CZ37157U1 - Jam, sourdough and dark bread - Google Patents

Description

Jam, sourdough and dark bread

Field of technology

The technical solution refers to dark rye or rye-wheat bread of the Nordic type, where the raw material for bread production is a special type of sourdough, which is made up of leaven, the cereal component of which is brewer's thresh.

Current state of the art

Dark breads of the Nordic (Scandinavian and Baltic) type are traditionally made with the help of so-called sourdough, which is a mixture of vital rye kvass and so-called leaven. Závarka is hydrothermally treated rye flour, rye jerky or rye scrap. Závarka is usually prepared as a suspension of rye fraction (flour, jerky or scrap) in water. The ratio of flour and water in the wort is most often in the range of 1:1.5 to 1:2.5 (weight of flour to weight of added water). The temperature during the hydrothermal preparation of the wort usually reaches values of 60 to 70 °C, the maturation time is most often in the range of 2 to 4 h.

The result is a product that, during maturation (hydrothermal treatment), goes through many physicochemical and biochemical processes, the most important of which is greasing and gradual enzyme hydrolysis of starch. Important products are dextrins and simple sugars, especially maltose and to a lesser extent glucose. At the same time, reactions take place between reducing sugars and amino acids or peptides resulting from the hydrolysis of proteins, which takes place simultaneously with the hydrolysis of starch. To increase the activity of enzymes (amylases and proteases), it is possible to add enzyme-active malt flour or malt extract.

After cooling to a temperature of 25 to 30 °C, the resulting brew is mixed with vital rye kvass, resulting in a so-called sourdough, which then matures for 8 to 24 hours, depending on the type and amount of kvass added. fermentation of sourdough to produce lactic and acetic acids, but also many other sensory and nutritionally significant substances. Ripe sourdough is one of the basic recipe components of this type of bread. The bread is characterized by a distinctly sweet and winding taste, a strong aroma and a dark color.

If the packaging and sub-pack layers of rye grain (whole-grain rye flour, jerky or meal) are a component of the jam, during the hydrothermal treatment and subsequent fermentation, fiber structures are loosened and their fractions are released, i.e. their bioavailability to the intestinal microbiome increases after eating bread. This is the reason for the favorable nutritional value and demonstrable health benefits of this type of bread.

The distinct sensory properties of this type of bread also allow the addition of salt to be reduced, as the background flavor of the bread is sufficiently rich and distinctive.

The traditional production process described above is relatively complicated and above all long. Therefore, in the production of similar breads, our bakeries mainly use the so-called direct line ("on the stop"). Although the bread is made from rye flour or a flour mixture with a predominance of rye content, both the hydrothermal treatment of part of the cereal content and the maturation phase of the sourdough with intensive lactic fermentation are completely missing. The resulting sensory properties, taste and aroma, are achieved by the recipe addition of flavorings (stable non-vital kvass with the addition of acids) and colorings (usually roasted malt). The bread produced in this way, whose production process is fundamentally shortened compared to the traditional procedure, resembles traditional bread of this type in color, taste and aroma (depending on the quality of the sensory active recipe ingredients used).

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The problem with the abbreviated production process, which results in bread that mimics the characteristics of bread created by the aforementioned traditional sourdough process, is mainly that the depth and variety of aroma and taste of traditionally prepared bread is not achieved. Bread made using a shortened process also lacks the majority of nutritionally significant and biologically active substances. Although it is possible to partially compensate the sensory properties by adding salt, this is not advisable for health reasons.

Another disadvantage is that rye flour, meal and other raw materials of rye origin are relatively expensive and thus increase the final price of the product. It would therefore be advantageous if it were possible to replace at least part of the rye raw material with a cheaper and more readily available cereal component, without affecting the sensory and nutritional properties of the bread.

The mash is the solid residue (sludge) after draining the wort. Brewer's mash contains a high proportion of protein, fiber and residues of lubricating and hydrolyzed starch, as well as residues of largely degraded proteins. Hydrolases (amylases, proteases) and other enzymes in the threshing are inactivated (thermal denaturation). However, the threshed contains barley husks, which are essentially inedible under normal conditions.

The essence of the technical solution

The technical solution concerns Nordic-type dark rye or rye-wheat bread, which eliminates the above-mentioned disadvantages by the fact that the raw material for its production is a special type of sourdough, which is made up of leaven, the cereal component of which is brewer's mash. Surprisingly, it was found that brewer's mash not only does not deteriorate the sensory properties of the produced bread, but significantly increases its nutritional value, as will be discussed in more detail below.

