U.S. patent application number 10/837988 was filed with the patent office on 2004-10-14 for dough composition and method of baking yeast-fermented frozen bread products.
This patent application is currently assigned to MAPLE LEAF BAKERY INC.. Invention is credited to Cooper, John.
Application Number | 20040202763 10/837988 |
Document ID | / |
Family ID | 32092331 |
Filed Date | 2004-10-14 |
United States Patent
Application |
20040202763 |
Kind Code |
A1 |
Cooper, John |
October 14, 2004 |
Dough composition and method of baking yeast-fermented frozen bread
products
Abstract
A method of making a bread product comprising formulating and
mixing a bread dough having flour as a major ingredient, and having
the following additional ingredients, where percentages are based
on the flour weight: 1 Ingredients % Salt 1.8-2.3 Yeast 3.0;
2.5-4.5 Sweetener 0.3-2.0 Gluten 0.5-4.0 L-Cysteine 10-100 PPM
Water 50-65 Oxidant 0.1-0.5 Enzymes 0.01-0.5 Gum 0.01-0.5
pre-forming the dough into open molds shaped suitably for the bread
product; pre-proofing the dough for less than 30 minutes in at
least 70% relative humidity at a temperature in the range of
80.degree. F., to 100.degree. F.; freezing the pre-proofed dough to
a temperature below 0.degree. C.; partially defrosting the dough
for a period of time of 60 minutes or less; and placing the
partially defrosted dough in a pre-heated oven at a temperature of
about 170.degree. C. to 180.degree. C. to produce the bread product
in less than 3 hours.
Inventors: |
Cooper, John; (Daleville,
VA) |
Correspondence
Address: |
MARSHALL, GERSTEIN & BORUN LLP
6300 SEARS TOWER
233 S. WACKER DRIVE
CHICAGO
IL
60606
US
|
Assignee: |
MAPLE LEAF BAKERY INC.
Des Plaines
IL
|
Family ID: |
32092331 |
Appl. No.: |
10/837988 |
Filed: |
May 3, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10837988 |
May 3, 2004 |
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10258280 |
Apr 28, 2003 |
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10258280 |
Apr 28, 2003 |
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PCT/US02/33333 |
Oct 18, 2002 |
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Current U.S.
Class: |
426/549 |
Current CPC
Class: |
A21D 6/001 20130101;
A21D 2/264 20130101; A21D 2/245 20130101; A21D 2/06 20130101 |
Class at
Publication: |
426/549 |
International
Class: |
A21D 002/00 |
Claims
1. A dough composition suitable for baking into yeast-fermented
bread products, after freezing, with reduced post freezing
fermentation, comprising flour, and the following additional
composition components, with percentages based on the weight of the
flour contained in the composition:
13 salt: 1.8-2.3% leavening agent: 2.5-4.5% emulsifier: 0.01 to
0.5% sweetener: 0.3-2.0% L-Cysteine: 0.001-0.1% gluten: 0.5-4.0%
oxidant: 0.01-0.5% enzymes: 0.01-0.5% water: 58-65% gum:
0.01-0.5%
2. A dough composition in accordance with claim 1, further
including malt flavoring in an amount of about 1% to about 3% and
an oil in an amount of 0.1 to 0.5%.
3. A dough composition in accordance with claim 1, wherein the
oxidant is selected from the group consisting of ascorbic acid,
azodicarbonamide, potassium bromate, and a combination thereof; and
the sweetener comprises a monosaccharide.
4. A dough composition in accordance with claim 3, wherein the
monosaccharide comprises dextrose.
5. A dough composition in accordance with claim 1, wherein the
dough composition comprises the following, based on the weight of
flour:
14 salt: 2.0-2.1% leavening agent: 2.8-3.2% dextrose: 0.3-1.0%
L-Cysteine: 0.001-0.1% fats and/or oils: 0-1.0% gluten: 0.5-1.5%
oxidant: 0.01-0.3% enzymes: 0.01-0.3% water: 58-62% gum:
0.01-0.5%
6. A dough composition in accordance with claim 5, wherein the
dough strengthener additive is selected from the group consisting
of SSL, DATEM, and a combination thereof.
