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Wire Cut CookiesE-Learning TutorialStoryboardScreen TitleScreen NumberSPLASH SCREENProduction NotesSee belowModule titleIntroductionScreenNarrationText on ScreenScreen DescriptionWelcome to the Wire Cut Cookies Tutorial!This program teaches the correct procedures and steps required to produce a proper wire-cut product. The program follows the logical flow of the manufacturing process and provides information on the critical process points to be adhered to in order to successfully manufacture product.Welcome!(cover page)The video on this page shows you a working Wire Cut machine. The process you see here is what defines the cookie as Wire pared to other cookies, these cookies use more sugar and shortening and have a porous quality. Depending on the ingredients that go into them, you might describe Wire Cut cookies as “crisp/tender” to bite or “soft and chewy.” Chocolate chip and oatmeal cookies are examples of a type of cookie that may be made using the Wire Cut process.What is a Wire Cut cookie?Video: working Wire Cut machineWire Cut Running 20120305142809.m2tsHave a little fun by guessing which of these cookies might be a Wire Cut cookie! Don’t worry about getting them right: no one’s keeping score.Take a Guess!InteractionNeed PICProduct on cooling conveyor2.m2ts extract image example of non wire cut(SME: please give us some other pictures and yes/no on them)Show pictures of cookies. Clicking the cookie “flips” the picture and lets the student know if they were right. Example:133223022225Yes00YesThis program is intended for individuals on the line responsible for producing wire-cut cookies.It’s also useful for those who want to gain insight into a process normally learned over time through experience.This program is intended for: Individuals on the line responsible for producing wire-cut cookiesIndividuals who want insight to a process normally learned over time through experienceYou will learn the basic Wire Cut formula, proper mixing, machining and baking and basic safety and sanitation for each process.You will learn:The basic wire-cut formulaProper MixingProper Machining and BakingBasic Safety and Sanitation for each process”The program is separated into the following five subject sections:The Wire Cut FormulaMixingFormingBaking Delivery “Process chartHighlight the process chart sections aligned to narration. Will provide sample.(Circle chart)Need explanation for designerWhen finished you will understand the critical points to the process that must be established and maintained.You’ll learn the importance of following each process correctly and consistently and your role in executing a successful process. You’ll see how all processes are interconnected with each other and realize that communication is critical if there is any deviation from the correct procedure. The success of the line depends on each position consistently following the correct procedures. Add to the process chart critical points and Yes/No handoffs between different roles. Will provide sample.Creating wire cut cookies involves a series of conversions. We begin with ingredients defined by a formula. These are mixed to create a dough mass…which is then machined into dough that can be baked. Finally, the dough is baked…and then cooled and packaged into wire cut cookies.Timeline: Use graphics to depict each of the conversions on a linear bar, similar to a timeline. Ingredients, mixer, forming machine, oven, and finished cookie packageShow conversion timeline graphic, flash each picture aligned to narrationBefore you get started on the next lesson, take a moment to find the Glossary. This is always available to you, so be sure to look up any unfamiliar terms.Ready to go on to the next lesson? Click (tab? menu item?).TerminologyDon’t understand a term? Use the glossary whenever you want to look something upHighlight glossary button or link to glossary in LMS.Discuss: Can student click a Menu to switch back and forth between lessons? Or just click Next to go on?END OF MODULEModule titleThe Wire Cut FormulaScreenNarrationText on ScreenScreen DescriptionEvery product starts with a good formulation. This sample formula looks easy enough, but remember your principles: aeration, consistency, temperature, and proper development time. In the next lesson, we’ll zero in on the Mixing process and go into more detail about the stages you see here. Before we do, get ready for a quick exercise. HINT: take a good close look at this page before you go on or we’ll see you back here in a minute or two.Wire Cut Sample FormulaStage 1Granulated Sugar – 30 lbs.Solid Shortening (preferred) – 25 lbs.Salt – 2 ozCrème 6 minutes at low speedStage 2Water / Ice – 20 lbs.HFCS – 5 lbs.Mix 3 minutes, scrape down bowl, mix 1 minute. Stage 3*Flour , pastry 90 lbs.Flour, cake 10 lbs.Soda – 1 lb.SAPP – 6 oz Mix 3 minutes at low speedStage 4**Chocolate Chips – 25 lbs.Mix 1 minute(chart: something like this)Ingredients by themselves have no value in terms of cookies. It is only when they are mixed together in certain proportions that we have the basis to create wire cut cookies.The formula is the beginning of the wire cut process that converts ingredients into usable dough mass. Timeline: Use graphics to depict each of the conversions on a linear bar, similar to a timeline. Ingredients, mixer, forming machine, oven, and finished cookie packageHighlight IngredientsEach position on the line has some type of pre-operation check that is specific to their job function. The mixer inspects the mixing area and equipment to be sure it is deemed safe.Process flowProcess chart, annotate with pre-operation checks by line position.Before you even begin to think about making Wire Cut cookies, it’s necessary to perform a Pre-operation check. The area and the equipment must be inspected and deemed safe. Each ingredient you’ll use has an MSDS sheet and you should be sure you’ve read it. Also, some ingredients may be allergens and mustn’t be mishandled or cross-contaminated.Click the (link? Resources button? Discuss) to print the MSDS sheets that pertain to Wire Cut cookies.SafetyIs the area safe?Is the equipment safe?Are the ingredients safe?MSDS sheetsAllergens Found an issue? Report it to your supervisor. Safety first!Note: red text at bottom is a takeaway. They should be formatted the same way on each page they are used on - should stand out!