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Schools Information Pack

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Madeira Cakes. Chocolate Cakes. Rich Fruit Cakes. Celebration/Novelty Cakes. Oven-finished Fruit Cakes. Cut Section Fruit and Madeira Cake. Vacuum Sealed Fruit Cakes ... – PowerPoint PPT presentation

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Title: Schools Information Pack


1
Schools Information Pack
Revised February 2006
2
Our Product Range
  • Iced Christmas Cakes
  • Madeira Cakes
  • Chocolate Cakes
  • Rich Fruit Cakes
  • Celebration/Novelty Cakes
  • Oven-finished Fruit Cakes
  • Cut Section Fruit and Madeira Cake
  • Vacuum Sealed Fruit Cakes
  • Iced Fruit Cakes
  • Corn and Rice Crisp Cakes

3
Innovation
  • Brainstorming Sessions New Ideas New
    Techniques New Decorations
  • Other characters pigs, teddies, cats, dogs,
    sheep, monsters
  • Licensed Film TV Characters
  • Simpsons
  • Thomas Friends
  • Shrek
  • Wallace Gromit
  • Special Occasions Valentines Day Easter Christma
    s Mothers Day Halloween Weddings Birthdays
  • Links with hobbies and interests, e.g. football,
    snooker
  • Consultation with retail buyers and suppliers

4
Types of Novelty Cakes
  • Fillings
  • Jams
  • Raspberry
  • Strawberry
  • Plum Raspberry
  • Buttercreams
  • Plain
  • Chocolate
  • Flavoured
  • Sugarpaste
  • White
  • Coloured
  • Chocolate flavoured
  • Fruit flavoured
  • Fondants/Fudgeicing
  • Plain
  • Chocolate
  • Coloured/flavoured
  • Enrobed
  • Bases
  • Madeira
  • Plain
  • Chocolate
  • Flavoured
  • Chocolate
  • Plain Genoese
  • Sizes/shapes 5 9
  • Round, square, oval, cut-out shape, 3D

5
Types of Novelty Cakes cont.
  • Decorations
  • Milk chocolate edible
  • decorations
  • Printed sugar plaques
  • Chocolate plaques
  • Moulded/reliefed
  • Sugarpaste
  • Fudge paste
  • Marzipan
  • Candy
  • Icing/Piping
  • Confectionery
  • Chocolate Beans
  • Liquorice
  • Chocolate Buttons
  • Packaging
  • Internal
  • Ribbons Bows
  • Printed card collars
  • Cake boards
  • External
  • Acetates
  • Enclosed cartons
  • Window cartons
  • Retailers own
  • Labelling
  • Manufacturers Label
  • In-store bakery

6
Types of Christmas Cakes
  • Bases Standard or luxury
  • Fruit Sultanas, glace cherries, glace pineapple
    and other fruits
  • Nuts Walnuts, almonds, pecans, brazils (chopped
    or nibbed)
  • Decoration Mainly iced, beneath the icing is
    usually a layer of marzipan (almond paste) or a
    more economical version made from apricot kernel
    paste Cakes may be top-iced or all-over-iced
  • Decorations may be piped or moulded, and
    non-edible decorations added Some cakes, instead
    of being iced, have a topping of nuts and glace
    fruits
  • Dundee Cakes A fruit base with a decorative
    pattern of whole almonds baked into the
    top Traditionally Dundee cakes have a flavouring
    of marmalade
  • Genoa Cakes A fruit base with a high percentage
    of glace cherries

7
Costings/Consumer Testing
  • Costings
  • Costings are a key financial control that ensure
    the business remains profitable and competitive.
  • All our products are accurately costed by valuing
    the raw materials, packaging and direct labour
    used to manufacture the cake. These costings can
    then be used as a standard against which we can
    measure the performance of the factory and so
    identify and eliminate areas of inefficiency and
    waste.
  • An agreed profit margin is applied to this
    standard costing so that it becomes a tool to set
    selling prices and evaluate new business and
    investment.
  • Consumer Testing
  • Products are assessed by taste panels at various
    stages in their development
  • Informally in the factory at the experimental
    stage
  • By the customers before the product is approved
  • Sensory testing by market research agencies, on
    panels of children and adults, to gauge reaction
    to our own-label products
  • In the factory at intervals to determine the
    products shelf life and keeping qualities
  • Testing is designed to judge not simply taste,
    but texture, visual appeal, smell etc.

