CA1136921A - Production of sponge cake - Google Patents
Production of sponge cakeInfo
- Publication number
- CA1136921A CA1136921A CA000372768A CA372768A CA1136921A CA 1136921 A CA1136921 A CA 1136921A CA 000372768 A CA000372768 A CA 000372768A CA 372768 A CA372768 A CA 372768A CA 1136921 A CA1136921 A CA 1136921A
- Authority
- CA
- Canada
- Prior art keywords
- cake
- weight
- batter
- mixing zone
- parts
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
- A21D6/00—Other treatment of flour or dough before baking, e.g. cooling, irradiating, heating
- A21D6/005—Irradiation
-
- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
- A21D13/00—Finished or partly finished bakery products
- A21D13/80—Pastry not otherwise provided for elsewhere, e.g. cakes, biscuits or cookies
Landscapes
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Food Science & Technology (AREA)
- Confectionery (AREA)
- Bakery Products And Manufacturing Methods Therefor (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
Sponge cake is formed by the utilization of a continuous process involving an initial batter formation and subsequent microwave baking. Cake-forming components and carbon dioxide are continuously mixed to form a gas-infused batter, Microwave energy expands and cooks the batter to form the sponge cake. Additional drying may be effected to any desired moisture level.
Sponge cake is formed by the utilization of a continuous process involving an initial batter formation and subsequent microwave baking. Cake-forming components and carbon dioxide are continuously mixed to form a gas-infused batter, Microwave energy expands and cooks the batter to form the sponge cake. Additional drying may be effected to any desired moisture level.
Description
Z~
PRODUCTION OF SPONGE CAKE
The present invention relates to a continuous procedure for the manufacture of sponge cake.
Sponge cake is traditionally made by forming a batter containing flour, sugar, eggs and water, along with baking powder to provide leavening and any desired flavouring agents, and baking the batter in an infra-red radiation oven, Such procedures require time to effect leavening. Further, the proportions of ingredients are critical to achieving the required texture. In addition, the baking procedure often forms a hard crust on the cake, which can lead to undesirably hard particles and crust coloration in a comminuted mixture, when the cake is to be used in crumb form.
The present invention overcomes the prior art problems and enables sponge cake with characteristics comparable to sponge cake made by conventional methods to be formed continuously without the necessity for a long leavening time, without the development of crust and with considerable flexibility of the proportion of ingredients. The present invention involves the utiliza-tion of a unique batter mixing procedure and microwave baking of the batter under controlled conditions.
In accordance with the present invention, there is provided a continuous process for forming a sponge cake, which comprises: intimately mixing cake~forming components including flour, sugar, egg and water with each other in a continuous mixing zone, extruding a sponge cake-forming batter from the continuous mixing zone, and substantially immediately after the extrusion, heating the batter by microwave energy to cause moisture in the batter to form steam to expand the batter and cook the same to a sponge cake.
The sponge cake which is produced by the process of this invention has characteristics comparable to those of conventional sponge cake, except that no crust is formed on the surface thereof. The absence of such crust avoids the presence of hard particles and crust coloration in the particulate form which results from comminution of the sponge cake, and this is quite desirable in many ., ~13tiS'~1 applications of the comminuted cake.
The comminuted cake crumbs may have any desired particle size) depending on the end use. The density~
resulting in part from the porosity of the cake and in 5 part from the size of the individual particles, ranges from about 0 2 to about 0.4 g/cc (12.5 to 25 lb/cu.ft.) and the shear value ranges from about 8 to about 25 kg.
In accordance with a specific embodiment of the invention, there is provided a continuous process for manufacture of sponge cake, which comprises: feeding cake-forming components including flour, sugar, egg and water to a continuous mixing zone in quantities such that the total quantity of moisture in the cake-forming components is about 20 to about 45% by weight, advancing the cake-forming components in plug flow manner through the mixing zone in about 20 to about 180 seconds, subjecting the cake-forming components to conditions of shear within the mixing zone such that the work done on the mater als within the mixing zone varies from about 4 to about 7 watt/hr/lb of cake-forming components to cause mixing of the components, subjecting the cake-forming components to a back pressure within the mixing zone of about 10 to about 75 psig, extruding from the mixing zone a cake-forming batter mix of density from about 0.65 to about 0.95 g/ccj substantially immediately after the extrusion, baking the extruded batter mix in a microwave baking zone using microwave radiation at an input of about 3 to about 12 kw min/lb. of batter while passing air through the zone to remove generated steam, and maintaining the batter in the zone for a time sufficient to result in a baked sponge cake having an internal temperature of about 180 to about 230F and to effect a loss of moisture of about 10 to about 23 wt.%.
