#flour test

The Falling Number (FN) test is one of the most widely used analyses to indirectly evaluate alpha-amylase activity in cereal and flour quality control processes. This method aims to measure the change in viscosity caused by the liquefaction of the gelatinized structure of a flour–water suspension under specific temperature conditions, depending on the rate at which alpha-amylase activity breaks down the gel structure.

Despite its simple principle, the Falling Number test has become a widely accepted reference measurement method in both academic and commercial environments worldwide. The main reason for this is that the test can rapidly and reproducibly determine sprouting damage and the related enzymatic deterioration levels and integrate these results directly into industrial decision-making processes.

A low Falling Number value generally indicates increased alpha-amylase activity and the associated starch degradation, whereas high values indicate low enzyme activity and a more stable starch structure. In this context, Falling Number analysis has evolved from being merely a laboratory measurement into an important decision-making parameter for flour mills, grain storage facilities, and grain trading organizations.

It also creates a common language that enables reliable quality classification of wheat batches coming from different production regions. The Falling Number test is considered one of the most effective methods to meet this need.

Today, standardized test protocols developed by the International Association for Cereal Science and Technology and other institutions play a key role in ensuring the international acceptance of the Falling Number test. These standards ensure that analysis conditions (such as sample moisture, temperature, mixing time, and measurement duration) are applied uniformly in all laboratories, thereby increasing the comparability of results.

Thus, the Falling Number value is not only a local quality parameter but also a common reference criterion in the quality evaluation of wheat originating from different countries.

However, it is well known that the Falling Number test alone does not explain all quality parameters; rather, it is a strong indicator for determining alpha-amylase activity and sprouting damage. Literature suggests that evaluating Falling Number results together with dough rheology tests such as the Farinograph Test and the Alveograph Test can provide a more comprehensive quality analysis.

Nevertheless, due to its rapid application, low cost, and industrial practicality, the Falling Number test is particularly useful in routine quality control analyses. Ultimately, this analysis indirectly measures the alpha-amylase activity, starch integrity, and biochemical stability of wheat, thereby supporting production safety in the flour-based food industry. It also enables early detection of field-originated quality losses, such as pre-harvest sprouting, ensuring quality continuity throughout the chain from producer to consumer.

Why Is the ICC 189 Standard Important?

Establishing a common language for analytical results used in trade worldwide is crucial. The ICC 189 standard test is an international protocol developed to eliminate such complexities and ensure a unified system of interpretation.

This standard uses an amperometric method and provides both microscopic measurement precision and macro-level economic impact.

The method study titled “Estimation of Alpha-Amylase Activity Level Based on Viscosity in Determining the Falling Number Using the Bastak Instruments FNCheq Device” was accepted in 2021 by the International Association for Cereal Science and Technology as ICC Draft Standard No. 189 and presented for global use.

For the grain industry, the accuracy of data is important, but its international validity is equally strategic. The Bastak Falling Number 5100 is the first and only registered device worldwide certified to comply with the ICC Draft Standard No.189 criteria.

One of the major benefits of this certification is that analysis results are automatically corrected according to ICC standards. This correction mechanism allows raw materials from different locations to be interpreted within the same scientific framework used in academic literature and international grain markets.

The technological infrastructure emphasized by ICC 189 almost eliminates errors in defining alpha-amylase activity and positions the device as a reliable assistant even under challenging geographical conditions. In particular, it automatically compensates for differences that may occur in tests conducted in regions with unfavorable altitudes.

As a result, using the Bastak 5100 transforms your operation from a local producer into a technology partner that both follows and contributes to global standards.

APPLICATION AREAS OF THE DEVICE

With more than 20,000 devices operating worldwide, Bastak devices are used in flour mills, bakeries, pasta and biscuit production plants, cereal industry laboratories, universities, and research institutions.

Within a maximum of 10 minutes, the device can determine malt enzyme or commercial alpha-amylase enzyme activity in samples such as:

commercial wheat flour

whole wheat flour

durum wheat flour

bulgur

vital gluten

vermicelli

semolina

Figure 1. Application Areas of the BASTAK 5100 FN Device

The Falling Number (FN) measurement mode is used to determine natural alpha-amylase enzyme activity, while the Fungal Falling Number (FFN) mode is used to determine total alpha-amylase activity (microbiological + natural).

BENEFITS OF THE BASTAK FALLING NUMBER 5100 DEVICE

The Falling Number analysis, recognized worldwide as the most modern and reliable method, is the most advanced system used to measure alpha-amylase enzyme activity in wheat and flour.

