BE1024347B1 - Method for the preparation of a bakery product and bakery product obtained thereby - Google Patents

Abstract

The present invention relates to a method for producing mainly organic bakery products with a high and uniform quality without adding multiple improvers. In a second aspect, the invention relates to a device for producing bakery products according to the aforementioned method.

Description

Priority date:

International classification: A21B 7/00, A21C 9/08, A21C 13/02 Application number: BE2016 / 5531

Date of submission: 30/06/2016

Holder:

BIO BAKERY DE TROG BVBA

8900, YPRES

Belgium

Inventor:

DURNEZ Hendrik

8670 OOSTDUINKERKE

Belgium

Process for the production of a bakery product and bakery product obtained thereby

The present invention relates to a method for producing mainly organic bakery products of a high and uniform quality without adding multiple improvers. In a second aspect, the invention relates to an apparatus for producing bakery products according to the aforementioned method.

BELGIAN INVENTION PATENT

FPS Economy, K.M.O., Self-employed & Energy

Publication number: 1024347 Filing number: BE2016 / 5531

Intellectual Property Office

International Classification: A21B 7/00 A21C 9/08 A21C 13/02 Date of Issue: 05/02/2018

The Minister of Economy,

Having regard to the Paris Convention of 20 March 1883 for the Protection of Industrial Property;

Having regard to the Law of March 28, 1984 on inventive patents, Article 22, for patent applications filed before September 22, 2014;

Having regard to Title 1 Invention Patents of Book XI of the Economic Law Code, Article XI.24, for patent applications filed from September 22, 2014;

Having regard to the Royal Decree of 2 December 1986 on the filing, granting and maintenance of inventive patents, Article 28;

Having regard to the application for an invention patent received by the Intellectual Property Office on 30/06/2016.

Whereas for patent applications that fall within the scope of Title 1, Book XI, of the Code of Economic Law (hereinafter WER), in accordance with Article XI.19, § 4, second paragraph, of the WER, the granted patent will be limited. to the patent claims for which the novelty search report was prepared, when the patent application is the subject of a novelty search report indicating a lack of unity of invention as referred to in paragraph 1, and when the applicant does not limit his filing and does not file a divisional application in accordance with the search report.

Decision:

Article 1

BIO BAKERY DE TROG BVBA, Rozendaalstraat 65, 8900 IEPER Belgium;

represented by

BRANTS Johan Philippe Emile, Pauline Van Pottelsberghelaan 24, 9051, GHENT;

a Belgian invention patent with a term of 20 years, subject to payment of the annual fees as referred to in Article XI.48, § 1 of the Code of Economic Law, for: Process for the production of a bakery product and bakery product obtained thereby.

INVENTOR (S):

DURNEZ Hendrik, Prins Boudewijnstraat 10, 8670, OOSTDUINKERKE;

PRIORITY:

BREAKDOWN:

Split from basic application: Filing date of the basic application:

Article 2. - This patent is granted without prior investigation into the patentability of the invention, without warranty of the Merit of the invention, nor of the accuracy of its description and at the risk of the applicant (s).

Brussels, 05/02/2018,

With special authorization:

BE2016 / 5531

METHOD FOR CREATING A BAKERY PRODUCT AND BAKERY PRODUCT OBTAINED THEREFOR

TECHNICAL DOMAIN

The invention relates to the food industry and in a first aspect comprises a method of producing bakery products and an apparatus for partially automating the production of such products.

STATE OF THE ART

Bakery products such as (baguette) breads are often industrially manufactured on a large scale. A problem with the known production lines for preparing bakery products is the lack of consistent and high quality. Due to the large-scale production, quality and freshness often lose in yield and production speed. In addition, in large-scale bread production, many additives - improvers - such as preservatives, flavor enhancers, dyes, emulsifiers, artificial flavors, flour correctors, etc. are added to the dough to manipulate lead time, crusting, texture, flavor, shelf life, dough quality, dough processability during the production process .

In a first aspect, the present invention contemplates a method of producing bakery products of a higher and more consistent quality, artisanal appearance, authenticity and correct structure without adding multiple improvers.

In a second aspect, the invention contemplates a production line that automates the production of the aforementioned bread products to a large extent, without sacrificing quality and artisanal processing principles.

SUMMARY OF THE INVENTION

The present invention relates in a first aspect to a method for preparing bakery products according to claim 1. In a second aspect, the present invention relates to an apparatus for producing bakery products, according to claim 15.

The invention relates to a method for producing bakery products of a high, artisanal and constant quality without the addition of several improvers. In a second aspect, the invention relates to an apparatus for producing bakery products according to the aforementioned method.