7. A dough composition in accordance with claim 5, wherein the
dough composition comprises the following, based on the weight of
flour:
15 salt: 2.0% yeast: 2.8-3.1% dextrose: 0.5% gluten: 1.0%
L-Cysteine: 0.03% ascorbic acid: 0.01-0.3% enzymes: 0.01-0.3%
water: 58-62% gum: 0.01-0.3%
8. A dough composition in accordance with claim 1, wherein the
flour is wheat flour having less than 16% by weight wheat
protein.
9. A dough composition in accordance with claim 1, wherein the
sweetener is selected from the group consisting of a
monosaccharide, a disaccharide, and a mixture thereof.
10. A dough composition in accordance with claim 6, wherein the
sweetener is selected from the group consisting of dextrose,
sucrose, fructose, corn syrup, lactose, maltose, and a mixture of
any two or more thereof.
11. A dough composition in accordance with claim 1, wherein the
enzymes are selected from the group consisting of an alpha amylase,
beta amylase, endoxylanase, a fresh enzyme, protease and a mixture
of any two or more of said enzymes.
12. A dough composition in accordance with claim 1, wherein the
enzyme is a combination of a proteolytic enzyme and an amylolytic
enzyme each in an amount of 0.01 to 0.03%, based on the flour
weight.
13. The dough composition of claim 7, further including an edible
animal or vegetable oil in an amount of 0.01 to 0.5% by weight,
based on the flour weight.
14. (Canceled).
15. (Canceled).
16. (Canceled).
17. (Canceled).
18. (Canceled).
19. (Canceled).
20. (Canceled).
21. (Canceled).
22. (Canceled).
23. (Canceled).
24. (Canceled).
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to yeast-fermented bread
products and a method of baking the yeast-fermented bread products,
that includes the steps of freezing the yeast-fermented bread
dough, and then baking the yeast-fermented dough at a single
temperature with an intermediate defrosting step that requires one
hour or less with little to no additional proofing required between
freezing and baking. More particularly, the yeast-fermented dough
and process of baking the yeast-fermented dough, as described
herein, unexpectedly provides freezer-to-oven yeast-fermented bread
products that, from freezer-to-oven, requires no additional
pre-fermenting, overnight retarding, complete thawing, or
additional proofing and unexpectedly increases the shelf life of
the bread products due to the increased amount of moisture retained
in the bread products.
BACKGROUND ART
[0002] Fully Fermented Frozen (FFF) Dough
[0003] The products available to the consumer which are declared
FFF are fully pre-proofed breads and rolls, meaning the production
facility would blend materials, mix, shape, and fully proof the
breads and rolls prior to freezing and boxing. The receiver of
these FFF breads would then remove the breads from the frozen case,
place them onto trays and bake them in a pre-set oven. The FFF
baking is cycled in two stages:
[0004] 1) Low temperature (325.degree. F.) for 15 minutes to
defrost.
[0005] 2) High temperature (380.degree. F.) for a further 20
minutes to complete the baking cycle.
[0006] Another type of freezer-to-oven (FTO) product would be
laminated dough and pastries. This includes Danish type pastries
and croissants. The products again are pre-shaped and fully proofed
at the bakery operational unit. Lamination of the dough is a
complex process which creates layers of fat between pure dough
layers. Lamination by itself is a way of applying volume to a
product during the final stages of baking. In essence the fat
between the layers melts, the moisture released turns to steam and
the steam trapped between the layers pushes the layers apart. This
process creates a very open, thin cell structure typical of a
Croissant or Danish type pastry.
[0007] Frozen Dough
[0008] Frozen Dough is pre-shaped bread or roll dough which has
either undergone pre-shaping and or bulk sheeting at the
manufacturing plant. Typically this type of dough requires a
minimum of 2-3 hours defrost time prior to use. If the Frozen Dough
has been pre-shaped, and depending on the unit weight, the dough
would need to undergo a defrost cycle (time according to unit
weight) and also a final proof cycle prior to bake off. Four to
five hours of defrost and proof time would not be unusual for the
receiver of the frozen dough.
[0009] Par Bake
[0010] Par Bake was developed in the early eighties to allow major
retailers to bring freshly baked products to the consumer without
the need to manufacture baked bread from scratch methods on site.
These methods are costly and the industry innovated an
alternative--that being Par Baked or partially baked bread.