In this process, a thick pudding-like mixture formed by combining flour and water is monitored to determine how quickly it is liquefied by enzymes.

With over 25 years of experience in food quality control technologies, Bastak manufactures Falling Number 5000 and 5100 models, which perform this sensitive measurement using advanced engineering.

Modern grain industries must accurately determine the biochemical characteristics of raw materials to ensure sustainable final product quality. The Bastak Falling Number 5100 transforms laboratory environments into high-technology centers.

One of the most important advantages of the device is that it performs the globally recognized Falling Number analysis within a fully automated digital system, minimizing human error.

The ability to analyze both natural (FN) and total (FFN) alpha-amylase enzyme activities simultaneously provides operational efficiency and time savings. The total analysis time is no more than 10 minutes.

Its ability to automatically correct pressure changes caused by altitude differences and optimize results according to ICC standards ensures universal measurement accuracy independent of geographic limitations.

This technology serves a wide range of applications from flour mills to research institutes, combining academic reliability with high-resolution touch panels and corrosion-resistant aluminum components.

By automatically calculating mixture ratios, the system eliminates costly trial-and-error processes in stock management. Ultimately, using a Bastak device is not merely a measurement procedure; it is a scientific assurance that supports the entire quality chain from raw material to final baked product.

DEVICE FEATURES

The device operates at 220V / 50 Hz.

After the device is turned on, altitude, date, and time information can be entered using the ENTER button on the control panel.

FN measures the Falling Number value of the sample.

FFN measures the fungal Falling Number value.

LEFT ID and RIGHT ID allow entry of sample names.

MOIST GR calculates the required sample amount automatically when moisture percentage is entered.

MOIST FN performs corrections according to ICC standards.

MIX calculates the ideal mixing ratio.

MALT calculates the required malt enzyme addition.

LN determines the liquefaction value.

AVER calculates the average of left and right sample results.

PRINT provides printed results, while FEED adjusts paper length.

STEP-BY-STEP FALLING NUMBER ANALYSIS WITH BASTAK 5100

After filling and activating the cooling tower water tank, the test tubes must be placed into the cooling slots on the FN device lid. The cooling water flow should be adjusted to 1 L per minute.

Before starting the analysis, the sample must be mixed to ensure homogeneity. From the homogenized sample, 7 grams of flour (adjusted to 14% moisture basis) is weighed from four or five different points. The same procedure is repeated for the second sample.

The weighed flour is transferred into clean and dry test tubes using a funnel.

Then 25 ml of distilled water at 22°C is added to each tube. The tubes are shaken for 20 seconds using the Bastak FNX 5050 shaker.

Any sample residue on the tube walls is pushed down into the tube using a stirring rod. The tubes are then placed into the tube holder.

Once the tubes are fully inserted into the device’s water bath, the analysis is started.

The device grips the stirring rods within 5 seconds and mixes the sample for 55 seconds. At the end of the 60-second test period, the rods are released. When the magnetic sensors detect the falling rods, the test ends.

The device automatically stops and prints the results, thereby determining the natural alpha-amylase enzyme activity.

IDEAL VALUES IN FALLING NUMBER ANALYSIS

In a good bread flour, the Falling Number value is ideally expected to be between 200–250 seconds. Values above 250 generally indicate that there is no climatic damage.

Figure 2. BASTAK Falling Number Ideal Values

If the Falling Number exceeds 300, alpha-amylase activity is low, fermentation is slow, and breads produced from such flour tend to have low volume, dry crumb, and shorter shelf life.

On the other hand, breads produced from flours with values below 150 are typically sticky, rapidly fermenting, darker in color, low in volume, and have short shelf life.

Falling Number Values in Different Wheat Varieties

Damaged Starch in Wheat Flour: Analysis & Impact on Baking Quality

Comprehensive Research on Starch Damage During Milling and Its Effects on Flour Performance

Introduction to Starch Damage in Wheat Flour

Starch granules in wheat endosperm are well-organized and reinforced by protein networks. However, mechanical forces during the milling process can partially or entirely damage these granules. As a result, produced flour contains a mixture of both intact and damaged starch granules.

The damaged starch content in flour depends on milling system characteristics and roller settings. Specifically, milling with high speed and pressure can increase the proportion of damaged starch due to the fragile structure of the granules. This characteristic has a significant impact on the flour's water absorption and dough behavior, directly influencing baking performance.

Key Insight: Damaged starch accelerates enzymatic reactions, altering the glycemic properties of the flour, an essential consideration in functional food production.

