Panko is Different Than Standard Bread Crumbs
Panko (Japanese-style bread crumbs) are made by taking the time to crush the bread.
As the main ingredient, high-quality bread is cooked to perfection at the hands of experienced master bakers every day
- in fact, we bake about 100,000 loaves daily.
Because our aim is to crush this bread to make panko products, it must be prepared in a certain way.
Manufacturing process
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- 1
- Flour Storage Tank
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- 2
- MixerMixing
Ingredients are loaded and kneaded well to complete the gluten, which provides the fibrous framework that makes the production of soft and fluffy bread possible.
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- 3
- Fermentation Room No.1Initial Fermentation
After the dough has been thoroughly kneaded, it is allowed to sit and ferment. It expands two- or threefold after sitting for about 60 minutes.
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- 4
- DividerDividing of Dough
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- 5
- ProoferIntermediate Fermentation
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- 6
- MolderGas Removal
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- 7
- PanningMolding
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- 8
- Final ProoferFinal Fermentation
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- 9
- OvenBaking
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- 10
- Mold-removal EquipmentRemoval from Molds
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- 11
- Vacuum CoolerCooling
Vacuum Cooler
Freshly baked bread is removed from the mold and cooled immediately. Vacuum-cooling makes it possible to cool bread from its core in a short time, preventing condensation, the invasion of bacteria and other potential problems after the bread is moved to storage.
Dried Panko Production Line
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- 12
- Storage FacilitiesStorage and Aging
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- 13
- GrinderGrinding
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- 14
- DryerDrying
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- 15
- Measurement and
Packing EquipmentMeasurement and
Packaging
Undried (Fresh) Panko Line
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- 12
- Storage FacilitiesStorage and Aging
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- 13
- GrinderGrinding
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- 14
- Measurement and
Packing EquipmentMeasurement and
Packaging
Manufacturing process
01Preparation of the dough
In general, dough preparation methods can be divided into two types. The first type, known as direct mixing, involves mixing of the main ingredients with water all at once. The second method, known as the sponge and dough method, involves first mixing about 70% of the flour, yeast and so forth (base ingredients) to make the sponge and, after this portion has fermented, mixing it with the remaining ingredients.
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Direct mixing method
This method creates flavorful panko that preserves the original bread’s taste. FryStar utilize this mixing method.
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Sponge and dough method
This method results in soft-textured panko, but its color fades slightly when deep-fried in oil.
02Baking to aromatic perfection
Bread-baking methods can be roughly divided into the following two types. The first type, known as the roasting method, involves roasting fermented bread dough in an oven and then crushing it to make panko. The second type, the electrode-cooking method, involves placing the fermented bread dough between electrode plates and baking it by passing an electrical current through, followed by crushing to make the final panko product.
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Roasting method
This method results in soft, flavorful panko with strong aromatic properties. FryStar utilizes this baking method.
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Electrode-cooking method
This method weakens the bread’s taste somewhat and results in panko that hardens when deep-fried. It is characterized by its white-colored panko.