Typically these breads are mixed, pre-formed, proofed and partially
baked at the manufacturer's site. The degree of baking is the only
factor separating Par Baked from conventional, fully baked bread,
both of which can be frozen and both can be defrosted and
pre-heated. The cost of purchase from the retail, compared to
in-store bakery, set up generated a significant saving in
equipment, labor and waste for those currently making bread at the
store level. The Par Bake bread products were merely taken from the
freezer and baked, eliminating waste time and overhead from the
store baker program.
SUMMARY OF THE INVENTION
[0011] The dough compositions and boxing process described herein
provide ready to bake frozen fermented bread products (FROBAKE3)
without the expected/required overnight retard or excessive defrost
time. The FROBAKE3 units, when received frozen only require a
minimal defrost time prior to bake off. Typically, 30 minutes
defrost time is ideal for bread product units weighting less than
300 grams and 60 minutes for bread product units weighting 300
grams or more. The compositions and processes described herein are
particularly suited for industrial bread product manufacture
wherein frozen dough bread products are mass produced in minimum
dough batches of about 400 pounds, producing at least 4,000 frozen
bread product units/hour and generally up to bout 10,000 frozen
bread product units/hour. The frozen dough units are then
distributed frozen to multiple supermarkets and other sellers of
the baked bread products, or can be sold frozen for others to bake
on a smaller scale.
[0012] The defrost time is also lessened on those frozen bread
product units like baguettes where the surface area is minimized
due to the length of the dough piece. Thus a 500 gram frozen bread
product unit measuring 8" length.times.3" wide.times.3" height
would be classed as a large product and, thus, 60 minutes defrost
would apply.
[0013] As another example, a long French stick measuring 21"
length.times.1.5" width.times.1" high would still be classed as a
large product, as defined by net dough weight. However, the defrost
time would be reduced to 30 minutes based on the unit volume
relative to defrost ratio (relative to depth and length) since
defrosting is faster than for the same weight bread product unit
that is shorter and deeper--the reduced defrost time is due to the
thickness, or smallest dimension resulting in a shorter necessary
defrost time.
[0014] FROBAKE3 products advantageously allow the receiver to take
the frozen bread product units from their boxes, lay the units onto
baking trays and within a one hour cycle have breads dressed,
optionally scored and ready for the oven. The optional scoring
technique is no different than when scoring a fully proofed
conventional dough or a fully prepared frozen dough. The breads do
not require any further defrost or fermentation prior to bake off.
Usually the operator at the bake off site would moisten the breads
with a water spray prior to dressing. This basically allows the
dressing medium, be-it seed or cereal, to adhere evenly across the
full upper surface of the dough. FROBAKE3 dough does not require
moistening prior to dressing and can be dressed and scored without
any form of moistener applied to the surface.
[0015] The bake off cycle for FROBAKE3 dough advantageously
requires only a single temperature pre-set oven, preferably with
steam injection at about 350.degree. F. Most FFF or frozen dough
require a two cycle bake off due to one stage (the first cycle)
being defrost and the final, higher temperature cycle, being
required to fully bake and color (dextrinate) the surface of the
bread.
[0016] FROBAKE3 has unexpected additional advantages over frozen
dough, FFF, and Par Bake in that at least double the normal shelf
life is provided when packed in open paper bags or sealed plastic
bags. This is due to the unexpected amount of moisture retained in
the bread products after bake off, which migrates through the bread
products upon cooling and displaying. Dehydration of moisture
occurs rapidly in the Par Bake process due to the two baking cycles
required. Typically 13% of the total moisture will be lost in the
first bake cycle and a further 5% at the final bake off. FFF and
frozen dough would lose about the same amount of moisture as Par
Baked products due to the full cycle proof and defrost requirements
of these prior art processes. FROBAKE3 loses less than about 10% of
the dough moisture, usually about 6% of the dough moisture, as
measured by weight loss at the end of the final bake cycle.
[0017] From a logistical standpoint, FROBAKE3 also provides a
substantial decrease in freight costs in being able to maximize
truck volumes unlike FFF and par bake which have a significantly
greater specific volumes as frozen.
