Optimization of Lamination Process for

Consistent Flakiness in Croissants

Final submission for the degree of
MASTER OF FOOD TECHNOLOGY

Submitted To-
Department of Food Technology
ITM university, Gwalior

Supervisor Submitted by:

ER. Akshay Singh Sengar SURBHI GIRI
Assistant Professor Food Technology MSFN1FT23006
ITM University, Gwalior ITM university Gwalior.

1
 Outline

• Introduction
• Objective
• Review of literature
• Materials & Methods
• Result & Discussion
• Conclusion
• References

2
 Introduction
• The croissant is a globally cherished pastry, renowned for its delicate, flaky layers
(Wickramarachchi et al., 2015).
• Achieving this signature texture requires a deep understanding of the intricate
lamination process, which is fundamental to the croissant's structure (Patient,
1994).
• The success of lamination is highly dependent on the precise control of variables,
especially the temperature and rheological properties of the butter.
– If the butter is too warm, it merges with the dough, leading to a greasy, dense
product.
– If it is too cold, it becomes brittle and shatters the delicate layers (Ghotra, B.
S., et al., 2002).
• Even minor inconsistencies can lead to common defects such as butter leakage
and uneven texture, making consistent, high-quality production a significant
challenge for bakers.

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• The complexity of this process underscores the need for a systematic, scientific
approach to optimize the critical parameters (Sluimer, P., 2005).
• This research focuses on optimizing the lamination process by investigating the
precise impact of butter temperature and thickness to establish a standardized
method for producing croissants with consistently superior flakiness and overall
quality.

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 Objective

• Determine the ideal butter temperature and thickness for lamination.

• Measure how these factors impact layer formation (flakiness).
• Identify the best sensory qualities (taste, texture).
• Create a standardized lamination method for production.

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 Review of literature
Sr. No. Author(s) Key Finding
1. Wickramarachc The croissant is celebrated for its unique flaky layers, which are
hi et al., 2015 achieved through a precise lamination process.

2. Patient, 1994 Achieving ideal croissant quality demands extensive knowledge of

the intricate lamination process.

3. Ghotra, B. S., et Butter's properties and precise temperature control during

al., 2002 lamination are critical for creating distinct flaky layers and avoiding
common defects like greasiness.

4. BAKERpedia, The fundamental lamination technique involves repeatedly folding

n.d. and sheeting dough around a butter block to build its multi-layered
structure.

5. Sluimer, P., The complexity of achieving consistent results underscores the need
2005 for a scientific approach to optimize lamination parameters.

6. Horra et al., The development of a good croissant structure depends on the

2015 ability of the dough layers to remain discrete and separate from the
fat layers during lamination and baking.

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 Materials and methods

Dry Ingredients
• All raw materials were sourced and stored as per the Product Technical
Dossier.
• Refined Flour: An in-house material, stored at ambient temperature.
• Hard Flour: Procured from Allana, stored at ambient temperature.
• Castor Sugar: Procured from Mavana, stored at ambient temperature.
• Salt: Procured from TATA, stored at ambient temperature.
• Compressed Yeast: Procured from Prestige, stored at ambient
temperature.
• Bread Improver: Procured from Kerry, stored at ambient temperature.
• Gluten: Procured from Pioneer Industries, stored at ambient temperature.

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Wet Ingredients & Fats
• Water: An in-house material, maintained at 1−4∘C before use.
• Butter (Unsalted, for dough):
– Purchased from Amul/Shudh Garwal.
– Stored at 1−4∘C and brought to 12±2∘C for use.
• Butter (Unsalted, for Lamination):
– Purchased from Amul/Shudh Garwal.
– Kept at 1−4∘C, with specific temperatures used for sheeting and
lamination.
• Milk (for Spraying):
– Obtained from Nandini and kept chilled until use.

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 Equipments
• Weighing Balances (100 kg & 5 kg): Used for accurately measuring all raw
ingredients.
• Planetary Mixer: For combining ingredients and developing the dough's gluten
structure.
• Vibro Sifter (20 & 40 mesh): To sieve flours and dry ingredients, ensuring a
fine, uniform texture.
• Dough Sheeter: For rolling dough and butter to precise, uniform thicknesses
during lamination.
• Rotary Oven: Provided even baking with consistent heat circulation for a
golden-brown finish.
• Blast Freezer (-30°C): Used to rapidly cool the dough, maintaining butter
integrity between folds.

