indicators, and measures of tortilla quality” 2016 and... · 5690 lindbergh lane • bell, ca •...
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5690 Lindbergh Lane • Bell, CA • 90201 Phone: 562-806-7560 • www.solvaira.com
“Pointers,Indicators,andMeasuresofTortillaQuality”
TomJondiko,Ph.D.
Consumersperspective:• Thedefinitionofagoodqualitytortillaencompassestheabilitytoretainitsflexibility,remainstrongsothereisnocrackingortearing,andofcourse,tastegood.(Waniska etal2004,Jondikoetal2016).
TortillaProducersperspective:• Qualityincludesuniformshapes,toastmarks,soft,fluffy,adequateshelflifefordistributionandsales.
Overallperspective:• Quality=Qualityrawmaterial+Qualityprocessing+
Qualityofpersonnel.
Tortilla Quality
Tortilla Formula Composition
60.0%
29.0%
6.0% 5.0%
Flour Water Shortening Batch Pack
Batch Pack:Salt, Sugar, LeaveningDough Conditioners & Preservatives
Tortillas must meet consumer expectations.• Physical parameters (Soft, pliable).• Good diameter, uniform, toast marks and long shelf life.
Defining Quality
• Goodqualitytortillasproducedusingwheatflourofintermediateproteinandlowlevelofstarchdamage(Waniska etal2004).
Starchcharacteristics:– Measuredusingrapidvisco analyzer.– Peakandfinalviscosity.– Affectcookingconditions.– Tortillaflexibility.– Tortillashelfstability.
Flour: Starch Quality
• Evaluate quality of new flour compare to standard.• Starch is gelatinized causes rise in viscosity.• Tortillas start sticking on each other.
New Flour Starch Quality
High Protein
All purpose
New Flour 1
New Flour 2
Pastry Flour
James Chapa 2016, Solvaira R&D
ProteinContent• Goodqualitycanbeproducedusingwheatflourofintermediateproteincontent(Waniska etal2004).
Proteincontentisnotanadequateindicatoroftortillaquality• Proteincontentcannotsimultaneouslypredictbothdiameterandrollability
• Lookatproteinfractions?
Protein Quality vs Quality
10 15 20 25
LU
0.80.91.01.11.21.31.4
10 15 20 25
LU
1.01.251.51.752.02.252.5
Elution time (min)
Abs
orba
nce
at 2
10 n
m
Flour protein fraction and tortilla quality
Parameter RangeGlutenin: Gliadin Ratio 0.5 – 0.9Mono & Polymeric proteins 12 – 65HMW & LMW – GS 0.3 -0.6
• Wheat protein fractions in gluten play a significant role in tortilla making (Jondiko et al. 2012)
• Variation of flour protein molecules can improve tortilla quality.
• Tortilla diameter can be predicted using a protein molecule content and dough rheological properties
• Tortilla softness depends on the ratio of the gluten protein molecules
Relationship of tortilla diameter, flexibility & flour protein
Total Protein content and Functionality
Good Flexibility Small diameter
Acceptable Diameter Flexibility
Not Acceptable:Falling apart and sticking
Not Acceptable:Very week, sticky
dough, brittle tortillas
Gluten Acid TestCorrelationBetweenProteinContentandViscosityat3minutesMeasuredintheWheatGlutenAcidTests
High Protein Flour
All Purpose Flour 1All Purpose
Flour 2
Pastry Flour
New High Protein Flour Samples
y = 0.0028x + 7.9225R² = 0.9948
8
9
10
11
12
13
14
250 450 650 850 1050 1250 1450 1650 1850 2050
Protein Co
nten
t (%)
Viscosity (cP)
James Chapa 2016, Solvaira R&D
• New High protein flour 13% total protein has only 11% functional protein• Can result in tortilla quality defects• Evaluate the functionality of new flour when received
Gluten Quality: Viscosity & Temperature
Qualityvariation: Higherviscositymeanshigherglutenquality TortillaSticking Oventemperatureadjustment
High Protein Flour
All Purpose Flour
Pastry Flour
New Protein Flour
James Chapa 2016, Solvaira R&D
Functional Protein Content & Flexibility
Intermediate Functional Protein Content
(10.5 % – 12.0%)
Low Functional Protein Content
(8.0 – 10.5% )
Predicting Flour Functionality for Tortillas
F_25Area
1) Prediction value > or = 0: Suitable flour for quality tortilla2) Prediction value < = 0: Unsuitable for good tortilla
Good Rollability and Diameter = -10.15 – 0.19*Weight + 10.58Glu:GliRatio – 0.05*IPP –0.22*Area + 1.4*F_25 + 0.36*F_100 + 0.02*CompForce;
• Thesecondlargestcomponentoftortillas.
• Optimumtortillamoisturecontent:29– 32%affects:– TortillaTexture– Shelf‐life– Excesswatercreatesteamandweakenstortillastructure
• Monitormicrobialcountsonwaterused.
• Watertemperatureofusedtomakedough.
• WaterpH:– DependingsourcewatercanbetreatedtoadjustpHhencemeasurepHregularly
– Measureconductivitytodeterminehardness
Water Quality
Animportantcomponentoftortillas• Typeused:
– liquidoil– Solidshortening
• Affecttortillatexture:– Slowstaling– Interactwithflourcomponents– starch&protein
• Improvesdoughmachinability&reducestickiness
• Providedesiredflavorintortillas
• Prevents&reducestortillastickingduringstorage
Shortening/ Fat Quality
RawMaterialQuality: TestforpH,CO2,Sodium,moisture
Microbialloads
ParticleSizedistribution
Puritytests
Baketestsforfunctionality
Stickingtest
Flexibility,&AcceleratedShelflife
Functional Ingredients
• Temperaturereductionafterbaking,duringpackaging,intransportationandinstorage.
• Monitoranddocumentparameters:– Doughmixing– Dividing&rounding– Pressingmethod– handstretch,hotpressordiecut– Oven– Cooling– Packaging
Processing and storage conditions
• pH:Idealbetween5.2– 5.8flourtortillas.
• Preservatives:SorbatesandpropionateeffectiveatlowpHwhereasParabensathighpH(QuestionsaroundsafetyofParabens).
• Microbialload:Establish&monitorCOAlimitsforallsuppliers.
Other aspects of shelf stability
Therecipetodelivergoodqualitytortillas
QualityofFlour. QualityofWater. QualityofShortening/Oil Qualityoffunctionalingredients. Qualityofpersonnel:qualification,training&continuousimprovement.
Consistentdocumentationandmonitoringofdata.
Conclusion