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Page 3 SUGGESTED STUDENT ACTIVITIES Prior to viewing the video students could be asked any of the following questions: 1. What is a biscuit? 2. What was the first biscuit like? 3. How do biscuits vary between different cultures? 4. What are the most popular types of biscuits eaten by members of your class, group or family? 5. How have biscuits changed in the last few decades and what might the next new biscuit be like?

PROGRAM SUMMARY
The video is suitable for food technology or home economics courses at secondary level. It shows stages in food processing and manufacture, within the prescribed context of Food Technology. The video is a study of biscuit manufacture, a behind-thescenes visit to the Arnott's biscuit factory. Food ingredients are examined using two types of biscuit dough. The video explains how fat is used to give a short texture. The detailed commentary outlines how biscuits are formed, shaped, baked and hygienically packaged on the production line. Quality assurance is explained by testing a product for contamination. The video examines the development of a new product in the pilot plant, including testing and market research. Blackline masters support activities outlined in these teacher's notes. Two crosswords are also provided, one for senior (1), the other for junior (2) levels . The video can be played entirely, then sections replayed for in-depth study of specific aspects of food production. Times are included below as a ready reference. Timing information Please set your VCR to 00:00 at the program start. Minute Topic 00:00 Start of the program, music 00:37 What biscuits are made from 02:30 How biscuits are manufactured 05:30 Two types of biscuit dough 09:50 Baking on the production line 12:15 Quality assurance 14:25 Fancy biscuit manufacture 15:35 Packaging and storage 17:00 The management network 17:05 New product development.

with support from

HISTORY
Biscuits were first invented as a food for Nelson's Navy. They could be kept for a long time because they are a dry food product. Yet biscuits have really changed quite a bit since Nelson's times.

THE MAIN INGREDIENTS OF BISCUITS

The main ingredients of biscuits are wheat, flour, fat and sugar. Water is also added, helping the process of making biscuits but is not a final ingredient, that is it is not a component of the final food product. Wheat is the best grain to provide the flour used in biscuit making. This grain has special properties which are most suitable for biscuit making. A wheat grain, like most cereal grains, is made up of three important parts: 1. the bran layer - the outer shell of the grain 2. the starch and protein matrix (or network) which makes up the largest portion of the inner structure of the grain, and 3. the germ - a small part of the grain which germinates and grows. A labelled graphical representation of the cross-section of a grain of wheat is shown. Flour is made up of the starch and protein portion of grains, with the bran and germ removed.

Teacher's Notes

BISCUIT MAKING
Mass Production of Food ARNOTT'S BISCUITS
Duration: 22 minutes Years: 7-10 Also suitable for Years 11-12

Page 4 SUGGESTED STUDENT ACTIVITIES Students draw or are given a diagram (Figure 1) representing the cross-section of a cereal grain. They can label each of the main parts of the grain and identify the portion of the grain which makes up wheat flour.

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Page 6 various ingredients have on the food products produced. Short, crumbly doughs break easily because of the high amount of fat in the dough mixture. Elastic, stretchy doughs have a much smaller amount or no fat added. The elasticity of these doughs allows them to be layered, sheeted out and layered again to give a food product having a flaky texture. SUGGESTED STUDENT ACTIVITIES l Students can describe and explain the differences between the two different types of biscuit doughs described on the video in their notebooks. They can also test a sample of the two different biscuits featured on the video - Scotch Finger and Jatz - and record and compare the physical properties they observe, such as their appearance, how they feel, smell, break and taste. They can then test some unknown biscuits and describe the type of dough these biscuits are made from and how these biscuits are different to Scotch Finger and Jatz biscuits. l Students can also experiment with different mixtures using recipes of at least two different types of biscuits, for example, melting moments or shortbread, compared to cracker biscuits or crisp breads.

