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Bio- and food technology – Bio- and food technology – BFBF

CHALLENGES IN DESIGN CHALLENGES IN DESIGN TEA COOKIES TEA COOKIES

XXIII CONGRESS OF CHEMISTS AND TECHNOLOGISTS OF MACEDONIA8-11 OCTOBER, 2014, OHRID

Skopje Design Week 2014 23 - 28 September Kursumli An

Julijana Savic-Dineva , eng.food biotech, food product design for Super Grup , e-mail: [email protected]

Super Grup, Boris Trajkovski 107, Skopje, +389 2 279 1 279, [email protected]

mailto:[email protected]

mailto:[email protected]

http://www.ministryofpleasure.net/index.html


CHALLENGES IN DESIGN TEA COOKIESCHALLENGES IN DESIGN TEA COOKIES

In this review we present 3 months trial production of tea cookies. We faced various challenges in food product design, in making choices for raw material, processing time and conditions. We achieved different forms and quantitative and qualitative desired outcome, of new food product, tea cookies.

Standard process equipment was used, mixer, dosing and forming and tunnel owen. Small trial dough of about 8 kg was baked 11 times. Each trial is different and is recorded as recipe, process time, process conditions and sensory and quantitative basic measurement of finished product, tea cookies. We also compare our products with current tea cookies on the market as nutrient composition, form, color, taste, and price per unit product. So far basic design of package for 200 g net weight is chosen. Specification of process and product following GMP (Good Manufacturing Practice) and GHP (Good Hygienic Practice) is being prepared for optimal daily production.


CHALLENGES IN DESIGN TEA COOKIESCHALLENGES IN DESIGN TEA COOKIESSuper Grup Company produces various products in healthy life style foods. Cold pressed

oils as sesame oil, flaxseed oil, pumpkin seed oil, black seed oil (Nigella Sativa), and sunflower oil is in preparation. Also it produces defatted flour, as residue from oil extraction from the same type of raw materials, mentioned before. One biotechnology product is packing solution of Super Maya, enzyme from fungal origin (Rhizomucor miehei), and rennet for milk processing, for production of hard and soft cheese.

Main products are sesame paste tahini and traditional sweet, sesame tahini halva. And also grain energy bars cranberry and hazelnut. www.supergroup.mk

Most recent new raw material, that can be used for design of food product are natural sweeteners, fig , grape and carob syrup which can be used as they are or in healthy food recipes and also as mix with tahini paste.

Also production line for chocolate glaze is installed but so far this equipment is not being

used .With this trial production Super Grup Company is developing new production line of tea cookies and broadening spectar of healthy life style food products.

Super Grup Company is also performing social role in employing people with special need. Key words cookies, healthy, natural, design, food

http://www.supergroup.mk/



Basic recipe for trial production kg %Fats 1,4 17Sugar 1,8 22Flour 3,8 46Milled (sesame, linen, oats, coconut, cocoa) 0,2 2

Milled dried fruit (resins, dates, strawberries, lemon, orange, cranberry, fig)

0,2 2

Water 0,6 7Baking powder, salt, lecithin, enzymes-freshey, aroma (vanilla, cinnamon, strawberry, hazelnut, cranberry, orange, lemon)

0,2 2

Total 8,2 100



no. Process flow1 Each ingredient is weight on the scales as in recipe formulation.2 First fats are placed in mixer.3 Water is added and then liquid compounds.4 Sugar , aroma and fruit paste are added while mixing.5 All ingredients are added while mixing.6 Add rest of the water and active enzymes.7 Salt and baking powder are added in flour.8 Flour is added in small amounts while dough is mixing.9 Each dough is mixed 20 minutes. And then transferred to dosing and forming machine.

10 You can choose form in which dough will be deposited on the trays (shape of cookies).11 In the dosing and forming machine you can choose the amount of dough (weight of cookies).12 Prepare 7 trays for 8.3 kg dough (dough shouldn’t stay long).13 Tunnel owen is prepared in advance 60 minutes before.14 Temperature of baking is chosen and speed of wire conveyor is chosen.15 Trays with baked cookies are placed for cooling. Ready product is packed by hand.16 Working areas and machines are cleaned after production batch is finished.



