DD290795A5 - METHOD FOR THE PRODUCTION OF ZWIEBACK - Google Patents

Abstract

The invention relates to a process for the production of rusks, which can be applied both in craft enterprises and in Groszbetrieben the bakery industry. The object of the invention is to identify process conditions in which as low as possible technical-technological effort a Einback can be produced, which due to its shape and properties, in particular its crust / Krumen ratio, after cutting and Roesten not the typical Has rusk defect. The object is achieved in such a way that a rusk dough is formed into a dough sheet of arbitrary width and a thickness of * mm, trimmed at the sides and divided into arbitrarily large dough sheets by cutting in the transverse direction. During the formation and division of the dough into individual dough sheets, the dough is subjected to an alternating load in the form of rolls - stretching - upsetting - rolling - upsetting. After ripening, the dough plates are baked with reduced top heat and a baking air humidity of 1 * 200 g / kg dry air. After storage of * h, the dough plates are sliced in lengths and the baking lengths are sliced. The roasting of the baking sheets is carried out in a known manner {biscuit; Einback; dough sheet; sheet of dough; Einbacklaenge; To form; Divide; To cut; rolling; Stretch; upsetting}

Description

Field of application of the invention

The process for the production of rusk is particularly suitable for artisanal production, but also in large factories of the bakery industry can be worked by the process.

Characteristic of the known state of the art

Zwieback is a baked and roasted pastry made from yeast dough, which is characterized by a mellow break and an offensive roasted flavor. Rusk is said to keep his roast over Mcnate. These properties are not achieved simply by baking a yeast dough twice for so-called baking and roasting of the deposited caking-in, but require a technology in which, in particular, dough-forming plays a special role.

The composition and the preparation of the rusk dough correspond roughly to cake dough.

But it can also be prepared for making rusk from flour, dough liquid and the whole yeast a Vorteig.

This is kneaded intensively and after a Abstehzelt is prepared with the remaining ingredients of the dough, which is also intensely kneaded. The dough preparation and the subsequent shaping can be carried out either batchwise or continuously.

The further processing is carried out in such a way that abgegotellte dough pieces are machined round. After a short Zwischengare to relax the dough, the dough is divided by Toigtoil- and knitting machines, formed into small round pieces and short lengths. The formed sparrows were placed next to each other in special shapes. This creates a strand with transverse depressions. Of course, the round pieces can also be placed directly on baking trays and pressed a little bit wide. In industrial production, split, weighed pieces are initially also round machined. After a short Vorgare these pieces are either rolled into pancakes and rolled into a cylindrical shape and placed in Zwiebackformen or machine rolled out by special Langrollvorrichtungen, possibly manually leveled and stored in forms. The dough lengths thus formed pass through a finishing station and are subsequently baked. To obtain a smooth surface, the rusk molds can be covered (see the brochure of Werner and Pfleiderer on complete rusk plants). However, only relatively large bumps are compensated because the height of the rusk forms is such that the lids do not rest directly on the baking lengths after the ripening of the doughs has ended.

The baked at about 220 ° C Einback is stored after removal from the molds for about 24 h before it is cut and roasted in special Röstöfen. Optionally, the baked dough lengths can be dressed prior to storage.

The individual processing stages in the dough forming are very complicated, but extremely important for the emergence of a friable ι Ί delicate breakage of the rusk. A short break requires a high number of pores with thin pore walls (Doose, O. Verfahrenstechnik bakery, Gildeverlag Alfeld [1978] p.294-296).

The origin of the pores is mainly due to small air germs, which are enclosed by dough films and reach the dough in the dough preparation. By gas formation of the yeast, the air bubbles are increased. When processing the dough by kneading and kneading, the number of pores is determined. During the Stückgare or maturation, the pores only increase.

