Oriented on making people closer

Altyn ASHYROVA

Due to the development of non-state sector of the economy of Turkmenistan, private companies of various types are opening every day. Talhan bakery under Gül Zaman House of Fashion and Flowers is joined the ranks a year and half ago. Today, it is a well-known bakery and confectionery shop in Ashgabat.

Scientists have long found that the aroma of freshly-baked bread can trigger a more positive mood along with pleasant emotions. There is something warm in this smell ... That is why ORIENT could not pass by Talhan bakery, a wonderful aroma of which lured us to get in and learn how it works. Technologist Hasiyat Bayramova was pleased to make a tour for us. But details of shop excursion a bit later…

Talhan Bakery is controlled-access enterprise. There are two shifts: during the daytime, confectioners work mainly; there is a magic in the confectioner's shop with aroma of chocolate and powder as well as glitter of mastic paste and glaze. Bakers work on the night shift, so that in the morning customers can enjoy the taste of warm, freshly-baked bread.

In accordance with European standards, the bakery starts ... from adjacent territories. The site where the company locates is delighting the eye with the green, well-kept flowerbeds and clean paths.

At the entrance of the bakery, there is a security guard. Visitors are welcome here, but they have to pass through several levels of sanitary protection. The first, all those who come to the bakery should go to the dressing rooms: women and men. All workers should wear special outfits: disposable shoe covers, trousers and jacket, apron, removable shoes, caps, and should take off jewelry and accessories. Shoe covers, caps and robes are given to visitors also (robes with snap fasteners, so that a button not come into one of the products accidentally). The requirements for safety and sanitation in the bakery are comparable to the intensive care units.

The next control point is the sanitary inspection room. The special apparatus looks rather formidable, but it performs a very important function – it cleans the shoes and hands of the workers and visitors of the bakery from any possible microbes. It is impossible to deceive the machine: getting on the platform for cleaning shoes, each user arrives at the turnstile, which will not let it go until the visitor puts his hands into special holes and receives the dose of disinfectant solution in his palms. As soon as the solution is on the hands, the green arrow lights up. On the other side of the turnstile, all those who come should wear rubber gloves and disposable masks, and then they can start the work. Or start a bakery tour.

It should need to mention that almost sterile cleanliness both inside and outside the bakery. All surfaces of up-to-date equipment of famous MIWE Michael Wenz Gmb" and DIOSNA Dierks & Söhne GmbH (Germany), Mac.Pan (Italy), Glimek (Sweden), RONDO (Switzerland) and Varimixer (Denmark) are spick and span. The equipment looks like a mirror.

“Our bakery can be compared to an elite car,” Ilya Tributsky, Deputy Director General of Gül Zaman says. “All equipment is state-of-the-art and top quality, like our products.”

Hasiyat Bayramova leads us along a unidirectional production process. It is one of the main requirements of HRAs – the European standard for bakery and confectionery shops. Raw materials and pastries should not come together, and the whole process should go smoothly from start to finish.

Conveyor production begins with a flour warehouse. Before using the flour, it is necessary to sift through Mac.Pan flour-sifter, where the flour is saturated with oxygen and all impurities are removed. Then the flour is weighed and measured into the bowl – a special container on the wheels, in which the flour from the warehouse is transported to the main shop.

There, pressed yeast that is pre-weighed on an electronic scale according to the recipe for each type of bread is added to the flour. Table salt, margarine and baking improving agents are also added according to the recipe.

Each type of bread has its own cooking recipe. French baguette, Italian ciabatta, Turkish simit, Turkmen chorek – each bread is unique and inimitable in its taste. Bread improving agents are a ready-made high-quality mixture of ingredients designed for baking a certain type of bread. Talhan has 48 different breads that produced now! And the company intends to expand the assortment of breads.

When ingredients are weighed and mixed, the bowl is rolled under DIOSNA dough kneader. Water for kneading dough comes automatically from Glimek water mixer. The operator needs only to enter data on required quantity and temperature, which are also given in the recipe. The machine itself will do the rest. Then, the dough kneader is switched on. The dough for each type of bread is kneaded at certain speed and for a certain time.