ANALYSIS OF TRIAL COOKIES WITH DIFFERENT DOSING 1, 1.5 , 2 ANALYSIS OF COOKIE 1 no. type value unit comments

1 7 DOTS FLOWER 7,1 g minimal 2 1 LINE 7,3 g 3 8 RAYS FLOWER 10,7 g 4 5 LINES SUN 11 g maximal 5 HALFMOON FORM 9,7 g 6 HEART FORM 9,9 g TOTAL 55,7 g AVERAGE 9,28



ANALYSIS OF COOKIE 1.5 no. type value unit comments 1 7 DOTS FLOWER 8,3 g min 2 1 LINE 9,7 g 3 8 RAYS FLOWER 13,7 g 4 5 LINES SUN 14,7 g max 5 HALFMOON FORM 13,8 g 6 HEART FORM 13,3 g TOTAL 73,5 g AVERAGE 12,25



ANALYSIS OF COOKIE 2 no. type value unit comments 1 7 DOTS FLOWER 10,6 g min 2 1 LINE 11,5 g 3 8 RAYS FLOWER 17,2 g 4 5 LINES SUN 17,1 g max 5 HALFMOON FORM 13,7 g 6 HEART FORM 15,7 g TOTAL 85,8 g AVERAGE 14,3



FOOD PRODUCT DESIGN GOALS1. FORMULATE NEW AND EXSISTING PRODUCTS TO MEET OBJECTIVESSENSORY NUTRITIONAL QUALITY COST TIMELINE MANUFACTURABILITY 2. DESIGN AND CONDUCT EXPPERIMENTS TO EVALUATE FORMULATION, PRODUCTPARAMETERS AND PACKIGING PROCESS 3. MONITOR SENSORY CHANGES AND MICROBIOLOGY SHELFLIFE OF TEST PRODUCTS 4. MAINTAIN DETAILED, COMPREHENSIVE RECORDS OF FORMULATIONS, PROCESSPARAMETERS , FINISHED PRODUCT RESULT AND SENSORY EVALUATION 5.TECHNICAL AND PRODUCTION CHALLENGES, DATA COLLECT PATTERN ANALYSIS 6.RECOMMEND, SET UP, CALIBRATE, BASIC EQUIPMENT AND LAB EQUIPMENT



Trial production Time Line1 week 49 date 05-12-20132 date 06-12-20133 w50 date 11-12-20134 w2 date 08-01-20145 date 10-01-20146 w3 date 17-01-20147 w4 date 23-01-20148 w5 date 30-01-20149 w6 date 07-02-201410 w7 date 13-02-2014

11 w8 date 20-02-2014


CHALLENGES IN DESIGN TEA COOKIESCHALLENGES IN DESIGN TEA COOKIESBaking time and temperature (oC) for 13-02-2014

entrance of material part 1 part 2 part 3 part 4

1 2 3 4

upper heaters 190 260 250 210

190 260 250 210

lower heaters 170 210 190 165

170 210 190 165

type value unit

time for baking 12 min

speed of conveyor 27,1 rpm

max time START END

time for mixing dough 30 min 9.00 h 11.00 h

time for dosing ,forming 30 min

time for baking 30 min

time for 1 trial 2 casa

dosing dough cookies 1,5 unit

shape of cookies S-shape

Basic Material Balans

type value unit

no. of tray 8 tray

no. of cookies on 1 tray 54 cookies

time of mixing 20 min

total dough 8300 g

dough in dosing machine 2000 g

no. of baked cookies 432 cookies

average baked cookie 12,3 g

total cookies 5313,6 g

total dough for cookies 6300 g

1 package cookies 200 g 16 cookies

1 batch 27 packages



ANALYSIS OF THE COOKIES ALREADY IN THE MARKET, SIZE, SHAPE ,COMPOSITIONANALYSIS OF COOKIES no. TYPE

1 COOKIE (g)

1 PACKAGE (g)

NO. COOKIES

1 musli int 15 115 8

2musli int cocoa 15 115 8

3 vita day 26 200 84 ocake 13 210 165 coko donia 12 300 25

6tea cookie mako 11 180 16

7my cookie butter 5 100 20

8 vitalix 10 200 209 nutri keksic 7 150 21

10 sunday biscoti 16 350 2211 balans vincini 11 180 16

12my cookie cocoa 12 300 25

13 medenka 50 50 1



composition vitaday polski

balance ocake muesli sweet plus

muesli integ sweet plus

no nutrition information 100g product

100 g product

100 g product

100 g product

100 g product

1 energy 465 kcal,1944 kJ

412 kcal, 1732 kJ

427 kcal. 1788 kJ

461 kcal, 1937 kJ

674 kcal, 1997 kJ

2 proteins (g) 5.4 g 8.5 g 8,1g 6.5 g 6.4 g3 carbohydrates (g) 52.4 g 63 g 60,9 g 68 g 65.2 g