Dor described prior art has many shortcomings. To emphasize is the large manuolle or machaschinolle effort, which is connected with the shaping of the rusk dough. Baking in the form of dough lengths, be it in rusk molds or lying freely on metal sheets, requires well-kneaded doughs whose surface should be smooth and slightly dry. Poorly made doughs run off the sides and the baked lengths have a bad shape. In the DD-WP 150687 an ancestor for the production of Einback is described in which the Einback is continuously gobackon in U-shaped profiled back bands in the form of endless Strange. A nachorg method of intensive kneading horgostolltor Einbaughig is formed into a breiton Toigband. This is subjected to the lateral trimming in the course of a fermentation process in a Vorgärkanal and divided before dom inserting into the U-shaped profiledon gutters the Backbändor into individual dough strands. After being placed in the gutters, the dough strands pass through the final fermentation channel and then through a continuous furnace. The method according to DD-WP 150687 has many shortcomings. If there are irregularities in the coordination of the 8andsystemo Vorgärkanal, Endgärkanal and Durchlaufbackofer, the entire system must be switched off to avoid unwanted congestion or stretching of dough bands and strands, as these lead to quality defects. Dividing the Teigbändor into strips and inserting the strips In continuous a Nachgärkanal and oven traversing channels is complicated and space consuming. The cutting of the dough bands in strips of dough after the pre-fermentation affects the quality of the final product negative, since the formation of the gluten structure is disturbed at the interfaces and thus the Einback achieved an insufficient volume.

For continuous production of fat and zuckorreichem Einback is prepared according to DD-WP 221063 a pre-dough, at dom the usual ingredients are processed with a higher liquid content, so that the dough liquid-flour ratio is 1.18: 1. The main dough is made from the Vortoig, a margarine-sugar mixture, the main part of the flour and water. The Toig is rolled into a dough band, divided into dough sticks the size of usual Zwiebacklangon and placed in bakeware. Characteristic of this method is that only about 13% of the water are used directly in the dough preparation, the remaining dough liquid is included in the pre-dough and in the margarine-sugar mixture. A disadvantage of this method is that it comes to the formation of relatively large pores in the dough in the pre-dough due to existing free water, which do not lead to the desired quality. Also, the dough length due to the wet dough tend to stick to the baking mold walls. This also negatively affects the quality of the baking. In addition, the entire dough preparation is very expensive.

In rusk frequently occurring errors are the so-called. Waist formation of the Einbacks and thereby hairline cracks of rusk. According to Huber, H. and Fauth, H. (Waist formation in rusk production, confectionery 14 (1979) 10, pp. 483-489), the waist is formed by a labile crust which influences the deformation, by the weight of the stakes on the side crust and by In their opinion, waist formation can be avoided by a strong and stable crust, but a hard crust leads to crust (~ 10%) and crumbs (~ 10%) due to the different moisture content behind the pelvis. ) during roasting due to the different contraction of crust and Krurri6 to Krumespannungen, which even later in storage lead to hairline cracks in the rusk.This not yet solved optimal ratio of soft crumb to more or less hard crust is another disadvantage of the prior art of the technique.

Object of the invention

The aim of the invention is the production of rusks good sensory quality while reducing the technical-technological effort in the process steps of dough processing. The production should be feasible both in craft enterprises as well as in large enterprises of the bakery industry.

Explanation of the essence of the invention

The invention has the object of demonstrating process conditions in which an insight can be produced with the lowest possible technical-technological effort, which does not have the typical Zwiebackfehler due to its shape and properties, in particular its crust / crumb ratio, after cutting and roasting ,

According to the invention the object is achieved in the following manner. A biscuit dough prepared discontinuously or continuously is formed into a dough sheet of any width and thickness of 20 ... 25mm, trimmed at the sides and divided into arbitrarily sized dough sheets by cutting in the transverse direction, forming and dividing the dough into individual dough sheets Dough is subjected to an alternating load in the form of rolling - stretching - upsetting - rolling - upsetting, the dough sheets are placed on baking tray, punctured and subjected to maturation at 20 ... 32 ⁰ C 30 ... 35min, then at reduced top heat and baked a baking moisture of i 300 ... 2 200g / kg dry air, stored after removal from the oven 6 ... 24h and then sliced into individual lengths and the Einbacklängen and these roasted in a known manner.

