Exploring Quality Assurance and Waste Management in Davies Bakery

Davies Bakery has achieved remarkable success within the international bakery industry by emphasizing superior product quality and customer satisfaction. The organization’s operational excellence is demonstrated through rigorous adherence to quality assurance protocols like HACCP/SQF 2000, ensuring safety and high standards in food production. Davies Bakery's strategic focus on effective dough handling and fermentation processes significantly enhances their products' texture and taste. Furthermore, the company invests heavily in employee training, equipping staff with essential baking skills to meet customer demands proficiently. These practices have positioned Davies Bakery as a preferred supplier for several prominent Australian companies, thereby solidifying its market presence and fostering long-term business relationships.

Running head: BAKERY OPERATIONS
Bakery Operations
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Table of Contents
Introduction......................................................................................................................................2
Production Targets...........................................................................................................................2
Production Requirements.................................................................................................................3
Production Processes.......................................................................................................................4
Production Schedule........................................................................................................................5
Production Flow...............................................................................................................................6
Production Outputs..........................................................................................................................7
Conclusion.......................................................................................................................................8
Reference.........................................................................................................................................9

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Introduction
Bakery industry is a highly specialized and diversified food manufacturing and marketing
industry. The employees of the bakery industry are indulged in making different varieties of
baked foods that include cakes, donuts, yeast bread products, pizza, cookies, pies and other
delicious food items. The employees are proficient in preparing, mixing, identifying and
applying the ingredients in a perfect proportion to deliver mouth watering dishes to the
customers. The bakery industry is equipped with skilled employees who have added more flavors
in the culinary sector (Abdel-Aal and Rabalski 2013).
Production Targets
Davies bakery is a 130 years old business owned by the family of John Davies. The
owner of the company was a genuine hard- working man who had an affinity for super quality
bread. They have turned out to be the fifth generation in the bakery industry and are regarded as
one of the largest in the same. They are equipped with a modern plant which manufactures and
produces premium quality frozen and fresh bakery products. They are concerned with baking
flavored foods and continuously put their effort to provide good products to the customers. They
are recognized for their fresh production and efficient distribution network which makes them
trust- worthy and reliable. They excel in distributing frozen product throughout the world
including some of the popular companies in Australia (Bilge et al. 2015).
The bakery collects information to identify the number of visitors in their online site. The
copyright of all the information is owned and licensed by them. The legal policies of the
company do not allow using the information in some other way without written permission.

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The classic recipes which are used in the production process of Davies bakery make them
outstanding. Their sales have experienced remarkable improvement with the introduction of their
new packaging. They have made use of their design thinking and doing to get effective results. In
2015, the company was considered for the Hall of Fame in the Australian Society of Baking,
which was something new acquired by only nine people in 35 years (Cauvain 2015).
Boulder brands in 2013, has acquired Davies bakery to produce superior quality and
innovative gluten free products. They will utilize the retail relationships and the expertise
opportunities to launch bakery products.
Production Requirements
It is important to take delivery, store and prepare the raw materials, processing of the
ingredients and then mixing and blending of the ingredients in the appropriate proportion to get
the best quality products is the main criteria required for the workers employed in the bakery
industry. The required equipment in the bakery industry are ovens, fryers, mixers, proof boxes
and bakery racks. The equipment remains same for the start- ups and well- established
companies (Dagnas et al. 2017).
It does not require too many ingredients for a bakery company. The essentials are yeast,
flour, water, milk, buttermilk, cream, juice, sweetener, salt, eggs and fat. The ingredients are
required in different quantities for the different recipe. The proportion should be appropriate in
order to bring the good taste.
The bakery industry shares the most of publicly traded producers of the baked goods that
are sold. The baking business is mostly regional for providing fresh foods and baked products to
the customers. The award- winning bakery companies such as Davies bakery have adopted the