of which sugars 20.6 g 19,9 g 29 g 29 g4 fats (g) 25.7 g 15.8 g 18,5 g 17.5 g 20.5 g of which no

saturated fats9.3 g 4,2 g 7 g 7 g

5 fiber (g) 6.36 g 7,9 g 2.9 g 2.6 g6 salt, natrium (g) 0.4 g 0,37 g 0.171 g 0.252 g



cookie card oat -lemon type description smell very slight fragrance from lemon aroma color light, light brown from integral flour taste sweet , from lemon comes freshness a citrusy flavor length 50 mm thickness 7 mm wide 50 mm average weight 12.7 g texture soft enough, bottom and crust formed other

descriptionthese cookies have a lot of oats, but it isn't dominant

these are slim cookies, form and taste and time of baking are right these type of cookie has natural style color and taste for healthy food

products



cookie card oat -coconut type description smell very slight fragrance from coconut

color light, cream white from coconut and integral flour taste sweet , slight coconut flavor length 55 mm thickness 10 mm wide 55 mm average weight 11,7 g texture soft and wet inside ,bottom and crust formed other

descriptioncookies should be made with other fresh coconut flour aroma

these are slim cookies, form and taste and time of baking is not good cookie is wet

these type of cookie has natural style color and taste for healthy food products



cookie card oat -orange type description smell very slight fragrance from orange

color light, cream white and integral flour taste sweet , slight orange flavor length 50 mm thickness 11 mm wide 35 mm average weight 12,33g texture soft and wet inside ,bottom and crust formed other description cookies are made with fresh orange, aroma, dates ,raisins

these are bigger cookies, super taste, time of baking should be 2 min more these type of cookie has natural style color and taste for healthy food products



cookie card oat - fig type description smell very slight fragrance from fig

color light, light brown taste sweet , slight fig flavor length 40 mm thickness 7 mm wide 40 mm average weight 7,7 g texture soft but not crumbly ,bottom and crust formed other description cookies are made with fig marmalade, vanilla aroma

these are small flat cookies, time of baking and form are correct these type of cookie has natural style color and taste for healthy food products



cookie oat-strawberry type description smell neutral

color light pink, light brown, aroma compound is intensive red taste sweet only length 40 mm thickness 11 mm wide 40 mm average weight 9,2 g texture soft but not crumbly ,bottom and crust formed other

descriptioncookies are made with dried strawberries, and aroma

taste is not achived in cookies, time of baking and form are correct aroma compound should be colorless and maby strawberry marmalade for taste



cookie card oat-flax-malt type description smell neutral, slight malt aroma

color light, light brown, golden taste not sweet , slight aroma malt length 50 mm thickness 7 mm wide 50 mm average weight 11.9 g texture not soft but chewy ,bottom and crust formed other

descriptioncookies are made with specific aroma and taste of barley malt

taste is not achived in cookies,flat cookies, time of baking and form are correct these type of cookie has natural style color and taste for healthy food products



cookie oat-malt-cranberry type description

smell smell and aroma cranberry and malt color light, light brown,

taste not sweet , malt aroma, slight bitter length 50 mm thickness 10 mm wide 40 mm average weight 11 g texture soft and wet inside ,bottom burned and crust formed other

descriptioncookies are made with malt, which is dominant taste and aroma

taste is barley malt ,thick cookies, time of baking is not correct these type cookie has malt taste for healthy food, slight bitter



cookie card oat-cranberry type description smell intensive smell and aroma cranberry

color light, light brown, taste very sweet , used 3 type of sweetners length 50 mm thickness 10 mm wide 32 mm average

weight8.4 g

texture soft ,bottom and crust formed other

descriptioncookies are made with specific aroma and taste of cranberry

taste is very very sweet,flat cookies, time of baking and form are correct these type cookie has very intensive sweet and cranberry taste for healthy

food



cookie flax-hazelnut type description smell smell and aroma hazelnut, not very intensive color light, light brown, natural