In a preferred embodiment, the dough is subjected during the shaping and division of the alternating load in the form of rolling - stretching - upsetting - rolling - upsetting in such a way that the shaped dough sheet of any width and a thickness of 20 ... 25mm formed by Teigbandformer is connected to the simultaneous stretching of the dough sheet upon transfer to a Teigförderband in which the ratio of Umlaufgeschwindigkeiten roller of Teigbandformers to Teigförderband is set to 1: 0.8 ... 0.98, the stretched dough sheet with a thickness from 12 ... 17 mm is slightly compressed when fed to a leveling roller and brought to a thickness of 11 ... 16mm by means of leveling roller, then the dough is divided into individual dough trays and this under compression to a thickness of 14 ... 18mm be stored on baking tray.

It has surprisingly been found that the molding of Zwioback dough to dough lengths and the baking of the length can be dispensed with Einback and that the problem d jr frequently occurring Zwiebackfehler "waist formation" and "hairline cracks" is solvable, as shown according to the invention a dough sheet in shape single, arbitrarily large dough sheets, z. In size

normal baking trays, baked crusted and then cut into lengths and slices. The connection between the baking in the form of dough plates and the type of baking as crust-poor baking with reduced top heat and specially adjusted Backluftfeuchto is very essential.

The production of dough sheets in the manner described in the invention, in which the dough is subjected to alternating load in the form of rolling - stretching - upsetting - rolling - upsetting, leads to the formation of a good gluten network structure and thus to a pore structure which ripens after the subsequent process stages and crust-poor baking results in a quality-consistent Einback without waisting, which leads to roasting to rusk without hairline cracks. A good, uniform pore structure is characterized by as many, as small and, above all, round, fine pores. This is achieved in the present case by the alternating compression and extension of the dough strip and by the tension-free placement of dough sheets on the baking tray. For this purpose, a simultaneous stretching of the dough strip is carried out during the formation of a dough sheet intended for cutting into individual plates. The dough sheet formed by a dough roller mill is transferred to a dough conveyor belt, with the rotational speed of the roller of the dough belt former being related to the speed of the conveyor belt such as 1: 0.8 ... 0.98. When feeding to the leveling roller a slight compression takes place by means of leveling roller is set to a thickness of 11 ... 16mm, so in turn stretched, and when depositing on individual baking trays, the dough is compressed again. A shrinkage of the dough when dividing into individual dough sheets, z. B. by squeezing, is prevented. By the usual folding, rolling or Einschlaglangrollen for forming the dough lengths of the dough is brought into a state of stress, which adversely affects the shape of the pores, as these in the further training and enlargement during maturation and in particular during the baking process in the direction of Zoom in on the voltage. As a result, the round shape of the pores necessary for good crumb formation and a delicate break is changed.

It is essential for the method according to the invention that the dough sheets, after they have been placed on the baking trays, achieve an almost complete relaxation of the tension, that is, by the formation associated with targeted stretching and compression the dough sheets have a stress-free state before the beginning of maturation reached. To avoid Gasbläschenagglomerationen the dough plates are tipped. This also supports the formation of fine pores.

On don very significant connection between the baking in the form of dough plates and a crust-poor baking has already been noted. A pastry crust is inevitably produced during baking by the forming during the baking process in the product evaporation zone, which migrates from the surface into the interior of the baked goods as the baking process. Below this zone, the Einback has a humidity of about 43%, above this zone 4 ... 8%. Above the evaporation zone, temperatures of over 100 ° C are reached, it form Maillard roasted products and thus it comes to crust formation. Too hard a crust favors the formation of hairline cracks, a non-hairy, crust-like crust, which forms predominantly in a hot baking atmosphere, leads to the baking of baking lengths in molds for sticking to the mold walls. Therefore, baking lengths are usually baked without adding steam.

