AU3557002A - Baked product, and method of manufacture and packaging - Google Patents

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Applicant: BAKED PRODUCT, AND METHOD MANUFACTURE AND PACKAGING BESJEN PTY LTD

OF

The following statement is a full description of this invention, including the best method of performing it known to me: 2 BAKED PRODUCT, AND METHOD OF MANUFACTURE AND PACKAGING This invention relates to a baked product as well as the manufacture and packaging of such a product. The invention is applicable to bread, and it will be convenient to hereinafter describe the product in relation to that application. It should be appreciated, however, that the invention is not limited to that application, but may be equally applicable to buns, biscuits, muffins, pizza, pastry, croissants, tortillas and pretzels.

Freshly baked bread, if not frozen, typically has a shelf life of up to a few days before turning stale or possibly developing mould. That short shelf life makes it difficult and expensive to transport the bread over international or long distances, and store for extended periods of time. As such, bread tends to be manufactured for localised markets. Those markets, in turn, depend on the available ingredients and capabilities of individual manufacturers for the range of breads that are made available for purchase and consumption. In many cases, that range can be quite limited.

It is an object of the present invention to provide a freshly baked product such as bread which has an extended shelf life.

It is a further object of the present invention to provide a freshly baked product, such as bread, which can be readily transported over international and long distances, and stored for extended periods of time, while remaining fresh prior to consumption.

With those objects in mind, the present invention provides, in one aspect, a baked product including a dough formulation containing an effective amount of organic flour, a leavening agent and water.

In another aspect, the present invention provides a packaged baked product including: a freshly baked product; and, a package enclosing the baked product, the package having a modified gaseous atmosphere for the product and being hermetically sealed so as to maintain the product in the modified atmosphere and thereby retain the freshness of the baked product for an extended period.

In a further aspect, the present invention provides a method of manufacturing a baked product, including: W kate\SPECI\Complete of PR3858.doc 3 providing a dough formulation containing an effective amount of organic flour, a leavening agent and water; combining the dough formulation to form a dough; and heating the dough sufficiently to cause baking to produce a baked product.

In yet another aspect, the present invention provides a method of packaging a freshly baked product, including: providing a package for the product; positioning the product in the package; establishing a modified gaseous atmosphere for the product within the package; and hermetically sealing the package so as to maintain the product in the modified atmosphere and thereby retain the freshness of the baked product for an extended period.

In at least one preferred embodiment of the present invention, the dough formulation contains organic wheat flour. That flour is white flour, in one embodiment.

Examples of suitable organic wheat flour include flour marketed under the brand names FRAME, JANZ and SWIFT.

In at least one preferred embodiment of the present invention, the dough formulation also contains rye flour. That flour is organic rye flour, in one embodiment.

In one preferred embodiment, the rye flour retains the rye husks. All of those husks from the ground rye are retained in the flour, in this embodiment.

The amount of rye flour in the dough formulation is substantially less than the amount of wheat flour, in one preferred embodiment of the invention. In that regard, in one preferred embodiment the ratio of wheat flour to rye flour is between 10:1 and 25:1 (by weight). In one particular embodiment, that ratio is greater than about 15:1, and may be up to about 20:1. In one specific example, the ratio of wheat flour to rye flour is 19:1 (by weight).

In one preferred embodiment, the dough formulation contains at least (by weight of dough formulation) flour. In one particular embodiment, the wheat flour content is at least 50%, and the rye flour content is less than about W:\kate\SPECI\Complete of PR3858.doc 4 In one specific example, those contents are about 55% and about 2.9%, respectively.

Examples of suitable organic rye flour include rye flour marketed under the brand names of BEVY and SA COMMERCIAL.

In at least one preferred embodiment of the present invention, the leavening agent includes a yeast. Any commercially available yeast, appropriate for the bakery product, may be used.

In one preferred embodiment, the yeast is present in an amount of less than 2% (by weight of the dough formulation). In one specific example, that amount is about 1.4%.