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strategy of selling their products on some routes along with the trucks and drivers thus creating a
bunch of entrepreneurs and reducing the company costs at one go (Junyapoon 2016). With the
rapid consolidation of the bakery industry, there is a constant selling of slightly weaker
companies to their better counterparts. This is because bakery is a segmented industry and
therefore the procurement provides the opportunity to gain the economies of scale.
Flawless interaction is crucial in the production process of the bakery industry and the
combined automation gives the perfect answer. There is efficient bakery production process
which delivers the best quality at a minimum cost.
Production Processes
The Davies bakery company utilizes the primitive method of long fermentation of bread
and laminated pasties. It refers that although the dough is mixed it is provided with a pre-
determined time at the regulated temperature for improvement in flavor and strength. The flavor
comes out well from the wheat with constant fermentation. It is a lengthy procedure which can
take up to hours and days.
The successful and gaining control of the frozen products require a normal standard of
product quality and situation and appropriate methods for identifying the level of product
performance with standards (Koy 2017). The bakery industry has improved at an extensive rate
in the past two decades and there is serious concentration on the regulation of sufficient
standards and the objective methods for measuring the required quality. These standards and
methods must be kept on a consistent basis to get the official and legal status.
The processing of dough involves mixing as its primary step. The temperature has to be
taken in consideration and the products must be kept under complete observation. All the

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ingredients have to be properly weighed and must not be forgotten to mix in the dough. The
ingredients include100 kg of flour, 62 kg of water, 2 kg of yeast and 1.8 kg of salt which are
mixed and baked at a temperature of 28 degree centigrade with the temperature of the flour at 35
degrees centigrade and the water at 6 degrees centigrade. The chemical change takes place with
the mixture of acids which reduce the baking time 20%- 30% (McCarthy 2015).
Production Schedule
The nutritional facts in the manufacturing of bakery products include biscuits made of
composite flour, of different flavors, special vitamin biscuits with high fiber and low sugar and
fat. Protein is considered as a vital nutrient in terms of quality and quantity. The wheat flour
protein, 12%- 16% deficient in the essential amino acids- 80and the quality of bread in the
bakery industry is controlled below mild and meat class. For getting 20% protein in bread by
using the dry non- fat milk with a minimum of 19% should be added to 100 parts of flour. The
basic bakery ingredients include flour, sugar, salt and fat. Changes cannot be brought in salt and
sugar but only modification can be brought in flour with the addition of soya and amaranth and
also isoflowones, high fiber and protein and solualve claims (Ponomaryova et al. 2015).
The bakery industry is looking forward to more efficient equipment that are well built
and can reduce time. To increase the maximum bakery capacity the energy efficient equipment
can be used which are for long term sustenance. The amazing methods of technology can be used
as innovative methods in the food industry. Smarter the equipment will be, better will be the
bakery industry with smooth operations.
The survey and research on the buying pattern of the bakery customers described their
characteristics. A qualitative approach was based on the interview of ten bakery managers and

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ten consumers. Again, a quantitative approach was aimed towards 465 bakery consumers. The
outcome of the research showed that the consumers pay a visit at the bakery store to for
purchasing perishable food or instant foods.
Production Flow
The production schedule of the Davies bakery as was discussed with the employees is
given below-
Week 1 2 3 4 5 6
Bread 195 180 200 170 195 160
Biscuits 170 165 220 130 180 175
Pastries 180 170 200 190 160 185
Projected
on- hand
6 700 420 250 70 600
Available to
promise
35 50 48 65 28 40
Fig- Production schedule
Source- As created by the author
The professional implementation of the industrial line for baked goods production calls
for detailed insight and a long term experience. Superior quality product, the best hygiene
standards along with the cleaning and maintenance system of the Davies bakery are set as the
prime requirements for modern plant concepts. Their concepts are the basis on which individual
industrial lines are equipped with to form reliability.