COMMERCIALLY PREPARING A DOUGH

The video shows the activities which take place on the dough mixing floor of the Arnott's factory in Brisbane, Queensland. The following activities are shown and explained: l the rolling of formed dough - including how the air pockets between layers of dough are formed. This involves the use of yeast or other suitable microorganisms, which are added to the flour and water of the dough mixture and then the mixture is allowed to ferment, l how formed dough is rolled and layered without destroying the protein network or matrix of the dough, l how the rolled dough is cut, and l what happens to the off-cuts or scraps of dough after cutting. SUGGESTED STUDENT ACTIVITIES Students can draw a flow chart in their notebooks which summarizes the various stages involved in the commercial manufacture of biscuits. At this stage they can include the features of l selecting and weighing the ingredients l mixing ingredients to form a dough l rolling the formed dough, and l cutting the rolled dough. A sample flow chart appears at the end of these teacher's notes.

HANDLING PROTEIN
The skill in biscuit making is in the way the protein is handled. The differences between dough before and after mixing are described and supported with microscopic views of the mixture and graphical representations of the different mixtures showing the changes which take place during the mixing process. Prior to mixing, the dough is a mixture of large protein globules and starch molecules. During mixing the globular protein molecules unravel (unfold) and link together, around the starch molecules, forming a continuous network or matrix. The linked protein molecules are like elastic strands which allow the formed dough to stretch. However if the formed dough is mixed even further, the continued mixing causes the linked protein molecules to break apart. This will destroy the protein network of matrix and the dough becomes useless. A perfect dough is formed by mixing the ingredients well to allow the protein molecules to link and form an elastic dough, yet not over-mixed. SUGGESTED STUDENT ACTIVITIES Students draw and label two diagrams of dough mixtures before and after mixing in their notebooks. Different coloured pencils can be used to distinguish the different types of molecules in the mixtures. Students include a short statement under their diagrams stating what the diagrams represent and the main difference between the mixtures shown.

FORMING BISCUITS FROM DIFFERENT DOUGHS

The way in which different types of doughs are formed into different shaped biscuits is shown. Different techniques used are described, including the use of rollers (and how they are assembled and tested) and extrusion dies and wire cutting. The video explains the use of a particular technique, in this case extrusion dies, with different doughs to produce food products having very different properties (in particular texture).

TWO DISTINCT TYPES OF DOUGH

Two distinctly different types of biscuit products are described and discussed in this section - soft, short biscuits, for example Scotch Finger biscuits, are compared and contrasted to hard, crispy cracker biscuits, for example Jatz crackers. The different properties of biscuits are demonstrated and explained in terms of their ingredients and the effects that the

Page 7 SUGGESTED STUDENT ACTIVITIES l Students can continue their flow chart, adding the different techniques which can be used to form biscuits. l They can also experiment with forming biscuits from different types of biscuit doughs. Students should record all the steps they follow, their observations, results and conclusions.

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PACKAGING AND CONTINUED QUALITY ASSURANCE

The packaging of the final food product is explained, including the importance of hygiene and continued quality assurance. Prior to packaging biscuits are checked by inspecting staff, who check the appearance of the final product and make sure that biscuits which reach consumers meet quality standards. Once packaged the biscuits are checked for weight and contamination, especially the presence of foreign bodies in the package, like metal for instance. This section of the video also demonstrates how fillings and toppings, including chocolate coatings are added to biscuit bases. SUGGESTED STUDENT ACTIVITIES Students can continue their flow chart, adding the stages looked at in this section.

OTHER ASPECTS OF A FOOD MANUFACTURING INDUSTRY

Other aspects of an industrial food manufacturing company are looked at briefly (Figure 2). These include: product development, marketing, sales, information services, technical services, logistics, plant engineering (maintenance), corporate engineering, plant accounting, finance and human resources. SUGGESTED STUDENT ACTIVITIES Provide students with a copy of Figure 2. Ask them to explain in their own words what is meant by a management network.