In the industry, the term "rye bread" usually refers to dark bread, which does not have to be purely rye - although it contains a predominance of rye flour, a mixture of rye and wheat flour is usually used due to the better structure and flexibility of the mixture. In the presented technical solution, the term "dark bread" means whole wheat or rye bread, in which the proportion of wheat or other flours in the flour mixture are less than 50% by weight, and the rest is rye flour. The rye-wheat mixture preferably contains 0 to 30% by weight. wheat share.

The technical solution also relates to jam for the production of dark rye or rye wheat bread, the cereal component of which, in contrast to jams known in the state of the art, consists of hydrothermally treated brewery mash.

According to the presented technical solution, wort means a suspension of brewer's wort in water, while the weight ratio of dry matter of brewer's wort and added water is preferably in the range of 1:5 to 1:4.

For better hydrolysis of the residual starch and its degradation products (dextrins) of the brewer's mash, the suspension may contain an addition of 0.5 to 1% by weight, based on the weight of the mash, enzyme-active malt flour or an equivalent amount of malt extract, in order to increase the concentration of fermentable and reducing sugars. The term "enzymatically active" here means that the malt has been dried in a gentle way before milling, thus preserving the activity of amylolytic and proteolytic enzymes. Malt flour of this type is available on the market and is called "diasta" in baking and milling terminology.

This suspension is advantageously processed in the field by conventional hydrothermal treatment. Hydrothermal treatment according to the presented technical solution preferably consists in the action of water on the suspension at a temperature of 50 to 70 °C for a period of 2 to 4 h.

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Sourdough for the production of dark rye or rye-wheat bread according to another subject of the technical solution is obtained by mixing the brewer's wort-based brew described above with common vital rye yeast after cooling, and the resulting sourdough is allowed to mature so that a sufficiently intense lactic fermentation occurs. Sourdough is then added in a significant amount, in the order of several tens of percent, to the dough for the production of Nordic-style dark rye or rye-wheat bread. The exact amount is chosen depending on the properties of the raw materials used, especially the flour, on the titration acidity of the sourdough and the required consistency of the dough for the production process used. The amount of sourdough added to 100 kg of flour can be, for example, 15 to 40 kg.

Thanks to the hydrothermal treatment and subsequent fermentation, the bread sourdough prepared in this way not only provides significant sensory properties that enable the reduction of the addition of salt to the dough, but also significantly increases the fiber content. The fiber of the wrapper and sub-wrap layers of barley, which contains a high proportion of beta-glucans, is found in a mature sourdough in a considerably loosened form, and is therefore easily accessible to the intestinal microbiome during the digestion of the bread produced in this way. The increase in the bioavailability of barley fiber fractions occurs both due to the effect of perfect hydration due to hydrothermal intervention during spreading and mashing in the brewery and during the subsequent creation of the wort, and at the same time due to the lactic fermentation taking place in the wort, which causes, among other things, a decrease in the pH of the environment.

Sourdough prepared in this way with a high content of brewer's wort contains a significantly higher proportion of protein and fiber than sourdough prepared traditionally (see below) from whole-grain rye meal or flour, and at the same time a significantly lower proportion of digestible carbohydrates (starch, sugars), i.e. compared to traditional rye sourdough also to reduce the glycemic index.

A special brew according to the technical solution can be prepared from the brewery's threshing floor as follows:

Brewer's wort with a dry matter of 20 to 25% is mixed with water in a ratio of 1 part by weight. of water per 1 part by weight threshed, the ratio can be adjusted according to the consistency, it is better to disintegrate the threshed granulation by grinding before use. Enzyme-active malt flour (0.5 to 1 wt.% based on the mass of the malt), or an equivalent amount of malt extract, is mixed into the resulting suspension. The suspension is tempered at a temperature of 50 to 70 °C for 2 to 4 h with constant mixing. After completion of the hydrothermal treatment, the resulting wort is cooled to a temperature of 25 to 30 °C.

To prepare the sourdough, the sourdough cooled to a temperature of 25 to 30 °C is mixed with vital rye yeast with a yield of 200 to 250% (up to 300% when using finely ground whole grain flour) and titration acidity of 70 to 150 mmol/kg. The mass ratio of wort and rye kvass is approximately 1 part of wort to 1 part of kvass, this ratio can be adjusted according to the yield (consistency) of the kvass and its acidity. The resulting titration acidity of the resulting mixture should reach values of 40 to 70 mmol/kg. The mixture (base) prepared in this way ripens at a temperature of 25 to 30 °C for 10 to 25 h. The titration acidity of the matured sourdough ranges from 90 to 150 mmol/kg.

