 20265/4 = 5066
Kg per hour: 5066 x 60 x 3.75/1000 = 1140
Output at 90% efficiency: 1025kg/hr

Nutritional data

Process 

Savoury crackers are mixed on horizontal mixers and the dough is stood to allow the action of the protoelytic enzyme on the gluten. Forming is by sheeting and cutting. Baking is on a Z47 type wire-mesh band. The crackers are oil sprayed immediately after baking.

Critical ingredients

1. Flour should be weak with a protein content of 8-9%.
2. Proteolytic enzyme (proteinase).
3. Oil for spraying: coconut oil or palm kernel oil are suitable and have a good resistance to rancidity.

Alternative formulations 
Similar products can be made using SMS (sodium metabisulphite) in place of the proteolytic enzyme. The SMS increases the extensibility of the gluten and does not require the 3 hour standing time.

Process:

Mixing 

An “all in” mix on a horizontal mixer
Temperature of final mix about 33°C for enzyme doughs
Temperature of final mix about 40°C for SMS doughs.
The vegetable flakes may be mixed into the dough.

Standing time 

After mixing the dough is stood to allow the enzyme to react with the gluten. The standing time is about 3 hours at 35°C. The time must be determined carefully depending on the amount of enzyme and the quality of the flour in order to achieve the soft, delicate eating texture of the cracker.
Doughs made with SMS do not require a standing time.

Forming 

The dough is sheeted, gauged and cut, (laminating is not required).

Typical roll gap settings are:

Sheeter:                      12mm
Gauge roll 1:              6
Gauge roll 2:              3
Gauge roll 3:              1.5

If the vegetable flakes are to be sprinkled, a suitable sprinkler unit before the final gauge roll is required.

Baking 

Baking time:  4.0 – 5.0 mins.
Temperatures: 220 / 220 / 210 / 180
High bottom heat in Zones 1 and 2 is required

Baking band 
Z47 type wire-mesh band
Pre-heat is required

Oil Spray 
The oil spray should be located immediately after the oven. An application of 10 – 16% by weight of coconut oil is recommended.

Production machines:

Mixing 

Horizontal 2 speed (30/60 rpm) or variable speed mixer
75 KW motor

Baker Perkins high speed horizontal mixer

Forming

DSM Dingson Food Machinery forming line 

3 roll sheeter with good scrap incorporation
3 pairs of gauge rolls (final rolls 400 mm diam.)
Rotary cutter (single roll or two roll system)
Vegetable flake sprinkler positioned before the final gauge roll unit

Baking 
Direct gas Fired Oven
Z47 type wire-mesh band
Pre-heat
Average oven burner rating 28 KW/m²

Baking temperatures: 220 / 220 / 220 /180°C
Baking time: 4.0 – 5.0 minutes 

Ingredient specifications:

Flour

The flour shall be milled from good quality soft wheat, free from infestation and impurities, especially pesticides. The flour shall not be treated with enzymes and shall not contain chemical additives. The appearance shall be a good white colour, free from bran particles. The odour shall be free from mustiness and foreign odours.

Two flours are required, described in the recipes as strong and weak. An analysis of each is given below.

Sugar 

The sugar shall be free from impurities and infestation. The appearance shall be a fine, white crystalline solid, free flowing and free from lumps.

The sugar shall have a sweet taste and be free from odours.

Moisture content:      0.06% maximum
Ash content:               0.03% maximum
Particle size:
Caster sugar:  MA = 276 to 300 um  CV = 16 to 26%
Icing sugar:                 Maximum held on a 100 um sieve 6%
                                       Maximum held on a 60um sieve 13%
                                       Tricalcium phosphate may be added to 1.5% max. 
Note: 
MA      Mean aperture
CV       Coefficient of Variation

Cane syrup 80% 

Syrups with 80% solids derived from the refining of cane sugar. Used for their excellent flavour.

Invert syrup 70% 

Syrup of 70% solids made by acid hydrolysis of sucrose. The result is a 50:50 mixture of dextrose and fructose which are both reducing sugars and contribute to the maillard reaction in baking.

Malt extract 80% 

A thick glutinous syrup of 80% solids usually non-diastatic and obtained by water extraction of malted wheat or barley. The heat treatment used to concentrate the solution destroys any enzymes. Used as an important flavour ingredient. Rich in maltose, which is a reducing sugar.

Dough fat 

The fat shall be free from impurities and appear clean and bright when melted. The fat should be odourless, free from rancid and foreign flavours. The fat should be produced from good quality crude oils by a process of refining, bleaching and deodorising. It should be made primarily from vegetable oils, but it may contain hydrogenated fish oils.

Free fatty acid (as oleic acid)                            maximum 0.08 %
Peroxide value (milli equivalent per kg)        maximum 1.0
Moisture                                                               maximum 0.1%
Slip melting point (BS 684 1.3 1976) 34 to 37°C.

