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.
Dimensions: 48 x 48mm
Appearance: Evenly blistered
Colour: Golden with vegetable flakes
Texture: Light and delicate with soft mouth-feel
Flavour: Aromatic flavour
- Flowpack with stack of 6 biscuits, packed in cartons.
- Biscuits on edge in trays and wrapped in Flowpack.
Oven cutting machine width 1250mm
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 mins
Biscuits per min. 21 x 965 = 20265/4 = 5066
Kg per hour: 5066 x 60 x 3.75/1000 = 1140
Output at 90% efficiency: 1025 kg/hr
|Vegetable cracker (1)|
|Recipe||Weight (kgs)||Moisture content and loss during baking %||Dry weight||Carbohydrate||Protein||Fat||Energy kcal|
|Total weight of mix||148.16|
|Total dry weight||105.48|
|Final moisture content||3.0|
|Yield of biscuits||108.74|
|Nutritional values of vegetable crackers per 100gm|
|(1) calculated from table of McCance and Widdowson 1991|
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.
Formulation (1) (2)
with enzyme with SMS
Flour (weak) 100.00 90.00
Cornflour – 10.00
Powdered sugar – 3.00
Invert syrup 70% 1.04 16.0
Malt extract 80% 2.08 –
Dough fat 13.54 14.0
Lecithin – 0.28
Ammonium bicarbonate 2.60 3.00
Sodium bicarbonate 0.44 1.00
Acid calcium phosphate 0.05 –
Salt 1.23 1.00
SMS – 0.05
Proteolytic enzyme 0.18 –
Dehydrated vegetable flakes 2.00 2.00
Water 25.0 25.0
- Flour should be weak with a protein content of 8-9%.
- Proteolytic enzyme (proteinase).
- Oil for spraying: coconut oil or palm kernel oil are suitable and have a good resistance to rancidity.
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: Dough mixing
An “all in” mix on a horizontal mixer. Horizontal 2 speed (30/60rpm) or variable speed mixer. 75KW motor
Temperature of final mix about 33 degrees C for enzyme doughs
Temperature of final mix about 40 degrees C for SMS doughs.
The vegetable flakes may be mixed into the dough.
After mixing the dough is stood to allow the enzyme to react with the gluten. The standing time is about 3 hours at 35 degrees 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.
The dough is sheeted, gauged and cut, (laminating is not required).
3 roll sheeter with good scrap incorporation
3 pairs of gauge rolls (final rolls 400mm diam.)
Rotary cutter (single roll or two roll system)
Vegetable flake sprinkler may be positioned before the final gauge roll unit
Typical roll gap settings are:
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.
Direct Gas Fired Oven
Z47 type wire-mesh band
Pre-heat is required
Average oven burner rating 28KW/m2
Baking temperatures: 220 / 220 / 220 /180 degrees C
Baking time: 4.0 – 5.0 minutes
High bottom heat in Zones 1 and 2 is required
The oil spray should be located immediately after the oven. An application of 10 – 16% by weight of coconut oil is recommended.