[0018] FROBAKE3 dough produces bread products with excellent
volume, open internal cell structure and flavor. The total process
time from make through to final full bake takes approximately 2.2
hours as follows:
2 Time Required Process Step 1) Line Processing 30 Minutes 2) In
Line Blast Freezing (-30.degree. F.) 30 Minutes 3) Defrost 60
Minutes TOTAL 2 Hours (120 Minutes) Prior Art Process Conventional
Par Bake 3.71 Hours (223 Minutes) Frozen Dough 9.3 Hours (includes
a required minimal 8 hours retard time) FFF Frozen Dough 3
Hours
[0019] Accordingly, one aspect of the bread products and methods
described herein is to provide yeast-fermented bread products and a
method of manufacturing the yeast-fermented bread products that
includes the steps of freezing the yeast-fermented bread dough, and
then baking the dough in a pre-heated oven with reduced defrost
time required before baking.
[0020] Another aspect of the bread products and methods described
herein is to provide yeast-fermented bread products and a method of
manufacturing the yeast-fermented bread products that includes the
steps of freezing the yeast-fermented bread dough, and then baking
the dough in a pre-heated oven, after a 30-60 minute defrost time
at room temperature, at a single temperature to provide bread
products having an increased moisture content and increased shelf
life.
[0021] Another aspect of the bread products and methods described
herein is to provide yeast-fermented bread products and methods of
manufacturing the yeast-fermented bread products that includes the
steps of freezing the yeast-fermented bread dough, and then baking
the dough with a defrost time less than 90 minutes, usually 30-60
minutes with little to no additional proofing required between
freezing and baking.
[0022] Another aspect of the bread products and methods described
herein is to provide a yeast-fermented bread product and a method
of manufacturing the yeast-fermented bread products that includes
the steps of freezing the yeast-fermented bread dough, and then
baking the dough to provide freezer-to-oven bread products that,
from freezer-to-oven, requires no additional pre-fermenting,
overnight retarding, complete proofing, and/or additional
proofing.
[0023] The above and other aspects and advantages of the
yeast-fermented bread products and methods described herein will
become more apparent from the following detailed description of the
preferred embodiments.
Definitions
[0024] Ranges may be expressed herein as from "about" or
"approximately" one particular value and/or to "about" or
"approximately" another particular value. When such a range is
expressed, another embodiment includes from the one particular
value and/or to the other particular value. Similarly, when values
are expressed as approximations, by use of the antecedent "about,"
it will be understood that the particular value forms another
embodiment.
[0025] As employed herein, the term "fermentation" is meant to
include all changes in the dough brought about by the action of
yeast which functions to aerate a dough and ripen the gluten. Total
fermentation time includes the time elapsed during fermentation of
the dough in bulk, resting or benching and proofing. For the sake
of clarity, traditional baking terminology is defined below and
employed when appropriate to identify the specific dough treatment
steps during which fermentation occurs.
[0026] "Fermentation in bulk" occurs after the dough formulation is
mixed and before it is divided into separate portions.
[0027] "Partial defrost" occurs when the frozen dough is subjected
to an ambient environment where it will undergo a level of defrost
at room temperature (about 25.degree. C.) for a period of time
equal to 0.1 to 0.7 the time required to fully defrost the frozen
dough and, thus, not "fully" thawing the frozen dough. It is
preferred that the dough is defrosted about 15 to 50% of the time
required to fully defrost the frozen dough at ambient conditions,
e.g., about 25.degree. C., and always has an internal core
temperature below 0.degree. C. when the bake process is
initiated.
[0028] "Resting" is used interchangeably with "benching" to denote
periods of time allowed to give the gluten of the flour time to
recover from any step such as dividing, molding, forming, and the
like, wherein the dough has been stretched or worked.
[0029] "Proofing" is the final step before baking or freezing
wherein time is allowed for the yeast to produce more gas to give
the correct volume and vesiculation to the molded or shaped dough
portion.
[0030] A "leavening agent" is a compound or mixture of chemical
compounds which produces carbon dioxide gas that functions to
aerate baked products. Thus, in yeast fermented bread, yeast is a
leavening agent.
[0031] The term "dough" comprises a mixture of flour with other
ingredients stiff enough to knead or roll.
[0032] The term "yeast-fermented bread products" includes white,
wheat, raisin and French-style or Italian-type breads, dinner-rolls
or soft-rolls, hard rolls, Kaiser rolls, hamburger rolls,
frankfurter rolls and other specialty rolls, rolled-in products
such as Danish or puff pastry in either a pre-form or bulk or slab
form, sweet yeast-raised dough items, such as cinnamon rolls,
coffee cakes or other plain or filled sweet dough items, and
yeast-raised dough for fried products, such as yeast-raised
doughnuts.