According to the method of the invention, the dough sheets are baked in such a way that by reducing the Obsrhitze and adding steam specifically the formation of only a weak, so thin crust is brought about. The moisture level in the oven is adjusted so that after a baking time of 5min a moisture content of 1300 ... 2000g / kg dry air is reached and this moisture level is maintained until the end of the baking process, in continuous furnaces to about 2 ... 3min before completion , with an increase to 2200g / kg dry air at the end of the baking process is advantageous. The baking plates are stored in a known manner 6 ... 24h. The slicing of the dough slices in lengths and lengths into slices can be done mechanically or manually, depending on the existing technique.

The roasting of a caking produced by the process according to the invention leads to rusk with very good quality, which has no hairline cracks even after prolonged storage. The grain structure of the caking, small round pores with a high number of pores, leads to a particularly sweet rusks.

A particular advantage of the method according to the invention is the low technical and technological complexity and the associated possibility of using the method both in small companies with low technical equipment as well as in large bakeries with a high technical level. Due to the geometrical accuracy of the dough sheets, the cutting waste is substantially reduced. In addition, the resulting accuracy of the geometrical shape of the biscuit slices ensures safe automatic packaging with the least amount of waste. The invention is explained in more detail by Ausführunysbeispiele.

Aiisführungsbelsplele

1. The following example uses aggregates known as "condyle" for the production of cut biscuits, yeast buns and biscuits, leaf biscuits and Danish pastries.

From 10.0kg wheat flour, 3.0kg water, 0.4kg whole milk powder (20Ma .-% fat), 0.6kg yeast, 0.9kg whole egg, 1.1kg granulated sugar, 1.6kg table butter, 0.08kg salt, 0 , 2kg vanilla sugar and 0.05kg lemon flavor are prepared either over a pre-dough or by means of intensive kneading 17.7 kg dough. The dough is placed in the hopper of a Teigbandformers and rolled out into a Teigband with a thickness of 23 mm and transferred to a Teigförderband, wherein at the same time by stretching the Teigförderbandgeschwindigkeit stretching the dough takes place. The ratio of the speed of the dough belt former roller to the speed of the dough conveyor belt should be 1: 0.8. The thickness of the stretched Teigbandos is 17 mm. The flour spreaders are to be adjusted to the most economical consumption. By means of a leveling mill, the dough is thinned to 13 mm after being previously compressed so that the strip had a thickness of 20 mm on entering the leveling mill. Followed cutting rollers on the leveling mill cut the dough band to the desired bread roll width. 4-edge or 3-edge sheets with 420mm width are commonly used in the Kondilinie. The shearing off of the dough bands to dough plates of length doi baking trays corresponding to (620 mm) is realized by means of running rubber squeegee roller. The sheets of dough (4.2 kg per plate) are placed on the sheets

a needle roller stabbed. At a sheet conveying speed of 2.5m / mln approx. 1000kg of dough are processed per hour. In this case, the sheet conveying speed is controlled so that upsetting of the dough takes place when depositing on the sheets and the dough sheets reach a thickness of 16 mm.

The filled baking trays are placed in an inclined trolley and boi 32 ⁰ C Matured in humid air for 30 ... 35min. The baking of the dough to Einback can be done in any ovens, preferably in Netzbanddurchlaufbacköfen at a temperature of 22O ⁰ C. The baking time is 30 ... 35min. Important when baking Is a reduction of the top heat and an intensive steam addition to a moisture content of 2000g / kg dry air, which must be maintained until the end of the baking process, with an increase to 2200g / kg dry air at the end of the baking process is advantageous. After the procedure described 960kg Einback / h are produced.

