Low-Cost Process Interventions for Quality and Efficiency Improvement in Traditional Pita Bread Manufacturing

Abstract

Objective: This study aims to optimize the artisanal production of pita bread in a small-scale bakery in Córdoba, Veracruz, Mexico, with the dual goal of enhancing product quality—particularly organoleptic attributes—and improving the thermal efficiency of the baking oven, thereby contributing to sustainable food processing practices. 

Design/methodology/approach: A process engineering framework was applied to refine critical control points in dough preparation and baking. Key variables included fermentation time, kneading intensity, dough division, circular stretching, and high-temperature baking. Adjustments to formulation and processing parameters were evaluated for their impact on sensory properties. Oven design and thermal performance were also assessed. Blind sensory evaluations were conducted to validate improvements.

Results: Optimized fermentation and baking conditions yielded significant improvements in softness, moisture retention, and overall sensory acceptability. Enhanced oven performance contributed to greater consistency in bake quality and reduced batch-to-batch variability. The implementation of a standardized protocol improved operational efficiency and product uniformity, supporting the viability of artisanal methods within modernized frameworks.

Limitations on study/implications: While the study is confined to a single bakery, the methodological approach and findings are transferable to similar small-scale enterprises aiming to modernize traditional practices. The results underscore the potential for technology transfer and process standardization in preserving culinary heritage while advancing sustainability.

Findings/conclusions: Integrating process engineering with sensory analysis offers a robust strategy for improving artisanal pita bread production. This approach supports the development of resilient and sustainable food systems, particularly within small enterprises engaged in traditional food manufacturing.