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 PROCESS FLOW CHART

Croissant Making process is divided into 2

parts:
1. Dough making & lamination
2. Sheeting, shaping, proofing & baking

CCP-1
Step 1: Collect all the ingredients (1 to 9) and Passing
weight separately. Sieve refined flour and hard through sifter
flour – sieve size to be 40 mesh for dry powder - chances of
physical
ingredient contamination

Cube Butter as
Step 2: Add all the ingredients (except water and shown in the
picture (only
butter) in the spiral mixer. Yeast should not come in the dough
direct contact with salt or sugar. butter) - keep
it separate

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 Step 3: 1st Mixing:
Mix all the dry ingredients at slow speed for 1
minute.

Step 4: 2nd Mixing:

Add water (1-4 °C) and mix at slow speed for 1
minute and then for 5 minutes at fast speed.

Chef's NOTE
Step 5: 3rd Mixing: Dough should
the dough is roughly mixed temp 20±1℃ NOT be
thoroughly mixed.
add in the butter cubes (Refer Step 2) and knead for Should be kneaded
80% only.
another 4 min at fast speed. Butter temp to be 20±2℃.

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 Step 6:
Remove dough from the dough machine and place
it onto the working table. Dough temperature to be
under 20℃. Portion 5 doughs of 3400 gm each.

Chef's NOTE
Step 7: All the doughs
Sheet the doughs in a Rough rectangular shape by should reach the
blast freezer within
sheeting it till 9mm on the dough sheeter. 5 minutes of
coming out of the
dough mixer.

Step 8:
Cover the doughs with poly bag and put them in the
blast freezer (−30℃) for around 40-45 min.

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 Step 9: Butter Sheeting
Make sheets of butter (for lamination) by sheeting butter in
between 2 poly bags or in a plastic bag.
Make sure of the following:
1. Butter temperature while slicing −10±2℃
2. Butter Sheet size −12×8 Inches ±1℃ inch on both sides
3. Butter Sheet thickness −12 mm ±1 mm
4. Butter Sheet holding temp −1−4℃ for 30 to 60 mins
5. Butter Sheet temp while lamination −10℃±2℃

Step 10: Dough Lamination

Sheet the chilled dough from the blast freezer to
11mm ± 2mm.

Dough sheet temp : −5℃±2℃

Step 11: Place butter sheet in the center of the dough

sheet and lock butter inside the dough by overlapping
the dough onto the butter sheet from all the sides.
Butter sheet temp : 10℃±2℃
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 Step 12:
Sheet the dough on the dough sheeter from 40 mm and take it up
to 9mm.

Step 13: 1st Plain Fold

Give 1st fold to the dough by over lapping the dough from both
the sides onto the center. It will show 3 layers of dough from the
side. And sheet it again until 9 mm.

Chef's NOTE
Step 14: 2nd & 3rd Plain Fold
Follow the same process for 2nd fold and after giving the third fold, Dough should be
properly covered
sheet the dough until 21mm only (unlike at 9mm during 1st and 2nd with plastic sheet
folds). from all the sides (to
make sure no ice
formation will occur
Laminated Sheet Temp after 3 folds: Below 12℃ . in Blast Freezer)

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 Step 15:
Blast freeze the laminated dough for 45±5 mins and
then transfer the dough to freezer ( −18℃ ) for at least
8 hours or more.

Step 16: After Resting the laminated dough in deep freezer (−18℃),
keep it for thawing in chiller (1−4℃) for around 3 Hours or until the
dough temperature is between −4 to 8℃ (dough should not be too
hard or too soft to touch).
Dough Sheet Temp: −4 to 8℃.

Chef's NOTE
Step 17: Sheeting and Shaping
For Croissant shaping, roll the laminated dough to the thickness of Use dry refined
3.5 mm on the dough sheeter and cut triangles flour for dusting
during sheeting,
making sure that
of 10.5 * 4.5 Inches (L*B) approx. Croissant to weight 85 ± 5 gm. the dough is not
Dough will yield around 215 ± 10 croissants. over dusted.

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 Step 17:
Stretch the triangle properly vertically to 13 ± 2
inches (approximately).

Step 18:
With soft hands, start rolling from the broader side
towards the tip, do it for all the croissants and give
a crescent shape .

Step 17:
Place shaped croissants on a baking tray not very
close to each other .

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 Step 18: Put the trolley full of croissants inside the Chef's NOTE
proofing chamber for 50 ± 20mins at: Keep a check
for Croissants
Humidity: 70% not to go Over
Temperature: 80 ± 5℃ Proof

Step 19: Preheat the oven at 220℃

and take milk wash into spray bottle. Once the
Croissants are doubled in size, spray milk wash and
bake them in a pre-heated oven at 200℃ for 14 ± 1
minute. Before baking give it a steam of 20 seconds.

