Section 11.10 Bakery Department: Bakery Products, Storage, Processing & Display

The purpose of this section is to ensure bakery products are processed and displayed in a manner that does not compromise food safety or quality.

Detailed instruction

Pastries

When preparing all bakery lines, clean, dry disposable plastic gloves must be worn.
All utensils must be clean prior to and as promptly as possible after production.
Only what is required for the next day is removed and placed on the baking racks This stock is transferred to the Bakery Coolroom to thaw overnight.
No stock is to be thawed at room temperature to prevent any contamination, i.e. pests.
The next morning, this stock is placed into the proofing oven. The proofer is pre-warmed by switching on and setting at 30°c-35° Pastries are proofed for about 1 hour.
Once proofed, they are the removed and each pastry is placed in the oven.
The oven is switched on and set to 170°c-180°c to preheat before the pastries are ready to be baked.
Once each tray of product is placed in the oven, the cook time is set to time, depending on load and a switched on to cook.
Once baked, the pastries are carefully removed and placed in the cabinet for self-serve or packed into a labelled container for sale for that day only.

Frozen Bread Rolls and Cookies

These products are treated as above except the proofing stage.
Loose bread rolls are sold on that day only They are markdown and disposed of at end of trade.
Prepack rolls are marked down on the3rd day and removed by end of trade?
Baked cookies are put into the appropriate container, labelled and given an 8-14-day shelf life depending upon product.

Donuts

Remove from freezer and tray up on oven trays
Bake for 3-5 mins on appropriate temperature.
Long donuts – Bake for 3-5 mins coat in sugar. Once cooled, filled with mock or fresh cream, and put in case for sale.

Filled sponges

Plain sponge cakes are brought in frozen and baked instore as required and are manually cut in half and Filled with jam/ apple and cream.
The cream is a pre-prepared mock cream that is simply whipped until firm.
When whipped cream is made, only what is required is used and any excess is stretch-sealed and kept in the coolroom for the next day.
Any leftover cream is disposed of after 48hrs.
Ensure we mark the made date on the whipped cream when placing in the coolroom.
The filled sponge cakes are packaged, labelled, and given a 6-day shelf life.

NOTE: Fresh cream is only applied onto a chilled or frozen sponge cake surfaces and is not to be directly applied onto just baked or heated cakes, to prevent spoilage. Any sponge cakes or other similar products containing fresh cream are given a 3-day shelf life & must be stored in 5°C temperature-controlled displays.

Bread

Follow manufacturers recipe cards for these products. Current method sheets supplied.

Markdown procedure

Breads

Any bread, rolls, Savouries, cheese twist etc. made on site – Made one day then marked down the following day, EG. If made on the 27th of November, these products are to be reduced for sale either late on the 27th or the first thing on the following day the 28th.

The marked down products should be displayed on an off-location area and should be removed from sale by 1pm that day. That means taken off the fixture for sale, recorded as further shrinkage and then dumped.

Cakes/ Biscuits

Any cakes, biscuits should be marked down 2 days prior to use by date or best before date (use by and best before dates are considered to be the same thing) and cannot be offered for sale on that date. EG if the use by or best before date is the 27th of November, nothing should be on show with that date.

Storage

Meats, Cheese, Prepared Products, etc – Chilled

Store in coolroom.
Temperature of product below 5°C.
Food products packaged or otherwise not to contact non-food contact surfaces.
No contamination from ventilation condensation drip.
Observe rotation ‘First in – First out’. Use by date to be written on all ingredient containers.
Observe Use by dates.
Implement segregation of meat, cheese and raw ingredients in designated racking.
Bacon (and other processed meats) stored separately from fully cooked products.
Designate and label a “credit/goods/ quarantine” section in the coolroom.
Label all designated areas for shared coolrooms.
Cover all chilled product in coolroom storage to prevent contamination and drying out.

Raw Non-Perishable, Raw Ingredients, International Packaged Lines, Packaging and Labelling

Opened bags of flour/ ingredients are opened they are to be stored in sealed containers.
Open bags and containers of food ingredients are stored in designated racking / shelving / benches. Ensure use by date batch number is placed in the container as well for identification and traceability.
Opened containers / bags of ingredients not to be stored in storeroom area.
Not to contact floor areas.
Maintain in clean area with tidy housekeeping.
Maintain clean storage shelving.
Packaging, Labelling, Trays and Containers etc to be stored to prevent contamination

Inspection

- All items must be regularly inspected for signs of deterioration and pest infestation.
- Bulk storage areas must be cleaned weekly.
- Spillage’s cleaned immediately.
- Inspection are to be carried out a minimum of seven times a week according to Form 24 Bakery Weekly Food Safe Checklist.

