Desarrollo de panificados libres de gluten

Abstract

In this work we develop the design of a food plant for the production of gluten-free baked goods. The project stems from the desire to use the knowledge acquired for the purpose of contributing to the welfare of society. Given the growing population of celiacs with its inability to use products containing gluten, the high sale price, the limited availability and quality of gluten- free products produced, and considering that the only alternative to eliminate the symptoms is gluten-free diet, it was decided to contribute to this sector of the population. A study of market in which there is tight supply in general savory products for this sector of the population, and in particular bakery. Because of this, within the range of gluten free products, is resolved to give priority to baked goods. The focus is mainly on developing two products: bread and prepizza, selected because they are mostly consumed in the traditional diet of Argentina, in addition to being recognized as basic foods that provide multiple culinary possibilities. The bread normally used as daily food supplement (and in preparations such as sandwiches, toast, etc) and the pizza because of mass consumption in its many varieties and of great importance in social life. In this context, it made all activities related to industrial development of the products in question, from its formulation to the design of the processing plant. The fundamental motivation is to get baked with similar characteristics to products made with wheat, at an affordable price from the production scale and with a guaranteed market availability, thus contributing to improving the quality of life of people with celiac disease. Celiac disease is a permanent intolerance to gluten prolamins present. The clinical expression of disease occurs when ingested gluten proteins present in wheat, oats, barley and rye. This condition is characterized by atrophy of intestinal villi triggered by proteins mentioned, malabsorption of nutrients and improvement of symptoms (diarrhea, abdominal distension, failure to thrive, decay, malaise, recurrent abdominal pain, weight loss, among others). The situation is reversed only by eliminating gluten from the diet. Through experimentation with different formulations and by sensory evaluations made, we obtain the final formulation of gluten-free products to be manufactured. These are to conform to base of maize and cassava, soya flour, milk, oil, yeast, water and additives allowed. Finally, once known physicochemical parameters characteristic of the products to develop, these are subsequently used for the selection and design of process equipment. The products are defined as gluten-free bread and gluten-free Prepizza, which are arranged in individual presentations 250g and 200g respectively. While primarily oriented to people with celiac disease, they can be consumed by anyone who so desires. From market research determines the production capacity of the plant. Taking into account the results of the survey conducted in the consumption of such products, the percentage of people who have a socioeconomic status could allow the purchase of products already developed, and covers a sector of the market (assuming that because existing competition is not envisaged to reach 100% market share). The same total daily production is about 680 kg of product ready for consumption. The plant was installed in the industrial park Gral Savio, property located on Provincial Highway No. 88, Km 6.5, near the town of Batangas City and 9 km from the city Mar del Plata. The occupied land covers an area of 2679 m2, of which 742 m2 built up area. Besides determining the manpower requirements of the project. We performed a Gantt chart to establish the sequence of operations and thus organize production. Prerequisites are made GMP and SSOP, and the analysis through the HACCP system to ensure product safety. Economic analysis is conducted of the project, analyzing the feasibility, cost and timing of investment. Determine what the minimum sale price for obtaining a profitable project for which the IRR is 15% and a payback time of 3 years and 7 months. It was determined that the entire project requires an investment of U.S. $. Also highlights the feasibility and timing critical of the project developed. In terms of environmental impact, performs the analysis of residues of the subsequent design process with a team of solids settler.