Coconut oil 

For use in oil spray.
Hydrogenated coconut oil, neutralised, deodorised and bleached.
Melting point: 32 to 34°C

Lecithin 

A complex natural surfactant obtained from soya beans

Ammonium bicarbonate (“Vol”) (NH₄)HCO₃         

A volatile salt, which, when heated liberates carbon dioxide, ammonia gas and water.

                                                                        Min.                Max.

Ammonium bicarbonate                           99.0%
Heavy lead                                                     0                     10ppm
Arsenic                                                            0                     1ppm
Basic magnesium carbonate                       0.5                  1.0

Sodium bicarbonate 

The most important aerating agent. When heated it liberates carbon dioxide and water, leaving sodium carbonate as the residual salt. Sodium carbonate has a softening action on gluten and darkens the biscuit.If sodium bicarbonate is heated, only half the carbon dioxide is released, but if an acid is present all the carbon dioxide is released and there is no softening action on the gluten or darkening of the colour of the biscuit.

ACP – Acid calcium phosphate 

Acid calcium phosphate is also known as monocalcium phosphate. It is fairly soluble in cold water, but for doughs which are used without standing, a good proportion of the reaction takes place during baking. It is used in conjunction with sodium bicarbonate and ammonium carbonate.

Salt 

Sodium chloride, used as a flavour enhancer and also to control the rate and extent of fermentation.

SMS – Sodium metabisulphite Na₂S₂O₅ 

A reducing agent for the modification of the strength of the gluten in doughs

Proteolytic enzyme (proteinase) 

Used to soften the gluten in doughs. A white, fine powder. 

Production machine requirements:

Mixing

High speed horizontal dough mixer

• 850 kg batch capacity
• tilting bowl (150 degree tilt)
• variable speed drive 75 KW
• water jacket with chilled water supply
• shaftless blade
• two – dry ingredient feed inlets
• four – liquid ingredient ports
• four – dough tubs (additional dough tubs will be required for fermentation)

Vertical spindle mixer

 
Thomas L Green 3 spindle mixer – Reading Bakery Systems 

• Capacity 800 kg
• three spindle mixing paddles
• mobile mixing bowls
• single speed drive (25 rpm)

Dough feed system

• tub tilt and tipping unit
• bulk feed dough hopper with dough breaker
• 2 roll dough feeder
• dough conveyors with metal detector and reject system
• dough shredder for rotary moulded doughs

Forming

• Vertical laminator
  Hopper with scrap incorporation
  3 roll sheeter
  Dough sheet conveyor
  Two gauge roll units with cartridge conveyors
  Dough sheet layering unit with cut sheet facility
  Fat/flour spreader
  inclined conveyor to feed first gauge roll unit

• 3 roll sheeter with hopper and scrap incorporation (420mm diam. top rolls)
• currant spreader
• 3 pairs of gauge roll units with bottom roll adjustment (2 units 300 mm diam., and one unit with 400 mm diam. rolls)
• vegetable flake sprinkler
• seed sprinklers
• flour sprinklers
• intermediate web
• rotary cutting web (endless cotton belt)
• rotary cutter (4 roll type)
• separate cutting ad embossing rolls
• scrap lift, cross conveyor and scrap return conveyor
• cross conveyor for side crap
• side scrap wheels
• scrap dough distributor over the sheeter of the laminator
• decorating conveyor
• salt sprinker with recovery system
• swivel panner with guide rollers for oven band and automatic band tracking

Baker Perkins rotary cutting line

Control system and components

• inverter variable speed drives
• cascade control
• adjustable roll gaps by handwheels with indicators
• roll scraper position adjustable on each gauge roll
• manual web tracking controls
• automatic web tension
• PU synthetic webs
• endless cotton cutting web

Baker Pacific DGF cracker oven

Baking oven

• 1.0 m wide x 56 m long
• Direct Gas Fired Oven
• burner rating of 30 KW per sq.m of oven band
• oven band pre-heat system
• high rate burners in first zone
• 5 temperature control zones
• automatic temperature control system
• top and bottom heat control
• 5 extraction flues with fans and damper controls
• pneumatic band tension system
• Z47 type baking band
• alternative CB5 baking band (specification page 105)
• variable speed oven drive
• baking time from 3 – 8 minutes
• automatic band tracking system
• emergency wind out system
• wire-mesh take off conveyor with retractable nosepiece
• cross conveyor for reject
• safety systems
• oven band cleaner
• cracker breaker

> More about: Biscuit Baking Tunnel Oven

Dingson Food machinery DSM oil spray

Oil Spray

• stainless steel oil spray machine
• drain conveyor 2.0m long
• spinning disc type with adjustable masks
• filter system
• mist collection system
• oil collection sump (removable for cleaning)
• oil circulation pump

Cooling system

• 1:1.5 baking to cooling ratio (1:2 baking to cooling ratio recommended for sultana biscuit)
• two tier cooling system 90m long
• automatic band tracking
• automatic band tension
• PU Synthetic webs
• all webs with scrapers and catch trays
• biscuit stacking machine with by-pass for cracker strips
• predictor controlled channelling board
• adjustable star wheel
• cracker breaker on packing table
• packing table with stainless guides

Quality control

The following is a checklist of the important quality control requirements. Most of these will be standard for all the products made in the factory.