The initial cake-forming ingredients used in this invention include those conventionally used in cake making- including water, flour, eggs and sugar. The term "flour" as used herein usually refers to a soft wheat flourv but includes any combination of wheat flours, including those known as cake or high ratio cake flours, .~
-` 113~Z~
2a Varying quantities of cake forming components may be used and the procedure of the invention enables less critical proportions of ingredientst to be utilized than is the case in conventional cake-making procedures, particularly additive components, such as, emulsifying agents and surfactants which are conventionally employed to improve the functional properties of the major components and to effect cost reductions with improvements in keeping quality from a staling or onset of undue firmness standpoint.
In addition to the basic cake-forming components, salt, flavouring agents, such as, vanilla and cocoa, and colouring agents usually are used. Baking powder, which is conventionally used along with entrained gas to provide the total leavening of the cake, is not required, since leavening is achieved by the generation of steam in the microwave baking step along with gas expansion.
Some baking powder may be used, however, to enhance the steam leavening.
The cake-forming components may be provided in the form of a dry mix containing sugar and flour and a wet mix containing egg and water. One suitable dry mix comprises:
Sugar about 40 to about 60 parts by weight Flour about 40 to about 60 parts by weight Sugar and Flour 100 parts by weight .
113~9~1 In addition, one or more of the following optional components may be added:
Bakin~ powder 0 to about 2.0 parts by weight Salt 0 to about 1.5 parts by weight, typically about 0.5 to about 1.5 parts by weight Cocoa 0 to about 15 parts by weight, typically about ~.5 to about 15 parts ~y weight One suitable wet mix comprises:
Llquid egg 100 parts by weight.
Liquid egg has a high moisture content typically about 74 wt.%, and this moisture provides part of the moisture requirement for the batter.
An optional component which may be present in the wet mix is:
Vanilla extract 0 to about 2% by weight of the egg In the process of the invention, the cake-forming components are fed to inlets at one end of a continuous mixing zone capable of plug flow therethrough. The mixing zone mav take the form of an elongate, screw-type mixer-extruder, suitably modified to provide the required processing conditions therein.
The dry mix~ wet mix and additional water are separ-ately metered to one end of the mixing zone in proportionssuitable to provide an overall moisture content of inter-mixed components of about 20 to about 45% by weight, preferably about 28 to about 38% by weight.
Within the mixing zone, the cake-forming components are continuously intermixed while they are conveyed from one end of the mixing zone to the other, over a time period of a~out 20 to about 180 seconds, preferably about 30 to 60 seconds.
A plurality of spaced gaseous inlets may be provided along the length of the mixing zone and a gaseous material, or mixture of gaseous materials, is injected into the mix through the openings. The gaseous material usually is carbon dioxide, often in admixture with nitrogen, although other materials, including air and oxygen, mav ~e used ~3~i~Zl When utilized, the total gas fed to the mixing zone is in the range of about 1.3 to about 18 SC~H, preferably about 4.4 to about 7 SCF~, per 100 lb. of cake-forming components.
The addition of gas in this way generally decreas2s the density and increases the shear value of the product obtained. In the a~sence of gas deliberately added in this way, there is always some entrained gas in the batter.
The cake-forming components and the entrained gas, together with any injected gas, are subjected to shear forces within the mixing zone, sufficient to cause simultaneous uniform mixing of the components and dispersion of the gas throughout the mix. The work done on the fiatter within the mixing zone yaries from about 4 to about 7 watt hr/lb.
of batter, preferably about 5 to 6 watt hr~lb.
The temperature within the mixing zone is controlled at a desired value, but the value is not critical to the process and heat generally is not used. The temperature generally corresponds to the inlet ambient temperature of the water and liquid egg, which may vary widely, depending 2Q on the time of the year, typically from about 5 to about 25C ~about 40~F to about 80~L. The batter which results from the operations ln the mixing zone is extruded therefrom under a low back pressure of about 10 to about 75 psig, preferably about 20 to about 50 psig.
The operations which are effected in the mixing zone result in the continuous extrusion of a uniformly-mixed gas-infused foaming batter having a density from about 0.65 to about 0.~5 g~cc and a moisture content corresponding to that fed to the m~xing zone.
The sugar which may be used in the cake-forming components in this invention lncludes crystalline sugar and liquid sugar, including those syrups derived from corn or other starches, or a combination of such sweeteners. In conventional cake batter-making operations, the crystalline form of sugar is required, since t~e abrasive nature of the sugar crystals fireaks up the egg and enables it to be evenly distri~uted throughout tfie batter, and mixing is effected to dissolve the sugar.
In this invention, the action of crystalline sugar 113~;9;~1 is not relied on to distri~ute the egg and it ~as been found that the mixing which occurs in the mixing zone in this invention results in solid phase sugar bein~ present in ~e batter, when crystalline sugar is used as the source of sugar. Liquid sugars normally cannot ~e used, for the above reason, but may ~e used in this invention to pro~ide texture improvements not readily achieved by conventional mixers, and improvements in keeping times by delaying the onset of staling or firming and provide the option to use the most economical sweetener blend.