BAKING BISCUITS COMMERCIALLY

Two principal stages of the commercial baking of crisp bread, for example, are described and shown. The initial baking stage involves the use of high heat to cook the dough, followed by low, slow heat which dries out the crisp bread. SUGGESTED STUDENT ACTIVITIES Students can develop a flow chart which summarizes the changes which take place in a crisp bread dough during baking.

DEVELOPING AND EVALUATING A NEW FOOD PRODUCT

The development and trialling of a new food product and the evaluation of the new food product are explained in detail in this section. The development of a new rice crispy biscuit is explained, and features of the various stages are shown and discussed by a research food technologist. The various stages of new biscuit development include: l deciding on a formula for the new biscuit l preparing a test mix in the lab l trialling the test mix in the pilot plant (which includes a number of steps - forming the biscuits from the test mix, baking the formed biscuits, and filling, topping or coating the biscuits), and l testing the sensory properties of the biscuit.

STORAGE AND DISTRIBUTION OF A MANUFACTURED FOOD PRODUCT

The various steps involved in the final packaging, storage and distribution of biscuits is briefly discussed. The use of dates and the importance of stock rotation are explained. SUGGESTED STUDENT ACTIVITIES l Students can continue their flow chart, adding the stages looked at in this section. l Students can explain the importance of the following features of industrial food production: * dates - use-by-dates and manufacture dates * stock rotation, and * distribution.

QUALITY ASSURANCE
The importance of quality assurance, in particular to ensure a food product of uniform quality, is discussed. In the production of biscuits by Arnott's, for example, quality assurance involves sampling biscuits on the conveyor belt, prior to packaging, every ten minutes. The samples are tested for moisture, colour and weight to make sure the biscuits being produced conform to quality standards. SUGGESTED STUDENT ACTIVITIES Students can continue their flow chart, describing the importance of the quality assurance stage in commercial mass food production.

Page 10 SUGGESTED STUDENT ACTIVITIES l Students can develop a flow chart which shows the key stages involved in the development of a new biscuit. It may help if the various stages are provided and they are asked to order them and summarise the main points about each stage. l They can also develop their own new biscuit based on a biscuit recipe they have tried before. Students will need to: * state the aims of the project, that is the reasons for developing the new food product and what properties they aim to develop in the final food product, * explain how they will achieve these aims, that is how and why they will change the recipe, and describe the formulation they will use, * trial their new recipe and evaluate the final food product produced, * explain the properties of the new food product and the changes which resulted in these properties, and * what changes, if any, they might make to improve their new food product. If students have time they could also test and evaluate any proposed new changes.

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MAKING BISCUITS INDUSTRIALLY

Sample Flow Chart
recipe formulation

Program Producer
amount and types of ingredients important to type of dough being made order and method ingredients mixed important to type of dough being formed handling affects texture of biscuit different doughs cut using different methods (depends on dough type and biscuit appearance wanted) baking process different for different types of biscuits

select and weigh ingredients

John Davis
Script Editor

mix ingredients to form a dough knead, roll and, if appropriate, layer dough

Sandra Fulloon
Teacher's Notes

Elizabeth Allotta
Post Production

cut dough into individual biscuit shapes

bake dough in commercial ovens

cool baked product and finish with topping, filling or coating quality assurance - check final biscuit

John Dobis Special Thanks to the Technical and Human Resources Staff at Arnott'sBiscuits
Copyright and Orders: CLASSROOM VIDEO Davis Film & Video Productions 1/1 Vuko Pl Warriewood NSW 2102 Australia Ph: (02) 9913 8700 Fax: (02) 9913 8077 Ph: 604 523 6677 Ph: 01454 324222 Ph: 1 800 665 4121 Fax: 604 523 6688 Fax: 01454 325222 Fax: 1 800 665 2909

check - appearance, weight, moisture and colour

package

quality check again check - broken biscuits, contamination and faulty packages date stamped and stock rotation
Canada: UK: USA:

storage and distribution

New Zealand: Combined Phone and Fax: 09 478 4540