In one preferred embodiment, the dough formulation has a relatively high water content. In this embodiment, water is present in an amount of at least (by weight of dough formulation). In one particular embodiment, that water content is between 35 and 40% and, in one specific example, the content is about 37%.

In at least one preferred embodiment of the present invention, the dough formulation includes an improver. Any commercially available improver, suitable for the intended baked product, may be used. That improver is present in an amount of less than 1% (by weight of dough formulation), in one particular embodiment. In one specific example, the improver is present in an amount of about 0.3%.

In at least one preferred embodiment of the present invention, the dough formulation may include one or more additives introduced for predetermined reasons, including flavour and nutritional value of the product. Those additives can include salt, fat and sugar. Each of those additives are organic, in a preferred embodiment of the invention.

The additives are each present in amounts of less than about 2% (by weight of dough formulation), in one particular embodiment. In one specific example, the salt, fat and sugar additives are present in amounts of about 1.4%, 1.1% and respectively.

In at least one preferred embodiment of the present invention, packaging of the baked product occurs shortly after its manufacture.

In at least one preferred embodiment, the package has a modified gaseous atmosphere containing carbon dioxide. The carbon dioxide has a W:kate\SPECI\Complete of PR3858,doc fungistatic and bacteriostatic effect on the product, retarding growth of microorganisms such as mould and aerobic bacteria.

In one preferred embodiment, the atmosphere contains at least 20% (by volume) carbon dioxide. However, in alternative embodiments the atmosphere can contain up to about 100% carbon dioxide.

In at least one preferred embodiment, the modified atmosphere may contain nitrogen. The nitrogen in the atmosphere provides mechanical protection to the package against collapse, as well as chemical protection to the product against oxidation.

Preferably, nitrogen forms at least substantially the balance of the atmosphere with carbon dioxide, and so in one preferred embodiment is present in an amount of up to about 80% (by volume). In one specific example, the atmosphere contains about 40% carbon dioxide and about 60% nitrogen.

The hermetically sealed package excludes oxygen so as to restrict growth of bacteria and moulds, and avoid oxidation and thus spoilage of the product. In order to absorb any oxygen either permeating the packaging into the modified atmosphere or emitted from the baked product, the package preferably contains an oxygen absorber within the container.

In alternative embodiments, the oxygen absorber is in packet and card formats positioned within the container.

The oxygen absorber is of any suitable formulation well known to those skilled in the relevant art. One suitable oxygen absorber is commercially available from Mitsubishi Gas Chemical Co. Inc. under the brand name

AGELESS.

In at least one preferred embodiment, the modified atmosphere may further include ozone to assist in preservation of the product. The ozone is present in a very small amount, for example up to 1 ppm of the volume of atmosphere.

In a preferred embodiment, the modified atmosphere may include acetic acid gas for inhibiting mould growth in the product. In one particular embodiment, the acetic acid gas is introduced into the package at an amount of about 1% or less by weight of the product. In specific examples the atmosphere contains 0.3% and 0.2% acetic acid gas by weight of the packaged product.

W:Akate\SPECIComplete of PR3858.doc 6 In a preferred embodiment of the present invention, the package includes a container such as a bag or wrapper which can be sealed closed about the product. In one embodiment the container is composed packaging is composed of food grade plastic packaging material in sheet or film format.

The packaging material, in one preferred embodiment is multilayered or laminated from two or more polymers in order to provide the necessary and desirable packaging properties, including gas barrier permeability, water vapour transmissibility, anti fog capabilities, and sealing reliability. In particular, the film is selected to produce low (less than 10 ml per 24 hours per square meter) oxygen permeability, whilst providing a high barrier to nitrogen and carbon dioxide permeating through the package.

The packaging material, in one preferred embodiment is also thermoformable to enable formation into suitably shaped and sized package, and sealing of the baked product into that package.