PREFERRED EMBODIMENTS
[0033] The present invention may be understood more readily by
reference to the following detailed description of the bread
products and methods described herein and the examples provided
therein. It is to be understood that this invention is not limited
to the specific components, articles, processes and/or conditions
described, as these may, of course, vary. It is also to be
understood that the terminology used herein is for the purpose of
describing particular embodiments only and is not intended to be
limiting.
[0034] The commercial marketing of frozen dough for home baking or
on-premises baking in supermarkets continues to grow in volume.
Today's modern supermarkets and bakeries can provide freshly baked
bread loaves, each day, to achieve the freshness sought by
consumers. In the interest of providing many such fresh loaves of
bread, and in the interest of reducing the time required to provide
the fresh bread, most supermarkets have provided loaves of bread
that are baked daily from frozen dough or partially baked frozen
dough. The bread-making process using frozen dough, however, has
several serious problems to be solved. Among them are the length of
time required for the preparation and thawing of the frozen product
before baking. As explained under "BACKGROUND ART", such
freezer-to-oven bread products have required much longer defrost
times between freezer and oven, longer baking times when inserted
directly into a cold oven, partial baking prior to freezing, and/or
two baking cycles at different temperatures for full defrosting and
baking.
[0035] As an alternative to two baking cycles, including a first
low temperature baking cycle for defrosting, others have placed the
frozen dough directly from the freezer and placed it in a cold oven
that is immediately turned on to a temperature of about 170.degree.
C.-180.degree. C. for a period of 45-60 minutes (see U.S. Pat. Nos.
4,374,151; 4,406,911 and 4,966,778). Further, the prior art
freezer-to-oven processes result in bread products with reduced
moisture contents due to the dough composition and baking cycles
used. Typical moisture contents for the bread products described
herein are 50-65% by weight, whereas prior art freezer-to-oven
bread products have moisture contents as follows: FFF: 45-55% by
weight; Frozen Dough: 45-55% by weight; and Par Bake: 40-50% by
weight.
[0036] In all cases, the moisture content of the bread products
produced as described herein have a moisture content at least 5%
more than the moisture content of the above-described prior art
freezer-to-oven bread products, resulting in at least double the
shelf-life.
[0037] The FROBAKE3 bread products described herein include the
essential bread components of flour, salt, yeast and water. The
flour can be wheat flour, rice flour, corn meal, or any other grain
flour conventionally used in bread product dough. The preferred
flour is wheat flour. However, the dough composition does not
require a melting point depressant, such as C.sub.1-C.sub.3
monohydric alcohols, e.g., ethanol, or C.sub.2-C.sub.3 polyhydric
alcohols (U.S. Pat. No. 4,374,151); or a high wheat protein level
of at least 17%, based on the flour weight (U.S. Pat. No.
4,966,773); and can be placed directly into a pre-heated oven after
30-60 minutes of defrost at room temperature. The wheat protein
level in the dough compositions described herein is about 10-16% by
weight, preferably about 12% to 14.5%, based on the flour
weight.
[0038] The dough compositions described herein are yeast-leavened
at a veast content of about 2.5% to 4.5%, preferably about
3.0%-4.0% by weight, based on the flour weight.
[0039] A preferred embodiment of this invention is a yeast-leavened
dough which is proofed before freezing and held for baking at a
later time which will maintain quality during normal commercial
frozen storage temperature ranges, and can be conveniently prepared
from the freezer to a finished baked loaf having good loaf volume
and oven spring with a 30-60 minute defrost at room temperature
prior to being inserted into an oven pre-heated to 170.degree. C.
to 180.degree. C., for about 30-40 minutes, preferably about
175.degree. C. for 35 minutes. This frozen dough, which is proofed
before freezing, eliminates the usual thawing and proofing step,
which usually requires 2-12 hours for the thawing and 2-4 hours for
the proofing, before the dough is placed in the oven for
baking.
[0040] The method of producing the frozen dough composition and
bread products comprises the following steps: formulation; mixing,
preferably at room temperature; pre-forming; pre-proofing for 10-20
minutes at 80.degree. F. to 100.degree. F. and 70-90% relative
humidity; freezing below 0.degree. C., preferably at -15.degree. C.
to -30.degree. C.; partial defrosting, preferably at room
temperature for 30-60 minutes; and then placing directly in a
pre-heated oven at 170.degree. C. to 180.degree. C. for about 30-40
minutes, preferably including steam injection for 15-20 seconds to
achieve 100% water saturation in the oven atmosphere.