Raw materials

Flour 
Moisture content
Gluten content (Kjedahl)
Ash
Detection of flour treatment

Fats and Oils 
Acid value
Kreis test for rancidity
Slip melting point 

Process

Mixing 
Ingredient weights
Feeding sequence and timing
Mixing time
Temperature
Dough consistency
PH

Fermentation 
Dough volume
Temperature
PH

Forming 
Dough sheet thickness (after sheeting and gauge rolls)
Dough piece weights (across the band and with time)
Dough piece dimensions
Dough piece form

Baking 
Colour
Moisture content
Biscuit weight
Biscuit dimensions

Oil spray 
Oil weight (across the band and with time)

Packaging 
Metal detection
Number of biscuits in pack
Pack weights (minimum / average / maximum)
Labelling
Date codes

TechTalks Discussion

Recipe for soda crackers - lamination and drying methods?
I need cream crackers recipe with fermentation mixing, lamination and drying methods. 

Laminated Cracker Seasoning Application
Is there anyone out there that is familiar with alternative applications where the oil spray is not so thick and with other was to apply the seasoning such as a dry powder sprinkle etc?

Laminated snack crackers in steel belts?
Has anyone ever tried to make laminated biscuits (snack cracker type) in a steel oven band?

Cracker ovens
What would be the best specification for a hybrid oven to bake (1) snack crackers, 'Ritz' type, and (2) cream crackers

Topping salt detaching from crackers between application and packaging
What is the best way to assure that the topping salt in crackers will not detach from the product until packaging?

Ammonia Bicarbonate in Soda Crackers
What is the recommended quantity for whole wheat crackers?

First time doing crackers I have some problems
Is the kneading time and rph very important?   what would the ideal time? and at what rph would you suggest, please?    My equipment are small, more like bakery-style than industry, I have a kneader, a laminator, and a rotative oven.

Golden fish crackers
Any can help me with a recipe for goldfish crackers?

Improvement of shelf life and stability of recipe for hard dough biscuits

I would like to keep the formula stable for at least 4 months, preserve flavor without chemical additions to the recipe.

Production without fermentation
I am producing hard dough crackers biscuit-like salty and vegetable crackers. Now i would like to do production without fermentation by using hot water in the dough.

l am trying to source a gluten-free cracker manufacturer uk
Hi, l am having trouble sourcing a bakery to produce my gluten-free crackers. All ingredients have been sourced and premixed by the supplier.

Hard soda crackers
Hopefully, someone can help me with the solution on how to make our soda crackers have a softer bite.

Blister Problem
How to solve the blister problem in Enzyme Crackers/Ritz Crackers biscuit.

Cracker cutter - pilot
Anybody that can recommend a cutter for crackers for pilot test? Ideally it should be a cutter equipped with docker pins, i imagine something with a spring inside the cutter to perforate with the pins when cutting.  Hope anyone can give some good advice here. 

The crackers shape is changing
After forming the dough piece's shape is ok. But after the oven crackers, the shape is changing. Crackers going to be larger in width and smaller in length.

Cheese Crackers, puffing, hard crust soft crumb
I am working on a cheese cracker, I am using fresh yeast at 0.9% also using chemical leaveners, SMBS, enzymes, dough conditioner in my formulation. After baking crackers are getting hard outside and soft inside, with no light and crispy texture sometimes it also gets puffed, my target is to achieve thin and light and crispy crackers.

Oil absorption time in crackers
How to determine the best oil absorption time in crackers? How to determine the temperature effect?

Laminator RPM speed for soda crackers
What is the rpm that a 4-6 roll laminator should work. Should all rollers work at the same RPM´s?

How to eliminate blisters on crackers?
How do we eliminate blisters on fermented crackers like water crackers or cream crackers from an equipment standpoint? 

Seasoning for Potato crackers

Hi guy, what would be the best type of seasoning unit for Potato crackers weighing around 2 grams, 46mm round dia? The type of seasoning that applies is chilly flakes, pepper, etc. The normal sprinkling unit wouldn’t work as it used more coarse materials like salt, sugar, nuts, etc. Bieber the flavoring drum might also break the biscuit. Any suggestions?

DISCLAIMER

Baker Pacific Ltd. have used several reliable sources for the information provided in this document. However, Baker Pacific Ltd does not accept liability for any omissions, errors either of content or interpretation.  Baker Pacific Ltd does not accept liability or responsibility for any consequences whatsoever arising from the use of information contained in this document.

Find more Insights in Biscuit People Magazine