The ~atter, extruded from the mixing zone then enters a microwa~e baking oven, usually in the form of a long tunnel through which the ~atter is conveyed in a continuous fashion. The microwave energy causes the water in the batter to be rapidly heated to produce steam which expands and cooks the cake. The dissolved gaseous material also expands, and any leavening a~ent present, is activated.
The microwave baking is effected at an energy input of from about 3 to about 12 kw min/l~. of batter, preferably about 4 to about 8 kw min~lb. of batter, for a time sufficient to raise the temperature to about 180 to 2300F, preferably about 200 to a~out 212F, and to result in a moisture loss of a~out 10 to a~out 23 wt.~. An air stream, which may ~e of am~ient temperature or higher, is passed through the microwave oven to remove generated steam.
The sponge cake which results from the microwave ~aking step is fully cooked but relatively moist at a moisture level of about 12 to a~out 33 wt.%. The cake may be dried to a desired moisture level, usually about 3 to akout 8 wt~% in any convenient manner, including continued application of microwave energy, and, if to be used in a comminuted form, such as, in pudding mixes, then comminuted to sponge cake crumbs of any desired particle size. The cake crumbs have a density from a~out 0.2 to about 0.4 g/cc and a shear Yalue of about 8 to about 25 kg.
The continuous procedure of the invention, therefore, comprises essentially two steps, namely ~atter mixing and microwave ~aking. The result is a sponge cake of properties corresponding to those formed ~y conventional 4Q baking, ~ut produced in a continuous manner.
1~3S~21 The invention is illustrated by the following Examples:
Example 1:
This Example illustrates the formation of d vanilla sponge cake by two separate procedures, one involving the addition of gas and the other wherein gas addition is omitted.
An initial dry mix containing the following ingredients was prepared:
ComponentParts by Weight Flour 46.7 Salt 1.0 Baking powder 1.1 Sugar 50.5 Myvaplex 600* 0.7 100 . O
*Monoglyceride emulsifier sold by Eastman Chemical Products Inc. (Trademark).
An initial wet mix was also prepared, containing the following ingredients:
Liquid whole egg (74% moisture) 98.9 Colour 0.2 Vanilla o.g 100 . O
The dry mix, wet mix and water were fed into one end of an extruder at the following flow rates:
Dry mix 8.75 parts/min Wet mix 4.46 parts/min Water 0.68 parts/min These flow rates correspond to a moisture content of 32%, The components were continuously intermixed during passage from one end of the extruder to the other in about 35 seconds. In one run, carbon dioxide was fed into the extruder at six different locations along the length of the extruder at a rate of 5.75 SCF/100 lb. of batter whereas in another run no gas feed was employed, Work of 5 watt hr/lb. of batter was applied to the batter during formation thereof and passage through ~ .
' - 1~36921 6a the extrusion and a back pressure of 35 psig exited at the extruder outlet orifice.
A gas-infused evenly-mixed batter of temperature 54.5F was extruded from the extruder and fed directly into a 1~3~21 continuous microwave oven where~n the batter was su~jected to microwave energy at an energy input of 4.75 kw min~lb.
of ~atter as it passed t~rough the o~en in 150 seconds.
A ~low of air at am~ient temperature was passed through the oven to remove moisture. The microwave ~aking was effected to result in a moisture loss of 14~5% by weight (to 20,4 wt.%l and an internal temperature of 212F.
The resulting sponge cake was dried to a moisture level of S wt,% and cut into convenient lengths. The lQ samples ~rom the two runs exhi~ited the following properties:
With gas No gas add`itlon addition Density ~g/cc)Q.29 0~35 Shear (kg) 21 11 It will be seen from these results that the addition of the gas decreases the density of the product while increasing the shear value thereof.
Example 2 -This ~xample illustrates the formation of a chocolate sponge cake.
The procedure of Example 1 was generally repeated using the following components to form the batter.
Dry mix Sugar 50.22 Flour 36.31 Salt O.qg Baking powder1.34 Sodium bicar~onate 0.32 Cocoa 10.82 100. 00 Wet mix Liquid whole egg ~q.16 Vanilla 0.84 lOO.OQ
Feed rates Dry mix 8.848 parts~min Wet mix 4.350 parts/min Water 0.68 parts/min ~13G9~1 The batter had a moisture content of 33 wt.% and a temperature of 56F. Microwave baking was effected as follows:
Energy used 5.88 kw min/lb. of batter Temperature rise to 212F
Moisture loss 21.7 wt.% ~to 14.4 wt.%) After drying to 5 wt.% moisture, the sponge cake had a density of 0.2~ g/cc and a shear value of 13 kg.