[0041] The process and bread products have excellent volume, open
internal cell structure and flavor. The total process time from
make through to final full bake takes less than or equal to 2.7
hours, split out as follows:
[0042] Line Processing: 30 minutes
[0043] In line blast freezing to -30.degree. F.: 30 minutes
[0044] Defrost: 30-60 minutes
[0045] Baking (directly in pre-heated oven): 30-40 minutes
[0046] Total: 2.0 to 2.7 hours
Prior Art Time Required
[0047] Conventional Par Bake time: 3.71 hours (223 minutes), prior
to baking
[0048] Frozen Dough: 9.3 hours (includes a required minimal 8 hours
retard time), prior to baking
[0049] FFF frozen dough: 3 hours, prior to baking
[0050] Process Details
[0051] (1) Mixing--Spiral mixer twin arm/dual speed.
[0052] (2) The dough was mixed for 9 minutes in total at a
temperature of 78.degree. F.
[0053] (3) No rest was required prior to mechanical sheering and
forming.
[0054] (4) The dough was divided into units weighting 500
grams.+-.10 grams.
[0055] (5) Once divided, the dough is subjected to pre-forming
through set molders before being automatically set into pre shaped
baking pans.
[0056] (6) The filled pans travel along an automated belt to an
online proofing box. The product is be subject to 15 minutes
pre-proof at 90.degree. F. with a chamber relative humidity of 85%
prior to being deep frozen at -30.degree. C.
[0057] Final test bakes where carried out in the baking oven at
350.degree. F. for 35 minutes. To determine sufficient volume by
baking, frozen dough blanks made under conventional methods were
used in comparison to finished FROBAKE3 products. The following
results were obtained:
[0058] Volume: Before baking/after baking/variance acceptability
compared to frozen dough.
[0059] After 7 days freezer storage--Symmetrical appearance;
Sustained volume loss: 0%.
[0060] After 14 days freezer storage--Symmetrical appearance;
Sustained volume loss: -0.1%.
[0061] Rheological Mechanics
[0062] The process of a true freezer to oven yeast-fermented bread
product refers to the minimizing of what is considered natural
fermentation through yeast activity in the dough. Yeast levels
determine the time and length of fermentation activity within a
given formula. The FROBAKE3 formula requires a yeast level of 2.5
to 4.5% by weight, preferably 3.0 to 4.0% yeast level, based on the
flour weight, is sufficient to create the desired volume and
physical characteristics of a publicly perceived good loaf of bread
both proportionally and gastronomically.
[0063] The fermentation methods applied to FROBAKE3 are physically
controlled throughout the baking period of the breads, as opposed
to the final proof periods standard on normal yeast-raised
fermented bread products. The temperature range of 170.degree. C.
to 180.degree. C. is important to control oven-forced fermentation
which relies upon the formulation of a correct level of materials,
including emulsifiers and enzymes, which become both activated and
deactivated during specific bake time applied.
[0064] Yeast fermentation requires heat, time and temperature to
evolve. Yeast fermentation also requires the breaking down of
natural occurring sugars, i.e., sucrose, dextrose to obtain a
desired level of yeast food along with the additional amylayses in
the form of fungal and cereal enzymes to accelerate the gas
production in the dough during the bake off. Additionally, it has
been found that natural dough surface dextrination occurs more
rapidly due to the minimized fermentation period applied to
FROBAKE3, and residual sugars being more readily available for
conversion.
[0065] The preferred FROBAKE3 formulation, based upon total flour
weight, is as follows:
3 % % % Preferred Preferred Range Range Lbs GMs Wheat 100 100 100
100 454 flour Salt 2.0 1.8-2.3 1.9-2.1 2 908 Yeast 3.0 2.5-4.5
3.0-4.0 3 363 Dextrose* 0.5 0.3-2.0 0.5 225 Gluten 1 0.5-4.0 1-3.0
1 454 L- 30 PPM 10-100 PPM 10-50 PPM trace 000.03 Cysteine
Improver.sup..dagger. 1 1-3 1-2 1 454 Malt 2 0-5 1-3 2 908 Water 58
50-65 50-60 58 360 TOTAL 167.5 167.5 2764 *Dextrose is the
preferred sugar, but can be substituted with any other mono-or
diglyceride to achieve a bread product having a greater or lesser
sweetness, as follows:
[0066]
4 Sugars Sweetness Level Sucrose 100 Fructose 140-150 dextrose*
70-75 corn syrup 65-70 Lactose 30-35 Maltose 30 to 35
[0067]
5 Enzymes Preferred Dosage Levels alpha and beta Amylase 6-50 PPM
Endoxylanases 28-110 PPM Fresh Enzymes 100-500 PPM Protease 100-250
PPM
[0068] L-Cysteine a naturally occurring amino acid which is added
to aid the dough in relaxing sufficiently during both dough make up
and final bake also contributes to the weakening of the dough
through reducing the gluten structure and enabling that structure
to gain proportionate volume during the combined proof and bake
while in the oven.
