50373692 8 bakey technology
TRANSCRIPT
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Dr. Li Wenzhao
Department of Food Science and
Engineering
Bakery Technology
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1 History Bread being one of the earliest
processed food
Manufacturing industry from 3,000B.C.E. in Egypt
$16 billion industry in the US
Wheat consumption ~100 Kg/person/year
a central ago, 50 Kg 1960s, 70 Kg 1980s,
2000 65 Kg
European as high as 140 Kg/person/year
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BreadsLeavened
Flatbread (unleavened)Labeling
Wheat bread = white flour Whole wheat = whole grain
Multigrain, cracked wheat, or 7-grain may not be whole grain
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Leavened Breads
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Unleavened Breads
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Oats, barley, and some foodproducts made from cereal grains
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A wheat field in Dorest, England
Wheat
Planting
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2 Wheat morphology and chemistry
Section of a grain of wheat
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a Kernel of Wheat
83% of kernel isendosperm
14.5% of kernel is Bran
2.5% of kernel is Germ
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1) Bran Layer
14% of kernel
Several thin layer Contains aleurone layer
viable, protected layer,
surrounds endosperm
enzyme activity
Contains: protein, lipid,
minerals, vitamins, phenolic
compounds, cellulose
Graphic: http://www.generalmills.com/wholegrain/101/
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Source: Hoseney, R.C. Principles of Cereal Science and Technology, 2nd Edition, pg. 17.
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2) Starchy Endosperm 83% of kernel
Non-viable, but may haveenzymatic activity
Contains high levels of starch
75% of wheat endosperm source of fermentable sugars
Contains extensible gluten
proteins Very little mineral, fiber, fat &vitamins
Graphic: http://www.generalmills.com/wholegrain/101/
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3) Germ 2-3% of kernel Viable tissue
Contains embryo all rudimentary growth
tissues
Responsible forgermination e.g. during malting of barley
Contains higher quantitiesof lipid than otherfractions
Graphic: http://www.generalmills.com/wholegrain/101/
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3 Milling of Wheat
Flowchart ofwheat milling
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Wheat Mill Fractions
Wheat Flour Germ Bran
Protein 12.0 11.0 30.0 14.5
Ash 1.8 .4 4.0 6.0
Fiber 2.5 - 2.0 10.0Fat 2.9 .88 10.0 3.3
Source: Hoseney, R.C. Principles of Cereal Science and Technology, 2nd Edition, pg. 137.
Milling is a process which attempts to cleanly separate the
anatomical parts of the grain to produce a product (flour), which
is chemically, compositionally, and functionally very different.
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FlourFlour
All-purpose flour
Cake flour Instant/quick-mixing flour
Self-rising flour
Whole wheat flour
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All-purpose flour
Milled and sifted blend of different varietiesof wheat.
Made primarily of endosperm
Can be bleached or unbleached: nonutritional difference between the two
General baking and cooking
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Cake Flour Made from a class of wheat called soft
wheat.
Used for making cakes and other bakedproducts with delicate textures.
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Instant or quick-mixing flour All-purpose flour that has been specially
treated to blend easily with liquids.
Used to make gravies and sauces.
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Self-rising flour Is an all-purpose flour with added
leavening agents and salt.
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Whole Wheat Flour
Made by milling the entire wheat kernelso it contains the bran, germ, and
endosperm.
Gives baked products a nutlike flavor and
coarser texture than does all-purposeflour.