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The Davies bakery produces a wide variety of bread, pastry and specialty products which
is a large automated process (Soukoulis et al. 2014). The company has used the approach of
formalizing management commitment to develop project targets. They provide training to all the
staffs for assessing the production operation with respect to production target. They have a
developed set of employees who are identified to implement successful options and evaluate
their performance.
The variances require not to involve in low risk establishments that meet the criteria of
selling raw, pre- packed, or hazardous foods; no preparation of hazardous foods; no cooling of
the hazardous foods; processing limited to non- potential hazardous food; limited storage of non-
potential hazardous food. The Davies bakery looks into the preparation of food done in a
licensed kitchen under the supervision of a full- time certified manager.
Production Outputs
Davies bakery is in constant search for ensuring superior quality standards in all their
products. They stick to the standards of quality assurance and the safety of the personnel. They
abide by the laws applicable in the food manufacturing facility (Sun 2016).
Davies bakery worked out on the tracking of waste and the cause behind waste
generation. They were successful in identifying the main waste drivers and recognize the
targeted actions for waste reduction.
Fermentation, the most critical part in baking is taken proper care in the Davies bakery.
They have an improved characteristic of handling dough and the perfect fermentation conditions
result in enhancing the texture of finished product (Varzakas and Tzia 2015).

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Conclusion
So it can be concluded from the assignment that Davies bakery has become successful in
the bakery industry by supplying a variety of bakery products throughout the world and
maintaining the quality standards. They have always focused on the superior quality food
products for the customer and that is why they have adhered to the proper mixing and blending
process in their factory. Their HACCP/SQF 2000 certification reflects their commitment of
producing the premium quality bakery food products. The employees are properly trained on the
basic skills of baking so that they can serve their customers well. These services have made them
the popular provider of some of the largest Australian companies.

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Reference
Abdel-Aal, E.S.M. and Rabalski, I., 2013. Effect of baking on free and bound phenolic acids in
wholegrain bakery products. Journal of Cereal science, 57(3), pp.312-318.
Bilge, G., Boyacı, İ.H., Eseller, K.E., Tamer, U. and Çakır, S., 2015. Analysis of bakery products
by laser-induced breakdown spectroscopy. Food chemistry, 181, pp.186-190.
Cauvain, S., 2015. Process Control and Software Applications in Baking. In Technology of
Breadmaking (pp. 213-227). Springer International Publishing.
Dagnas, S., Gougouli, M., Onno, B., Koutsoumanis, K.P. and Membré, J.M., 2017. Quantifying
the effect of water activity and storage temperature on single spore lag times of three moulds
isolated from spoiled bakery products. International journal of food microbiology, 240, pp.75-
84.
Junyapoon, S., 2016. Biogas Production from Bakery Wastewater in Two-Stage Anaerobic
Digestion System. KMITL SCIENCE AND TECHNOLOGY JOURNAL, 17(1).
Koy, R., 2017. Lactic acid bacteria as bio-preservatives in bakery–Role of sourdough systems in
the quality, safety and shelf life of bread (Doctoral dissertation, University of Plymouth).
McCarthy, B.L., 2015. Trends in organic and green food consumption in China: Opportunities
and challenges for regional Australian exporters. Journal of Economic and Social Policy, 17(1),
p.0_1.
Ponomaryova, E.I., Lukina, S.I., Magomedov, M.G. and Roslyakova, K.E., 2015. Production
technology of functional bakery products. European Journal of Natural History, (6), pp.59-59.

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Safronova, T.N., Evtukhova, O.M. and Fedotova, I.Y., 2016. Production technology of bakery
products containing processed artichoke and chokeberry products, with low yeast
content. Baking in Russia.
Soukoulis, C., Yonekura, L., Gan, H.H., Behboudi-Jobbehdar, S., Parmenter, C. and Fisk, I.,
2014. Probiotic edible films as a new strategy for developing functional bakery products: the
case of pan bread. Food hydrocolloids, 39, pp.231-242.
Sun, D.W. ed., 2016. Handbook of frozen food processing and packaging. CRC Press.
Varzakas, T. and Tzia, C. eds., 2015. Handbook of food processing: food safety, quality, and
manufacturing processes(Vol. 35). CRC Press.