How is Flour Made?

How is Flour Made?

Flour is a fundamental ingredient in many foods, yet many are unaware of its origins and production process. Understanding how flour is made enhances our appreciation for this staple product.

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Understanding Wheat Types

Wheat comes in six primary classes, comprising approximately 30,000 varieties:

• Hard Red Winter
• Hard Red Spring
• Hard White Winter
• Durum
• Soft White Winter
• Soft White Spring

The first four classes are popular choices among bread bakers due to their higher protein content, while softer varieties suit pastries, as they require less gluten formation.

In the United States, wheat is cultivated over 54 million acres, thriving in diverse climates.

The Flour Milling Process

After wheat is harvested, it undergoes a sweating process lasting six weeks, which enhances the quality of the milling grain by reducing its moisture content from around 17-18% to approximately 13-14%.

Quality control follows, eliminating foreign matter before the wheat is tempered with chlorinated water to mitigate microbial growth and facilitate grain separation. Tempering typically lasts about six hours in the U.S., while traditional European methods can extend this to 24-48 hours.

Once tempered, the wheat is ready for milling, where the extent of milling influences the yield of flour. For example, from 100 pounds of grain, approximately 75 pounds of flour can be obtained, with the bran and germ often repurposed for animal feed. Whole wheat flour, on the other hand, utilizes 100% of the grain’s components.

Various Milling Machine Types

• Stone Mills: Characterized by two large stones, this age-old method preserves the nutritional quality of grains while grinding them into powder.
• Hammer Mills: These machines employ metal hammers that shatter the grain into fine pieces, allowing for ultra-fine flour production.
• Roller Mills: Utilized broadly by the flour milling industry, two revolving steel rollers pulverize and separate the grain components effectively.

Regardless of the milling process, all types of mills often add some bran and wheat germ back into the white flour to make whole wheat flour. It's essential to note that the bran and germ might be milled to smaller sizes afterward, sometimes diminishing the flour's nutritional value.

Flour Freshness Advantages

Choosing to mill your flour can greatly enhance flavor and freshness. According to Simon Bowden, head baker at Leaven & Co., numerous factors must be considered when opting for freshly milled flour:

1. Flavor
2. Nutrition
3. Choice and provenance
4. Storage
5. Equipment
6. Percentages used
7. Mixing and proofing considerations

Freshly milled flour boasts a more complex and robust flavor profile, rivaling that of freshly ground coffee beans. Early experiences with fresh milling often reveal a surprising and delightful aroma that elevates baked goods.

Storage Benefits

Storing whole wheat berries offers a longer shelf-life compared to commercial flour. When stored correctly, they can last for years, whereas store-bought flour has limited longevity due to the perishable components of bran and germ.

Choosing Your Milling Equipment

Many milling machines, like the flour roller mill, cater to different production scales. Initial investments in elegant small batch equipment can begin around $200, while industrial mills designed for larger operations are priced significantly higher.

To dive deeper into the intricacies of flour production, consider exploring the operations at a Wheat Flour Processing Plant.

In conclusion, the flour-making process involves a blend of agricultural knowledge and milling technology, underscoring its significance in the culinary world.