Example 3 This Example illustrates the formation of a vanilla sponge cake wherein baking powder is completely a~sent.
The proced~re of Example 1 was again repeated using the following components to form the batter:
Drv mix -Sugar 51.233 Flour 57.759 Salt 1.008 lao. ooo Wet mix .
Liquid whole egg 9~.0 Vanilla 0.~1 100. 00 Feed rates ~ =.
Dry mix 8.75 kg~min Wet mix 4.375 kg/min Water 1.04 kg/min The batter had a moisture content of 34 wt.% and a temperature of 57F. The batter was subjected to microwave baking under the following conditions:
Energy used 7.45 kw min/lb.
Temperature rise to 219F
Moisture loss 21 wt.%~to 16.4 wt.%2 After drying to 5% moisture content, the sponge cake had a density of 0.28 g~cc and a shear value of 12 kg.
SUMMARY OF DISCLOSURE
In summary of this disclosure, the present invention provides a unique procedure for the baking of sponge cake, by using steam generation ~or leavening, microwave energy ~3f~9Z~
for cooking and continuous operation. Modifications are possi~le within the scope of the invention.
PRODUCTION OF SPONGE CAKE
The present invention relates to a continuous procedure for the manufacture of sponge cake.
Sponge cake is traditionally made by forming a batter containing flour, sugar, eggs and water, along with baking powder to provide leavening and any desired flavouring agents, and baking the batter in an infra-red radiation oven, Such procedures require time to effect leavening. Further, the proportions of ingredients are critical to achieving the required texture. In addition, the baking procedure often forms a hard crust on the cake, which can lead to undesirably hard particles and crust coloration in a comminuted mixture, when the cake is to be used in crumb form.
The present invention overcomes the prior art problems and enables sponge cake with characteristics comparable to sponge cake made by conventional methods to be formed continuously without the necessity for a long leavening time, without the development of crust and with considerable flexibility of the proportion of ingredients. The present invention involves the utiliza-tion of a unique batter mixing procedure and microwave baking of the batter under controlled conditions.
In accordance with the present invention, there is provided a continuous process for forming a sponge cake, which comprises: intimately mixing cake~forming components including flour, sugar, egg and water with each other in a continuous mixing zone, extruding a sponge cake-forming batter from the continuous mixing zone, and substantially immediately after the extrusion, heating the batter by microwave energy to cause moisture in the batter to form steam to expand the batter and cook the same to a sponge cake.
The sponge cake which is produced by the process of this invention has characteristics comparable to those of conventional sponge cake, except that no crust is formed on the surface thereof. The absence of such crust avoids the presence of hard particles and crust coloration in the particulate form which results from comminution of the sponge cake, and this is quite desirable in many ., ~13tiS'~1 applications of the comminuted cake.
The comminuted cake crumbs may have any desired particle size) depending on the end use. The density~
resulting in part from the porosity of the cake and in 5 part from the size of the individual particles, ranges from about 0 2 to about 0.4 g/cc (12.5 to 25 lb/cu.ft.) and the shear value ranges from about 8 to about 25 kg.
In accordance with a specific embodiment of the invention, there is provided a continuous process for manufacture of sponge cake, which comprises: feeding cake-forming components including flour, sugar, egg and water to a continuous mixing zone in quantities such that the total quantity of moisture in the cake-forming components is about 20 to about 45% by weight, advancing the cake-forming components in plug flow manner through the mixing zone in about 20 to about 180 seconds, subjecting the cake-forming components to conditions of shear within the mixing zone such that the work done on the mater als within the mixing zone varies from about 4 to about 7 watt/hr/lb of cake-forming components to cause mixing of the components, subjecting the cake-forming components to a back pressure within the mixing zone of about 10 to about 75 psig, extruding from the mixing zone a cake-forming batter mix of density from about 0.65 to about 0.95 g/ccj substantially immediately after the extrusion, baking the extruded batter mix in a microwave baking zone using microwave radiation at an input of about 3 to about 12 kw min/lb. of batter while passing air through the zone to remove generated steam, and maintaining the batter in the zone for a time sufficient to result in a baked sponge cake having an internal temperature of about 180 to about 230F and to effect a loss of moisture of about 10 to about 23 wt.%.
The initial cake-forming ingredients used in this invention include those conventionally used in cake making- including water, flour, eggs and sugar. The term "flour" as used herein usually refers to a soft wheat flourv but includes any combination of wheat flours, including those known as cake or high ratio cake flours, .~
-` 113~Z~
2a Varying quantities of cake forming components may be used and the procedure of the invention enables less critical proportions of ingredientst to be utilized than is the case in conventional cake-making procedures, particularly additive components, such as, emulsifying agents and surfactants which are conventionally employed to improve the functional properties of the major components and to effect cost reductions with improvements in keeping quality from a staling or onset of undue firmness standpoint.