Next, the dough is divided into pieces. Each piece is weighed and, in accordance with the standard, is sent to the rounder, and then to Glimek dough forming machine. The machine gives to the dough the shape of the necessary product: baguette, burger bun or long loaf.

The ready kneaded dough is laid out in transparent boxes pre-lubricated with vegetable oil, as well as is covered and sent to an industrial MIWE unit for rising. There, the dough rises at a certain temperature and humidity. The timer is installed on each rising unit. On an average, up to 5 trolleys with molded dough are placed in such unit, and each trolley may have a different type of bread. The unit allows to set up to 5 different timers. The timer sounds such aloud, so it can be heared in every corner of the workshop. Senior baker Ovliyakuli Ovezberdiyev responds with jokes to another loud alert from the smart unit: “I'm coming, dear, I'm coming! ...”

The dough that has risen is took out to complete design. Baguettes are notched with a special knife to get the classic diagonal stripes; buns are sprinkled with various powders. Some types of baking are returned back to the unit for final rising. Others are neatly shifted to a baking tray covered with parchment sheet, and sent to the oven.

The smell of freshly-baked bread near MIWE Roll-in e+ rotary ovens is wrapping around, so you don’t want to go somewhere further. Of course, it is very nice to watch how whitish pieces of dough turn into toasted bread. Bakery employees have become accustomed to the fact that guests sometimes freeze at the ovens. It is impossible to get a burn – the oven is isolated and is not heat up outside, no matter how hot inside. Therefore, the visitors are out of danger. Besides, they do not interfere with the process – the ovens are conveniently located at the very end of the production conveyor, and there is a small space for visitors next to them.

Before “getting dressed” in the Talhan branded packaging, baking is cooled in clean, well-ventilated expedition rooms for 1-2 hours. Then the workers of the packaging workshop carefully wrap and label products, pack them in special containers up to type and transport them to the shipping workshop. There, products are sorted in accordance with the orders submitted and loaded into cars that deliver warm and delicious pastries to points of sale.

“Every day we receive an order for a certain number of products from shops, restaurants and private buyers. We calculate the required amount of raw materials for production and, based on these data, do our work. There is no extra-production, it is waste-free, nothing is thrown away. Products that are not sold in stores within 72 hours are returned back. We use them to make crackers and breading. The waste of the confectionery is used as the basis for experiments. Recently, our pastry chefs have developed their own recipe for potato pastry, where the rests of biscuits from the cakes is used. It was very tasty. So it turns out that we have no waste products, everything is used to bake something. Moreover, we can increase production volumes, remaining this principle,” Hasiyat Bayramova says, treating us with tea with tasty oatmeal cookies and amazing éclairs.

There is something unique. Talhan bakery has its microbiological and physic-chemical laboratory. Every day, two bakery products of each type are produced extra to the quantity requested by the purchasers. These “two extra” are checked in laboratories for compliance with all nesessary quality standards. This is how high production criteria and concern for the health of consumers are maintained.

Thanks to the ever-growing trust and demand, Talhan plans to open its own bistros, where both skylarks, who are rushing to work in the morning, and nighthawks, who start the day late, can have a cup of wake-up coffee or tea and enjoy delicious pastries.

“We keep learning and improving. In addition, we are in searching for something new to satisfy any our customer’s wishes,” bakery workers say.

Having looked at the list of 48 bread products, it is hard to believe that one can wish something else. Rye bread, toast bread, classic ciabatta, with cheese, with olives, dairy bread, bread of 11 cereals, donuts, croissants, simits, more than 5 types of buns ... and one project more is underway.

It would be hard to hold out against this magic of tastes. So, subscribe for gym cards and bicycles, so you stop to worry about each eaten bun. ORIENT wishes you a Bon Appetite!

[video poster="https://cdn.orient.tm/storage/app/media/ru/2018/10/Ch.jpg" width="854" height="480" mp4="https://cdn.orient.tm/storage/app/media/ru/2018/10/Gul_Zaman_выпечка_WEB.mp4"][/video]