(If possible, include the MSDS sheets for Wire Cut as resources, or else available as PDF downloads in the LMS.)Safety precautions might seem tedious, but they are very important to remember. You might be saving someone’s life – maybe your own.Spot QuizWhat should you do if you suspect a piece of equipment is no longer safe?Order a replacement partAsk for an MSDS sheetReport it to your supervisorCarry on unless you’re SURE it’s brokenSingle Quiz QuestionFeedback on wrong answer: That’s not the best answer. Try again.The work area, utensils and mixer should be inspected to ensure proper sanitation. You need to be sure no residual dough from prior use remains in the mixer. IMPORTANT: When inspecting the interior, the mixer should be correctly “locked out” electrically to avoid accidental mechanical movement.SanitationIs the work area clean?Are the utensils clean?How about the mixer?Watch out for residual doughMake sure the mixer is “locked out” before inspection!Need PIC Dennis We missed this oneSME: Need picture of residual doughNot sure if we have a video or picture of “lock out”? If not, need one, if so, please give file name.Here’s our sample formula again.Now let’s take a more depth look at it from the mixer’s point of view. There are some critical Mixing Principles a mixer should understand.Both the ingredients used and the order or style of mixing combine to make a Wire cut cookie what it is. The formula is the method for conveying this information: both the amount of ingredients and the directions for mixing.Wire Cut Sample FormulaStage 1Granulated Sugar – 30 lbs.Solid Shortening (preferred) – 25 lbs.Salt – 2 ozCrème 6 minutes at low speedStage 2Water / Ice – 20 lbs.HFCS – 5 lbs.Mix 3 minutes, scrape down bowl, mix 1 minute. Stage 3*Flour , pastry 90 lbs.Flour, cake 10 lbs.Soda – 1 lb.SAPP – 6 oz Mix 3 minutes at low speedStage 4Chocolate Chips – 25 lbs.Mix 1 minute.Show formula again(Tab interaction – each point should be narrated separately)It is critical to mix ingredients in the order listed on the formula for several reasons. The first is to assure a lump-free, properly mixed dough. The other reason is to achieve aeration, which is critical for creating a tender cookie.The mixing procedure is critical because oven spread is affected by dough consistency. With wire cut cookies, the dough is particularly soft and upon baking may spread to approximately double in size. The mixing style is designed to prevent the overdevelopment of dough, which will affect oven spread.Final dough temperature is also critical to control oven spread. The final dough temperature is affected by the mixing bowl temperature, the individual ingredient temperatures and the mixing time and speed.PrinciplesTab interactionTabs numbered 1-4. Text / graphic for each point. Clicking the tab reveals each point and triggers narration.Glossary note: Pop-up when mouse over on oven spread: Definition: The change in size between when the dough enters and leaves the baking chamber.Take this short quiz.Did you get it right? If you did, congratulations: these principles will save you lots of time and effort. No? Why not go back a page and read those principles again? No rush; we’ll wait for you here.Just Checking…What’s the most common problem with Wire Cuts?Overdevelopment of doughAerationDough consistencyDough temperatureSpot QuizFeedback on wrong answer: That’s not the best answer. Try again.Each of these principles will apply several times during the mixing process. Following them correctly is essential if you want to mix wire cut cookies.As you proceed, always keep the principles forefront in your mind. We’ll continue to point out the key places within the process that the principles apply.Click next when you’re ready to go on to the Mixing Lesson.Temperature ControlAerationLump ControlDough DevelopmentHave these terms circle around the process chart and land near Mixing.Production Note: Green highlit text indicates the SME may add to this list – possibly wait to build?END OF MODULEModule titleMixingScreenNarrationText on ScreenScreen DescriptionThe first major process in making Wire Cut cookies is Mixing. We’ll take a moment to learn some valuable principles, review the equipment and then we’ll get right into each important stage.Mixing:PrinciplesEquipmentStagesLay TimeProcess graphic, highlight Mixing box, add bullets beneathMixing is the first conversion in the wire cut processMixing takes the dough that is based on the formula to a mass.Timeline: Use graphics to depict each of the conversions on a linear bar, similar to a timeline. Ingredients, mixer, forming machine, oven, and finished cookie packageHighlight mixer(discuss progression, highlight all completed or just the one we’re one)Mixing involves three critical components:The Mixing Operator (a person well-versed in both the formula and how to use the equipment)The Mixing Formula: (the directions applied by the Mixing Operator)The Mixing Equipment. (How we go from formula to dough) The mixer, equipment and mixing style combine to achieve the formula principles. Venn diagram of three critical componentsEach formula relies on equipment that can best achieve the desired results. For wire cut cookies, a horizontal mixer is the best choice. When establishing mixing stages and times, it’s important to consider:The size of the mixing bowl. This establishes the batch size.Blade configuration, either single or double arm and the RPM of the blade. This establishes the mixing time per stage.Cooling assistance (either water jackets or CO2). This helps to achieve final dough temperatureWire-cut dough is mixed in a horizontal mixer, single or double blade.Single or double blade will directly affect dough aeration The horizontal mixer bowl can be water jacketed to assist in maintaining proper dough temperatureControlling dough temperatures will control oven spread.Need PICText accompanied by pictures, align with narration.Mixing Stage 1 First stage of a wire cut cookie dough.jpgFront View of Horizontal mixer and Panel.jpg Horizontal Mixer Control Panel.jpgToo little or too much dough in the mixer affects how well the dough will mix. The rule of thumb regarding mixing bowl size is that the dough should neither be below the center shaft- too little dough or above the blade in relation to the top of the mixer – too much dough.Single or double blades directly affect aeration. You’ll cut down your mixing time with double blade. If you’re using single blade, you’ll have to extend your mixing time.Similarly, a water jacket is a good cooling assistant, but they can only do so much. If you need to get the temperature very low, you’ll need to add CO 2 to the mix. Remember that controlling dough temperature controls oven spread. Mixing bowl size: The amount of dough should neither be:Below the center shaft is too littleAbove the blade in relation to the top of the mixer.Blades:Double blade: Cuts down mixing timeSingle blade: Extend your mixing timeCooling:Water jackets are a good cooling assistAdd CO 2 to the mix if you need very low temperatureNeed PICDoubleBlade.jpgThis shows bowl and bladeDennis to supply pic of water jacket and Co2Pictures to illustrate points. Align bullets to narration.(Tab interaction – each bullet (including sub bullets) should be narrated separately)Water JacketsThe use of water jackets should be used with caution to avoid build-up of shortening on the inner mixing wall.They can create more problems if not used properly. Jackets should be turned on during the liquid additions, Stage 2, and kept on throughout the flour and inclusions additions, Stage 3 and 4. If dough is held in the mixer, jackets should be turned off.Mixing Blade SpeedUpright mixers will generally have a low and high speed represented as revolutions per minute (RPMs). Typically, the high speed will be twice that of the low speed (e.g., 24 RPM low speed and 48 RPM high speed). Horizontal mixers also have a low and high speed. If a mixer has a different speed, the new mixing time(s) can be found by multiplying the current mixing speed by the current minutes of mixing and then dividing by the new mixer speed. Example: 24 rpm x 6 min = 144 / 28 rpm = 5 min mix time Precautions – Expert TipsTab interactionTabs numbered 1-2. Text / graphic for each point. Clicking the tab reveals each point and triggers narration.Need PICHorizontal Mixer Control Panel.jpg use this to satisfy pic belowSME Note: Need photos for all of this. Also this text is very long! If it’s possible, help us cut it down.On water jackets…When should water jackets be turned OFF?During all StagesDuring Stage 2During Stages 3 and 4When the dough is held in the mixerSpot QuizFeedback on wrong answer: That’s not the best answer. Try again.