taste sweet , hazelnut aroma, slight flax length 60 mm thickness 10 mm wide 45 mm average weight 14,2 g texture firm shape ,bottom and crust formed , enough crumbly other description taste is good but pieces of hazelnut stuck in dosing forms! so only use powder or paste nuts and fruits, or else cookies will deform in shape these type cookie has hazelnut taste, natural colour and is healthy food productcookie flax-hazelnut type description smell smell and aroma cinnamon color light, light brown, natural

taste sweet , cinnamon aroma, slight flax length 60 mm thickness 10 mm wide 45 mm average weight 11.7 g texture firm shape ,bottom and crust formed , slight crumbly other description taste is good but pieces of hazelnut stuck in dosing forms! so only use powder or paste nuts and fruits, or else cookies will deform in shape these type cookie has hazelnut taste, natural colour and is healthy food product



cookie card flax-cocoa type description smell smell and aroma of cocoa

color dark, dark brown, taste enough sweet ,cocoa aroma, slight bitter, like chocolate length 50 mm thickness 12 mm wide 30 mm average weight 8.11 g texture soft and slight wet inside ,bottom and crust formed other description cookies are made with dominant taste and aroma of cocoa time of baking is correct, taste is like chocolate, flax and cocoa make dark color these type cookie has taste and colour for natural healthy food



cookie sesame-vanilla type description smell smell and aroma of vanilla

color light, light brown, seeds of sesame are visible taste enough sweet ,maby more fat taste , from sesame length 60 mm thickness 8 mm wide 40 mm average weight 10 g texture soft inside ,bottom and crust formed other

descriptioncookies are made with sesame deffated flour, and sesame seed

time of baking is correct, taste is more on fat, because of the sesame these type cookie has taste and colour for natural healthy food



cookie sesame-strawberry type description smell smell and aroma of straberry

color light, light brown, taste enough sweet ,strawberry length 47 mm thickness 9 mm wide 42 mm average weight 8.3 g texture soft inside ,bottom and crust formed other description cookies are made with dried strawberies, time of baking is correct, taste is fresh these type cookie has taste and colour for natural healthy food



cookie flax-cinnamon type description smell smell and aroma cinnamon color light, light brown, natural taste sweet , cinnamon aroma, slight flax length 60 mm thickness 5 mm wide 60 mm average weight 15 g texture firm shape ,bottom and crust formed , enough crumbly, thin other description these cookies are with T-500 wheat flour and whey so this combination makes cookie very hard for bite, but when broken is crumbly these type cookie should be made with dosing speed 1, and whole wheat flourcookie flax-cinnamon type description smell smell and aroma cinnamon color light, light brown, natural taste sweet , cinnamon aroma, slight flax length 60 mm thickness 10 mm wide 50 mm average weight 16.2 g texture firm shape ,bottom and crust formed , slight crumbly other description these cookies are with T-500 wheat flour and whey so this combination makes cookie very hard for bite, but when broken is crumbly these type cookie should be made with dosing speed 1, and whole wheat flour


CHALLENGES IN DESIGN TEA COOKIESCHALLENGES IN DESIGN TEA COOKIEScookie sesame-vanilla type description smell smell and aroma vanilla color golden brown, natural taste sweet , vanilla aroma, taste is very good length 60 mm thickness 7 mm wide 60 mm average weight 14 g texture firm shape ,bottom and crust formed , enough crumbly,

thin other description these cookies are with wholewheat flour and whey so this combination makes cookie very hard for bite, but when broken is crumbly these type cookie should be made with dosing speed 1, and do not use wheycookie sesame-vanilla type description smell smell and aroma vanilla color golden brown, natural taste sweet , vanilla aroma, taste is very good length 60 mm thickness 10 mm wide 45 mm average weight 14 g texture firm shape ,bottom and crust formed , slight crumbly other description these cookies are with wholewheat flour and whey so this combination makes cookie very hard for bite, but when broken is crumbly these type cookie should be made with dosing speed 1, inside the cookie is wet



cookie coconut-pumpkin type description smell smell and aroma of fat compounds, slight coconut color golden brown, natural taste sweet , coconut, taste is not good, too much fat compounds length 60 mm thickness 7 mm wide 60 mm average weight 13 g