[0069] Having both starch attacking enzymes, referred to as
amylases, and the reducing agent referred to as L-Cysteine is
important since these functional materials, when combined,
determine the overall external and internal appearance of the
breads during both make up and bake off.
[0070] The flour is a standard roller milled patent flour and
contains no additional enhancing materials with which to aid
fermentation.
[0071] The non-diastatic Malt flour is a deactivated malt flour.
Its function is purely to contribute malt flavor without breaking
down additional starches to release more natural sugars. These
flavors are very apparent in the final baked breads.
[0072] To achieve the full advantage of the present invention, the
dough composition should include additives or conditioning agents
including an oxidizing agent or oxidant, such as ascorbic acid;
fungal and/or cereal enzymes; as well as one or more edible
gums--each in an amount less than about 1% by weight, preferably
0.01-0.5%,, preferably 0.1 to 0.3%, based on the flour weight. An
oil, such as soybean oil may also be added in an amount of at least
0.01% up to about 0.5% based on the flour weight. Each of these
additives can be added to the dough separately, or one or all of
these additives can be combined by the addition of a dough
conditioner, such as, a generic conditioner, or a specific dough
conditioner, for example, containing an emulsifier, such as DATEM,
an oil, such as soybean oil, an oxidant, such as ascorbic acid, and
enzymes. Optionally, the conditioner can contain wheat flour,
L-Cysteine, and other additives. The conditioners improve volume,
crumb structure, flavor and shelf life.
[0073] Suitable food gums can be any food gum normally used in a
frozen food product. Exemplary food gums including, but are not
limited to, locust bean gum, quince gum, guar gum, gum tragacanth,
gum arabic, ghatti, gum karaya, agar, xanthan gums, carrageenan,
alginates, and similar food gums, and mixtures thereof. Guar gum
and xanthan gums are preferred food gums.
[0074] The preferred ingredients are as follows:
[0075] Flour: Patent wheat flour produced for Maple Leaf Bakery is
the material prepared from the milling and bolting of clean, sound
100% hard red spring wheat so that no less than 98% of the flour
passes through a 212 micron cloth. The flour is unbleached. The
flour may be enriched with niacin, iron, thiamin mononitrate,
riboflavin and folic acid if necessary to satisfy the standards for
Enriched Flour and entoleted just prior to packing.
6 PHYSICAL & CHEMICAL SPECIFICATIONS: Minimum Maximum Moisture
13.60% 14.00% Protein (14% mb) 12.80% 13.20% Ash (14% mb) 0.50%
0.54%
[0076] Salt: Fine granulated salt with yellow prussiate is a
screened, granular, white crystalline solid. It is manufactured by
a vacuum pan evaporation system from saturated brine to which
yellow prussiate has been added. The salt is dried and screened to
insure uniformity of the crystalline form. It contains virtually no
insolubles and dissolves quickly. It functions as a nutrient for
yeast in the fermentation process and contributes to the overall
flavor profile of the bread products which contain it. The yellow
prussiate is added to improve the resistance of the salt to caking.
It is somewhat hygroscopic and should be stored in a cool, dry
place.
7 PHYSICAL & CHEMICAL SPECIFICATIONS: Purity (NaCl - dry basis)
99.86% Minimum Granulation Minimum Maximum On US # 30 Screen 20%
44% On US # 40 Screen 25% 55% On US # 50 Screen 10% 35% On US # 70
Screen -- 8% Thru US # 70 Screen -- 3%
[0077] Yeast: Compressed Yeast compressed yeast that is a strain of
Saccharomyces cerevisiae cultivated for uniformity, activity and
stability. It is a leavening agent, which relies upon living cells
to produce gas during fermentation. The cultured yeast is passed
over a rotary vacuum dryer to reduce the moisture content. The
yeast is subsequently extruded and formed into blocks for
packing.