(Discuss whether these pdfs should be in resources, link to LMS, etc.)Here we are in Stage 1! Ready, Get Set, Go!The granulated sugar, solid shortening and salt are combined in Stage 1. These three ingredients must be uniformly joined to create a lump-free mix and to incorporate air into the mass.The shortening should be at the proper temperature so it is pliable and will not lump in the mixer. The proper temperature is dependent on the melt point of the shortening (see the Shortening glossary entry).The correct mixing time and speed provides the desired aeration.Photo of Stage 1Remember: consistency, temperature, aerationNeed PICNeed photos for this, please list file namesUse group of photos prefixed with Stage1 or Mixing Stage 1Mixing Stage 1 First stage of a wire cut cookie dough.jpgDon’t go back and check right away, but see if you can remember which ingredients are mixed in Stage 1. Click an ingredient to add it to the mixer. When you think you have it, click the Begin Mixing button. If you don’t have it right, start again by clicking the Empty the Mixer button. If you really can’t remember, go back and check.Exercise: Add the ingredientsNeed PICHorizontal Mixer Control Panel.jpgPicture of a mixer. Lots of ingredients, but make sure to include granulated sugar, solid shortening, and salt. Clicking an ingredient should add (animated?) it to the mixer even if it’s wrong. There should be two buttons, if possible:Begin MixingEmpty the MixerForward navigation should not be allowed until it’s right. Great! You made it to Stage 2! For fun, see if you can guess what Stage 2 is all about. Click the card you think is correct.Flipcard interaction.The Shortening StageThe Flour StageThe Liquid StageThe Inclusions Stage(Feedback on wrong answer: That’s not it. Try again.)Mixing Stage1 end Stage 2 Begin Oak State Bakery 174.jpgLiquids are generally added in Stage 2. The liquid joins with the shortening and sugar mass to make a homogeneous mix. The liquid is kept away from the flour as long as possible to avoid the formation of gluten (see gluten entry in the Glossary).Liquid, in particular water, is one of the means of controlling the final dough temperature. City water will normally run 55 to 60 degrees F. Some facilities have chilled water systems that deliver water at temperatures as low as 38 degrees F.Photo of Stage 2 accompanied by text:Temperature can be controlled by liquid.Need PICNeed photos for this, please list file namesUse group of photos prefixed with Stage2 or Mixing Stage 2Also this text is very long! If it’s possible, help us cut it down.In extreme summer conditions, ice may be required in combination with water. The ice should be in a form that will quickly go from a solid to water phase. Water is important because ingredients such as sugar and salt rely on water to reduce crystal size. In winter, it may be necessary to temper city water with warmer water to achieve desired dough temperature.Wire Cut dough requires a lower dough temperature than rotary or cracker dough. Show a split screen, summer and winter. For summer, annotate: More cool water or ice may be needed to achieve lower dough temperatureFor winter, annotate, More warm water may be needed to achieve higher dough temperatureLet’s see if you remember a key point from the previous page.Pretend it’s a very hot summer day and you need to bring the temperature of the dough down to adjust for this. Exercise: Add the ingredientsMixer as before, but with these ingredients:measuring cup with water labeled 80°Fmeasuring cup with ice and water labeled 60°Fmeasuring cup with water labeled 38°FForward navigation should not be allowed until it’s right. Good job! You have arrived at Stage 3.During this stage, the flour is added and then the Soda and SAPP is sifted on top of the flour.The flour will generally be from a soft wheat variety, in order to control the spread of the product. Cake flour can also be used in a Wire Cut formula. Generally, cake flour is used in conjunction with pastry flour (see the Flour glossary entry).Photo of Stage 3Different flour varieties control SpreadNeed PICNeed photos for this, please list file namesUse group of photos prefixed Stage 3 or or Mixing Stage 3Mixing Oak State Bakery 186 Drawing Flour.jpgFlour stage of wire cut dough.jpgTwo of the ingredients deserve a little extra attention. Soda controls pH and, when combined with acid SAPP (see Glossary), creates leavening (lift and spread). These ingredients should be placed on top of the flour to avoid direct contact with liquids. Contact with liquids will cause a premature reaction that will vary baking results.Because soda is used to control pH, it can be added to the 1st stage of the mix. In this way the soda will begin to neutralize the other ingredients, leaving the residual soda to react with acid leavening such as SAPP and to raise the final product pH at or above Neutral (7.0) as necessary.Soda and SAPP SodaSAPPcontrols pHacidSoda can be added during Stage 1, if desiredTwo ColumnsProduction Question: Can we pop-up some definitions in-line as shown here?Play hangman to see if you remember some of the facts you were given on the previous page.Hangman learning game with the following entries.Soda controls: _ _ (pH)Leavening affects: _ _ _ _ _ _ _ _ _ _ _ _ _ (lift and spread)SAPP is an example of an: _ _ _ _ (acid)If soda and SAPP have contact with the liquids, it could cause a: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ (premature reaction)Note, if we can’t do hangman, let’s find another type of interaction but not a simple fill-in-the-blank quiz where something could be right and only spelled wrong. Whether you have inclusions (for example, chocolate chips) or not, you next need to check the dough’s temperature.If the temperature is out of the specified range an adjustment needs to be made. Typically the water temperature needs to be varied. However, if ice and / or mixing water jackets are an option, the following course of is recommended.If dough is too warm use coldest water first, a water/ice combination second and employ water jackets last,If dough is too cold, turn-off water jackets first, reduce or eliminate ice second, and temper the water last. If it is determined that the dough temperature is out of range to the point of being detrimental to the finished product, than dough disposition should be decided by a manager. NOTE: This is especially important with an inclusion like chocolate chips: it may be better to discard the dough before adding the chips.Check the Temperature(two columns)Too Warm?coldest waterwater / icewater jacketsToo Cold?turn off water jacketsreduce or eliminate icetemper the waterOut of range? Contact a manager!Need PIC20120306061129 Water jacket.m2tsStage 4 check temp 20120306061545.m2tsNeed photos for this, please list file namesThis text is very long! If it’s possible, help us cut it downIn some mixing rooms, CO2 gas is used to chill dough to desired temperatures. Because the temperature of CO2 gas is well below the temperature of ice, the bakery must experiment with how long to inject the CO2 gas into the mixer in order to provide the desired dough temperature. All safety precautions must be followed by the employee to assure the safe handling of the CO2 gas.CO2 Gas – Safety PrecautionsUse CO2 gas safely!