The basis for the production of bread is rye bread flour or finely ground whole grain rye flour, or a flour mixture with a predominance of rye flour (rye-wheat mixture with a content of 0 to 30% by weight of wheat). Flour is mixed with sourdough, water, baker's yeast and other recipe ingredients are added (see below), while the weight of sourdough added to the dough per 100 kg of flour is 15 to 40 kg, depending on the titration acidity of the sourdough.

Furthermore, recipes for the production of dark bread are compared, while recipe a) is according to the presented technical solution and recipes b) and c) are according to the state of the art.

a) with sourdough with a brewer's pestle (according to the technical solution):

rye flour or rye wheat flour mixture 100 kg sourdough with a threshing according to the technical solution 15 to 35 kg salt 1 to 2 kg yeast 1 to 3 kg spices (cumin) 0 to 0.5 kg

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water according to the consistency of the resulting dough yield 160 to 170%

b) with sourdough with rye flour/rye meal (comparative):

rye flour or rye wheat flour mixture leaven with whole grain rye flour salt yeast spices (cumin) water according to consistency resulting dough yield 100 kg 15 to 35 kg 2 kg 1 to 3 kg 0 to 0.5 kg 160 to 170% c) using the direct guidance procedure (comparative) rye flour or rye-wheat flour mixture preparation to achieve sour taste and dark color of bread (depending on the type of preparation) salt yeast spices (cumin) water according to consistency, resulting dough yield 100 kg 2 to 5 kg 2 to 3 kg 1 to 3 kg 0 to 0.5 kg 160 to 170%

In accordance with the above, according to the technical solution, dark bread has, for example, the following composition:

rye flour or rye-wheat flour mixture sourdough with a threshing according to the technical solution salt yeast spice water according to consistency resulting dough yield 100 kg 20 to 35 kg 1 to 2 kg 1 to 3 kg 0 to 0.5 kg 160 to 170%

The resulting dough yield is the weight of the dough prepared from 100 kg of flour (mixed with all other ingredients, including water).

The rye flour mixture preferably contains up to 30% by weight. wheat share.

Salt (meaning table salt, or salt with iodine and/or fluorine additives) is also technologically important in the production of bread and pastries, especially if wheat flour is part of the recipe. Salt stabilizes the structure of the wheat portion in the dough. However, approx. 0.5% by weight is sufficient for this. of salt per weight of flour. For example, for ordinary wheat bread (roll, bun, lid), 2 wt.% and more salt. Since the bread according to the technical solution containing thresh has a relatively rich flavor background, the salt content can be advantageously reduced to no more than 1.5% by weight, more preferably no more than 1.2% by weight, most preferably no more than 1% by weight . table salt, based on the weight of the flour.

The spices used are usually chosen according to local customer preferences, e.g. cumin, fennel, etc.

Yeast is, for example, commonly used baker's yeast in the field.

The mash, which contains barley flakes, which are very difficult to consume under normal conditions, with double hydrothermal treatment and subsequent fermentation becomes an inherent part of the homogeneous dough and in no way disturbs the sensation when chewing the mixture.

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Examples of implementing a technical solution

Example 1: Preparation of a special wort according to the technical solution from the brewery's threshing floor

Brewer's wort with a dry matter of 22.5% is mixed with water in a ratio of 1 part by weight. of water per 1 part by weight threshed, the granulation of the threshed having been disintegrated by grinding prior to use. Enzyme-active malt flour (0.75% by weight per threshed weight) and an equivalent amount of malt extract are mixed into the resulting suspension. The suspension is tempered at a temperature of 60 °C for 3 h with constant mixing. After completion of the hydrothermal treatment, the resulting wort is cooled to a temperature of 27.5 °C.

Example 2: Preparation of sourdough from the special brew from example 1

The wort, cooled to a temperature of 27.5 °C, is mixed with vital rye yeast with a yield of 225% and titration acidity of 110 mmol/kg. The mass ratio of wort and rye kvass is 1 part of wort to 1 part of kvass. The resulting titration acidity of the resulting mixture was 55 mmol/kg. The mixture (base) prepared in this way ripens at a temperature of 27.5 °C for 17.5 h. The titration acidity of the matured sourdough is 120 mmol/kg.

Example 3: Production of whole bread according to the technical solution

The following recipe and manufacturing process was used:

Rye bread flour 100 kg sourdough with a threshing according to the technical solution 30 kg salt 1 kg yeast 2 kg spices (cumin) 0.2 kg water according to the consistency resulting dough yield 165%

Manufacturing process:

- mixing the dough for 8 min (slow speed);

- dough ripening 25 min, temperature 28 °C;

- proofing in molds, weight 910 g, proofing time 60 min, temperature 30 °C, relative humidity in the proof room 65%;

- baking bread for 55 min at temperatures of 240/200 °C (initial temperature/final temperature), in the first stage of baking steaming of the oven space.