In addition to the basic cake-forming components, salt, flavouring agents, such as, vanilla and cocoa, and colouring agents usually are used. Baking powder, which is conventionally used along with entrained gas to provide the total leavening of the cake, is not required, since leavening is achieved by the generation of steam in the microwave baking step along with gas expansion.
Some baking powder may be used, however, to enhance the steam leavening.
The cake-forming components may be provided in the form of a dry mix containing sugar and flour and a wet mix containing egg and water. One suitable dry mix comprises:
Sugar about 40 to about 60 parts by weight Flour about 40 to about 60 parts by weight Sugar and Flour 100 parts by weight .
113~9~1 In addition, one or more of the following optional components may be added:
Bakin~ powder 0 to about 2.0 parts by weight Salt 0 to about 1.5 parts by weight, typically about 0.5 to about 1.5 parts by weight Cocoa 0 to about 15 parts by weight, typically about ~.5 to about 15 parts ~y weight One suitable wet mix comprises:
Llquid egg 100 parts by weight.
Liquid egg has a high moisture content typically about 74 wt.%, and this moisture provides part of the moisture requirement for the batter.
An optional component which may be present in the wet mix is:
Vanilla extract 0 to about 2% by weight of the egg In the process of the invention, the cake-forming components are fed to inlets at one end of a continuous mixing zone capable of plug flow therethrough. The mixing zone mav take the form of an elongate, screw-type mixer-extruder, suitably modified to provide the required processing conditions therein.
The dry mix~ wet mix and additional water are separ-ately metered to one end of the mixing zone in proportionssuitable to provide an overall moisture content of inter-mixed components of about 20 to about 45% by weight, preferably about 28 to about 38% by weight.
Within the mixing zone, the cake-forming components are continuously intermixed while they are conveyed from one end of the mixing zone to the other, over a time period of a~out 20 to about 180 seconds, preferably about 30 to 60 seconds.
A plurality of spaced gaseous inlets may be provided along the length of the mixing zone and a gaseous material, or mixture of gaseous materials, is injected into the mix through the openings. The gaseous material usually is carbon dioxide, often in admixture with nitrogen, although other materials, including air and oxygen, mav ~e used ~3~i~Zl When utilized, the total gas fed to the mixing zone is in the range of about 1.3 to about 18 SC~H, preferably about 4.4 to about 7 SCF~, per 100 lb. of cake-forming components.
The addition of gas in this way generally decreas2s the density and increases the shear value of the product obtained. In the a~sence of gas deliberately added in this way, there is always some entrained gas in the batter.
The cake-forming components and the entrained gas, together with any injected gas, are subjected to shear forces within the mixing zone, sufficient to cause simultaneous uniform mixing of the components and dispersion of the gas throughout the mix. The work done on the fiatter within the mixing zone yaries from about 4 to about 7 watt hr/lb.
of batter, preferably about 5 to 6 watt hr~lb.
The temperature within the mixing zone is controlled at a desired value, but the value is not critical to the process and heat generally is not used. The temperature generally corresponds to the inlet ambient temperature of the water and liquid egg, which may vary widely, depending 2Q on the time of the year, typically from about 5 to about 25C ~about 40~F to about 80~L. The batter which results from the operations ln the mixing zone is extruded therefrom under a low back pressure of about 10 to about 75 psig, preferably about 20 to about 50 psig.
The operations which are effected in the mixing zone result in the continuous extrusion of a uniformly-mixed gas-infused foaming batter having a density from about 0.65 to about 0.~5 g~cc and a moisture content corresponding to that fed to the m~xing zone.
The sugar which may be used in the cake-forming components in this invention lncludes crystalline sugar and liquid sugar, including those syrups derived from corn or other starches, or a combination of such sweeteners. In conventional cake batter-making operations, the crystalline form of sugar is required, since t~e abrasive nature of the sugar crystals fireaks up the egg and enables it to be evenly distri~uted throughout tfie batter, and mixing is effected to dissolve the sugar.
In this invention, the action of crystalline sugar 113~;9;~1 is not relied on to distri~ute the egg and it ~as been found that the mixing which occurs in the mixing zone in this invention results in solid phase sugar bein~ present in ~e batter, when crystalline sugar is used as the source of sugar. Liquid sugars normally cannot ~e used, for the above reason, but may ~e used in this invention to pro~ide texture improvements not readily achieved by conventional mixers, and improvements in keeping times by delaying the onset of staling or firming and provide the option to use the most economical sweetener blend.
The ~atter, extruded from the mixing zone then enters a microwa~e baking oven, usually in the form of a long tunnel through which the ~atter is conveyed in a continuous fashion. The microwave energy causes the water in the batter to be rapidly heated to produce steam which expands and cooks the cake. The dissolved gaseous material also expands, and any leavening a~ent present, is activated.
