FACULTY:

SCHOOL OF INDUSTRIAL SCIENCES AND TECHNOLOGY

DEPARTMENT:

FOOD PROCESSING TECHNOLOGY

TITLE:

DESIGNING A PROCESS OF PRODUCING EXTRUDED PRODUCTS FROM STALE BREAD

NAME:

WILLARD MWAI

REG NUMBDER:

H0710444S

COURSE:

CAPSTONE STONE PROJECT

Introduction Left over bread can be used, under the condition that it is hygienically fit and complies with health and safety regulations as extruded products and animal feeds.The left over bread which does not have mycotoxins, metabolites of moulds, can be processed by extrusion for human consumption or used as a protein- energy ingredient in animal feed. Exploring the use of stale or left over bread involves the designing of a process and possible ways of converting stale bread into bread extruded products such as bread crackers, bread chips and bread sticks. Background There are no official statistical data on the quantities of leftover and discarded bread. According to the survey conducted, there is a significant amount of leftover bread in Serbia. One of the habits of population in Serbia is to discard bread which is not consumed in one single day (A. Mari,at al,2009) . According to the survey carried out in January - March 2010 by the Institute for Food Technology in Novi Sad (FINS) the amount of leftover bread in Serbia ranges from 5-10% of the produced quantity. It was found that from one million of 0.5 kg loaves produced in Vojvodina, a minimum of 50, 000 loaves are discarded what makes total of 25 tons of bread per day. Leftover bread represents an environmental problem, but also potentially valuable raw material for human food and animal feed. Preliminary literature Review From safe leftover bread that is without the presence of harmful substances a very attractive raw material can be obtained. Mycotoxins from unsafe leftover bread pose a serious health threat for the part of population who collect food from street dustbins. A significant amount of leftover bread comes from: 1. Households (it is thrown away together with other waste or in separate bags); Bread is 1-5 days stale and of problematic microbiological safety. 2. Large bakeries - undelivered products or products returned from supermarkets. 3. City dumps where large quantities of bread ends up mixed with and contaminated by other waste. 4. Small bakeries quite rationally and economically organize their production. Leftover bread is not a problem for them according to the survey carried out with small bakeries. There is no organized way of leftover bread collection and distribution for possible further processing. As a result, there is evident increase of environment pollution and related problems in the food chain. Our food industry is a major generator of waste, and reuse of leftover bread is way to overcome the ecological problems. According to A. Mari, at al, 2009 bread which complies with health and safety regulations can be used further processed into food and feeds. The stale bread complying with microbiological accuracy regulations can be further processed into extruded products such as bread croutons, bread sticks, bread chips and bread crackers. Bread which do not comply with

microbiological accuracy regulations can be further processed into animal feeds. The animal feeds includes fish feed, pet feed, bull calves, pigs and lamp feeds. Bread which does not comply with health and safety regulations can be used in biofermentations synthetic alcohol production and also brickets processing. Statement of the problem The bakery industry has been experiencing profit loss due to staling of bread and in process losses during bread production. Scope of Study The project is only focusing on the designing of a process for producing a product from stale bread that does not need equipment that is not readily available in Zimbabwe. Limitations There is lack of enough time to really explore all the possible products that can be processed such as animal feeds. Objectives

To produce extruded products from stale bread. To design the extrusion process.

Research Questions
1. What are the present amounts of stale bread in a bakery daily, weekly?

2. What is the best time after baking to do the process? 3. What pre-treatment is needed? 4. What are the various unit operations in an extrusion process? Research Methodology Method used to collect data Primary and secondary sources of data are to be used during the research process. The data to be collected is on the amount of bread that is being returned(stale bread) and also the amount of bread that gets deformed during the process of baking for example a significant amount gets deformed during depanning(removing from the baking pans) process. Interviews are going to be used to gather information on the amount of bread that is returned at various bakeries such as Bakers inn and also small bakeries. Internet, journals, books are the secondary sources of data to be used during data collection. For areas that cannot be easily accessible because of the distance the telephone method is to be used as a research tool.

Methods used to analysis of data The stale bread samples are to be taken, with one to seven days after production and analysed for the level aflatoxins with the number of days after the date of production. Bar graphs are to be used to represent the relationship between levels of aflatoxins with the number of days after production. A series of practical experiments of the extrusion process are carried out to come up with the best product. This is then followed by the analysis and conclusion. Design demonstration method of research is to be used during the research, since a new process is to be designed, tested and evaluated to come up with the suitable process. Significant of study The project can be a benefit to the industry by reducing the losses of profits in the bakeries. There is no organized way of leftover bread collection and distribution for possible further processing. As a result, there is evident increase of environment pollution and related problems in the food chain. Our food industry is a major generator of waste, and reuse of leftover bread is way to overcome the ecological problems. Hence it can be a benefit to the environment. Schedule of activities GUANTT CHART

1
2 3
4

Dec

Jan

Feb

Mar

April

May

TIME Key

1- Collection of data, that is by visiting the Baker`s inn Factories and also some other Bakeries that are in and outside Harare. 2- Samples of bread are to be taken to the Laboratory for microbial and different toxins tests. 3- Series of experiments of the extrusion process are then carried out to come up with the best product. 4- Analysis and conclusion of results

References 1. A. Mari, S. Arsovski, J. Mastilovi: Contribution to the improvement of products quality in baking industry, 3rd ICQM Proceedings, Kragujevac,(2009), 21-28 .
2. FAO/WHO Consultation on the Health Implications of Acryl amide in Food. Geneva, 2527 June 2002. Summary Report
3. Kothari, C.R.,1985, Research Methodology- Methods and Techniques, New Delhi,

Wiley Eastern Limited.

4. Dawson, Catherine, 2002, Practical Research Methods, New Delhi, UBS

PublishersDistributors.