Transcript Schools Information Pack

Schools
Information Pack
Revised: February 2006
Our Product Range
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Iced Christmas Cakes
Madeira Cakes
Chocolate Cakes
Rich Fruit Cakes
Celebration/Novelty Cakes
Oven-finished Fruit Cakes
Cut Section Fruit and
Madeira Cake
• Vacuum Sealed Fruit Cakes
• Iced Fruit Cakes
• Corn and Rice Crisp Cakes
Innovation
• Brainstorming
Sessions:
New Ideas
New Techniques
New Decorations
• Other characters
– pigs, teddies,
cats, dogs,
sheep, monsters
• Licensed Film & TV
Characters:
• Simpsons
• Thomas & Friends • Special
• Shrek
Occasions:
Valentine’s Day
• Wallace & Gromit
Easter
Christmas
Mother’s Day
• Links with hobbies
Halloween
and interests, e.g.
Weddings
football, snooker
Birthdays
• Consultation with
retail buyers and
suppliers
Types of Novelty Cakes
• Fillings
Jams:
- Raspberry
- Strawberry
- Plum & Raspberry
Buttercreams:
- Plain
- Chocolate
- Flavoured
Sugarpaste:
- White
- Coloured
- Chocolate flavoured
- Fruit flavoured
Fondants/Fudgeicing:
- Plain
- Chocolate
- Coloured/flavoured
- Enrobed
• Bases
Madeira:
- Plain
- Chocolate
- Flavoured
Chocolate
Plain Genoese
Sizes/shapes 5” – 9”
Round, square, oval,
cut-out shape, 3D
Types of Novelty Cakes
cont.
• Decorations
Milk chocolate edible
decorations:
- Printed sugar
plaques
- Chocolate plaques
Moulded/reliefed:
- Sugarpaste
- Fudge paste
- Marzipan
- Candy
Icing/Piping
Confectionery
- Chocolate Beans
- Liquorice
- Chocolate Buttons
• Packaging
Internal:
- Ribbons & Bows
- Printed card collars
- Cake boards
External:
- Acetates
- Enclosed cartons
- Window cartons
- Retailer’s own
Labelling
- Manufacturer’s
Label
- In-store bakery
Types of Christmas Cakes
• Bases
Standard or luxury
• Fruit
Sultanas, glace cherries, glace pineapple
and other fruits
• Nuts
Walnuts, almonds, pecans, brazils (chopped
or nibbed)
• Decoration
Mainly iced, beneath the icing is usually a
layer of marzipan (almond paste) or a more
economical version made from apricot kernel
paste
Cakes may be top-iced or all-over-iced
Decorations may be piped or moulded, and
non-edible decorations added
Some cakes, instead of being iced, have a
topping of nuts and glace fruits
• Dundee Cakes
A fruit base with a decorative pattern of
whole almonds baked into the top
Traditionally Dundee cakes have a flavouring
of marmalade
• Genoa Cakes
A fruit base with a high percentage of glace
cherries
Costings/Consumer Testing
Costings
Costings are a key financial control that ensure the business
remains profitable and competitive.
All our products are accurately costed by valuing the raw
materials, packaging and direct labour used to manufacture the
cake. These costings can then be used as a standard against
which we can measure the performance of the factory and so
identify and eliminate areas of inefficiency and waste.
An agreed profit margin is applied to this standard costing so that
it becomes a tool to set selling prices and evaluate new business
and investment.
Consumer Testing
Products are assessed by taste panels at various stages in their
development:
1.Informally in the factory at the experimental stage
2.By the customers before the product is approved
3.‘Sensory’ testing by market research agencies, on panels of
children and adults, to gauge reaction to our own-label products
4.In the factory at intervals to determine the product’s shelf life
and keeping qualities
Testing is designed to judge not simply taste, but texture, visual
appeal, smell etc.
Ingredients/Packaging
Ingredients
The majority of our novelty cakes are suitable for vegetarians. We
use the best ingredients we can obtain, and conduct rigorous
assessments of our suppliers in order to ensure that quality is
maintained. We use as few additives as possible, and declare
them in accordance with the Food Labelling Regulations.