The microwave baking is effected at an energy input of from about 3 to about 12 kw min/l~. of batter, preferably about 4 to about 8 kw min~lb. of batter, for a time sufficient to raise the temperature to about 180 to 2300F, preferably about 200 to a~out 212F, and to result in a moisture loss of a~out 10 to a~out 23 wt.~. An air stream, which may ~e of am~ient temperature or higher, is passed through the microwave oven to remove generated steam.
The sponge cake which results from the microwave ~aking step is fully cooked but relatively moist at a moisture level of about 12 to a~out 33 wt.%. The cake may be dried to a desired moisture level, usually about 3 to akout 8 wt~% in any convenient manner, including continued application of microwave energy, and, if to be used in a comminuted form, such as, in pudding mixes, then comminuted to sponge cake crumbs of any desired particle size. The cake crumbs have a density from a~out 0.2 to about 0.4 g/cc and a shear Yalue of about 8 to about 25 kg.
The continuous procedure of the invention, therefore, comprises essentially two steps, namely ~atter mixing and microwave ~aking. The result is a sponge cake of properties corresponding to those formed ~y conventional 4Q baking, ~ut produced in a continuous manner.
1~3S~21 The invention is illustrated by the following Examples:
Example 1:
This Example illustrates the formation of d vanilla sponge cake by two separate procedures, one involving the addition of gas and the other wherein gas addition is omitted.
An initial dry mix containing the following ingredients was prepared:
ComponentParts by Weight Flour 46.7 Salt 1.0 Baking powder 1.1 Sugar 50.5 Myvaplex 600* 0.7 100 . O
*Monoglyceride emulsifier sold by Eastman Chemical Products Inc. (Trademark).
An initial wet mix was also prepared, containing the following ingredients:
Liquid whole egg (74% moisture) 98.9 Colour 0.2 Vanilla o.g 100 . O
The dry mix, wet mix and water were fed into one end of an extruder at the following flow rates:
Dry mix 8.75 parts/min Wet mix 4.46 parts/min Water 0.68 parts/min These flow rates correspond to a moisture content of 32%, The components were continuously intermixed during passage from one end of the extruder to the other in about 35 seconds. In one run, carbon dioxide was fed into the extruder at six different locations along the length of the extruder at a rate of 5.75 SCF/100 lb. of batter whereas in another run no gas feed was employed, Work of 5 watt hr/lb. of batter was applied to the batter during formation thereof and passage through ~ .
' - 1~36921 6a the extrusion and a back pressure of 35 psig exited at the extruder outlet orifice.
A gas-infused evenly-mixed batter of temperature 54.5F was extruded from the extruder and fed directly into a 1~3~21 continuous microwave oven where~n the batter was su~jected to microwave energy at an energy input of 4.75 kw min~lb.
of ~atter as it passed t~rough the o~en in 150 seconds.
A ~low of air at am~ient temperature was passed through the oven to remove moisture. The microwave ~aking was effected to result in a moisture loss of 14~5% by weight (to 20,4 wt.%l and an internal temperature of 212F.
The resulting sponge cake was dried to a moisture level of S wt,% and cut into convenient lengths. The lQ samples ~rom the two runs exhi~ited the following properties:
With gas No gas add`itlon addition Density ~g/cc)Q.29 0~35 Shear (kg) 21 11 It will be seen from these results that the addition of the gas decreases the density of the product while increasing the shear value thereof.
Example 2 -This ~xample illustrates the formation of a chocolate sponge cake.
The procedure of Example 1 was generally repeated using the following components to form the batter.
Dry mix Sugar 50.22 Flour 36.31 Salt O.qg Baking powder1.34 Sodium bicar~onate 0.32 Cocoa 10.82 100. 00 Wet mix Liquid whole egg ~q.16 Vanilla 0.84 lOO.OQ
Feed rates Dry mix 8.848 parts~min Wet mix 4.350 parts/min Water 0.68 parts/min ~13G9~1 The batter had a moisture content of 33 wt.% and a temperature of 56F. Microwave baking was effected as follows:
Energy used 5.88 kw min/lb. of batter Temperature rise to 212F
Moisture loss 21.7 wt.% ~to 14.4 wt.%) After drying to 5 wt.% moisture, the sponge cake had a density of 0.2~ g/cc and a shear value of 13 kg.
Example 3 This Example illustrates the formation of a vanilla sponge cake wherein baking powder is completely a~sent.
The proced~re of Example 1 was again repeated using the following components to form the batter:
Drv mix -Sugar 51.233 Flour 57.759 Salt 1.008 lao. ooo Wet mix .