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4 Wheat protein and starch Flour composition critical for the
fermentation and physical structure ofthe dough and finished bread
Refined white flour used mostly in US,from endosperm portion
Consists mainly protein and starchSmall portion of hemicellulose and lipid
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Wheat Protein
8%-15% of wheat flour is protein
High protein flours from hard wheat
best for bread, >11% Low-protein flours from soft wheat
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Wheat Protein
Gliadin and glutenin the most
important ones, ~85%
When hydrated and mixed, form
gluten, key component of bread
Remaining globulins and albumins,- and -amylases
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Gluten Gluten consists of two protein
-Glutenin and
-Gliadin
They interact with each other by thekneading of a wet dough, to form a
protein complex Gluten is a highly elastic material
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Gluten
Protein complex gives bread
structure and elasticity and essential
doe the leavening process
Poorly formed or absent in non-wheat flours
Most commercial breads containsome wheat
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Benefits of Vital Gluten Instant protein source
Aids in water absorption, 1% added
increases dough absorption by 1.2% Benefits should include volume increases,
and increased processing tolerance for
bread and rolls Usage:
Whole grain breads:2-5%
High fiber, reduced calorie breads 5-12%
Pizza dough:0.5-1%
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Wheat Carbohydrate
75% of the total weightLargely compose of starch
Some other carbohydrates
A small amount of simple sugar,
cellulose, fiber (~1%)
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Wheat Starch Native starch granule insoluble
Amylose and amylopectin withinspherical granules in rigid, semi-
crystalline network Milling can damage a small
percentage, increase waterabsorption and enzyme exposure
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Starch StructureNatural Starch conformation
Mixture of amylose and amylopectin
Pure amylose not natural (only 85%)Waxy maize starch - amylopectin
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Starch CompositionTYPE OF
STARCH
AMYLOSE % AMYLOPECTIN
%
MAIZE 26 74
WHEAT 25 75
RICE 17 83
POTATO 21 79
CASSAVA 17 83
WAXY MAIZE 1 90
HIGH AMYLOSE 70 30
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Starch ConfigurationConfiguration = 3D structure
Not soluble in cold water
Settles
No adhesive powerNo binding capacity
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Starch ConfigurationTo have the previous properties the starch
slurry must be heated
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Amylose vs. Amylopectin
Starch is a food storage polysaccharide used byplants to organize glucose polymers
Two unique patterns of linear organization:AMYLOPECTIN (75%) AMYLOSE (25%)
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Amylose vs. Amylopectin Starch linear structural pattern confers
unique tertiary structure
AMYLOPECTIN (75%) AMYLOSE (25%)
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Amylose vs. Amylopectin
Literature suggests that amylopectin is morereadily digested by -amylase
Genetically modified maize, rice and barleycontaining 100% amylopectin starch aredigested faster than normal counterparts (Nodaet al. 2002)
Resistant starches (low GI starches) exhibitslow release of glucose into intestinal lumen,non-resistant starches (high GI starches) exhibit
rapid release of glucose into lumen (Bird et al.2007)
Resistant starches high amylose content
Non-resistant starches high amylopectin content
St h G l i P t i
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Starch Granules in Protein
Matrix
Source: Hoseney, R.C. Principles of Cereal Science and Technology, 2nd Edition, pg. 9.
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Starch Granules andGelatinization
In the storage areas of plant (seeds, roots),molecules of starch are deposited as tiny,organized unit granules
In cold water, starch granule is insoluble. In warm water, gelatinization
- swelling of granule as water is absorbed
- disruption of the granule structure
- loss birefringence
Starch Granules &
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Starch Granules &
Birefringence
Bright field microscopy Polarizingmicroscopy
Gelatinizatio
n
(h
eat+water)
Source: Hoseney, R.C. Principles of Cereal Science and Technology, 2nd Edition, pg. 53.
S h G l P l h Di ib i
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Wheat endosperms consist of three
distinct starch granules (Raeker et al.,
1998) A-granules: large, disc shaped
B-granules: small, spherical shape
C-granules: not well defined
Starch Granule Polymorph Distribution
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Riffkin et al. (1990) and Brosnan et al. (1999)
Contributary role of starch granule size distribution toethanol yield
Starch Granule Polymorph Distribution
A vs. B-granule
Structural Distinctions Amylose content
Lipid content
Size
Crystallinity
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Starch GelatinizationGelatinization only occurs with heat and water
Dry heating = dextrinization
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Starch Gelatinization5% Corn starch = start of heating only has
water absorbed onto granule surfacesGranules still clumping
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Starch GelatinizationAt 40oC more water as absorbed and granules
start to separate
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Starch GelatinizationAt 65oC more water as absorbed and granules
start to rupture
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Starch GelatinizationAt 70oC further rupture, leakage
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Starch Gelatinization
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Starch Gelatinization
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Factors AffectingGelatinization
Main determinants of gelatinization:
Water content
Starch concentration
Nature of starch
Degrading enzymesOther environmental factors
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Factors AffectingGelatinization
Main determinants of gelatinization:
Fat
Protein
Temperature
Hydrogen bonds
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Staling
Usually ascribed to :
Loss of moisture
Retrogradation
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Staling Bread and buns become firm (high-moisture,
yeast-raised products);
Crusty loaves dry out;
Crisp baked goods go soft (low-moistureproducts);
Off-flavours develop.