(SME: need a list of these precautions)If we get the list, display it as a thumbnail onscreen, able to be downloaded as a pdf.Time to mix! Add the right ingredients to the mixer and Begin Mixing when you think you have it right. Stuck? Click here to jump back a few pages and find the answer. (content for this is on page 9)Exercise: Add the ingredientsMixer as before, lots of ingredients. The right ones are:FlourSodaSAPPForward navigation should not be allowed until it’s right. Stage 4 at last! If you have nothing to add to the dough, you would skip this stage altogether.Chips should be at or below the final dough temperature so they will not melt and discolor the dough. Chips should be held in the refrigerator up until the time of staging into the mixer. This will help to minimize melting in the when mixed. Mixing chips too long can discolor the dough. This occurs when the chocolate starts to melt as a result of friction created by the mixing action.Check dough temperature at the completion of mixing. If it is out of the specified range, an action needs to be determined.Photo of Stage 4Remember: this stage is only needed if you have inclusions!Need PICNeed photos for this, please list file namesUse group of photos prefixed Stage 4 or Mixing Stage 4 or FinalStage 4 Adding inclusions - Choc Chips 20120306063616.m2tsMixer adding Choc chips to the final mixing stage .jpgDough being checked for temp manually 20120306061406.m2tsThis text is very long! If it’s possible, help us cut it downTime to mix! In this case, we’ll do it for you, so just sit back and watch.Animation: chips added to mixerSame mixer as before, but just show the chips being added and the mixing process occurring.Just for fun, see if you can pick out other possible inclusions.We’re almost done, but let’s take a moment to find out about an important timing element. Click to advance when you’re ready.flipcard interaction: What Else Might Be Added?Pictures of ingredients:nutsraisinsoat flakesother?Tab Interaction: each set below narrated separately.Lay Time (tab interaction)Need PICUse Group prefixed with Lay TimeSME Note: Need photos, please list file names.Lay time is the time between the dumping of the dough and when it goes to the machine to be processed.Dough lay time serves the following purposes:Creates a buffer time between mixing and machining.Provides time to more fully hydrate the dough. This creates a drier less tacky dough. Dough will machine more consistently and transfer with less difficulty.Water reduction or increase is not a substitute for an anticipated reduction or increase of the dough lay time.Standing dough should always be covered with proper sanitary covers to prevent the entry of foreign materials and to avoid drying or crusting of the dough surface. The cover type should be in compliance with Good Manufacturing Practices (GMPs). Congratulations! You’ve reached the end of this lesson on Mixing. This is a good time take a short break before we go on to the next major process, Forming.Mixing:PrinciplesStagesLay TimeEND OF MODULEModule titleFormingScreenNarrationText on ScreenScreen DescriptionThe next major process in making Wire Cut cookies is Forming. We’ll learn about the Wire Cut machine and how it works, review important safety rules and then the Machine Operator’s role and responsibilities. Forming:Wire Cut Machine and Die ConfigurationSafetyThe Machine OperatorProcess graphic, highlight second box and list bullets.You just learned about the first of three major conversions, mixing. Forming is the second conversion.Forming takes the dough mass down to an individual dough piece will be eventually baked in a consumable product. This conversion takes place using wire cut equipment fitted with a precise die.Let’s take a look at the equipment.Timeline: Use graphics to depict each of the conversions on a linear bar, similar to a timeline. Ingredients, mixer, forming machine, oven, and finished cookie packageHighlight forming on the timelineThere are four important components of wire cut equipment: the die, the filler block, the pressure rolls and the wire harp.These components work in a sequence…Dennis add toSimple diagram hereProduction Note for this and next screen – this scripting still in progress, hold for edits.Dennis: Resequence, and add note to have the student click in a distinct sequence rather than randomly.Interaction: each piece of narration should be separate.The Wire Cut dough is deposited into a hopper comprised of two feed rolls that force the dough through a Wire Cut die. (Top-down view of the feed hopper and rollers.) Need PICThe use of a “filler block” or “sump restrictor” is optional. However, its use is becoming more popular because of its ability to control dough piece weight across all cups.Need PICdie assembly and filler block.JPGFiller block and die chamber of the wire-cut machine.jpg (Shot of the filler block out of the machine (if possible) and In the machine in a top-down view )A wire harp then cuts off the dough and the pieces drop onto a moving conveyor or oven band which transports the pieces into the oven for baking. For certain applications (dough with large particulates, nuts, chips etc.) a serrated “blade” can be used in place of a wire. The blade will cut through the particulates as opposed to pushing through them, which could cause the dough piece to distort and/or be thrown, disturbing the alignment and causing double after the bake-out. Note: Safety gloves should be used when handling and installing a cutting blade.The Wire Cut machine will have either a stationary band raise roller or a mechanical apparatus. The stationary type is adjusted to a specific height that facilitates the best cutting and placing of the dough piece onto the band. The mechanical type rises and falls with the stroke of the wire and provide precise placement of the dough piece. The mechanical apparatus is preferred, but is generally only available on newer equipment. Need PIC 20120306052147 Band raise.m2ts(Show the mechanical band raise in operation.)Either the wire or the blade can be mounted on an optional vibratory holder assemblyThe die configuration refers to the number of cups and the cup diameter. The number of cups and the cup diameter are determined by the width of the band, final cookie diameter and the necessary side-to-side spacing between each cookie after bake-out. The die cups can be made from bronze (die cast), stainless steel (machined) or from hi-slip polymers (molded). The type of cup that is used is dependent on the product and desired finished product appearance. Need PICdie assembly and filler block.JPG (Show the die assembly.)Front-to-back spacing is controlled by the speed or number of strokes per minute of the wire harp. The Wire Cut Machine and Die Configurationguided tour interaction?This is where we do our big animation with highlit areas to click.If possible, animate where appropriate – probably need SME discussion with production team.Need PICTop View of dough feeding to wire cut hopper 20120306055108 .m2tsVideo of many of these sequences available, see file names, perhaps we can have a photo and when they click, they see a small video clip.Interaction: each piece