Step 20: After baking, let the croissants cool down

at ambient temperature, for 60 mins ± 20 mins.

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 Step 21:
Packaging, Labelling & Batch coding.

Step 22:
Pass through a metal detector.

Step 23:
Transfer the packed croissants to the Blast Freezer
at -18℃ and store.

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 Experimental Design
We tested 3 butter temperatures and 3 thicknesses in a controlled
experiment. The factors and their corresponding levels are outlined
below:

Factor Levels Tested

Butter Temperature 8°C, 10°C, 12°C (±2°C)

Butter Thickness 11mm, 12mm, 13mm (±1mm)

Total batches = 9 (3 Temperatures × 3 Thicknesses)

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 Measuring Result
To quantitatively and qualitatively assess the quality of the croissants from each
experimental batch, the following methods were used:

1. Flakiness (Layers/mm)
• This was the primary physical measurement used to assess the success of the
lamination.
• Method: Cooled croissants were sliced vertically, and the number of distinct
layers were counted within a defined 10mm section of the internal crumb.
2. Sensory Testing
• Organoleptic characteristics were evaluated to determine consumer
preference.
• Method: A 10-member trained panel rated samples on a 5-point scale for key
attributes including flakiness, butteriness, texture, and overall acceptability.

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3. Defect Tracking
• A systematic visual inspection was performed to identify common lamination
failures.
• Method: Croissants were monitored during proofing and baking for butter
leakage and visually assessed after baking for uneven layering, dense spots,
and surface greasiness.
4. Moisture & Ash Content Analysis
• Physicochemical properties were determined to understand the final product
composition.
• Method: Moisture content was measured using the standard oven-drying
method, and ash content was determined using the dry ashing method in a
muffle furnace.
5. Final Good Analysis
• Physical dimensions of the optimized croissants were measured against quality
benchmarks.
• Method: The final weight, length, width, and height of the best-performing
samples were recorded to check for consistency and conformance to target
specifications.

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 Result

1. Flakiness Analysis & Key Sample Screening

• Initial screening of the 9 samples revealed that 6 had significant defects (e.g., poor
layering, dense texture) and were considered undesirable.
• Three promising samples (S1, S5, S9) were selected for detailed analysis.
• Sample S5, prepared with butter at 10°C and a thickness of 12mm, demonstrated
significantly higher flakiness.

Sample Temperature (°C) Thickness (mm) Layers/mm

S1 8 11 1.2
S5 10 12 5.5
S9 12 13 2.1

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2. Sensory Evaluation
• The three promising samples were presented to a 10-member panel for
sensory evaluation.
• Sample B (S5), representing the 10°C / 12mm parameters, received the
highest sensory scores for overall acceptability.

Sample Code Temperature/Thickness Sensory Score (1-5)

A 8°C / 11mm 3.8
B 10°C / 12mm 4.6
C 12°C / 13mm 2.3

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Sensory Evaluation Graph

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3. Defect & Physicochemical Analysis
• Butter Leakage: Leakage was observed in Sample S9 (12°C butter),
indicating fat instability at higher temperatures. No leakage was observed
in the optimized S5 sample.
• Moisture Content: The optimized Sample S5 (10°C / 12mm) exhibited
the lowest moisture content (10.8 ± 0.3%), contributing to a desirable crisp
texture.
4. Final Product Analysis
• The final optimized croissant (Sample S5) was analyzed and met all pre-
defined target specifications for weight (77-87g), length (16-19cm), width
(9-12cm), and height (5.5-6.5cm), confirming product consistency.

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 Defect Analysis
1. Methodology
• A systematic visual inspection was performed during processing, baking, and
final analysis to identify and record key defects typical of inefficient
lamination.
• Defects Monitored:
• Butter Leakage: The amount of fat loss during proofing and baking was
qualitatively assessed (e.g., no leakage, mild oiling, pooling).
• Uneven Layers: The internal crumb structure was observed for uniformity,
layer distinctness, and signs of compressed or doughy layers.
• Dense Spots: The internal crumb was inspected visually and by touch for any
dense, under-baked spots resulting from poor layer separation or fat smearing.

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2. Key Observations
• Overall Defect Rate: Of the 9 initial experimental samples, 6 showed
significant defects and were deemed undesirable for further analysis.
• Butter Leakage in Promising Samples: Butter leakage was a key
differentiator between the promising samples, directly linked to the
butter's temperature.