Example 4: Production of whole grain bread according to the technical solution

The following formulation and manufacturing procedure was used in Example 3 above:

whole grain rye flour 100 kg sourdough with a threshing according to the technical solution 30 kg salt 1 kg yeast 2 kg spices (cumin) 0.2 kg water according to the consistency final dough yield 170%

Example 5: Production of rye wheat bread according to the technical solution

The following formulation and manufacturing procedure was used in Example 3 above:

rye bread flour 75 kg wheat bread flour 25 kg sourdough with a threshing according to the technical solution 30 kg salt 1 kg

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0.2 kg

165%

Bread made only from rye flour had a rich flavor background, even with the amount used of only 1.25% by weight. table salt, based on the weight of the flour. At the same time, the threshing did not interfere with the sensation when chewing the pulp.

The bread had a reduced relative starch content, an increased fiber content (especially in the form of barley beta-glucans) and an increased protein content. These changes lead to an improvement in the nutritional value of the bread and a reduction in its glycemic index.

The discovered advantages of using sourdough with a brewer's pestle can be summarized as follows:

1. Compared to the traditional procedure when using rye bread flour and when using whole-grain rye flour (groats) for the preparation of jam, as well as when using a direct dough guide, when using a brewer's thresher there is a significant reduction in the relative starch content, an increase in the fiber content (especially in in the form of barley beta-glucans) and an increase in the content of proteins, which are the most significant component of threshing. This increases the nutritional value of the bread and lowers its glycemic index.

When comparing the content of the listed components in traditional wort and brewer's wort with a brewer's wort, according to the technical solution, in the wort with a wort, the proportion of starch will decrease fifteenfold, the protein content will increase fourfold, and the fiber content will increase more than twice.

2. Compared to traditional and common recipes, it is possible to dose a reduced amount of salt (e.g. only 1% by weight, based on the weight of the flour) thanks to the significant sensory profile of the bread.

3. The use of brewery mash represents the evaluation of a by-product from the production of beer, which is otherwise used as a valuable feed for farm animals, but whose production significantly exceeds the needs of feed processing, and therefore new ways are being sought to use it other than as an energy raw material (fuel). or fertilizer.

Industrial applicability

The technical solution can be used in the production of Nordic-type dark rye or rye-wheat bread, which has an improved nutritional value compared to ordinary products due to the brewer's malt content, in particular a significantly reduced relative starch content, an increased fiber and protein content and a lower glycemic index and, at the same time, a reduced salt content. In addition, the use of a brewery's threshing floor represents the valorization of a by-product from the production of beer. At the same time, a reduction in the consumption of rye flour (groats) for the preparation of the jam is achieved.

Claims (11)

1. Brewery for the production of dark rye or rye wheat bread, characterized by the fact that its cereal component consists of brewer's malt. 2. Brew according to claim 1, characterized in that it is formed by a suspension of brewer's wort in water, while the mass ratio of dry matter of brewer's wort and water is in the range of 1:5 to 1:4. 3. Brew according to claim 2, characterized in that the suspension contains an addition of 0.5 to 1% by weight, based on the weight of the malt, enzyme-active malt flour or an equivalent amount of malt extract. 4. Sourdough for the production of dark rye or rye wheat bread, characterized in that it contains the leaven according to any one of claims 1 to 3 and vital rye yeast in a weight ratio of 1:0.8 to 1:1.2. 5. Dark bread, characterized in that it contains leaven according to any one of claims 1 to 3. 6. Dark bread, characterized in that it contains sourdough according to claim 4. 7. Dark bread according to claim 5 or 6, characterized in that it contains no more than 1.5% by weight. table salt, based on the weight of the flour. 8. Dark bread according to claim 5 or 6, characterized in that it contains no more than 1.2% by weight. table salt, based on the weight of the flour. 9. Dark bread according to claim 5 or 6, characterized in that it has the following composition: rye flour 100 kg of sourdough according to claim 4 20 to 35 kg of salt 1 to 2 kg of yeast 1 to 3 kg of spices 0 to 0.5 kg of water depending on the consistency of the resulting dough yield 160 to 170% 10. Dark bread according to claim 5 or 6, characterized in that it has the following composition: rye flour mixture 100 kg of sourdough according to claim 4 20 to 35 kg of salt 1 to 2 kg of yeast 1 to 3 kg of spices 0 to 0.5 kg - 7 CZ 37157 U1 water according to the consistency of the resulting dough yield 160 to 170% 11. Dark bread according to claim 10, characterized in that the rye flour mixture contains up to 30% by weight. wheat share.