Materials suitable for forming the packaging material include nylon, polypropylene, polystyrene, polyvinylchloride, polyvinylidene chloride, ethylene vinyl acetate, and ethylene vinyl alcohol. In one specific example, the material is a laminate of nylon coated on at least one side thereof with polyvinylidenechloride.

In at least one preferred embodiment of the manufacture of the product, the dough formulation is combined by mixing the formulation ingredients together for a predetermined period of time. In one embodiment, the mixing occurs initially at a lower mixing rate, and then finally at a higher mixing rate.

The higher mixing rate is for a longer period of time, such as about 3 times longer, than the period of time for the lower mixing rate.

In one preferred embodiment, the ingredients are combined in a fork mixer.

In at least one preferred embodiment, the manufacturing method further includes allowing the dough to rest or quiescently set for a predetermined period of time following mixing. That period of time is approximately minutes, in one embodiment.

Where the dough is formed in a commercial batch, then the rested or set dough batch can be divided and shaped into dough pieces prior to heating.

W:kkateSPECIlComplete of PR3858.doc 7 In at least one preferred embodiment, the method further includes proofing the dough. That proofing occurs after resting or setting of the dough batch or dough pieces. Preferably, proofing occurs at 80% humidity. That proofing is for a predetermined period of time of up to about 1 hour, for example 45 minutes, in one embodiment of the present invention.

In one preferred embodiment, the proven dough is heated by placing in an oven for a predetermined period of time until cooked. The oven is a convection oven, in one embodiment.

During baking, the oven receives a steam injection, to facilitate retention of moisture within the baking dough. That injection is at the beginning of the baking period, in one preferred embodiment. The injection extends for a period of time of about 20 seconds.

The baked product is packaged using any suitable packaging machinery, including thermoforming machines, and form, fill and seal machines. In this embodiment, those machines incorporate facilities to inject gas into the package to create the modified atmosphere in which the product is maintained.

In at least one preferred embodiment, the packaging method includes allowing the cooked product to cool prior to placing in the package. That cooling is to between about 150C and 300C, and preferably to below 250C. In one specific example, that cooling is achieved by exposing the baked product for up to about 1 hour to filtered cooling air. In this example, the air is refrigerated, and treated with UV and sanitiser to ensure it is free from moulds and bacteria.

In one preferred embodiment, cooling of the baked product occurs immediately after baking, and the baked product is packaged immediately following cooling.

In at least one preferred embodiment, packaging of the product may include treating the product with ozone immediately prior to placement in the container. In that embodiment, the cooled and unpacked products are exposed to ozone such as by passing through an ozone layer or curtain, or by receiving a spray of ozone.

In order to assist an understanding of the present invention, example methods of manufacturing and packaging a white bread product are described W:e\kateSPEC\Complete of PR3858.doc 8 hereinafter. The particularity of the examples is not to be understood as superseding the generality of the preceding description.

In a first example, 35 gram white bread rolls were produced using the following dough formulation: Ingredients Weight (kg) Organic wheat flour 97.85 Organic rye flour with husks 5.15 Organic salt 2.575 Organic fat 2.06 Organic sugar 0.515 NASAA certified organic water 66.95 Improver 0.515 Yeast 2.575 The ingredients were mixed in a fork mixer, initially for 5 minutes at a first lower speed and then for 15 minutes at a second higher speed, to form a dough mixture.

The dough was removed from the mixing bowl and rested or set for minutes.

The dough was then divided and shaped into 35 gram bread rolls, and allowed to proof for about 45 minutes at 80% humidity.

The dough pieces were then fully baked for 13 minutes in a convection oven at 1800C, with a 20 second steam injection into the oven at the beginning of the baking period.

The freshly baked rolls were then removed from the oven and cooled to about 250C over about one hour prior to positioning in a package.

