The Gardenia production and sales teams work throughout the night to ensure that only the freshest bread reaches you. Nothing is rushed. The entire process takes 8 hours to complete.
How We Made Our Bread
Gardenia uses the traditional
American Sponge and Dough bread-making method
to bake you that soft-textured loaf with a tender crust and distinct taste. This unique method ensures that Gardenia's bread stays fresh longer and tastes so good you can even eat it on its own.
1. Automatic blending
The production process begins with a computerized blending of the exact amount of quality ingredients needed. This helps to ensure equal goodness in every loaf.
2. Production of sponge mix
The specially formulated Gardenia enriched flour, purified water, yeast, vitamins and minerals are added together to form the sponge which is released into a trough.
4. Production of dough mix
At this stage, the sponge is mixed again with other ingredients to form the dough. Depending on the type of bread to be baked, these can include skimmed milk powder, vegetable shortening, wheatgerm, bran, malt or honey.
3. Fermentation room
The sponge dough is then kept in a fermentation room, under controlled temperature and humidity for four hours, so that carbon dioxide is released, and the sponge can rise. This fermentation process helps the sponge to develop a unique Gardenia bread texture, aroma and taste.
The dough is then divided into the required weight for each loaf and conveyed to a rounder.
At the rounder, each piece of dough is kneaded so that carbon dioxide is trapped and the bread can develop a soft texture when it is baked.
8. Intermediate proofer
The dough is then left to rest in the intermediate proofer for 10 minutes before being moulded and placed into the baking pans.
The dough pieces then go through the checkweigher. Here, pieces that are over or under the required weight are automatically rejected.
Here, the dough is shaped according to the desired configuration and then automatically placed into the pans.
10. Automatic lidder
The pans are lidded automatically to give the bread its uniform rectangular shape.
12. Tunnel oven
Here, Gardenia breads are baked for about 20 minutes at a temperature of approximately 200 degrees Celsius in the state-of-the-art tunnel oven.
11. Final proofer
At this final proofer stage, the yeast is allowed to rise further under controlled temperature and humidity. Once the dough has risen to the desired height, it is finally ready for baking.
13. Automatic delidder and depanner
Hot from the oven, the freshly baked loaves are then removed by vacuum suction before being conveyed to a bread cooler.
14. Bread cooler
This bread cooler can hold up to 8000 loaves of bread per hour. The freshly baked and hot bread loaves need to be kept in the cooler for about an hour until slightly above room temperature before it is ready for packing.
16. Daily delivery
In the early hours of the morning when most people are still asleep at about 3am, Gardenia begins preparation for its daily deliveries, 364 days a year. The freshly baked breads are stacked into the Gardenia’s fleet of delivery trucks seven days a week, come rain or shine and delivered to some 3000 retail outlets throughout Singapore.
15. Automatic slicer and bagger
When the loaves are sufficiently cooled, it is then ready to be sliced, wrapped and made convenient for consumption in attractive Gardenia packaging mechanically sealed with kwik-loks tags that are printed with the use-by dates.
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