After forming, steamed buns and mantou need to be proofed so the dough rises and becomes soft and fluffy. There are no universal numbers for proofing time, temperature, and humidity; they depend on the recipe, yeast, and bun size. The size of the proofing cabinet should be worked out backward from batch output and steamer capacity.
Bun factories steam with everything from bamboo steamers and steam cabinets to continuous steamers. Continuous steamers suit factories with simple product ranges and high volumes. If steam comes from a boiler, depending on capacity it may be classified as hazardous equipment that must pass inspection and be operated by qualified personnel.
Products like sweet potato balls, taro balls, and croquettes are often fried after forming. Continuous fryers are consistent, while batch fryers are flexible; oil temperature control affects crispness outside, softness inside, and oil absorption; and under Taiwan's Regulations on Good Hygiene Practice for Food, frying oil must be completely replaced once total polar compounds reach 25%.
How good frozen dumplings taste depends largely on whether they were frozen fast enough. Taiwan's FDA notes that the longer food stays in the "zone of maximum ice crystal formation" between -1°C and -5°C, the larger the ice crystals. IQF, tunnel, and spiral freezers each suit different products and volumes.
Frozen finished goods must be kept at -18°C or below, and chilled goods at 7°C or below but above freezing point, as set by Taiwan's Regulations on Good Hygiene Practice for Food. Equipment must have temperature indicators with records kept, and records must be retained for at least 5 years. Freezer capacity should be estimated from output, days of inventory, and stacking method.
Frozen dumplings can be packaged by hand bagging and sealing, premade pouch machines, vertical form-fill-seal machines, or flow wrappers. Vacuum packaging may crush soft dumplings out of shape; weighing and counting each suit different products. Packaging materials must meet Taiwan's sanitation standard for food utensils, containers, and packages, and outer packaging must be labeled under Article 22 of the Act Governing Food Safety and Sanitation.
What machine-made food fears most is blade fragments, screws, or steel brush bristles getting into the product. Taiwan's Regulations on Good Hygiene Practice for Food require processes to have measures preventing metal or other foreign matter from entering products; metal detectors catch ferrous, non-ferrous, and stainless steel, while X-ray machines can also catch bone, glass, stone, and other dense foreign matter.
No matter how fast the encrusting machine runs, if finished products still have to be arranged on trays one by one by hand, labor gets stuck there. A set panner automatically arranges formed products onto baking trays, steaming trays, or conveyors, typically following the encrusting machine and feeding steamers, blast freezers, or packaging.
Dough sticks to hands, machines, and conveyor belts, and dusting flour is the lubricant of the production line. A flour duster keeps the amount even and consistent, and a flour brusher removes the excess. Too much flour leaves finished products white on the surface with a dry, floury texture, and fills the workroom with dust.
Under Article 22 of Taiwan's Act Governing Food Safety and Sanitation, the outer packaging of frozen foods must list the product name, contents, net weight, manufacturer, country of origin, expiration date, nutrition labeling, and more, and under the labeling rules for prepackaged frozen foods, storage methods and heating instructions must also be added. This article also covers how to assign lot numbers and the requirements for traceability systems.
An encrusting machine has a whole pile of parts to remove and wash every day, and crates, trays, and carts need washing daily too. The temperature, water pressure, and capacity of household dishwashers usually aren't suited to industrial parts; dedicated parts washers and crate washers make cleaning quality consistent. Detergents must be food-grade cleansers that meet sanitation standards.
What's often overlooked when buying a machine is what has to be connected behind it: power, compressed air, water, steam, and drainage. Requirements vary widely between models and should be provided for before installation. Compressed air that contacts food must be filtered and oil-free, and air receivers may be classified as pressure vessels depending on capacity.
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