Liquid whole egg 9~.0 Vanilla 0.~1 100. 00 Feed rates ~ =.
Dry mix 8.75 kg~min Wet mix 4.375 kg/min Water 1.04 kg/min The batter had a moisture content of 34 wt.% and a temperature of 57F. The batter was subjected to microwave baking under the following conditions:
Energy used 7.45 kw min/lb.
Temperature rise to 219F
Moisture loss 21 wt.%~to 16.4 wt.%2 After drying to 5% moisture content, the sponge cake had a density of 0.28 g~cc and a shear value of 12 kg.
SUMMARY OF DISCLOSURE
In summary of this disclosure, the present invention provides a unique procedure for the baking of sponge cake, by using steam generation ~or leavening, microwave energy ~3f~9Z~
for cooking and continuous operation. Modifications are possi~le within the scope of the invention.
Claims (21)
1. A continuous process for forming a sponge cake, which comprises:
intimately mixing cake forming components including flour, sugar, egg and water with each other in a continuous mixing zone, extruding a sponge cake-forming batter from said continuous mixing zone, and substantially immediately after said extrusion, heating said batter by microwave energy to cause moisture in the batter to form steam to expand the batter and cook the same to a sponge cake.
intimately mixing cake forming components including flour, sugar, egg and water with each other in a continuous mixing zone, extruding a sponge cake-forming batter from said continuous mixing zone, and substantially immediately after said extrusion, heating said batter by microwave energy to cause moisture in the batter to form steam to expand the batter and cook the same to a sponge cake.
2. The process of claim 1 including drying the resulting sponge cake and comminuting the same to crumb form.
3. The process of claim 1 wherein said cake-forming components are fed to the mixing zone in the form of (1) a dry mix comprising:
sugar about 40 to about 60 parts by weight flour about 40 to about 60 parts by weight sugar and flour 100 parts by weight baking powder 0 to about 2.0 parts by weight salt 0 to about 1.5 parts by weight cocoa 0 to about 15 parts by weight (2) a liquid mix comprising:
liquid whole egg 100 parts by weight vanilla extract 0 to about 2% by weight of egg, and (3) water.
sugar about 40 to about 60 parts by weight flour about 40 to about 60 parts by weight sugar and flour 100 parts by weight baking powder 0 to about 2.0 parts by weight salt 0 to about 1.5 parts by weight cocoa 0 to about 15 parts by weight (2) a liquid mix comprising:
liquid whole egg 100 parts by weight vanilla extract 0 to about 2% by weight of egg, and (3) water.
4. The process of claim 3 wherein said sugar in said dry mix is in crystalline form and said extruded batter contains crystalline sugar.
5. A continuous process for manufacture of sponge cake, which comprises:
feeding cake-forming components including flour, sugar, egg and water to a continuous mixing zone in quantities such that the total quantity of moisture in the cake-forming components is about 20 to about 45%
by weight, advancing the cake-forming components in plug flow manner through said mixing zone in about 20 to about 180 seconds, subjecting said cake-forming components to conditions of shear within said mixing zone such that the work done on the materials within the mixing zone varies from about 4 to about 7 watt/hr/lb, of cake-forming components to cause mixing of said components, subjecting said cake-forming components to a back pressure within said mixing zone of about 10 to about 75 psig, extruding from said mixing zone a cake-forming batter mix of density from about 0.65 to about 0.95 g/cc, substantially immediately after said extrusion, baking said extruded batter mix in a microwave baking zone using microwave radiation at an input of about 3 to about 12 kw min/lb. of batter while passing air through said zone to remove generated steam, and maintaining said batter in said zone for a time sufficient to result in a baked sponge cake having an internal temperature of about 180° to about 230°F and to effect a loss of moisture of about 10 to about 23 wt.%.
feeding cake-forming components including flour, sugar, egg and water to a continuous mixing zone in quantities such that the total quantity of moisture in the cake-forming components is about 20 to about 45%
by weight, advancing the cake-forming components in plug flow manner through said mixing zone in about 20 to about 180 seconds, subjecting said cake-forming components to conditions of shear within said mixing zone such that the work done on the materials within the mixing zone varies from about 4 to about 7 watt/hr/lb, of cake-forming components to cause mixing of said components, subjecting said cake-forming components to a back pressure within said mixing zone of about 10 to about 75 psig, extruding from said mixing zone a cake-forming batter mix of density from about 0.65 to about 0.95 g/cc, substantially immediately after said extrusion, baking said extruded batter mix in a microwave baking zone using microwave radiation at an input of about 3 to about 12 kw min/lb. of batter while passing air through said zone to remove generated steam, and maintaining said batter in said zone for a time sufficient to result in a baked sponge cake having an internal temperature of about 180° to about 230°F and to effect a loss of moisture of about 10 to about 23 wt.%.
