No-milling bread

A concept which halves the cost of raw materials used in making brown bread (because the wheat is not milled) and produces healthy, tasty bread, is being prepared for franchising in the form of micro-bakeries. The concept allows for bread to be sold at about a 15% discount to standard prices, according to its developer.
Wheat kernels, rathe A concept which halves the cost of raw materials used in making brown bread (because the wheat is not milled) and produces healthy, tasty bread, is being prepared for franchising in the form of micro-bakeries. The concept allows for bread to be sold at about a 15% discount to standard prices, according to its developer.
Wheat kernels, rather than flour are used to make the dough, while whole oilseeds like soy, sunflower and peanuts replace the fats and oils necessary to the baking process.
The baked product has a stronger bread flavor than normal bread. There is no beany taste from soy if it is used – the muffins can be up to 20% soy. The bread and muffins have a longer shelf life than normal bread because of the preservative qualities of soy.The process was developed by Shorty Hall, owner of Allwheat Bakeries of Winterton, South Africa, in conjunction with its originator, Mike Smith, a leading food technologist.
Parts of the process involved are not been revealed by Hall at this stage because it is being patented. The wheat is soaked for 24 hours and ‘prepared’ soy or other oilseeds are added to it, with salt, yeast and sugar. The mixture is mulched in a bowlcutter for about five minutes.
This ‘dough’ is placed in the bread pans, proved for 45 minutes at about 40™  º (in the oven or a special proven), and then the loaves are baked.
Bran is part of the dough, rather than being an addition, says Hall. People who are gluten-intolerant can enjoy this product.
Hall has been perfecting the system, and selling the products, for the past four years. He says the bread and muffins are popular with up-market, health-orientated consumers, but sales to the mass market now account for most of his turnover. “In the mass market, once the bread is tried it becomes popular. They are concerned with nutrition, especially if bread is a staple.”
The technology and process appear to be well settled. Franchising is about ‘proven concepts’ – and obviously this is not yet the case for Hall’s system. Nevertheless, Hall is offering the equipment and training to set up a micro-bakery, and ongoing raw material supply at competitive prices – about $7,000, plus 8% of turnover.
This price include a bowlcutter, two gas ovens with a capacity to bake 72 quarter-loaves each, trays, loaf tins, muffin tins, one ton of wheat and other ingredients.
Hall developed a cheap bowlcutter for the system, driven by electricity or petrol. He also designed the gas ovens.
The oven can also be used to bake conventional bread and pastries, to supplement turnover. All ingredients are also readily available from shops and markets.
As each bake takes about 35 minutes, the maximum capacity of his bakery would be 600 standard loaves per day.
ALLWHEAT Bakeries: troffle@futurest.co.za Tel +27 36 4881233 Fax: +27 36 4881233
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