of narration should be separate.The Wire Cut dough is deposited into a hopper comprised of two feed rolls that force the dough through a Wire Cut die. (Top-down view of the feed hopper and rollers.)The use of a “filler block” or “sump restrictor” is optional. However, its use is becoming more popular because of its ability to control dough piece weight across all cups. (Shot of the filler block out of the machine (if possible) and In the machine in a top-down view )A wire harp then cuts off the dough and the pieces drop onto a moving conveyor or oven band which transports the pieces into the oven for baking. For certain applications (dough with large particulates, nuts, chips etc.) a serrated “blade” can be used in place of a wire. The blade will cut through the particulates as opposed to pushing through them, which could cause the dough piece to distort and/or be thrown, disturbing the alignment and causing double after the bake-out. Note: Safety gloves should be used when handling and installing a cutting blade.The Wire Cut machine will have either a stationary band raise roller or a mechanical apparatus. The stationary type is adjusted to a specific height that facilitates the best cutting and placing of the dough piece onto the band. The mechanical type rises and falls with the stroke of the wire and provide precise placement of the dough piece. The mechanical apparatus is preferred, but is generally only available on newer equipment. Need PIC20120306052147 Band raise.m2tsSee video named Die Assembly (Show the mechanical band raise in operation.)Either the wire or the blade can be mounted on an optional vibratory holder assemblyThe die configuration refers to the number of cups and the cup diameter. The number of cups and the cup diameter are determined by the width of the band, final cookie diameter and the necessary side-to-side spacing between each cookie after bake-out. The die cups can be made from bronze (die cast), stainless steel (machined) or from hi-slip polymers (molded). The type of cup that is used is dependent on the product and desired finished product appearance. Need PIC die assembly and filler block.JPG(Show the die assembly.)Front-to-back spacing is controlled by the speed or number of strokes per minute of the wire harp. The video on this screen shows how it all comes together when everything is working correctly. Take a few moments to watch!Movie Need PICWire Cut Running 20120305142809.m2tsThe video on this screen shows how it all comes together when everything is working correctly. Take a few moments to watch!Again, safety and sanitation are always a priority. It’s a key machine operator responsibility. Dennis, reword this onePre-Operation Check(two columns)SafetyIs the area safe?Is the equipment safe?Are the ingredients safe?MSDS sheetsAllergens SanitationIs the work area clean?Are the utensils clean?How about the mixer?Watch out for residual doughBe Sure It’s Safe and Clean!Production Note: This screen’s narration script still in progress.Before we go on to learn about your responsibilities, there’s one more topic that’s important to understand in regard to sanitation.If compressed air is used to remove debris from the interior of the equipment, certain precautions must be considered:Compressed air must be regulated not to exceed 40 PSIThe hose and hand held on/off valve must be secure to avoid a “run-away” hose situationSafety glasses must be worn to avoid eye pressed air should never be directed towards a co-workerNote: Compressed air should not be used to clean extremely dusty materials such as flour from machine surfaces. This practice causes dust to become airborne creating a sanitation problem in other areas, a breathing hazard to employees and, in certain situations, could cause a dust pressed Air – PrecautionsCompressed air must be regulated not to exceed 40 PSIThe hose and hand held on/off valve must be secure to avoid a “run-away” hose situationSafety glasses must be worn to avoid eye pressed air should never be directed towards a co-workerBe Careful with Compressed Air: follow the precautionsNeed PICNeed photos.Here’s a little spot check to make sure you were paying attention. If you don’t get it right, go back a page and find out what the right answer is.Quick Fact Check…Don’t use compressed air on extremely dusty materials, because:The dust will become airborneYou can create a sanitation problemYou can create a breathing hazardYou can cause a dust explosionAll of the aboveSpot QuizFeedback on incorrect answer. That’s correct, but it’s not the best answer. Try again.In order to properly machine the dough, the machine operator must know:Which die to useProper installation of the wire-harp and its relationship to die cups.Number of strokes per minuteRaw Dough Weight (RDW)Labeled graphic interaction, if possibleEach bullet comes in with an arrow pointing to the appropriate part of the machineUse photos prefixed with Setup & Wire CutWire Cut die cup set.jpgCenter 2 center 20120306052909.m2tsCenter 2 center 20120306053019 .m2tsSide View of wire arm depicting band raise importance.m2tsDepicting improper wire adjustment in relation to the cup Result20120306054623.m2tsOperator taking weights to verify correct deposit 20120306052244.m2tsDSC00042Product lined up like soldier indicating excellent machine adjustment.jpgWire Cut Running Good depiction of wire stroke and band raise function.m2ts(Tab interaction – each bullet (including sub bullets) should be narrated separately)Machine set-upWire-armstroke setting: setting the strokes per specificationsSpeed and pressure setting of the pressure rolls: adjusting the speed of the rolls to maintain proper weight. If the Wire Cut is equipped with adjustable rolls, it is the operator’s responsibility to set the pressure rolls at the correct opening. If a filler block is used it is the operator’s responsibility to set the gap between the rolls and the block to maintain positive dough pressure while avoiding roller to block contact. Some Wire Cut machines are equipped with fixed pressure rolls and no adjustment is possible. In this case the filler block is designed to be correctly gapped when properly inserted.Proper dough level in the hopper (only if the hopper is not automatic). If the hopper is not automatic, the machine operator adjusts the speed of the incoming dough to equal the speed of the outgoing dough.Raw Dough Weight. It is the machine operator’s responsibility to follow the procedure and frequency for weight control. Each plant should develop its own plan for taking Raw Dough Weights (RDW). The plan should include: The number of dough pieces to be checkedThe frequency of the checksThe pattern in which dough pieces should be selectedThe re-check processThe corrective actions for out of specification weights. (Show an operator checking weights in some sort of pattern to include picking up dough pieces and weighing them on the scale. We should try to depict a soft and a firm dough to show technique.)The machine operator is responsible for the proper alignment of the dough pieces, in the front-to-back position, on either the conveyor or oven band. This is affected by the set-up of the wire on the harp and the position of the closeness of the wire to the cup outlet during the stroke. (Close-up of the wire-position in relation to the cup.)The overall front-to-back spacing can vary if either the strokes are set improperly or if the speed of band is incorrect or a combination of both. The operator should measure the center-to-center distance between dough pieces to help to determine correct dough spacing on future runs. This measurement should be taken when the operator is sure that the strokes and band speed are correct. (Show an operator checking center-to-center spacing of the product in the direction of flow.)Tab interactionNeed PIC20120306051651 Setup .m2tsOperator taking weights to verify correct deposit 20120306052244.m2tsUse photos prefixed with Setup & Wire CutNeed photos for this, please list file namesThis text is very long! If it’s possible, help us cut it downThat was a lot of information! Let’s play a little hangman to help you remember some of these important facts. If you don’t get it right, just try it again.Hangman learning game with the following entries.RDW stands for: - - - - - - - - - - - - - - (Raw Dough Weight)If a filler block is used it is the operator’s responsibility to set the gap between the rolls and the block to maintain _____________ while avoiding roller to block contact.