DK179359B1

DK179359B1 - A process for producing packed ready-to-use dough

Info

Publication number: DK179359B1
Application number: DKPA201700454A
Authority: DK
Inventors: Rasmus Linnet; Anders Høy Thomsen; Steffen Bagge; Rasmus Maarbjerg
Original assignee: Smartbake Dk Aps
Priority date: 2017-08-18
Filing date: 2017-08-18
Publication date: 2018-05-22
Also published as: DK201700454A1; SE541457C2; NO343518B1; NO20180407A1; SE1850318A1

Abstract

The present invention relates to a process for preparing a packed ready-to-use dough. The process comprises the steps of a) flour, liquid, yeast, and, optionally, flavorings are mixed and kneaded to a dough; b) the dough is divided into predefined portions with a volume v within the range of 100- 5000 cm3, and are subsequently subjected to freezing at a temperature T1 below -4°C, and the freezing is continued for a period t1 long enough for a portion of dough to obtain a frozen shell of 1-10 mm thickness; c) a portion of dough with a frozen shell is placed in a separate packing, said packing being able to enclose a volume of at least 2 times the volume of the portion of dough with a frozen shell; and d) the packed portion of dough is then subjected to cooling at a temperature T2 above 0°C and below 15°C for a period t2, which period is terminated when the packed portion of dough has finished rising.

Description

<¹θ> DANMARK (10)

<¹²> PATENTSKRIFT

Patent- og

Varemærkestyrelsen (51) lnt.CI.: A21 D 6/00(2006.01) A 21 D 10/02 (2006.01) A 21 D 13/00 (2017.01)

B 65 D 85/30 (2006.01) (21) Ansøgningsnummer: PA 2017 00454 (22) Indleveringsdato: 2017-08-18 (24) Løbedag: 2017-08-18 (41) Aim. tilgængelig: 2018-05-22 (45) Patentets meddelelse bkg. den: 2018-05-22 (73) Patenthaver: Smartbake.dk ApS, Jegstrupvej 54, 8361 Hasselager, 8361 Hasselager, Danmark (72) Opfinder: Rasmus Linnet, Søndergade 40, 3, 8000 Århus C, Danmark Anders Høy Thomsen, Stjær Bakker 96, 8660 Skanderborg, Danmark Steffen Bagge, Frederiksgade 9,1,4., 8000 Århus C, Danmark Rasmus Maarbjerg, Marmorvej 7 B, 2 tv., 2100 København 0, Danmark (74) Fuldmægtig: Larsen & Birkeholm A/S Skandinavisk Patentbureau, Banegårdspladsen 1,1570 København V, Danmark (54) Benævnelse: A process for producing packed ready-to-use dough (56) Fremdragne publikationer:

WO 2010095939 A2 US 3346399 A US 2005271773 A1 (57) Sammendrag:

A process for producing packed ready-to-use dough

Technical field of the invention

The present invention relates to packed ready-to-use dough.

Background of the invention

When making yeast bread, a dough comprising the basic ingredients flour, liquid and yeast is prepared. The ingredients are mixed, and after mixing the dough is kneaded by hand or by machine. After kneading, the dough must have some rise time. During rising, the yeast ferments the sugar and develops the dough. The rising process therefore influences both the flavor and texture of the baked bread.

Generally, it is found to be difficult to store and transport prepared yeast dough due to the rising process, which the dough undergoes until the dough is subjected to heat treatment and all yeast activity is terminated. At temperatures, around 20°C, a yeast dough is normally left for rising for 20 to 90 minutes, and the time needed for rising primarily depends on the added amount of yeast.

It is known to subject yeast dough to cooling to prolong or stall the rising process, and by cooling the dough to below 5-10°, the rising process may be prolonged to several hours e.g. 8-12 hours.

WO2010095939 discloses a frozen non-leavened farinaceous dough that can be leavened under ambient conditions before being baked, fried and/or boiled to produce a ready-to-eat foodstuff. The frozen non-leavened farinaceous dough contains at least 103 cells/g viable cells of an S. bayanus strain.