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Staling 1 to 5% of baked goods are lost
Climate plays a role
Storage conditions
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StalingMostly ascribed to:
Retrogradation
Moisture exclusion (crystallinity)
Brittle crumb
Low temperature speeds up the
process
Freezing prevents staling
5 Bread Unit Operations
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p
Modern Bread Technology Straight dough process
Homemade, one-batch-at-a-time, not much by the
baking industry Sponge and dough process
Mostly used, using partially concentrated portion
of dough-sponge to ferment, and then mixing withthe remaining ingredients
Liquid sponge process
Continuous bread-making, liquid sponge, savelabor and time, using thin, quality not as good
Chorleywood Process
General Manufacturing
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General Manufacturing
Principles
W ei g h an d m i xi ng red i en t s d o u g h F e rmen tedd o u g h
Por t i onedan d
shapedb ak e Coo l
sl i ce p ack
fermentation
fermentation
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Formulation Flour- Usually all purpose flour used forbaking breads. Main function is to give
structure to the bread. Leavening Agents- Produce gas in
batters that make baked products rise.
Steam: high temperatures used in baking heatliquid ingredients enough to form steam.
Yeast Baking soda and powder
Formulation
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Formulation Liquids- Water, milk, and juice are
common. They serve to hydrate starch to
absorb water. Fats- Tenderizes the product.
Eggs- Add color, flavor, and contribute tostructure.
Salt and sugar- Adds flavor and
regulates the action of yeast.
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Typical recipies
161,200 kg165,700 kg158,200 kgtotal
2,500 kg4,000 kg1,000 kgImprover
1,700 kg1,700 kg1,700 kgSalt
2,500 kg5,000 kg2,500 kgYeast
55,000 kg55,000 kg53,000 kgWater
100,000 kg100,000 kg100,000 kgFlour
BaguettesBread rollPlain white
bread
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Typical recipies
189,700 kgTotal172,700 kgTotal
15,000 kgImprover
10,000 kgRaisins1,500 kgImprover
2,000 kgSugar2,500 kgOlive oil
1,7000 kgSalt1,700 kgSalt
8,000 kgYeast1,000 kgYeast
53,000 kgWater66,000 kgWater
100,000 kgFlour100,000 kgFlour
Raisin breadCiabatta
Mixing
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Mixing
Dough Formation
Doughs are viscoelastic (flows andrecoils)
Structure largely from proteins calledglutens
consist of gliadins and glutenins
30% of amino acid residues arehydrophobic
water insoluble; can bind water
Kneading
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Kneading
Kneading bread subjects it to shearforces
promote interactions between gluteninmolecules
H- bonding, hydrophobic interactions, S-Sbonds
creates elastic protein networks (films)
which trap gasviscosity enhanced by gliadins and starch
molecules
Kneading is important
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Kneading is important
After forming the dough for yeast breads,
you MUST knead it!!!! Almost all of the gluten forms during the
kneading stage. It is important to not add
too much extra flour while kneading. Thiswill make the dough far too stiff.
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Dough Formation Knead to optimum rheology optimumdough strength
over-kneading breaks protein structure
before kneading after optimal kneading
50 m 1 m
Temperature control is very
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important
Fermentation rate will change in function ofthe temperature : in the same time more (orless) CO2 will produced. If the bread is 10% bigger you need also 10 % more trucks.
Relationship between humidity and
temperature : or the dough will get sticky orcrusty in the proofer
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Dough consistency will change in function of thetemperature i.e. the behaviour on the line will bedifferent
During lamination the butter or margarine will getcolder or warmer in line with the doughtemperature. To make good puff both should
have the same consistency
In 1 hour in 1 kg dough of 28C the yeast will
metabolise about 10 g of sugar. If the doughhas 29C, the yeast will metabolise 10 % moresugar. Result the bread is less sweet.
Mixing
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Mixing
Temperature control can happen indifferent ways :
Adding ice to the dough
Use cold water Cooling the mixing bowl
Use salt as a saturated solution
Cool down flour during pneumatic transportwith CO2 (and not injecting CO2 in the dough)
Bread Fermentation
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After you knead the dough, what do youdo???
When you let it rest in a warm place, theyeast acts upon the sugar and the carbondioxide causes the bread to rise. This iscalled FERMENTATION!
The bread should at least double in sizeduring fermentation
The fermentation occurs during bread manufacturing
is different from most other food fermentations Purpose
Fermentation end products
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About Yeast Single celled, microscopic plant.