Packaging
The supermarkets who are our main customers arrange the
design of the packaging, all of which has to accord with the Food
Safety Act of 1995 and with the Food Labelling Regulations.
Packaging must be sturdy enough to withstand stacking and
transportation. Most novelty cakes are sold in window cartons,
which enable the cake to be seen by the purchaser. Labels must
carry a “best before” date. This is determined by shelf life testing
during development.
Launch Procedures &
Production Process
Launch Procedures
Before a cake can be launched there must be a:
Definite approval from the customer
At least one factory trial putting the cake through the full process
in the factory, to determine where adjustments are necessary
Delivery of ingredients and packaging
A time-table for production and delivery into depot
Production Process
Production is planned 13 weeks in advance, but with the flexibility
to change from week to week. The intention is generally to
produce the largest volumes at the beginning of the week and
taper off towards the end. This allows the capacity to respond to
delays or problems.
Approximately 160 people will be involved in the manufacture of a
single product. On the “line”, which takes a baked cake base
through to the packing stage, a team of up to 57 people work.
There are three lines, one dedicated to chocolate cakes, plus
specialised lines for the production of Viennese Whirls and Corn
Crisp.
Cakes are made in two separate areas of the factory, one known
as “nutted” and the other as “nut free”. This enables us to ensure
that all cakes which do not contain nuts are produced in a strictly
nut free environment, for the benefit of those consumers who are
allergic to the slightest trace of nuts.
The following page shows a summary of the
production process
Process Flow Diagram –
Novelty Cake Manufacture
Product Quality (HACCP)
There are 13 quality critical control points:
CCP No.
Process/Event
Hazard
1
Raw material intake
Material not to specification
2
Weigh down
Incorrect material
3
Mixing
Incorrect cake
height/incorrect texture
4
Depositing, jam &
cream, sheeting,
flooding
Incorrect product
component weights
5
Baking
Under/over bake
6
Pack into retail
Appearance not to
specification
7
Flow wrap
Drying of product over life
8
Outer pack
Incorrect labelling
9
Outer pack
Incorrect ‘sensory’
characteristics
10
Pack into retail
Product damage
11
Check weigh
Product falls outside
average weights
12
Drying
Product damage
13
Warehouse/despatch
Insufficient life at delivery to
depot
Food Safety (HACCP)
There are 10 safety critical control points:
CCP No.
Process/Event
Hazard
1
Raw material intake
Presence of
Salmonella/Microtoxins
2
Raw material intake
(egg)
Microbial survival
3
Raw material egg
intake
Microbial growth
4
Raw material intake
Product contamination
5
Mix
Microbial growth (high
egg temperature)
6
Bake
Microbial survival
7
Adherent Coat
Microbial growth
8
Metal Detect
Metal contamination
9
Cooling
Microbial growth
10
Weigh Off
Foreign bodies
At each of these points, control procedures
specify control measures, critical limits,
monitoring procedures, corrective action, the
accountable person and the control
documentation.
Step by Step Manufacturing
Process
Weighing
All ingredients at this
stage are weighed and
batch coded, this gives full
traceability throughout the
manufacturing process.
Mixing
Bulk ingredients such as
Flour, Sugar and Water
are weighed and added
straight to the mixer, this
avoids heavy handling and
speeds up mixing time.
Depositing
Cake batter is deposited to strict
weight tolerances, this ensures
consistency in the finished
product. This automated process
uses a travelling conveyer which
feeds into the oven.
Step by Step Manufacturing
Process
Baking
We use travelling ovens,
these have three zones to
give varying bake profiles.
Bake times can vary from
50 minutes to 2 ½ hours.
Cutting & Creaming
The cake is cut into 2/3
layers. Jam and buttercream
are automatically deposited.
Weight checks are taken here
to ensure product quality.
Sheeting
The filled cake travels
under a sugarpaste
sheeter. The sugarpaste
icing is hand moulded and
trimmed ready for
decorating.
Step by Step Manufacturing
Process
Component Placing
We make our own
components. These are
hand placed to a specified
design. All our decorating
team are trained to a high
standard.
Ribbon Placing
For a finishing touch, we
add a coloured ribbon
around the finished
product.
The Finished Product
The finished products are
checked against quality
standards, again this
ensures the consumers
are satisfied with the
finished products.