- - - - - - - - - - - - - - - - - - - - - (positive dough pressure)The machine operator is responsible for:- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - (proper alignment of the dough pieces)Hangman or similar, make sure they don’t have to know how to spell right to win.But what if everything ISN’T working correctly? Walk through this case study step by step to see if you can figure out what’s wrong and how to fix it. Ask the Expert to check your answer and gain more information.SME Input Required here.Step 1: Deposit the DoughSME: what can go wrong here? What should be done to fix it?Step 2: Filler BlockSME: what can go wrong here? What should be done to fix it?Step 3: Dough is CutSME: what can go wrong here? What should be done to fix it?Ask the ExpertCase Study ExerciseNeed SME expert notes here. Let’s give the student a chance to guess the solution before consulting the expert.)Need PICProduction Q – wonder if we can use animation to show these. If not, need to clip video, or use photos showing something wrong.Congratulations! You’ve reached the end of this lesson on Forming. This is a good time take a short break before we go on to the next major process, Baking.Forming:The Machine OperatorSafetyWire Cut Machine and Die ConfigurationEND OF MODULEModule titleBakingScreenNarrationText on ScreenScreen DescriptionThe next major process in making Wire Cut cookies is Baking. We go through a series of important principles in this lesson and then we’ll learn all about the oven.Baking:PrinciplesThe OvenThe Baker’s Role and ResponsibilitiesProcess flow graphic, highlight third box, list bullets.We’ve arrived at the fourth and most important conversion, in which the dough converts into baked consumable product.The oven dictates everything that happened before and what will occur afterward. The bigger the oven, the faster you can bake. This is an important economic factor …All ovens Timeline: Use graphics to depict each of the conversions on a linear bar, similar to a timeline. Ingredients, mixer, forming machine, oven, and finished cookie packageHighlight OvenProduction Note: Narration script still in progressIn order to properly bake the dough and deliver an acceptable product, the baker must know:Correct Bake time and/or Band speedCorrect oven profile (Zone temperatures and Damper settings)Any pre-oven band or chamber conditioningAny post-oven treatment to the productFinal baked product specificationsLabeled graphic interaction, if possibleEach bullet comes in with an arrow pointing to the appropriate part of the ovenDennis – add safety check?Production Note: Narration script still in progressInteraction: each piece of narration should be separate.The Wire Cut dough is either dropped onto or transferred from a conveyor to an oven bandThe Baking surface (Oven band) for Wire Cut cookies will be solid and is continuous. The formed dough will pass through a number of baking zones. The number of zones is based on the oven length. Generally, the longer the oven, the greater the number of zones.Each zone will have independent control of temperature (top and bottom) and damper. Dampers help to control the baking chamber atmosphere.For each item and oven type, a particular baking profile is established. The baking profile includes the bake time and the zone temperatures and damper settingsOven guided tour interaction?Production Note: If we can, let’s do another animated guide here, with highlighted areas on the oven. If not, a series of pictures with text captions at the bottom and a way to navigate them.(Glossary interaction – each bullet (including sub bullets) should be narrated separately) Intro: Many ovens are equipped with one or more of the following accessories.Band Scrapping knives: (Photo of scrapper knives in place at various locations of the oven) These are generally located in more than one place with the sole purpose of removing debris from the band surface and from the band interior as well as built up carbon from the band surface. It is important to verify that these knives are in place and properly positioned to facilitate good cleaning and more importantly to avoid band damage. Band Brush: (Video that shows the Band Brush in operation.) Band brush assembly is generally located at oven discharge end, on the return side of the band. It is located in a position that is easily accessible by the baker. The band brush is generally "spiraled" on its mounting rotates counter to the flow of the band. The brushes are spiraled to facilitate the removal of debris from the band and to prevent "band scoring" or damage to the band coating. Care should be taken to assure that the contact of the band brush to the band is not over done. Also the band brush motor should be inoperable if the band stops or if the oven is powered off. This will prevent band wear and damage. Band Brush assemblies must periodically cleaned to remove oil and debris build-upOiling systems: (Video showing oiling systems. We should show an example of a simple application and a spray system.) Many ovens have band-oiling system to facilitate the transfer of product from the oven band surface, over the knife and onto the cooling conveyor. The oiling system can be as simple as applying oil to the band followed by either a stationary or mechanical wiping system helps to spread the oil more across the band. Oil can also be applied by spray application and wiping may also be used for uniformity. More sophisticated spray oiling systems utilize electrostatic spray systems, which provide the most uniform coverage with relatively small amounts of oil. These types systems are quite expensive but are needed for products that require band oil, but where excessive amounts of oil are detrimental to the product usually affecting the products dimension. The type of band oil used is important and should be sourced through a manufacture dedicated to products for this use. The Band Knife (Photo of different Band Knife configurations. We may want to add a video of product flowing over the knife.) The band knife is critical to removing the product from the baking surface to the cooling conveyor. The band knife size (width), angle with regard to position on the drum and configuration is dictated by the type of product being produced. The band knife width should be