When you add sugar to yeast, it reacts to thebacteria and creates carbon dioxide. Thisleavens the baked product.
Water mixed with yeast MUST be between 110and 125 degrees in order to keep the yeast alive.
Available in three forms:
Active dry (what we use)- Compressed( very perishable)
- Fast rising yeast (rises twice as fast)
Types of Yeast
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yp Commercially available
Yeast cream
Used directly, highly perishable Yeast cake
Yeast cream through filtration press or vac. filter
Refrigeration required, shelflife a few week Metabolically active, quick fermentation
Dry active yeast
Home bread making, small business operation Last 6 months or longer
Require hydration, not as active
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S. cerevisiae, or bakersyeast Properties and characteristics for bread
making
Gassing power
Flavor development
Stable to drying Stable during storage
Easy to dispense
Ethanol
cryotolerant
Yeast Cultures
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Growth medium Molasses or another inexpensive source of sugar and
various ammonium salts
Other yeast nutrients Ammonium phosphate Magnesium sulfate Calcium sulfate, trace minerals (zinc, iron)
Cell mass production required conditions O2 level Temp (30C)
pH (4.0-5.0) continuous
Fermentation
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Fermentation
Lag phase usually
Bakersyeast facultative metabolism Aerobic (via TCA cycle)
Anaerobic glycolytic fermentation pathway
Glucose inhibit TCA enzymes
CO2
Sugar metabolism by bakers yeast
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g y y
Carbohydrate sources Starch
Sugars (glucose and maltose) Transport and utilization
Sequential use Regulation-glucose represses enzymes involved in
maltose transportation
Maltose represses invertase expression
Mutants available Sugar transport
Glycolysis
Fermentation
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End products
CO2
Other compounds Various acids and organic compound by yeasts
By LAB
Flavor and rheology of the dough
Factors affecting growth
Temp-hold at 25-28 instead of the optimalgrowth temp 36-39 to minimize microbailcontamination, and maintain yeast activity
Relative humidity 70-80%
Glucose
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Glucose 6-phosphate
Fructose 6-phosphate
Fructose 1, 6 phosphate
DGAPDihydroxyacetone
PGALGlyceraldehyde
3-phosphate
PEP
Phosphenopyruvate
Pyruvate
Oxaloacetate
Respiration Chain
TCA Cycle
CO2
CO2Lactic acid Acetyl CoA
+36 ATP
Ethanol
CO2+2 ATP
+2 ATP
Factors affecting fermentation
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g
Too much salt inhibits yeast activity, reducing
the amount of carbon dioxide gas producedand decreasing the volume of the loaf.
No salt Normal salt Double salt
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Punching Down! When the dough has risen all
the way and has doubled insize, you have to punch it
down to release some of the
carbon dioxide. Some dough requires a
second rising period.
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Avoid Over fermentation
Gluen streches, becomes weak andcan collapse
Coarse grain & sour odor due toexcess acid production
Less color in baked crust
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Oven spring The quick expansion of dough during the
first ten minutes of baking, caused byexpanding gases.
Baking
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30 C1.CO2-gas expands
2.increased enzymatic activity3.reduced solubility of CO2 in water
45 50 C1.yeast dies
50 60C
1.intensive enzymatic activity2.starch begins to gelatinise
Baking
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Types of ovens
1. According to heating system directly fired
indirectly fired (air, oil)
2. According to product movement static ovens
continuous belt ovens (tunnel ovens) rotary ovens (horizontal & vertical)
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Types of ovens
3. According to type of fuel
gas
gasoil
4. According to heard type
stone metal (including baking trays)
Cooling & Freezing
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Don't touch the bread as long as the crumb hasmore then 80C (semi liquid damage of
structure staling)
During cooling and freezing bread looses about
2 % of its weight (i.e. water loss)
Freezing : only water freezes. Because of the
difference in moisture content between the crustand the crumb, the crust can flake off.
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Cooling & Freezing
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In the case of frozen dough, special attention hasto be paid to :
1.Freshness of the yeast, type of yeast (freezetolerant), quantity of the yeast (more but toomuch can be negative weakening ofgluten structure).
2.Avoid that fermentation starts beforefreezing (unless you make preproofed frozen
of course)3.Handling in the shop : slow thawing to get
even temperature distribution in the product
before proofing and baking (retarder-proofer)
Cooling & Freezing
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During storage at - 18C theproduct looses moisture and
becomes drier and drier(flaking).