BE2016 / 5531

DETAILED DESCRIPTION

In a first aspect, the invention relates to a method for producing mainly organic bakery products such as organic (baguette) bread with a high, artisanal and constant quality without the addition of one or more improvers. In a second aspect, the present invention includes an apparatus for producing bakery products according to the aforementioned method.

In the proposed invention, the terms top, bottom, top, bottom, higher, lower, horizontal, vertical, etc. are to be understood in the normal sense of the word.

Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meaning generally understood by those skilled in the art of the invention. For a better assessment of the description of the invention, the following terms are explicitly explained.

The term product dough as mentioned below refers to the dough which includes all the ingredients for the final bakery product and is formed by the combination of a pre-ferment (sourdough, poolish), intermediate dough and hand components.

The term intermediate dough as mentioned below refers to an intermediate step in the preparation of the product dough and includes a mixture of water and flour without the addition of hand components, mother dough, poolish or sourdough.

The term hand components as mentioned below refers to components that are added depending on the final bakery product and include syrups, seeds, fruits, yeast, salt, other flours, etc.

The term proofing as mentioned below refers to the development of the dough where CO2 and aromas are formed by a long lead time for baking. In the description below, the term fermentation is used to refer to the fermentation process of yeast cells or lactic acid bacteria, producing, among other things, carbon dioxide that is responsible for the leavening of the dough.

The term leavening agent as mentioned below refers to living yeast cells and / or lactic acid bacteria that convert fermentable sugars into carbon dioxide gases and thus proving the dough. In the description below, the term leavening agent may also refer to a sourdough. This is a mixture of water, flour and mother dough with lactic acid bacteria that fermented spontaneously for a few days of fermentation.

BE2016 / 5531

The term yeast or yeast cells as mentioned below refers to natural Saccharomyces cerevisiae or baker's yeast.

The terms poolish and sourdough as mentioned below refer to a preferment that - after a proofing process - is added to the intermediate dough together with the hand components to form the final product dough.

The term pre-ferment as mentioned below refers to proving the dough by fermenting the leavening agent present before adding it to the intermediate dough. As a leavening agent, one or more types of lactic acid bacteria and / or naturally occurring yeasts are added in a sourdough dough by adding part of the mother dough. A first type of pre-ferment is sourdough, which includes water, flour, flour, lactic acid bacteria and yeasts, and aims at the production and release of lactic acid in the mother dough, and CO2 production for the rice. Sourdough dough and products have a mildly sour taste due to the lactic acid present, inherently have better preservation qualities and have a more resilient texture than other doughs or bakery products. A second type of preference is poolish which includes a limp and sticky mixture of water, flour, flour and yeast. The goal of a poolish is to use less yeast, give it more aroma and develop a good structure.

The term wafer as mentioned below refers to edible bio-identification which is placed decoratively on the bakery products.

The term dough portion as mentioned below refers to portioned dough.

The term rolling pin as mentioned below refers to long-made dough portions.

The term preparation process as mentioned below refers to the preparation of the rolling pins from the start of the start of the production process until just before the initiation of the second proofing phase.

The term organic as mentioned below refers to an agricultural and food industry form that explicitly takes into account environmental effects, cultivation and animal welfare. Stricter rules apply to such methods than to those of conventional agriculture. The use of the term organic in the description below implies conformity to the above-mentioned regulations.

BE2016 / 5531

One, de and the in this document refer to both the singular and the plural unless the context clearly assumes otherwise. For example, a segment means one or more than a segment.

When around or around this document is used with a measurable quantity, a parameter, a duration or moment, and the like, variations of +/- 20% or less, preferably +/- 10% or less, more at preferably +/- 5% or less, even more preferably +/- 1% or less, and even more preferably +/- 0.1% or less than and of the quoted value, insofar as such variations apply in the disclosed invention.

The terms include, include, consist of, consist of, include, contain, contain, control, controlling, contents, containing are synonyms and are inclusive or open terms that indicate the presence of what follows, and do not exclude or prevent the presence of other components, features, elements, members, steps, known from or described in the prior art.

Claiming numerical intervals through the endpoints includes all integers, fractions and / or real numbers between the endpoints, including these endpoints.

In a first aspect, the present invention relates to a method for producing mainly organic bakery products of a high, artisanal and constant quality without the addition of one or more improvers. The described method comprises, in a first step, mixing flour and water. Some of the water is added very slowly at the end of the kneading to prevent the dough from sifting (basin). The resulting mixture is further named in the description below as an intermediate dough.