The Einback is stored at a relative humidity of 70% and a temperature of 12 ... 2O ⁰ C 20h. The stored Einb'ackplatten be cut manually with a knife or knife shaft or machine with a cake cutter in lengths of 8cm width. The Einbacklängen can also be cut manually with a knife or machine with a gate cutting machine or even circular or beater knife. Depending on the system used, discs 80mm x 60mm x 11mm are obtained. The slices are roasted max. 20min at 180 ... 23O ⁰ C. From 10,0kg gluten-rich wheat flour, 0,75kg margarine, 1,8kg granulated sugar, 0,17kg malt extract, 0,08kg salt, 0,03kg ammonium, 0,55kg yeast and 2, 38 kg whole milk is produced either over a pre-dough or directly an intensely kneaded dough with approx. 15.7 kg mass. After a rest period of 30 minutes, the dough is kneaded again for 3 minutes. After a dough break of 10 minutes, the dough is placed in the hopper of the dough sheeter using lifting tippers and rolled out to a thickness of 20 mm. By compared to the roller peripheral speed higher Teigförderbandgeschwindigkeit the dough sheet is stretched to a thickness of 15mm. After about 10 seconds, the dough passes over an inlet ramp in which the dough band is compressed to a thickness of 18 mm, under the leveling roller, in which the dough sheet is brought to a thickness of 14 mm. The flour spreading device for both the lower and the Teigbandoberfläche is einpestellt on the most economical consumption. 'Via a bevel reaches the endless Teigband in the 3-edge baking trays, it is slightly compressed, so that a thickness of 16mm is formed, and culminating over a Gummiquetschwalze to the transverse sheet edge divided into finite dough plates. The plate dimensions are 480mm x 250mm. The dough-coated baking trays pass through a proofing cabinet in a mechanically operating conveyor hanger for 30 minutes. The fermenter moisture content is 85% and the temperature 32 ⁰ C. Then enter the baking trays automatically in the mesh belt oven and baked at 220 ° C in 35 min. In this case, the baking regime is carried out according to Example 1. The system is driven so that a Teigbandge3achwindigkeit of 4.9m / min is formed. Thus, the processing of about 1900kg dough / h is possible. After baking, the sheets are placed in a trolley and stored for 5 hours in a normal indoor climate. Then the 480 mm χ 250mm dough sheets are removed from the sheets, cut into 3 strips each80mm χ 480mm by means of circular or band knife, the two edge strips are removed and then the strips are cut by tape cutting machines to 80mm χ 60mm x 11 mm Einbackscheiben, the mechanically placed and roasted in a known manner.

Claims (3)

1. A process for the preparation of biscuits in a known manner batchwise or continuously prepared rusk dough, forming the dough, baking to Einback, storing and cutting the Einbackes and Equipping the Einbackscheiben, characterized däß a Teigband any width with a thickness of 20 .. . 25mm, this is trimmed on the sides and divided by cutting in the transverse direction into arbitrarily large dough sheets, wherein during the formation and division of the dough into individual dough sheets, the dough of an alternating load in the form of rolls - stretching - upsetting - rolling - upsetting The dough clump is placed on the baking tray carrier, punctured and subjected to ripening at 28 ... 32 ⁰ C 30 ... 35min, then baked at reduced top heat and a baking air humidity of 1300 ... 2200g / kg dry air and removed after removal be stored in the oven 6 ... 24h, then sliced into individual lengths and the Einbacklängen and these are roasted in a known manner. 2. The method according to claim 1, characterized in that the dough strip of any width with a thickness of 20 ... 25 mm is formed by Teigbandformer, wherein the shaping is associated with simultaneous stretching of the dough strip upon transfer to a dough conveyor, the stretched dough with a thickness of 12 ... 17mm when fed to a leveling roller slightly compressed and brought by leveling roller to a thickness of 11 ... 16mm, the dough band divided into individual dough plates and this while simultaneously compressing to a thickness of 14 ... 18mm on baking tray be filed. 3. The method according to claim 1 and 2, characterized in that the ratio of the rotational speeds of the roller Teigbandformers dough conveyor to dough conveyor belt is set to 1: 0.8 ... 0.98 for stretching the dough sheet on transfer to the dough conveyor.