Summary of the invention

The present invention discloses a ready-to-use dough where yeast is used for leavening, which dough is packed and transported to a position of use. At the position of use the dough could be shaped and then the dough is ready for baking, the dough will not need further rising or other treatment.

A first aspect relates to a process for preparing a packed ready-to-use dough, which process comprises the steps of:

- flour, liquid, yeast, and, optionally, flavorings are mixed and kneaded to a dough;

- the dough is divided into predefined portions with a volume v within the range of 100-5000 cm³, and are subsequently subjected to freezing at a temperature T1 below -4°C, and the freezing is continued for a period t1 long enough for a portion of dough to obtain a frozen shell of 1-10 mm thickness;

- a portion of dough with a frozen shell is placed in a separate packing, said packing being able to enclose a volume of at least 2 times the volume of the portion of dough with a frozen shell;

- the packed portion of dough is then subjected to cooling at a temperature T2 above 0°C and below 15°C for a period t2, which period is terminated when the packed portion of dough has finished rising.

A second aspect relates to a packed ready-to-use dough comprising a portion of dough and a packing;

- the portion of dough at least comprising flour, liquid, yeast, and, optionally, flavorings; wherein the portion of dough has a volume v within the range of 100-5000 cm³; wherein the portion of dough has a frozen shell of 1-10 mm thickness; and

- the packing comprises a plastic foil being able to enclose a volume of at least 2 times the volume of the portion of dough with a frozen shell.

Detailed description of the invention

The ready-to-use dough is prepared according to a recipe comprising flour, liquid and yeast. The amount of yeast is preferably adapted to a long rising period, i.e. less than 40 g yeast is added per 1000 g flour, normally less than 30 g yeast is added per 1000 g flour. The amount of yeast added per 1000 g flour may be adapted to obtain different optimized periods for packing and transport, i.e. if packing and transport is estimated to last 15 hours, the amount of added yeast is optimized for this period according to the specific ingredients of the dough and the product i.e. the type of bread to be achieved.

In addition to the basic ingredients, the dough may be added grease in fluid or solid form, salt, spices, seeds, kernels or other flavoring or nutritional components. The liquid may e.g. be water, an aqueous solution, or milk.

During storage and transport, the ready-to-use dough must be packed in a packing adapted for protecting the ready-to-use dough from the surroundings. The packing thereby prevents the dough from being contaminated. As the packing is in direct contact with the dough, the packing material must be non-toxic and approved for being in contact with food. Also, the packing must function as a water vapor barrier to maintain the doughs moisture content during the rising period, if the moisture content is not kept stable, it will not be possible to obtain a satisfying product when the dough is baked.

As the dough rises, carbon dioxide (CO2) is developed inside the packing and the volume of the dough is increased up to 3 times the original volume of the mixed and kneaded components. To avoid destruction or cracking of the packing due to the increasing dough volume, the packing must allow for this expansion of the dough. I.e. either the packing has a volume which is at least 2, 3 or 4 times larger than the doughs original volume, or the packing material has a volume which is less than 2, 3 or 4 times larger than the doughs original volume but the packing material is flexible and able to expand.

To prevent the pressure inside the packing from increasing, the packing may be provided with a valve through which valve produced CO2 gas is released to the surroundings. Reducing the CO2-pressure inside the packing improves the development of the packed dough compared to a situation where the packed dough is subjected to an increased CO2pressure. An increased CO2-pressure may reduce the yeast activity and may cause an undesired development of the dough providing large holes or pockets inside the dough.

The packing may comprise or be constituted of a plastic foil or a plastic bag, e.g. prepared from a thermoplastic material e.g. low-density PE or high-density PE. The thickness of the plastic foil or plastic bag material should be at least 30 pm, at least 35 pm, at least 40 pm, or at least 45 pm, in order to withstand the forces exerted by the rising dough.