as narrow as practical to reduce the amount of contact and drag on the product. The knife is generally less wide than the product so that the baked piece cannot come to rest on the knife surface having to be pushed from off the knife by the next cookie piece. This could distortion of the baked product.The position of the knife is generally set somewhere between the horizontal and vertical position of the band as related to the curvature of the band drum. The angle should be such that the product has an easy transition from band to knife. The knife tip should be beveled and contact with the band should lie on the bevel and not the tip.The knife configuration can be flat, serrated or rippled. The configuration depends on the type product. The rippled knife is flat where it contacts the band but becomes rippled and raised afterwards. This type of knife is used on oily products or products containing chocolate chip or other inclusions. The purpose of this knife is to allow any residue that might build-up on the knife to be below the where the product and to be channeled off the knife. The ribbing or channeling also helps to break any suction between the product and the knife allowing the product to flow more freely.Most band knifes are stationary, but it is possible to have a vibratory knife that will assist in removing large or oily products from the band. Your oven manufacturer can be of help in this area. It is important to note that band knife cannot properly free a stuck product from the band without ripping portions of the bottom from the product or creating excessive crumbing upon transfer. Good product transfer is dependent on 1) a clean band surface and proper conditioning of the band 2) formulation: generally the use of lecithin in the dough will help product bottom condition and reduce band sticking. 3) Oven profile: providing adequate bottom heat in Zone 1 will help to prevent sticking 4) over band cooling at the discharge end of the oven will help to set the product sooner allowing product to move across the knife without distortion. Oven: AccessoriesGlossary style interaction with list of entries and picture/text definitionsNeed PICNeed photos of these and really must cut down the text here!Need PIC see video requirements on far left (Tab interaction – each bullet (including sub bullets) should be narrated separately)Zone temperatures and damper settings. The baker is responsible for the set-up and ongoing monitoring of the zone temperatures and conditions. Bake time and/or Band speed as required by the product.Pre-oven preparation or treatment. The baker is often responsible for the start-up of the oven, which includes light up and pre-heat of the oven. The baker is responsible for any band pre-treatment, such as oiling and on-going wiping. The baker should also assure that band brushes are against the band and turning. The baker is responsible to assure that the product transfer from the oven band to the cooling conveyor is in good order to assure proper presentation to manual or automated packaging stations. Equally important for proper baking of a product is preparing and maintaining the band surface prior to and during the process.Post-oven conditions and or applications. The baker is responsible for product conditioning after the baking chamber and prior to the transfer from the oven band. This includes band cooling and, in some cases, application of a roller to the product to equalize the height.Product specifications directly related to the baking process. The baker is responsible for monitoring and recording the product specifications. These checks are generally performed on a time basis corresponding to the running time of the dough. The baker will normally check the following:Weight per Piece or Count per PoundLength, width or diameterPiece thickness or Stack height of x piecesMoisture, pH and color Generally, these specifications will have an acceptable +/- range around a target. The baker is responsible for responding to product out of range or product off target for a designated number of checks.Baker’s Role and ResponsibilitiesTab interactionNeed PICNeed photos for this, please list file namesThis text is very long! If it’s possible, help us cut it downLet’s take a moment to compare two roles in a quick exercise. Notice that the page is divided in half. Beneath the two areas is a single list of responsibilities. Drag each one to the correct role: Machine Operator or Baker.Drag and Drop Role Exercise(two columns)Machine Operator:Baker:(one column)Alignment of the dough piecesBake time and/or Band speed Overall front-to-back spacing Post-oven conditions and or applicationsPre-oven preparation or treatmentProduct specifications directly related to the baking process. Proper dough level in the hopper Raw Dough Weight.Speed and pressure setting of the pressure rollsWire-armstroke settingZone temperatures and damper settingsDrag and Drop. If dropped to the wrong place, doesn’t stick. If dropped correctly, stays and sparkle sound. Correct Answers:Machine Operator:Wire-armstroke settingSpeed and pressure setting of the pressure rollsProper dough level in the hopper Raw Dough Weight.Alignment of the dough piecesOverall front-to-back spacingBaker:Zone temperatures and damper settingsBake time and/or Band speed Pre-oven preparation or treatmentPost-oven conditions and or applicationsProduct specifications directly related to the baking process.(Tab interaction – each bullet (including sub bullets) should be narrated separately)The bake time for Wire Cut cookies is generally between 6 and 14 minutes. These times are longer relative to other types of products because the dough formulation contains more sugar and shortening, softer dough, and the size development from dough piece to final product.The bake time is the most important specification in the process because it dictates the product quality and product throughput. Product throughput is the basis for the cost of the final product. Therefore, faster or slower bake time has a negative impact quality, while slower bake time has a negative impact cost. Having the correct relationship between the Wire Cut machine (strokes per minute) and the band speed or bake time is critical in order to produce the correct end product ready for packaging.The measurement of bake-time begins when the product enters the baking chamber and ends when the product exits the baking chamber. This measurement includes the proper front-to-back spacing of the product. The band speed (stated in feet per minute) is measured or calculated after the bake-time is established. The band speed can be measured using a tachometer or can be calculated by dividing the oven length by bake time. Regardless of the oven length, bake time remains the same. What varies is the band speed and that dictates product throughput.Principles: Bake TimeTab interactionNeed PICNeed photosHere are two questions for you to answer as a spot check. See if you know the answers, and if not, go back one page for a quick review.Quiz: Bake TimeThe measurement of bake time begins:When the product exits the baking chamberWhen the product enters the baking chamberAt the start of the Forming ProcessAt the start of the Mixing ProcessBand speed:is stated in feet per minutecan be measured using a tachometercan be calculated by dividing oven length by the bake timeall of the aboveSpot Check QuizFeedback on wrong answers: That’s not the best answer. Try again.