Research Methodology

At Bastak Instruments, a globally leading R&D center, five distinct bread wheat (Triticum aestivum L.) samples, termed as "Sample-01, Sample-02, Sample-03, Sample-04, and Sample-05," were milled using the Bastak 4500 double-pass laboratory mill with varied roller gap settings.

Samples originated from different regions worldwide and were of local, medium-hard types. The wheat samples were milled using a total of five rolls (three break rolls and two reduction rolls), resulting in flours with varying levels of damaged starch. Flour yield was calculated as a percentage of the cleaned and tempered wheat initially milled.

The damaged starch levels in the flours, obtained by milling with roller gaps ranging from 0.1 mm to 0.7 mm, were measured in six minutes using the Bastak SD Cheq 15000 device via the amperometric method under international standards.

Physical and Chemical Characteristics

The wheat samples were analyzed using Bastak's Hectoliter 7000 device for hectoliter weight (kg), Bastak 16000 moisture meter with high-precision gold-plated sensors for moisture content (%), and the Bastak protein analysis device for protein content (%).

Table: Average Physical and Chemical Data of Five Different Wheat Samples and Flour Yields Obtained Through Milling with Various Roller Settings

Damaged Starch Analysis Results

Damaged starch levels in flours obtained through milling at different roller gaps (0.1 mm–0.7 mm) were measured using the Bastak SD Cheq 15000 starch damage analyzer in six minutes via the amperometric method, adhering to international standards.

Figure: Damaged Starch Levels Obtained by Milling Different Wheat Samples at Various Roller Gaps

Impact on Dough Quality and Baking Performance

To assess the baking quality of flour, dough analyzes were conducted to examine the impact of damaged starch levels on dough quality. For optimal dough consistency and high-quality bread production, the amount of damaged starch in flour must remain balanced.

Critical Finding: Flours with excessively damaged starch have a high water absorption capacity, which increases the dough's absorption, disrupting its homogeneity during kneading and reducing elasticity. These types of flours, which tend to absorb more water, cause excessive softening of the dough and prevent adequate gluten formation.

Eventually, the dough's gas-holding capacity diminishes, and due to the inability to retain gases produced during fermentation, the bread volume decreases, resulting in a denser crumb structure.

This imbalance negatively affects the outer crust formation throughout the baking process, compromising crust quality. Research suggests that using flours with optimal levels of damaged starch supports dough development and fermentation, enhancing bread volume and creating a porous, uniform crumb structure.

Water Absorption Comparison: While intact starch granules can absorb approximately 0.33 times their weight in water, damaged starch granules can absorb their entire weight in water. Therefore, the amount of damaged starch significantly affects the baking quality of flour.

Advanced Dough Analysis with Bastak Instruments

Dough analysis was conducted using Bastak's state-of-the-art Absograph 500 and Resistograph 500 dough rheology devices.

Dough analyses, including water absorption capacity/stability, were performed using flour samples containing varying levels of damaged starch. Using 300 g of flour samples, dough samples were prepared in the Absograph 500 device by subjecting them to mixing for 5 and 20 minutes.

Figure: SAMPLE-01 (Roll gaps distance: 0.5 mm), Absograph Stability Graph - UCD: 23.5

Figure: SAMPLE-02 (Roll gaps distance: 0.2 mm), Absograph Stability Graph - UCD: 33.3

In addition, using the Bastak Resistograph 500 device, the dough's rheological properties were assessed over sufficient test durations of 45, 90, and 135 minutes. The testing process utilizes a special rail dough-stretching mechanism moving upward to eliminate gravitational effects, recording applied force for graphical analysis.

In dough samples prepared with flour containing high levels of damaged starch, it was observed that the excessive increase in damaged starch reduces gas retention capacity, as there is not enough gluten available to cover the increased surface area. This significantly affects the fermentation process, deteriorates the internal structure of the bread, and ultimately affects overall bread quality.

Conclusion

The research demonstrates that controlling damaged starch content within an optimal range is a critical parameter in bread production. The elasticity, resistance, and energy of the dough were determined according to international standards using Bastak's advanced instrumentation to achieve baked goods with ideal characteristics.

Proper management of milling parameters and precise measurement of starch damage using instruments like the Bastak SD Cheq 15000 are essential for optimizing flour quality and ensuring consistent baking performance.