6. The process of claim 5 wherein said moisture content in the mixing zone is about 28 to about 38% by weight.
7. The process of claim 5 wherein said cake-forming components are advanced through the mixing zone in about 30 to 60 seconds.
8. The process of claim 5 including introducing at least one gas to said cake-forming components at a plurality of locations during passage of said components thorugh said mixing zone at a gas flow rate of about 1.3 to about 18 SCF/100 lb, of cake-forming components.
9. The process of claim 8 wherein said gas feed is about 4.4 to about 7 SCF per 100 lb. of cake-forming components.
10. The process of claim 8 wherein said moisture content is about 28 to about 38% by weight, said cake-forming components are advanced through the mixing zone in about 30 to 60 seconds and said gas feed is about 4.4 to about 7 SCF per 100 lb. of cake-forming components.
11. The process of claim 10, wherein said back pressure is about 20 to about 50 psig and said work done is about 5 to 6 watt hr/lb. of cake-forming components.
12. The process of claim 5, 10 or 11 wherein said mixing zone has a temperature corresponding to the ambient temperature of said water in the range of about 40° to about 80°F.
13. The process of claim 8 or 10 wherein said gaseous material comprises carbon dioxide,
14. The process of claim 5 wherein said cake-forming components are fed to the mixing zone in the form of (1) a dry mix comprising:
sugar about 40 to about 60 parts by weight flour about 40 to about 60 parts by weight sugar and flour 100 parts by weight baking powder 0 to about 2.0 parts by weight salt 0 to about 1.5 parts by weight cocoa 0 to about 15 parts by weight (2) a liquid mix comprising:
liquid whole egg 100 parts by weight vanilla extract 0 to about 2% by weight of egg, and (3) water.
sugar about 40 to about 60 parts by weight flour about 40 to about 60 parts by weight sugar and flour 100 parts by weight baking powder 0 to about 2.0 parts by weight salt 0 to about 1.5 parts by weight cocoa 0 to about 15 parts by weight (2) a liquid mix comprising:
liquid whole egg 100 parts by weight vanilla extract 0 to about 2% by weight of egg, and (3) water.
15. The process of claim 14 wherein said sugar in said dry mix is in crystalline form and said extruded batter contains crystalline sugar.
16. The process of claim 1 or 5 wherein said sugar comprises liquid sugar.
17. The process of claim 5, 10 or 14 wherein said microwave energy input is about 4 to about 8 kw min/lb of batter.
18. The process of claim 5, 10 or 14 wherein said temperature rise is about 200° to about 212°F.
19. The process of claim 5, 10 or 14 wherein said microwave energy input is about 4 to about 8 kw min/lb.
of batter, said temperature rise is about 200° to about 212°F.
of batter, said temperature rise is about 200° to about 212°F.
20. The process of claim 1 or 5 including drying the sponge cake resulting from said microwave baking step to a moisture content of about 3 to about 8 wt.%.
21. Sponge cake particles having a porosity of about 0.2 to about 0.4 g/cc, a shear value of about 8 to about 25 kg and a moisture content of about 3 to about 8 wt.%, whenever prepared by the process of claim 1 or 5.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000372768A CA1136921A (en) | 1981-03-11 | 1981-03-11 | Production of sponge cake |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000372768A CA1136921A (en) | 1981-03-11 | 1981-03-11 | Production of sponge cake |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1136921A true CA1136921A (en) | 1982-12-07 |
Family
ID=4119422
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000372768A Expired CA1136921A (en) | 1981-03-11 | 1981-03-11 | Production of sponge cake |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1136921A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0617896A2 (en) * | 1988-06-29 | 1994-10-05 | The Pillsbury Company | Starch-based products for microwave cooking or heating |
| US20140205719A1 (en) | 2011-06-20 | 2014-07-24 | Generale Biscuit | Healthy layered cookie |
-
1981
- 1981-03-11 CA CA000372768A patent/CA1136921A/en not_active Expired
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0617896A2 (en) * | 1988-06-29 | 1994-10-05 | The Pillsbury Company | Starch-based products for microwave cooking or heating |
| EP0617896A3 (en) * | 1988-06-29 | 1994-12-07 | Pillsbury Co | Starch-based products for microwave cooking or heating. |
| US20140205719A1 (en) | 2011-06-20 | 2014-07-24 | Generale Biscuit | Healthy layered cookie |
| EP2720559B1 (en) * | 2011-06-20 | 2018-01-24 | Generale Biscuit | Preparation of a baked cereal product with slowly available glucose |
| US10306897B2 (en) | 2011-06-20 | 2019-06-04 | Generale Biscuit | Breakfast biscuit with slowly available glucose |
| US10357041B2 (en) | 2011-06-20 | 2019-07-23 | Generale Biscuit | Healthy layered cookie |
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