During the preparation process, the temperature of the dough made is kept constant to guarantee optimal dough quality and to be able to control the processes without having to add one or more improvers. As a result, before adding to the flour, the water must be cooled or heated to a temperature that is calculated using an algorithm based on the ambient temperature, the temperature of the flour, the temperature of the mother dough, the temperature of the pre-ferment and the heating of the dough due to the kinetic energy during kneading. The water is cooled using ice, or warmed by adding warm water.

BE2016 / 5531

Maintaining a constant dough temperature firstly contributes to a high, artisanal and constant quality of the bakery products in the same batch, but also between bakery products that are prepared on different days or in different batches.

In a preferred embodiment, the temperature of the dough is kept constant between 22 ° C and 23 ° C.

Before kneading the flour and water into a middle dough, an autolysis is performed to make the gluten smoother to replace improvers.

In a preferred embodiment, the autolysis is performed by adding water and flour.

During the kneading of the intermediate dough, the pre-ferment (sourdough and / or poolish) and the hand components are added. Depending on the type of sourdough - both poolish and sourdough - are prepared in advance. This allows the pre-fermentations to rise for at least 12 hours in advance to develop complex flavors, aromas and aromas.

In a preferred embodiment, kneading is carried out using a fork kneader because they release the lowest amount of kinetic energy - and thus heat. This minimizes heating of the dough and oxidizes the dough less.

In a more preferred embodiment, kneading is performed using an automatic fork kneader.

In the present invention, sourdough includes water, flour and a consortium of a stable microbiome of lactic acid bacteria including Lactobacillus sanfranciscensis and natural yeasts, among others. Poolish in the present invention includes water, flour and a natural baker's yeast, while sourdough as a master dough includes water, flour, lactic acid bacteria and spontaneously fermenting natural yeasts. As mentioned above, the sourdough and poolish are pre-fermented for at least 12 hours before being added to the intermediate dough.

The sourdough is propagated during each use, which means that part of the mother dough is used to start up a next mother dough culture. The mother dough is subjected to quality tests to check the quality and adjust the process if necessary.

BE2016 / 5531

The use and addition of a pre-ferment such as sourdough or poolish - due to the long fermentation - ensures a higher development of flavors and smells, a firm and resilient texture and increases the shelf life of the bakery product. The use of a particular master dough and the course of the proofing process - temperature, duration, humidity - that it undergoes has an important influence on the taste and texture of the final bakery product.

In one embodiment, a poolish is prepared about 12 to 16 hours before commencement of product dough preparation. After a proofing process of at least 12 hours, the poolish - together with the hand components - is added to the intermediate dough to prepare the product dough.

In a preferred embodiment, sourdough is added to the intermediate dough. Sourdough is prepared about 12 to 18 hours in advance and undergoes a proofing process of at least 12 hours before being added to the middle dough.

In another preferred embodiment, three paired quality tests are performed to ensure the quality and uniformity of the master dough.

In a preferred embodiment, the quality tests are paired taste and pH tests performed during the propagation process.

In a preferred embodiment, the first paired test is performed just before the propagation and aims for a sour taste and a pH of about 5.0 to 5.2. The second paired test - just after propagation - aims for a neutral taste and a pH of about 3.8 to 4. The third paired test - just before using the master dough - checks for a yogurt-like taste and a pH of about 3.8 - with an absolute minimum of 3.5.

After confirmation of the taste and pH tests, the production process is continued by kneading, sealing and then leaving the dough to rest.

In a preferred embodiment, the product dough is slammed shut for the first time just before the dough's dormancy period and then left to rest under cover so that the flour absorbs the added water for the better without the dough drying out. Good hydration is also provided during slow and long kneading. After a rest time of 30 to 40 minutes, the dough is closed a second time, after which it undergoes a second rest time of 75 to 90 minutes. The duration

Rest periods BE2016 / 5531 depend on the weather conditions and the quality of the flower.

After the rest period, the dough is proportioned into a number of dough portions based on weight. This is in contrast to the conventional method in the current state of the art where the product dough is proportioned on the basis of volume. In this way, all bakery products produced by the present invention comprise the same amount of dough, thereby contributing as a second aspect to the uniform quality of the products. Due to this way of stress-free processing, the built-up dough structure is very well preserved. Proportioning can be done manually or automatically by means of a suitable device.

In a preferred embodiment, dough portions are lengthened using a longmaker. In another embodiment, this can be done manually.

In this way, the dough portions are transformed into dough rolls in a stress-free manner that define the final shape of the finished bakery products.