The cooled rolls were then enclosed in a package in the form of a bag composed of food grade plastic packaging film. The bag was injected with gas containing 60% nitrogen and 40% carbon dioxide to establish a modified atmosphere for the rolls. That atmosphere was also provided with an oxygen absorber. The bag was finally hermetically sealed.

In a second example, 35 gram white bread rolls were produced and packaged as in the first example, except that the cooled rolls were passed W:\kate\SPECilComplete of PR3858.doc through a curtain of ozone prior to placement in a bag and the atmosphere established in the bag contained 1% acetic acid (by weight of the product), ozone up to l1ppm (by volume) and the balance carbon dioxide. In this example, the bag was composed of a laminate of nylon coated on one side thereof with polyvinylchloride.

In each example packages of the rolls have been opened and the rolls inspected after shelf periods of up to 3 months. The rolls have exhibited excellent freshness and no visible sign of mould or other deterioration.

Moreover, it is expected that longer shelf life can be achieved using the present invention.

The present invention provides a baked product that has an extended shelf life compared with existing products. Tests to date indicate that the shelf life will be in the order of several months without any requirements for special transportation or storage. During that extended period freshness of the product is retained. Such a long shelf life makes the baked product readily accessible to a much wider market.

The manufacturing and packaging methods utilise conventional baking and packaging equipment. Accordingly, the cost of manufacturing and packaging the product will compare favourably with the cost of conventional product manufacture and packaging, particularly when the increased versatility of the product due to its extended shelf life is taken into account.

Finally, it is to be understood that various alterations, modifications and/or additions may be introduced into the baked product and its method of manufacture without departing from the ambit of the present invention as defined in the claims appended hereto.

W:\kateSPEC1\Complete of PR3858.doc

Claims (44)

1. A baked product including a dough formulation containing an effective amount of organic flour, a leavening agent and water.

2. A baked product as claimed in claim 1, wherein the organic flour includes organic wheat flour.

3. A baked product as claimed in claim 1 or 2, wherein the organic flour includes white wheat flour.

4. A baked product as claimed in any preceding claim, wherein the organic flour includes rye flour.

5. A baked product as claimed in any preceding claim, wherein the organic flour includes organic wheat and rye flours in the ratio of between 10:1 and 25:1 (by weight).

6. A baked product as claimed in any preceding claim, wherein the dough formulation contains at least 50% (by weight of the dough formulation) flour.

7. A baked product as claimed in any preceding claim, wherein the dough formulation contains at least 30% (by weight of dough formulation) water.

8. A baked product as claimed in any preceding claim, wherein the product is par baked.

9. A packaged baked product including: a freshly baked product; and, a package enclosing the baked product, the package having a modified gaseous atmosphere for the product, the modified atmosphere at least substantially excluding oxygen, and the package being hermetically sealed so as to maintain the product in the modified atmosphere and thereby retain the freshness of the baked product for an extended period.

A baked product as claimed in claim 9, wherein the modified atmosphere contains carbon dioxide.

11. A baked product as claimed in claim 10, wherein the modified atmosphere contains at least 20% (by volume) carbon dioxide.

12. A baked product as claimed in any one of claims 9 to 11, wherein the modified atmosphere contains nitrogen.

13. A baked product as claimed in claim 12, wherein the atmosphere contains up to about 80% (by volume) nitrogen. W:fkatelSPECI\Complete of PR3858.doc 11

14. A baked product as claimed in any one of claims 9 to 13, the package contains an oxygen absorber to absorb any oxygen permeating the package into the modified atmosphere or emitted from the product.

A baked product as claimed in any one of claims 9 to 14, wherein the package includes a container composed of food grade plastics material.

16. A baked product as claimed in claim 15, wherein the container includes a bag or wrapper composed of plastic sheet or film.

17. A baked product as claimed in any one of claims 9 to 16, wherein the modified atmosphere contains ozone.

18. A baked product as claimed in any one of claims 9 to 17, wherein the modified atmosphere contains acetic acid.

19. A baked product as claimed in claim 17, wherein the modified atmosphere contains up to about 1% (by weight of the baked product) of acetic acid.

