The rusk-making process is a lengthy process of preparing the rusk dough and baking it in the rotary oven. So, here we shall be going through the complete procedure of rusk making via the rusk making plant set-up.
What is rusk?
Rusk is a light weight dry piece of biscuit or twice baked bread slightly longer than a biscuit. The main ingredients are wheat flour, sugar, skimmed milk powder, vegetable oil, gluten, soy flour, yeast and water.
People often confuse between toast and bread. Toast is a dry bread on the other hand, we bake rusk twice. People can run a small-scale rusk making to large-scale rusk making process business as per their affordability.
Required Machinery in Rusk Making
You need rotary rack oven, dough kneader, rusk cutter/slicer and Trays and moulds. Further, you will require spiral and planetary mixer for dough kneading. Let’s know about each machinery part used in rusk making.
- Rotary Rack Oven: Rotary rack ovens have a rotary trolley with many tray columns to disperse and control the heat evenly throughout the oven. We use rotary rack ovens to cook bakery products such as breads, pastries, meats and casseroles evenly.
- Dough kneader: A commercial dough kneader makes mixing of the dough easier for preparing pizza, bread, rusk, etc. We use planetary and spiral mixers for commercial dough kneading. They differ in working and dough quantity. below is brief about each of them:
- Planetary mixer: a planetary mixer uses a single motor and a stationery bowl. They come in smaller countertop versions and large floor-standing models and are ideal for versatile use and robust kneading.
- Spiral mixer: A spiral mixer works best for mixing artisan and bust dough. It gently and efficiently mix dough which develops gluten structure. You will also require a spiral mixer for dough kneading. A spiral mixer makes bread and dough by means of the compression and decompression action.
Rusk Making Process
Once you have arranged all the machinery required, you are all set to make rusks. Here, I am specifically mentioning the Hindchef’s machinery.
Spiral mixer of Hindchef is available in single and double speed with single or three power load. Now, we understand the process of dough kneading:
- Firstly, you knead the dough using the spiral mixer mentioned above in Moulds.
- When you keep the dough in moulds, you cover the Moulds and keep it for two-hour proofing.
- After the two hour proofing, trolley is ready for baking. The trolley going for baking is Ladi preparation in Hindi. Now, leave the ladi for 30 minute inside the Rotary oven. The Ladi baking consumes 2-2.5 litre diesel per hour.
- As soon as you take out ladi from moulds, keep it for cooling in the Ladi cooling rack.
- Then cool it and put the rusks inside the rusk cutter.
- Arrange the slices in the trays after cutting rusk pieces. Now, place the trays in the trolley for final baking.
- After the final baking, leave the baked rusks for 15-20 minutes and avoid touching the trolley.
Finally, rusks get ready for packaging. Pack these by placing a sticker inside it.
Note: You can pack rusks manually or using a machine
Read more: Rusk making bakery setup
Staff required
- Small Scale business: For small scale rusk making, three to four staff members are required. one chef, one co-chef, and one or two helpers.
- Large-Scale business: For large scale rusk making more than four staff members are required.
FAQs
- What are the main ingredients of rusk?
The main ingredients of rusk are wheat flour, salt, and raising agents.
- How can you dry rusk quickly?
Place rusks on drying rack and maintain 80 degree Celsius temperature.
- What are the steps in rusk making process?
The important steps are dough kneading, proofing, baking, cooling, again baking and again cooling, slicing and packaging.
- What is margin in rusk making business?
Those who are planning to start a rusk making business can get a profit margin of 10 to 15%. The company manufacturers 55 types of cookies and supplies to 300 retail small and big retail store.