The dough portions are each placed in a textile dough holder. This is an important step in the present invention. Since the textile of the dough holders will induce a non-uniform moisture extraction during the proofing process, the crusting of the dough is prevented and a good crusting is obtained afterwards in the oven.

In a preferred embodiment, the shape of the dough container is selected so that about three quarters of the surface of the dough portion is contacted by the dough container.

The dough portions - partly covered by the dough holders - are moved to the proofing chambers where they rise in three stages: proofing, cooling and conditioning.

In a preferred embodiment, a wafer is also provided on each portion of dough before the start of the proofing process.

In a more preferred embodiment, a wafer with bioidentification is decoratively provided on each dough portion before the proving process begins.

The non-uniform moisture extraction of the dough portions as a result of the contact between the dough and the textile of the dough holders is induced by moisture extraction. As a result, the outer dough layers at the level of the contact surfaces between the dough portions and the dough holders will be drier than the

BE2016 / 5531 outer dough layers where the dough does not make contact with the dough holder. It is mainly the outer dough layers of the upper surface portion of the dough portions - which do not come into contact with the dough container during the proofing process - and thus retain relatively more moisture - actually lose less moisture - than the outer dough layers of the other surface portions of the dough portion. It is evident that there is no differential moisture extraction at the inner dough layers of the dough portions.

In addition to the non-uniform moisture extraction, during the 3-step proofing process, a temperature difference is also formed between the inner and outer dough layers of the dough portions because the outer dough layers of the dough rolls act as heat insulators for the inner dough layers. As a result, the inner dough layers of the dough portions will be warmer - and as mentioned above, also more humid - than the outer dough layers of the dough portions.

The dough holders and thus also the dough portions are then turned through 180 °, so that the dough surface that was in contact with the dough holder is placed on top. The dough holder is removed and the dough portion is sprinkled with flour and cut.

In a preferred embodiment, the turning of the dough holders with dough portions is automated.

In a preferred embodiment, three incisions are made at angles of 45 ° to the longitudinal axis of elongated dough portions and at the portion of the dough portion that was at the bottom during the proofing process (but now by turning the dough holders at the top is located). Because this part of the dough was in contact with the dough holder and these outer dough layers are drier (than the outer dough layers of the portion of the dough portion that was on top during the proofing process), it is easier to cut the cuts here. bring. It should be noted that the portion of the dough portions where the cuts are made is referred to as the top from here on. As a result, the portion that was located at the top of the dough portion during the proofing process - and is therefore even more humid because it was not in contact with the dough container - is referred to as the bottom from here on.

In a preferred embodiment, the incision is done by means of an intelligent robot with product detection. Due to the product detection, the robot knows how to make the cuts

BE2016 / 5531 must be applied. Important matters such as the cutting angle and moistening the blade before cutting are preserved.

The flour-sprinkled and cut dough portions are placed on plates with the cuts upwards and placed in the oven via a nibble belt. Due to the non-uniform moisture extraction, the built-up temperature difference between the inner and outer dough layers of the dough portions during the proofing process and the turning of the dough portions according to after the proofing process, the inner dough layers will expand - faster and more than the outer dough layers and thus result in very characteristic bulging of the inner dough layers along the top of the bakery products. The protuberances mentioned as a result of the non-uniform drying and the turning of the rolling pins after the proofing process give the obtained bread a rustic and authentic character.

In a preferred embodiment, the dough portions are baked to a core temperature of 95 ° C for about 15 minutes, after which the bakery products are removed from the oven and cooled and transported to the packaging department for packaging.

In a second aspect, the invention relates to a device for the production of mainly organic bakery products according to the method described above.

The device in question comprises means for automating certain steps of the above-mentioned method for the production of bakery products. This has the advantage that the prepared dough can be processed more efficiently and the potential difference in quality between the first and last dough portion within the same production process is negligible. Nevertheless, certain steps in the production line are performed manually because automation of these steps would result in a decrease in the dough quality or its uniformity. This is different from the conventional methodology in the prior art with regard to commercial bread production. In addition, steps that are ergonomically too burdensome and provide no added value have been automated.

The device contains a specific sequence of different modules with the addition of a custom module.

In a first aspect, the device includes an automatic kneading machine.

In a preferred embodiment, the kneading of the master dough, intermediate dough and product dough is carried out by a fork kneader because these - in

BE2016 / 5531 compared to other kneaders - releases the lowest amount of kinetic energy, and thus heat. This minimizes the heating and oxidation of the dough and the dough temperature remains almost constant. This is very important for the further progress of the process. «

In a second aspect, the device comprises one or more proofing chambers for the regulation of one or more proofing processes of the master dough, intermediate dough, product dough or the dough portions.