Sample Temperature (°C) Thickness (mm) Butter Leakage

Observed
S1 8 11 NO
S5 10 12 NO
S9 12 13 YES

• Interpretation: The observation of butter leakage in Sample S9

(12°C) confirms that higher butter temperatures lead to fat instability
and loss during baking, compromising the final product.

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 Butter Leakage Analysis
• During the proofing and baking stages, the different croissant samples were
observed for butter leakage. Here's what was found for key samples:
• Sample S1 (prepared with butter at 8∘C and 11mm thickness) showed No
Leakage.
• Sample S5 (prepared with butter at 10∘C and 12mm thickness) also showed
No Leakage.
• Sample S9 (prepared with butter at 12∘C and 13mm thickness) exhibited Yes,
Leakage Observed.

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 Moisture Content Analysis

• The moisture content of the baked croissants was analyzed to understand the
impact of different lamination parameters. The findings for key samples are
presented below:
• Sample S5, prepared with butter at 10∘C and 12mm thickness, exhibited the
lowest moisture content (0.8±0.3%).
• This suggests that the optimized lamination conditions in Sample S5 likely
resulted in more effective water evaporation and a crisper texture, which is
often associated with lower moisture.

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 Final Product Analysis
Following the identification of optimal lamination parameters (10°C butter,
12mm thickness), the sensory-preferred sample (Sample S5) underwent a final
analysis to ensure it met pre-defined quality benchmarks. This involved
measuring key physical attributes to confirm product consistency.

The results for two separate batches (Sheet 1 and Sheet 2) of the optimized
croissant were as follows:
Physical Target Specification Result (Sheet 1) Result (Sheet 2) Met
attribute Specification

Weight (g) 77 - 87 78 82 yes

Length 16 - 19 17 18 yes
(cm)

Width (cm) 9 - 12 10 12 yes

Height 5.5 - 6.5 6 6 yes

(cm)

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 Discussion
• The results confirm that the final quality of a croissant is fundamentally
dependent on the precise control of butter temperature and thickness during the
lamination process.
• The optimal butter temperature of 10°C was critical for maintaining ideal fat
plasticity. This ensured the butter was firm enough to create distinct layers, yet
malleable enough to prevent fracturing, which avoided defects like butter
leakage and poor flakiness.
• The optimal butter thickness of 12mm provided the necessary structural
integrity. This allowed the dough to effectively entrap steam during baking,
which is essential for creating the light, open honeycomb crumb structure
characteristic of a high-quality croissant.
• By controlling these two key variables, the complex physicochemical events of
baking occur in a coordinated manner, leading to the consistent production of a
superior final product with ideal volume, texture, and sensory attributes.

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 Conclusion
This research successfully identified and optimized key parameters for the
croissant lamination process, aiming for consistent flakiness and quality. The
most favorable results, which significantly enhanced flakiness and sensory
attributes, were achieved with a butter temperature of 10∘C and a butter
thickness of 12mm. Departing from these optimal conditions, such as through
higher or lower butter temperatures or different thicknesses, led to observable
defects and a decrease in product quality. Therefore, practical takeaways from
this study include the crucial need for precise temperature control of both butter
and dough, consistency in butter preparation, and detailed documentation of all
process parameters. These suggestions collectively offer a valuable structure for
industry standards in croissant production, with a focus on ensuring consistent
quality and meeting consumer expectations. Ultimately, this study enhances the
understanding of crucial factors in croissant lamination and provides actionable
steps to improve production efficiency and the final product.

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 References
•BAKERpedia. (n.d.). Dough Lamination.
•Ghotra, B. S., Dyal, S. D., & Narine, S. S. (2002). Lipid determinants of butter
functionality. Food Research International, 35(10), 1035-1042.
•Horra, A., Steffolani, M. E., Barrera, G. N., et al. (2015). Yeast-Leavened
Laminated Salty Baked Goods.... Food Technology and Biotechnology, 53(4),
447-456.
•Patient, D. (1994). Professional Pastry Chef: Techniques and Inspiration for the
Modern Professional. Van Nostrand Reinhold.
•Renzetti, S., Harder, R. de, & Jürgens, A. (2015). Puff pastry with low
saturated fat contents.... Journal of Food Engineering, 170, 24-32.
•Sluimer, P. (2005). Principles of Bread Technology. AACC International.
•Wickramarachchi, K. S., Sissons, M., & Cauvain, S. P. (2015). Puff pastry and
trends in fat reduction: an update. International Journal of Food Science &
Technology, 50(5), 1065-1075.

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THANK YOU

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