8
Ingredients/Packaging
Ingredients The majority of our novelty cakes are
suitable for vegetarians. We use the best
ingredients we can obtain, and conduct rigorous
assessments of our suppliers in order to ensure
that quality is maintained. We use as few
additives as possible, and declare them in
accordance with the Food Labelling
Regulations. Packaging The supermarkets who are
our main customers arrange the design of the
packaging, all of which has to accord with the
Food Safety Act of 1995 and with the Food
Labelling Regulations. Packaging must be sturdy
enough to withstand stacking and transportation.
Most novelty cakes are sold in window cartons,
which enable the cake to be seen by the
purchaser. Labels must carry a best before
date. This is determined by shelf life testing
during development.
9
Launch Procedures Production Process
  • Launch Procedures
  • Before a cake can be launched there must be a
  • Definite approval from the customer
  • At least one factory trial putting the cake
    through the full process in the factory, to
    determine where adjustments are necessary
  • Delivery of ingredients and packaging
  • A time-table for production and delivery into
    depot
  • Production Process
  • Production is planned 13 weeks in advance, but
    with the flexibility to change from week to week.
    The intention is generally to produce the
    largest volumes at the beginning of the week and
    taper off towards the end. This allows the
    capacity to respond to delays or problems.
  • Approximately 160 people will be involved in the
    manufacture of a single product. On the line,
    which takes a baked cake base through to the
    packing stage, a team of up to 57 people work.
  • There are three lines, one dedicated to chocolate
    cakes, plus specialised lines for the production
    of Viennese Whirls and Corn Crisp.
  • Cakes are made in two separate areas of the
    factory, one known as nutted and the other as
    nut free. This enables us to ensure that all
    cakes which do not contain nuts are produced in a
    strictly nut free environment, for the benefit of
    those consumers who are allergic to the slightest
    trace of nuts.
  • The following page shows a summary of the
  • production process

10
Process Flow Diagram Novelty Cake Manufacture
11
Product Quality (HACCP)
There are 13 quality critical control points
12
Food Safety (HACCP)
There are 10 safety critical control points
At each of these points, control procedures
specify control measures, critical limits,
monitoring procedures, corrective action, the
accountable person and the control documentation.
13
Step by Step Manufacturing Process
Weighing
All ingredients at this stage are weighed and
batch coded, this gives full traceability
throughout the manufacturing process.
Mixing
Bulk ingredients such as Flour, Sugar and Water
are weighed and added straight to the mixer, this
avoids heavy handling and speeds up mixing time.
Depositing
Cake batter is deposited to strict weight
tolerances, this ensures consistency in the
finished product. This automated process uses a
travelling conveyer which feeds into the oven.
14
Step by Step Manufacturing Process
Baking
We use travelling ovens, these have three zones
to give varying bake profiles. Bake times can
vary from 50 minutes to 2 ½ hours.
Cutting Creaming
The cake is cut into 2/3 layers. Jam and
buttercream are automatically deposited. Weight
checks are taken here to ensure product quality.
Sheeting
The filled cake travels under a sugarpaste
sheeter. The sugarpaste icing is hand moulded
and trimmed ready for decorating.
15
Step by Step Manufacturing Process
Component Placing
We make our own components. These are hand
placed to a specified design. All our decorating
team are trained to a high standard.
Ribbon Placing
For a finishing touch, we add a coloured ribbon
around the finished product.
The Finished Product
The finished products are checked against quality
standards, again this ensures the consumers are
satisfied with the finished products.
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