20. A baked product as claimed in any one of claims 9 to 19, wherein the freshly baked product is as claimed in any one of claims 1 to 8.

21. A method of manufacturing a baked product, including: providing a dough formulation containing an effective amount of organic flour, a leavening agent and water; combining the dough formulation to form a dough; and heating the dough sufficiently to cause baking to produce a baked product.

22. A method as claimed in claim 20, wherein providing the dough formulation includes providing organic wheat flour.

23. A method as claimed in claim 21 or 22, wherein providing the dough formulation includes providing organic rye flour.

24. A method as claimed in any one of claims 21 to 23, wherein providing the dough formulation includes providing organic wheat and rye flours in the ratio of between 10:1 and 25:1 (by weight).

25. A method as claimed in any one of claims 21 to 24, wherein providing the dough formulation includes providing at least 50% (by weight of the dough formulation) organic flour.

26. A method as claimed in any one of claims 21 to 25, wherein heating the dough includes initially heating sufficient to par bake the dough, and W: k te\SPECI\Complete of PR3858.doc 12 subsequently reheating the dough sufficiently to finally bake the dough and form the product.

27. A method of packaging a freshly baked product, including: providing a package for the product; positioning the product in the package; establishing a modified gaseous atmosphere for the product within the package, the modified atmosphere at least substantially excluding oxygen; and hermetically sealing the package so as to maintain the product in the modified atmosphere and thereby retain the freshness of the baked product for an extended period.

28. A method as claimed in claim 27, wherein establishing the modified atmosphere includes providing to the package a gas containing carbon dioxide.

29. A method as claimed in claim 28, wherein the gas contains at least about (by volume) carbon dioxide.

30. A method as claimed in any one of claims 27 to 29, wherein establishing the modified atmosphere includes providing to the package a gas containing nitrogen.

31. A method as claimed in claim 30, wherein the gas contains up to about nitrogen.

32. A method as claimed in any one of claims 27 to 31, wherein establishing the modified atmosphere includes providing to the package a gas containing ozone.

33. A method as claimed in any one of claims 27 to 32, wherein establishing the modified atmosphere includes providing to the package a gas containing acetic acid.

34. A method as claimed in claim 33, wherein the gas contains acidic acid in an amount of up to about 1% by weight of the baked product in the package.

A method as claimed in any one of claims 27 to 34, and including cooling the freshly baked product prior to positioning in the package.

36. A method as claimed in claim 33, wherein the baked product is cooled to between 15 0 C and 300C.

37. A method as claimed in claim 35 or 36, wherein cooling the baked product includes exposing the product for up to about 1 hour to filtered cooling air. W:~kate\SPECComplete of PR3858.doc 13

38. A method as claimed in any one of claims 27 to 37, and including exposing the baked product to ozone prior to positioning in the package.

39. A method as claimed in claim 38, when appended to any one of claims to 37, wherein the baked product is exposed to ozone after cooling.

40. A method as claimed in any one of claims 27 to 39, and including providing an oxygen absorber in the modified atmosphere prior to hermetically sealing the package thereby to absorb any oxygen therein.

41. A method as claimed in any one of claims 27 to 40, wherein positioning the product in the package includes positioning a baked product as claimed in any one of claims 1 to 8 in the package.

42. A baked product substantially as hereinbefore described with reference to any one of the examples.

43. A packaged baked product, substantially as hereinbefore described with reference to any one of the examples.

44. A method of manufacturing a baked product, substantially as hereinbefore described with reference to any one of the examples. A method of packaging a freshly baked product, substantially as hereinbefore described with reference to any one of the examples. DATED: 19 April 2002 PHILLIPS ORMONDE FITZPATRICK Attorneys for: BESJEN PTY. LTD. W:'kate\SPEC\Complete of PR3858.doc