General process information
The sifted flour is poured into an industrial mixer. Temperature-controlled water is piped into the mixer. This mixture is called “gluten” and gives bread its elasticity. A pre-measured amount of yeast is added. Yeast is actually a tiny organism which feeds off the sugars in the grain, and emits carbon dioxide. The growth of the yeast produces gas bubbles, which leaven the bread. Depending on the type of bread to be made, other ingredients are also poured into the mixer.
The resulted dough is than fermented.
After the dough has fermented, it is loaded into a divider that cut the dough into pre-determined weights. A conveyor belt then moves the pieces of dough to a molding machine. The molding machine shapes the dough into balls and drops them onto a layered conveyor belt that is enclosed in a warm, humid cabinet called a “proofer.” The dough moves slowly through the proofer so that it may “rest,” and so that the gas reproduction may progress.
When the dough emerges from the proofer, it is conveyed to a second molding machine which re-shapes the dough into loaves and drops them into pans. The pans travel to another proofer that is set at a high temperature and with a high level of humidity. Here the dough regains the elasticity lost during fermentation and the resting period.
From the proofer, the pans enter a tunnel oven. The temperature and speed are carefully calculated so that when the loaves emerge from the tunnel, they are completely baked and partially cooled.