If the packing comprises or is constituted of a plastic bag, the valve may simply be an elastic constriction at constricting the open end of the bag, which constriction allows escaping of produced CO2 gas at a certain overpressure. Alternatively, a plastic foil or bag may be provided with a commercially available one-way degassing valve as e.g. provided by Pacific bag Inc.

To obtain a ready-to-use dough using yeast as rising component, which dough has an excellent structure leading to tasty bread with good texture, the dough is subjected to the following procedure after having been mixed and kneaded:

1) the dough is provided in portions of volume v, preferably within the range of 100-5000 cm³, such as within the range of 200-4500 cm³, e.g. within the range of 300-4000 cm³, such as within the range of 400-3500 cm³, e.g. within the range of 500-3000 cm³, such as within the range of 600-2500 cm³, e.g. within the range of 700-2000 cm³, such as within the range of 800-1900 cm³, e.g. within the range of 900-1800 cm³, such as within the range of 1000-1700 cm³, e.g. within the range of 1100-1600 cm³, such as within the range of 1200-1500 cm³, e.g. within the range of 1300-1400 cm³.

2) The dough portions are subsequently subjected to freezing at a temperature T1 below -4°C (degrees Celsius), and the freezing is continued for a period t1 long enough for a portion of dough to obtain a frozen shell of 1-10 mm thickness. The freezing temperature T1 should preferably be within the range of -30°C to -5°C, such as within the range of -25°C to -6°C, e.g. within the range of -20°C to -7°C, such as within the range of -19°C to 8°C, e.g. within the range of -18°C to -9°C, such as within the range of 17°C to -10°C, e.g. within the range of -16°C to -11°C, such as within the range of -15°C to -12°C, e.g. within the range of -14°C to -13°C. The period for which the dough portions are subjected to freezing will depend on the freezing temperature and the temperature of the dough portions before freezing. However, normally the period will vary between 30 and 180 minutes, or between 40 and 170 minutes, or between 50 and 160 minutes, or between 60 and 150 minutes, or between 70 and 140 minutes, or between 80 and 130 minutes, or between 90 and 120 minutes, or between 100 and 110 minutes.

The freezing is continued until a frozen shell of at least 1 mm thickness is formed on the dough portion, and normally the frozen shell has a thickness of 1-10 mm, such as within the range of 2-9 mm, e.g. within the range of 38 mm, such as within the range of 4-7 mm, e.g. within the range of 5-6 mm.

It is crucial that only a frozen shell is made, as the yeast may be damaged if the entire dough portion is frozen. The desired thickness of the frozen shell may depend on the size of the dough portions and the planned durability of the dough, i.e. how long time the dough will have to rise before use.

A freezing temperature below -35°C is normally not desirable as such low temperature may damage the surface of the dough before a frozen shell of desired thickness is completed. A further advantage of the frozen shell is that it allows for easier handling of the dough portion during the packing process.

3) A portion of dough with a frozen shell is then placed in a separate packing, said packing being able to enclose a volume of at least 2 times the volume of the portion of dough with a frozen shell.

4) The packed portion of dough is then subjected to cooling at a temperature T2 above 0°C and below 15°C for a period t2, which period is terminated when the packed portion of dough has finished rising.

Preferably, the period t2 is at least 4 hours, such as within the range of 4-12 hours, e.g. within the range of 5-11 hours, such as within the range of 6-10 hours, e.g. within the range of 7-9 hours. The temperature T2 is preferably within the range of 0-10 degrees Celsius, such as within the range of 1-9 degrees Celsius, e.g. within the range of 2-8 degrees Celsius, such as within the range of 3-7 degrees Celsius, e.g. within the range of 4-6 degrees Celsius, more preferably within the range of 0-5 degrees Celsius. During this step, the dough will rise to a size at least 2 times the original volume, possibly at least 3 times the original volume, i.e. the temperature should be controlled to obtain completed rising of the dough at the time of expected use.

If passive cooling is employed, the temperature may be increased during the step, e.g. from around 0°C to around 5°C. Passive cooling means that the dough is not subjected to cooling as such, the dough is simply isolated from the surroundings, and due to the low temperature of the dough itself, the temperature will remain lower than the temperature of the surroundings. Passive cooling also includes isolating the dough from the surroundings and include cooling or freezing packs with the packed dough in order to prolong the time for which the temperature is kept below 5°C.