8 PHYSICAL & CHEMICAL SPECIFICATIONS: Minimum Maximum Moisture
-- 72.0% Protein 14.0% 19.0% Total Ash (DB) -- 6.0% CO.sub.2
Gassing Power Activity 235 315 Yeast Environment pH 4.0 6.0
[0078] L-Cysteine: L-Cysteine (tablets) is a dough conditioner,
which functions as a reducing agent in the dough composition. The
material is a naturally occurring amino acid that functions as an
enzyme, which decreases mixing time and improves the extensibility
and machineability of dough. It comes in tablet form for convenient
and accurate use and dissolves rapidly in water. Each tablet
delivers 10 PPM of L-Cysteine monohydrochloride when added to 100
pounds of flour.
9 PHYSICAL & CHEMICAL SPECIFICATIONS: Minimum Maximum Moisture
-- 0.7% Tablet Weight 1.90 g 2.0 g L-Cysteine HCL (per tablet) 0.50
g 0.50 g
[0079] Wheat Gluten: Vital wheat gluten is a creamy tan colored
powder produced by the low temperature drying of gluten extracted
from wheat flour. The ingredient is used as a non-organic additive
component in the dough composition.
10 PHYSICAL & CHEMICAL SPECIFICATIONS: Minimum Maximum Moisture
-- 10.00% Protein (14% mb) 75.0% -- Fat -- 2.00% Ash -- 1.00%
Typical Granulation: (ROTAP - 100 g for 5 minutes) Thru #40 Screen
100% -- Thru #60 Screen 97% -- Thru #100 Screen 75% --
[0080] Dextrose: Dextrose is refined corn sugar in a crystalline
form it is prepared by the enzymatic hydrolysis of corn starch and
refined by ion-exchange demineralization. It functions as a
nutrient for yeast in the fermentation process, provides for mild
sweetness, and assists in color development of the crust during
baking. It is highly hygroscopic and should be stored in a cool dry
place.
11 PHYSICAL & CHEMICAL SPECIFICATIONS: Appearance Free Flowing
Crystals Color White Aroma Sweet Flavor Cool, Bland and Sweet
Moisture 8[,]5% Maximum Purity 99.7% Minimum Ash 100 PPM
Granulation Thru US# 16 Screen 99% Minimum
[0081] Malt Powder: Malt Powder is a non-diastatic natural product
produced from barley and corn. The powder is produced by the
enzymatic reaction of barley and corn grits. The material is a fine
powder, which possesses a mellow sweet malt aroma and flavor. It is
normally used in formulations to provide a sweet malt flavor,
enhance the color of the crumb and crust, and act as humectants to
extend shelf life.
12 PHYSICAL & CHEMICAL SPECIFICATIONS: Minimum Maximum Moisture
2.0% 4.0% Ash 0.7% 0.9% Reducing Sugars (As Maltose) 57.0% 68.0%
Color Transmittance (at 570 mm) 80.0 88.0 pH 5.5 6.2 Granulation
Thru a US# 80 Screen 92% --
[0082] Oxidant; Emulsifier; Enzymes; Oil: All can be added by
incorporating a dough conditioner into the bread dough formulation.
One such conditioner is PURATOS S.RTM. Improver. As an example of a
suitable conditioner, PURATOS S.RTM. improver is a mixture of
ingredients designed for use with yeast raised bakery products,
namely, wheat flour, datum, soybean oil, dextrose, ascorbic acid,
L-Cysteine, and enzymes. It is a dough conditioner which serves to
improve volume, crumb structure, flavor and shelf life. The
conditioners are formulated so that they may be used at a level
equal to 1% to 2% of flour weight.
[0083] The PURATOS S.RTM. conditioning composition used at 1-2%
based on the flour weight, has a multifunctional role in that it
contains balanced micro ingredients, namely:
[0084] Dry flour (carrier)
[0085] Dextrose (Sugar)
[0086] Datem ester (Emulsifier)
[0087] Enzymes (proteolytic and amylolytic)
[0088] Fats
[0089] Oils
[0090] Ascorbic acid (oxidizing agent)
* * * * *