Related Research & Products

SD Cheq 15000 Starch Damage Analyzer Absograph 500 Dough Rheology Analyzer Resistograph 500 Dough Analyzer Flour Quality Research Milling Optimization Studies Bakery Applications

Bread production is a crucial process in human nutrition. The quality of flour, dough workability, rising potential, and the textural properties of the final product are critical parameters in bread production. In this context, the rheological properties of flour and dough are widely used parameters for quality control at different stages of the production process. Bread additives are various components developed to improve the rheological properties of the dough, enhance workability, and increase the final product's quality. These additives directly affect the rheological properties of flour and dough, such as water absorption capacity, development time, stability, extensibility, and elasticity, thus contributing to the optimization of the bread production process.

Accurately evaluating the effects of additives on dough is a critical step to achieving desired results in bread production. Rheological devices used to examine these effects simulate the physical behavior of dough and provide detailed data on how additives affect dough structure.  Bastak Absograph and Resistograph 500 are the most commonly used devices for such rheological analyses. The Absograph 500 measures flour's water absorption capacity, dough development time, and stability, while the Resistograph 500 is used to evaluate dough extensibility, elasticity, and energy value. These devices allow for a detailed examination of the effects of different additives on dough structure.

In the study evaluating the effects of various bread additives on the rheological properties of dough using the Bastak Absograph 500 and Resistograph 500 devices, the chemical and physical effects of ascorbic acid, sodium stearoyl lactylate (SSL), and Bastak enzyme blends (Purmix C + Armix 5000) on dough structure were examined, revealing how these additives play a role in bread production.

Experimental Study The experimental study conducted rheological analyzes on various flour samples using different bread additives. In these analyses, the water absorption capacity and stability of the dough were examined using the Bastak Absograph 500 device, while the extensibility and elasticity properties of the dough were evaluated using the Bastak Resistograph 500 device. The flour samples were divided into three groups, each containing a different additive: ascorbic acid, sodium stearoyl lactylate (SSL), and Bastak enzyme blend (Purmix C + Armix 5000). Flour without any additives was used as the control group.

Absograph 500 Experiments Absograph 500 experiments were used to measure the dough's water absorption capacity, development time, and stability. The flour samples were added to the Absograph 500 device during these experiments and mixed at the international standard speed of 63 rpm. The dough's water absorption rate was determined by the amount of water added during the formation of dough balls. Development time and stability were evaluated using the Absograph 500 curve data.

Resistograph 500 Experiments Resistograph 500 experiments were conducted to evaluate the dough's extensibility, elasticity, and energy values. Dough balls prepared in the Resistograph 500 device were allowed to ferment at a constant temperature of 30°C for 45, 90, and 135 minutes in fermentation chambers with sufficient fermentation time. The dough's elastic behavior was observed by stretching the dough at a specific speed of 14.5 ± 0.5 mm/s in a linear tower designed to eliminate the adverse effects of gravity through customized R&D work. The obtained data were used to determine the dough's extension resistance and elasticity.

Results Table 1 shows the water absorption capacity and stability results obtained with the Bastak Absograph 500 device. These results clearly demonstrate the effect of different additives on the dough's rheological properties.

Table 2 shows the extensibility and elasticity results obtained with the Bastak Resistograph 500 device. The data here provide an important reference for evaluating the effects of additives on the dough's elastic properties.

The data obtained from the experiments clearly show the effects of bread additives on the dough's rheological properties. Measurements made with the Bastak Absograph 500 demonstrate the effects of ascorbic acid, SSL, and enzyme blends on the dough's water absorption capacity and stability. Ascorbic acid, acting as an oxidation agent, stabilizes the flour's protein structure, increases the dough's elasticity, and prolongs development time. SSL enhances the dough's stability and extensibility, creating a stronger and more workable dough structure. Bastak enzyme blends (Purmix C + Armix 5000) increase the dough's water absorption capacity and, through proteolytic activities, improve the dough's softness, resistance, energy, and extensibility.

The grain sector is moving away from traditional methods such as Kjeldahl and Soxhlet, which are time-consuming, require extensive material usage, involve heavy chemical consumption, are prone to instability over time, and increase the likelihood of human error. These methods demand intensive labor, pose risks to human and environmental health, and may lead to serious long-term health issues.

Today, many reputable companies in the grain industry are transitioning to next-generation technologies based on Near-Infrared Reflectance (NIR) spectroscopy.

Figure 2. Representation of visible light and near-infrared (NIR) regions in the electromagnetic spectrum. The NIR region is defined within the range of 750–2500 nm (NIRLAB).