The temperature will normally be below 10°C through the complete rising step, normally below 7°C, or below 5°C. Alternatively, the temperature is below 10°C through at least 50%, or at least 70%, or at least 90%, of the duration of the rising step. Alternatively, the temperature is below 5°C through at least 50%, or at least 70%, or at least 90%, of the duration of the rising step.

The duration of the rising step will normally be between 4 to 24 hours, or between 4 to 18 hours, or between 6 to 24 hours, or between 6 to 14 hours.

In one or more embodiments, the cooling subjected after freezing is performed in a transport container adapted for receiving one or more packed portions of dough. This configuration allows for using the time for transporting the packed portion of dough to the customer as the cooling time. Thereby, the packed portion of dough will be ready-to-use as the transport container arrives at the customer.

In one or more embodiments, the cooling subjected after freezing is a passive cooling.

In one or more embodiments, the temperature T1 and the period t1 of the freezing period is determined as a function of the volume v of the portion of dough and the desired rising time t2.

In one or more embodiments, the freezing temperature T1 is between 30°C and -5°C.

In one or more embodiments, the frozen shell of the dough has a thickness of 1-5 mm.

In one or more embodiments, the packing comprises a plastic foil in form of a plastic bag with a foil thickness of at least 30 pm.

In one or more embodiments, the packing comprises a plastic foil in form of a plastic bag, and wherein the packing is provided with a valve for releasing a carbon dioxide overpressure from the packing to the surroundings.

Another aspect relates to a packed ready-to-use dough obtainable by the process according to the present invention.

Yet another aspect relates to a packed ready-to-use dough comprising a portion of dough and a packing;

As used in the specification and the appended claims, the singular forms a, an, and the include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from about or approximately one particular value and/or to about or approximately another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent about, it will be understood that the particular value forms another embodiment.

It should be noted that embodiments and features described in the context of one of the aspects of the present invention also apply to the other aspects of the invention.

Claims

patent claims

A process for preparing a packaged finished dough comprising the steps of:

- flour, liquid, yeast and possibly flavors are mixed and kneaded into a dough;

- the dough is divided into predetermined portions with an amount of the order of 100-5000 cm ³ and then subjected to a freezing at a temperature T1 below -4 ° C, and the freezing is continued for a period t1 long enough to get a portion of dough to obtain a frozen shell with a thickness of 1-10 mm;

- a portion of dough with a frozen must be placed in a separate package, the package being able to accommodate at least 2 times the amount of the dough portion with a frozen shell;

- the packaged portion of dough is then subjected to cooling at a temperature T2 above 0 ° C and below 15 ° C for a period t2, which period ends when the packaged portion of dough has raised; where the cooling done after the freezing is a passive cooling and where the cooling done after the freezing takes place in a transport container arranged to receive one or more packed portions of dough.

The method of preparing a packaged dough according to claim 1, wherein the packer is provided with a valve through which formed CO2 gas is released to the surroundings.

A method of making a packaged finished dough according to claim 2, wherein the pack comprises or is constituted by a plastic bag and the valve is an elastic constriction adapted to narrow the open end of the bag, which constriction allows formed CO2 gas to escape out at a certain overpressure.

The method of preparing a packaged finished dough according to claim 2, wherein the packing comprises or comprises a plastic bag with a one-way degassing valve.

A process for preparing a packaged finished dough according to any one of claims 1-4, wherein the freezing temperature T1 is between -30 ° C and -5 ° C.

A method of preparing a packaged dough according to any one of claims 1-5, wherein the frozen dough must have a thickness of 1-5 mm.

A method of making a packaged finished dough according to any one of claims 1-6, wherein the package comprises a plastic film in the form of a plastic bag having a film thickness of at least 30 µm.