In a preferred embodiment, the device comprises a first proofing chamber with a regulated temperature of 25 ° C and a regulated relative humidity of 75 to 80%, a second proofing chamber with a regulated temperature of 25 ° C and a regulated relative humidity of 70%, and a third proofing chamber with a regulated temperature of 4 ° C and a regulated relative humidity of 60%.

In a third aspect, the device comprises one or more conveyor belts for transporting dough portions from one module of the device to the next module of the device.

In a sensitive aspect, the device includes a robot for cutting the dough. Through product detection (~ taking a 3D photo), the robot 'knows' where to make the cuts. It is important to mention that the distinctive features of the manual cuts have been preserved during automation. Thus, the above-mentioned incision angle and the moistening of the knife before cutting the dough are retained.

In a fifth aspect, the device comprises an oven for baking the dough portions.

An important aspect of the device in the present invention is the unique and custom-made module capable of turning the dough containers with the dough portions after the proving process, and then separating the dough containers from the dough portions. As a result, the dough portions with their bottom - in contact with the dough holder and thus drier - come into contact with the dough during the proofing process. As described above, this is an important aspect of the present invention and this automated module also distinguishes the present invention from the prior art.

It is believed that the present invention is not limited to the embodiments described above and that some modifications or changes to the

BE2016 / 5531 described examples can be added without revaluating the added claims.

BE2016 / 5531

Claims (23)

CONCLUSIONS A method for producing a bakery product such as bread, comprising the following steps: making a dough comprising water, flour, pre-ferment, salt, yeast and / or hand components, portioning and rolling out the dough into a number of dough portions of desired shape, transferring the dough portions to textile dough containers that at least partly comprise the dough portions; proofing, cooling and conditioning of the dough removing the dough portions from the dough holders Baking off the dough portions, characterized in that the removal of the dough portions from the dough holders is effected by automatically turning these holders through a device provided for this purpose, so that the dough surface that was in contact with the dough holder comes to the top. Process according to claim 1, characterized in that the pre-ferment is a poolish or sourdough. Method according to claim 1 or 2, characterized in that the bakery product comprises a mainly organic bakery product. Method according to any one of the preceding claims, characterized in that the proofing and cooling of the dough takes place in three phases. Method according to any one of the preceding claims, characterized in that one or more cuts are made in the dough portions, for baking the dough. Method according to claim 5, characterized in that the incisions are made at an angle of 45 ° to the longitudinal axis of the rolling pins. A method according to any one of the preceding claims, characterized in that the dough temperature is kept constant between 22 ° C and 23 ° C during the preparation process. A method according to claim 7, characterized in that said dough temperature is kept constant by regulation of the ambient temperature in the production space. Method according to claim 7, characterized in that said dough temperature is maintained or brought to temperature by adding water and / or ice at a predetermined temperature. Method according to claim 8, characterized in that the predetermined water temperature is calculated on the basis of the desired dough temperature, the heating of the kneader, the ambient temperature, the flour temperature and the temperature of the mother dough. A method according to any one of the preceding claims, characterized in that water is added very slowly during the preparation of the dough and master dough. BE2016 / 5531 Method according to any one of the preceding claims, characterized in that the prepared dough consists of at least 80% water. Method according to any one of the preceding claims, characterized in that the prepared dough is portioned on the basis of weight. Method according to any one of the preceding claims, characterized in that the textile dough holders are made of linen. An apparatus for producing bakery products such as (baguette) bread, comprising a dough kneader, one or more proofing chambers, one or more conveyor belts for transporting dough portions, a robot for making cuts, and a baking oven, characterized in, that the device is provided with means for automatically turning dough portions in a dough holder after proofing. An apparatus according to claim 5 comprising a means for lengthening the dough portions. An apparatus according to claim 15 or 16, comprising a fork kneader as a dough kneader. An apparatus according to any one of the preceding claims, comprising a means for monitoring the dough temperature during the production process. An apparatus according to any of the preceding claims, comprising means for controlling the ambient temperature. An apparatus according to any one of the preceding claims, comprising a means for measuring the relative humidity in the production space and proofing chambers. A device according to any one of the preceding claims, comprising a means for regulating the relative humidity in the production space and proofing chambers. An apparatus according to any one of the preceding claims 15-21, comprising a means for portioning the dough on the basis of weight. A baguette obtained by a method or device according to any one of the preceding claims. BE2016 / 5531