Product & Case Preparation

The Bakery Manager is responsible to ensure all food preparation and display is conducted according to Health Regulations and in such a manner to prevent contamination and growth of food spoilage or poisoning micro-organisms.

Product and case preparation relate to

Product Preparation
Product Display
Chilled Display where present

Food Processing

The times during which foods are being prepared for cooking or otherwise processed are periods of particular danger.
Bacterial, foreign body or chemical contamination is most likely to occur at these times because the food is no longer protected by packaging and is subject to handling – added to this is the fact that bakery area temperatures are highly suitable for the growth of food spoilage or poisoning bacteria.
Bakery products particularly bread is not generally subject to food poisoning bacteria, however, high moisture, value added breads can be subject to food poisoning bacteria. Breads however are subject to mould and yeast spoilage which is directly attributable to poor sanitation and handling.
Bakery products are however, by the nature of the processing, subject to foreign body contaminants

Protection of Food During Processing

All Staff must observe high standards of personal hygiene.
All equipment and utensils used in food processing must be cleaned and sanitised
Contact between hands and foods is minimised by the use of utensils and where practical disposable gloves.
Disposable gloves are worn to limit health risk and to project a uniform image to our customers and are to be used when:

-Handling products after baking.

-Handling ready to eat foods.

-Serving customers.

Clean equipment regularly between processing and during the day.

Auto bread slicer – clean at the end of the day
Popcorn machine – to be cleaned daily as per cleaning procedures.
Coffee Machine – Perform an auto clean daily.
Fresh Blend machine – Perform an auto clean daily.
F-Real machine – to be cleaned daily as per cleaning procedures.

Serving Food

All food on display should be protected from contamination and the risk of food spoilage or contamination. Breads, cakes and donuts must be packaged or displayed under correct self-serve cases.
Sample tasting should be controlled adequately. Do not leave sample tastings on display for longer than half (1/2) an hour, to prevent excessive dehydration. Use the sample tasting as a merchandising tool but ensure the quality of product on display is high. Closely supervise the sample offer to ensure no contamination by customers occurs.
Ensure packaging that is to be used for serving of food is clean and in good condition.
Use only clean utensils when serving foods. Tongs to be sanitised every 3 hours.
Utilise gloves or tongs when serving cakes from cabinet. Never serve these foods with bare hands.

Housekeeping

Housekeeping is the term used to describe general storage and cleanliness requirements which are particularly important in the Bakery operation.

Bakery ingredients should be covered at all times. Store in sealed containers. At end of day, there should be no stock left open.
Ensure all ingredients are date coded and description is in the container for identification and traceability.
Never open more than one bag of the same variety flour or ingredient unless product is to be used immediately.
Stack ingredients on shelving, off floor. Always stack neatly. Rotate product “First In – First Out”.
Bulk dry goods should be neatly stored on pallets and separated from general grocery stock to prevent damage to bags or packaging. Bulk dry store is usually outside of department, therefore never leave opened bags in this area.
Bulk dry storage areas require minimum weekly clean down to prevent pest infestation. Spillage to be cleaned daily.
Dried fruit products will attract insects (vinegar & fermentation fly) so therefore ensure boxes and inner bag is always sealed.
Donut ingredients such as solid oil, toppings and icing must be kept covered to prevent contamination.
To prevent foreign body contamination of product, invert all bread and cake tins when stacking on trolleys after use. This will prevent insects or dirt falling into bottom of tray.
Do not allow excess rubbish build-up and place all dough scraps and empty flour bags into rubbish bins, during the day. Empty bins regularly.
Excess equipment and packaging materials should not be stored on top of ovens, provers or coolrooms due to fire and pest hazards.
Packaging bags and other materials should be stored neatly on shelving under benches. Keep lids of boxes closed to prevent contamination as per ingredients.
Ingredient bench – when one compartment is emptied the compartment must be thoroughly cleaned out before refilling.
Personal drinks (e.g. bottles/cans) must not be stored in coolrooms – only in lunchrooms. Glass bottles are not allowed in
departments. Porcelain/glass coffee cups cannot be used in the departments. Only water is allowed into the department in a plastic bottle.
No staplers, pins, etc to be stored in Bakery preparation area.
Personal belongings must be stored in locker room, not bakery food storage or preparation areas.

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