A method of producing a packaged finished dough according to any one of claims 1-7, wherein the package comprises a plastic film in the form of a plastic bag and wherein the package is provided with a valve for releasing a carbon dioxide overpressure from the package to the environment.

A packaged finished dough obtainable by the method of any one of claims 1-8.

A packaged dough comprising a portion of dough and a pack;

- the dough portion, which includes at least flour, liquid, yeast and possibly flavoring agents; wherein the dough portion has an amount of we on the order of 100-5000 cm ³ ; the dough portion having a frozen shell with a thickness of 1-10 mm; and

- the package includes a plastic film that can hold at least 2 times the amount of the dough portion with a frozen shell.

IMmsH Fäto? Asm Tsäömasma Öma

SEARCH REPORT - PATENT Application No. PA 2017 00454 1. 1 1 Certain claims were found unsearchable (See Box No. I). 2. 1 1 Unity of invention is lacking prior to search (See Box No. II). A. CLASSIFICATION OF SUBJECT MATTER A 21 D 6/00 (2006.01); A 21 D 10/02 (2006.01); A 21 D 13/00 (2017.01); B 65 D 85/30 (2006.01) According to International Patent Classification (IPC) or to both national classification and IPC B. FIELDS SEARCHED PCT minimum documentation searched (classification system followed by classification symbols) IPC & CPC: A21D, B65D Documentation searched other than PCT minimum documentation Electronic database consulted during the search (name of database and, where practicable, search terms used) EPODOC, WPI, FULL TEXT: ENGLISH C. DOCUMENTS CONSIDERED TO BE RELEVANT Category * Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim no. X WO2010095939 A2 (CSM NETHERLANDS B.V.) 2010.08.26 1-10 Abstract; page 4, lines 17-27; example 1; Senior Claims X US3346399 A (WATSON D.L., et al.) 1967.10.10 1-10 Whole document, in particular claims X US2005271773 Al (DOMINGUES D.J.) 2005.12.08 1-10 Abstract; paragraph [0014] 1 1 Further documents are listed in the continuation of Box C. * Special categories of cited documents: P Document published prior to the filing date but later than the A Document defining the general state of the art which is not priority date claimed. considered to be of particular relevance. T Document not in conflict with the application but cited to D Document cited in the application. An Earlier application or patent but published on or after the filing date. understand the principle or theory underlying the invention. X Document of particular relevance; the claimed invention cannot be considered novel or cannot be considered to involve an inventive step when the document is taken alone. Y Document of particular relevance; the claimed invention cannot be considered to involve an inventive step when the document is combined with one or more other such documents, such L Document which may throw doubt on priority claim (s) or which is cited to establish the publication date of another citation or other special reason (as specified). O Document referring to an oral disclosure, use, exhibition or other betyder. combination being obvious to a person skilled in the art. Document member of the same patent family. Danish Patent and Trademark Office Date of completion of the search report Helgeshøj Allé 81 DK-2630 TaastruD January 16, 2018 Denmark Authorized officer Telephone No. +45 4350 8000 Facsimile No. +45 4350 8001 Marianne Vind Sørensen Telephone No. +45 4350 8059

Search Report

SEARCH REPORT - PATENT Application No. PA 2017 00454 C (Continuation). DOCUMENTS CONSIDERED TO BE RELEVANT Category * Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim no.

Search Report

SEARCH REPORT - PATENT Application No. PA 2017 00454 Box No. In Observations where certain claims were found unsearchable

This search report has not been established in respect of certain claims for the following reasons:! □ Claims Nos:

because they relate to subject matter not required to be searched, namely:

2. I I Claims Nos:

because they relate to parts of the patent application that do not comply with the prescribed requirements to such an extent that no meaningful search can be performed, specifically:

3. I I Claims Nos .: because of other matters.

Box No. II Observations where unity of invention is lacking prior to the search

The Danish Patent and Trademark Office found multiple inventions in this patent application, as follows:

Search Report

SEARCH REPORT - PATENT Application No. PA 2017 00454 SUPPLEMENTAL BOX Continuation of Box [.]

Search Report