texture firm shape ,bottom and crust formed , enough crumbly, thin other description these cookies are with wholewheat flour and whey so this combination makes cookie very hard for bite, but when broken is crumbly these type cookie should be made with dosing speed 1cookie coconut-pumpkin type description smell smell and aroma of fat compounds, slight coconut color golden brown, natural taste sweet , coconut, taste is not good, too much fat compounds length 60 mm thickness 10 mm wide 50 mm average weight 14 g texture firm shape ,bottom and crust formed , slight crumbly other description these cookies are with wholewheat flour and whey so this combination makes cookie very hard for bite, but when broken is crumbly these type cookie should be made with dosing speed 1, inside the cookie is wet



cookie sesame-coconut type description smell smell and aroma of fat compounds,sesame ,slight coconut color white , slight yellow taste coconut, taste is not good, too much fat compounds length 90 mm thickness 10 mm wide 40 mm average weight 18 g texture firm shape ,bottom and crust formed , not baked other description these cookies are with T-500 flour and whey in the process of making , double amount of water is used, so cookie couldn’t form later additional flour is used, but taste is not achived, cookie is not bakedcookie sesame-coconut type description smell smell and aroma of fat compounds, sesame, slight coconut color golden brown, natural taste coconut, taste is not good, too much fat compounds length 78 mm thickness 8 mm

wide 42 mmaverage weight 14 g

texture firm shape ,bottom burned and crust formed , slight crumbly other description these cookies are with wholewheat flour and whey in the process of making , double amount of water is used, so cookie couldn’t form later additional flour is used, but taste is not achived, cookie is with burned bottom



cookie coconut-vanilla type description smell smell and aroma of fat compounds,sesame ,slight coconut color white , slight yellow taste coconut, taste is not good, too much fat compounds length 65 mm thickness 4,5 mm wide 65 mm average weight 12 g texture firm shape ,bottom and crust formed , not baked other description these cookies are with T-500 flour and whey in the process , double amount of water is used, so cookie couldn’t form later additional flour is used, but taste is not achived, cookie is thin cookie coconut-vanilla type description smell smell and aroma of fat compounds, sesame, slight coconut color golden brown, natural taste coconut, taste is not good, too much fat compounds length 65 mm thickness 4 mm wide 65 mm average weight 11 g texture firm shape ,bottom burned and crust formed , slight crumbly other description these cookies are with wholewheat flour and whey in the process , double amount of water is used, so cookie couldn’t form later additional flour is used, but taste is not achived, cookie is thin



cookie card vanilla T-500 type description smell smell and aroma of vanilla color light , light brown taste neutral length 40-60 mm thickness 5 mm wide 40-55 mm average weight 10.5 g texture these are firm cookies, flat and thin other description cookies are made with vanilla and flour T-500 time of baking is correct, but shapes are various and also weight these type cookie has taste and colour for standard tea cookies



cookie card 06-12-2013 type description smell sweet, fat, slight vanilla

color light brown taste sweet, fat, slight vanilla length 50 mm thickness 10-15 mm wide 60 mm average weight 20-25-30 g texture soft and crumbly other description these are large cookies, dosing is 2,5 and dough is soft time of baking is correct, taste is vanilla and sweet, but also fat compound these type cookie is very big and dosing should be less



cookie card 05-12-2013 type description smell sweet, fat, slight vanilla color light brown

taste sweet, fat, slight vanilla length 50 mm thickness 10-15 mm wide 60 mm average weight 20-25g texture soft and crumbly other description soft and not baked time of baking is not correct these are large cookies, not baked these type cookie are standard tea cookies, T-500 flour and vanilla



BASIC MATERIAL BALANCE AND BASIC TIME LINE FOR 100 KG DOUGH type value unit START END time for mixing dough 4*30 min min 8.00 h AM 10.00 h AM time for dosing ,forming 4*30 min min 10.00 h AM 12.00 h PM time for baking 4*30 min min time for trial 4 hours time for cooling cookies 4*30 min min 12.00 h PM 2.00 h PM time for packing cookies 4*30 min min 2.00 h PM 4.00 h PM dosing dough cookies 1-1,5 unit shape of cookies Y -shape average weight 10 g time for baking 12 min speed of conveyor 27,1 rpm



Basic Material Balans type value unit total dough 100 kg 1 batch dough 25 kg dough in dosing machine 2 kg dough for cookies 98 kg total baked cookies 82,44 kg 6,3 kg dough 5,3 kg cookies 1 cookie average weight 10 g baked total number of cookies 8244 pieces 1 package 200 g number of cookies 1pack 20 pieces total number of packages 412 pieces no. of cookies on 1 tray 54 cookies no. of tray 153 tray

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