(Tab interaction – each bullet (including sub bullets) should be narrated separately)Because there are independent baking zones in a band oven we are able to vary temperatures zone to zone. (Show an Oven Control Panel demonstrating the Zone controls. Add in drawing to depict the construction of the oven and the different oven types. We will need multiple drawings and I think we can get these from the B&CMA text books.)The baking profile for a Wire Cut cookie breaks-down as follows: Heat-up and spread Lift and rapid moisture releaseFinal dying and coloration Establishing bake time and a baking profile is based on meeting the finished product specification. The product specification generally addresses product formation, color and moisture. Product formation is primarily a function of formula, but can be affected by adjusting the baking profile to some degree. Adjusting the baking profile can vary the finished product color. Final product moisture is directly related to the baking profile, however if all product specifications are met and the moisture is either high or low, then the bake time must be adjusted.It is important to note that the preceding information emphasizes the importance of maintaining the correct bake time, but that both bake time and baking profile are established at product development and commercialization. The baking profile may be adjusted slightly on a day-to-day basis, but should never be varied as a correction for improperly prepared dough. Principles: Baking ProfileTab interactionNeed PICNeed photosHere’s a little spot check to make sure you were paying attention. If you don’t get it right, go back a page and find out what the right answer is.Drag to put the baking profile steps in order:Heat up and speedLift and rapid moisture releasefinal dying and colorationSpot Quiz(note, the steps are shown in the correct order but should be scrambled.)Ready to ask the expert? Let’s find out what to do when things go wrong.SME Input Required here.Step 1: Dough is dropped or transferredSME: what can go wrong here? What should be done to fix it?Step 2: Dough passes through zonesSME: what can go wrong here? What should be done to fix it?Step 3: Product emerges from ovenSME: what can go wrong here? What should be done to fix it?Ask the ExpertCase Study ExerciseNeed SME expert notes here. Let’s give the student a chance to guess the solution before consulting the expert.)Need PICProduction Q – wonder if we can use animation to show these. If not, need to clip video, or use photos showing something wrong.Congratulations! You’ve reached the end of this lesson on Baking. Take a short break before we go on to the final process, Cooling and Delivery.Baking:The Baker’s Role and ResponsibilitiesPrinciplesThe OvenEND OF MODULEModule titleCooling and Delivery ScreenNarrationText on ScreenScreen DescriptionThe next major process in making Wire Cut cookies is Cooling and Delivery. The purpose of the conveyors is to deliver the product to the packing area and to allow the product to cool from approximately 150 degrees F. down to 90 degrees or less.Cooling and Delivery Delivery ApronsProduct CoolingPackagingProcess flow graphic, highlight fourth box, list bullets.Cooling and delivery is the final conversion, in which the baked cookies are cooled and finally sealed into packages….(explain the importance of cooling)Timeline: Use graphics to depict each of the conversions on a linear bar, similar to a timeline. Ingredients, mixer, forming machine, oven, and finished cookie packageHighlight packageProcess – what this doesSafety checkFor delivery aprons to be effective it is important that:Transitions between aprons are smooth The aprons have variable speed controlThe aprons track evenly to assure a properly-aligned productDelivery Aprons(image)Need PICNeed photoInteraction: each piece of narration should be separate.The purpose for cooling the product is to facilitate the set-up of the product to allow for product handling either manually or automatically. Product cooling speeds the re-crystallization of the sugars. Product cooling is also important for sandwiched products or for enrobed products so that the fat matrix is not disturbed or melted by excessive heat. This can be accomplished either by the travel time under ambient conditions or by forced cooling.Typically when cooling under ambient conditions, the length of the cooling conveyor should equal the length of the oven. Fans can also be used to assist in the cooling process. Forced cooling, usually utilizes a refrigerated tunnel and fan combination. If space is limited, spiral cooling takes advantage of vertical space when building length is prohibitive. Need PIC (Photos or video of Spiral cooling set-up.)Product Coolingguided tour interaction?Production Note: If we can, let’s do another animated guide here, with highlighted areas on the oven. If not, a series of pictures with text captions at the bottom and a way to navigate them.Ready for some hangman? See if you remember the answer to these questions. If not, go back a screen and check.Hangman learning game with the following entries.Product cooling speeds the re-crystallization of the: - - - - - - (sugars)Two methods of cooling are:- - - - - - - - - - - - - - - - (ambient and forces)Hangman or similar, make sure they don’t have to know how to spell right to win.Interaction: each piece of narration should be separate.The primary purpose of packaging is to protect the product from damage and to preserve freshness. Wire-cut cookies larger than 13/4” diameter are generally packed in a celled tray and overwrapped in a protective film. The product can be placed into the tray either manually or automatically. In either case, the product must be presented in an organized rowed and stacked fashion to facilitate efficient handling. Product under 13/4” diameter is generally packed in a “bag in box” also known as a “dump-pack.” The product after cooling is combined onto a bulk conveyor and delivered to an auto-scaling area to be placed or dumped into a bag (protective film) and then placed in a carton. Single Serve packaging has also grown in popularity and depending on the size and weight of the product, either one or two products are packaged. There are many configurations. Depend on the product to determine what type of packaging will supply the best protection.. Packagingguided tour interaction?Production Note: If we can, let’s do another animated guide here, with highlighted areas on the oven. If not, a series of pictures with text captions at the bottom and a way to navigate them.Ready to ask the expert? Let’s find out what to do when things go wrong.SME Input Required here.CoolingSME: what can go wrong here? What should be done to fix it?PackagingSME: what can go wrong here? What should be done to fix it?Ask the ExpertCase Study ExerciseNeed SME expert notes here. Let’s give the student a chance to guess the solution before consulting the expert.)Need PICProduction Q – wonder if we can use animation to show these. If not, need to clip video, or use photos showing something wrong.Congratulations! You’ve reached the end of this lesson and the end of this course. Get ready to pass the Final Exam.Cooling and Delivery ConveyorsDelivery ApronsProduct CoolingPackagingEND OF MODULE ................
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