Differences between traditional gluten analysis methods not only impose significant economic burdens on producers but also create deviations in results that may lead to irreversible or difficult-to-correct issues in production processes. At this point, the BASTAK 9000 NIR device minimizes deviations and has a high capability to predict wheat functionality.

In today’s competitive food and agriculture industry, having high production capacity is not enough; producers must also prove product quality in a short time. The BASTAK DA (Diode Array) 9000 transforms long, complex, and error-prone laboratory processes into a fast, easy-to-use, high-precision analysis method with standardized measurement principles and a 13-inch LCD touchscreen interface.

2. Old Habits vs. NIR: Which One Moves You Forward?

2.1 Economic Losses, Penalties, and Waiting Times

In the modern flour industry, one of the most important conditions for profitability in sustainability is maintaining quality. Even small variations in quality can result in tons of defective products.

A single faulty shipment in a standard 25–30 ton truck can lead to economic losses ranging from $15,000 to $25,000. Especially in high-volume production, time must be managed efficiently. Reliable and rapid testing devices are essential in logistics.

Traditional methods such as Kjeldahl, oven drying, and manual gluten washing, although accurate, require long processing times:

Kjeldahl method: 2–4 hours per sample

Oven (moisture analysis): 1–2 hours + cooling time

Manual gluten washing: 45–60 minutes

Zeleny sedimentation test: requires shaking and long settling periods

These delays slow down laboratory workflows and increase costs. Trucks waiting for analysis results generate demurrage costs, and delays can lead to penalties, especially in maritime trade where container waiting costs are significantly higher.

The BASTAK 9000 NIR device delivers results within 30 seconds, providing critical parameters such as moisture, protein, ash, gluten, and Zeleny sedimentation quickly and accurately. This enables real-time decision-making and optimization of operational costs.

Scientific studies show that NIR systems operating within the 750–2500 nm wavelength range, combined with advanced algorithms, provide high accuracy in predicting grain quality.

Comparative analyses conducted to evaluate the performance of the Bastak NIR DA 9000 used reference values from traditional (wet chemistry) methods:

Protein: Bastak Kjeldahl System

Gluten: Bastak 6000 and 6100 Gluten Cheq

Moisture: Bastak Oven

Results showed minimal deviation and high repeatability, with a correlation coefficient of 99%.

Blind Production, Profit Loss, and Energy Inefficiency

One of the biggest mistakes is adjusting machines based on outdated analysis results or operator experience. Wheat hardness and moisture vary, requiring precise adjustments.

Incorrect settings may lead to:

Excessive pressure → bran mixing → higher ash → lower quality

Insufficient grinding → repeated processing → up to 2x energy consumption

Overheating → protein denaturation → poor baking performance

Increased wear → reduced machine lifespan → higher maintenance costs

Without real-time data, even a small miscalculation (e.g., 0.5% protein difference) directly reduces profit margins.

Labor and Chemical Costs

Traditional methods require skilled labor, attention, and experience. Human error in weighing, titration, and process management affects accuracy.

Challenges include:

Need for trained chemists/laborants

Long training periods for new staff

Limited daily sample capacity

Increased workforce with higher sample volume

In contrast, the Bastak NIR DA 9000 eliminates operator-related errors and provides highly repeatable results within seconds.

Traditional methods also rely heavily on chemicals:

High chemical costs (e.g., Kjeldahl reagents)

Hazardous material storage requirements

Disposal regulations requiring licensed companies

Additional costs (filters, glassware, cleaning)

They also consume high energy due to equipment like:

Ash furnaces (500–900°C)

Drying ovens

Distillation units

The Bastak NIR system only consumes power during analysis and eliminates chemical usage, significantly reducing operational risks and costs.

3. Application Areas of BASTAK DA 9000 NIR Device

Academic Research and R&D: Provides highly accurate and repeatable data, enabling faster and more reliable characterization of raw materials in research projects.

Licensed Warehouses: Time is critical during product acceptance. The device enables rapid determination of protein and moisture, ensuring correct silo allocation and preventing losses.

Flour and Pasta Industry: Maintaining final product quality requires stable raw materials. The device allows real-time monitoring of semolina quality and gluten levels, ensuring consistent production.

Bakery and Pastry Industry: The Bastak NIR DA 9000 can be used across all flour-based sectors such as bread, cakes, biscuits, and croissants. It measures:

Oil absorption (critical for biscuits)

Moisture balance (affects cake structure)

आज अगर ऐसा हुआ तो हरीश रावत फिर से बनेंगे उत्तराखंड के CM

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