This depends on the storageconditions (air velocity,temperature fluctuations and
relative humidity in thefreezer) = freeze burn
Understanding how bread rises
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When yeast (block or dried) is mixed with waterand sugar it becomes frothy.
The yeast cells multiply, this process is calledfermentation. Fermentation stops if the
water/dough is too hot or cold or if there is nosugar.
Yeast mixture or dried yeast is added to flour,t d th i di t k d d d
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The loaf tin is put in the oven, the heat killsthe yeast and cooks the dough leavening a'risen' loaf.
Carbon dioxide gas is produced by the yeastwithin the dough forming pockets whichmakes the dough rise in the warmth. Thisprocess is called proving.
water and other ingredients, kneaded andplaced in a loaf tin.
6 Bakery prodcut technology
l
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examples
Sour dough Bread
Bread product
Breakfast Foods
Example1- Sour dough Bread
Sour dough rye bread
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Sour dough rye bread Most studied bacterial bread fermentation
Popular in Europe
Micro-organisms isolated from sour rye Bacteria: Lb. plantarum, Lb. brevis, Lb. casei, Lb.
fermenti, Lb. pastorianus, Lb. buchneri, Lb.leichmannii, Lb. acidophilus, Lb. farciminis, Lb.alimentarius, Lb. vrevis var. lindneri, Lb.fermentum, Lb. fructivarans, Pediococcusacidilactici
LAB with very high amino acid requirementdominant
Yeasts: Candida krusei, Saccharomycescerevisiae, Pichia saitoi, Torulopsis holmii
Candida kruseidominant
Sour Dough Bread
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The San Francisco sourdough Frenchbread
Use start culture ormother-sponge Occurred in San Francisco, continuously used
for over 140 years
Ecosystem consists of on species of yeastand one species of bacteria
Occurred in a ratio of 1:100
Yeast- Candida milleri(or Torulopsis holmii)
Bacteria- Lb. sanfrancisco
Formulations for San Francisco Sour Dough
French Bread
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French Bread
Starter-sponge Bread dough
100 parts of previous sponge 20 parts starter-sponge
(40% of final mix) (11% of final mix)
100 parts flour (high-gluten) 100 parts flour (regular patent)
46-52 parts water 60 parts water
2 parts salt
Starting pH 4.4-4.5 Starting pH 5.2-5.3
Final pH 3.8-3.9 Final pH 3.9-4.0
Example2 Bread product
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Flour arrives in tankers at the bakery and isstored in silos. Typically holding 50 tons of
sifted flour.
Computer-controlled mixer weighs flour
and water. Batches of dough are mixedevery few minutes.
Yeast, salt and other ingredients are addedautomatically.
Batches of dough are divided into portionsfor 400g or 800 Conical moulders shapedough into balls to produce 8000 loaves
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dough into balls to produce 8000 loavesper hour. g loaves at a speed of125 loaves per minute.
Conical moulders shape dough into ballsto produce 8000 loaves per hour.
First prover allows dough to 'rest' for 6-8minutes.
Panner moulder shapes dough for final
product
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product
Dough spends 50 minutes in final prover andexpands in controlled humidity and temperature.
Bread travels through the oven for 20-25 minutes.Lids are added to some tins to produce flat-toppedbread. 6000 large or 8000 small loaves are baked perhour.
Lids and pans removed before cooling for 2-
3 hours in the cooler.
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3 hours in the cooler.
The bread is sliced and regular samples aretaken away to be inspected to ensure qualityis maintained.
Bread is packaged, stacked and put ontolorries for distribution.
Example 3 Break fast FoodsBreak fast Foods
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Ready-to-eat cereals Quick-cooking/instant cereals
Raw/old-fashioned cereals
Prepar ing Cook edPrepar ing Cook ed
Break fast Cerea lsBreak fast Cereals
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Break fast Cerea lsBreak fast Cereals Use recommended
amount of water.
To prevent lumping,slowly add dry cereal toboiling water or mix first
with cold water to form apaste.
Gently stir cereal with a
fork. Cook cereal until it
thickens and absorbs allthe water.
Prepar ing Ric ePrepar ing Ric e
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Cook over direct heat,
in a double boiler, or inthe oven.
Use recommended
proportions of rice andwater and cook until allliquid is absorbed.
National Chicken Council
Prepar ing Past aPrepar ing Past a
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Add pasta gradually toboiling water.
Simmer just until tender.
Drain but do not rinsecooked pasta.
National Pasta Association