EP1542539A1

EP1542539A1 - Method for producing baked objects, at least parts of which are a glossy brown

Info

Publication number: EP1542539A1
Application number: EP03757863A
Authority: EP
Inventors: Karl Tiefenbacher
Original assignee: Haas Franz Waffelmaschinen Industrie GmbH
Current assignee: Haas Franz Waffelmaschinen Industrie GmbH
Priority date: 2002-09-27
Filing date: 2003-09-18
Publication date: 2005-06-22
Also published as: AT502135B1; AU2003273898A1; CA2500242A1; US20060057269A1; AT502135A1; WO2004030461A1; WO2004030461A8

Abstract

The invention relates to a method for producing objects, at least parts of which are a glossy brown. In a first step, an at least par-baked, dimensionally stable shaped body is produced, said body is treated as a dimensionally stable pre-product in a second step at least partially with lye. The intermediate product thus obtained can be sprinkled with a granular topping in an additional step. In the final step, the intermediate product is subjected to renewed thermal treatment, in order to brown the areas treated with lye and optionally reduce the moisture in its interior.

Description

Process for the production of baked, at least partially shiny brown objects

The invention relates to the production of baked objects that shine brown at least in places and are designed or can be used as food products, or as containers for food products, or as edible packaging, etc.

State of the art:

In the production of pretzel products, it is known to produce individual dough strands from a kneadable pretzel dough with yeast as a leavening agent, to form them into sticks, pretzels etc. and to treat the shaped raw dough pieces with preferably hot, aqueous sodium hydroxide solution before baking. When baking, the dough pieces treated with lye result in somewhat larger, baked moldings which have a shiny, browned outer skin and are known as pretzel pastries, pretzel sticks, pretzels etc.

In the initial phase of the baking process, the raw dough pieces, which are exposed on the outside, are heated. This leads to internal deformation of the still deformable dough pieces as well as to visually visible changes in the very soft outer skin, which expands together with the dough pieces in the initial phase of the baking process and is stabilized and solidified only in the further course of the baking process. Inside the dough pieces there is a viscous flow of the dough mass and the dough is loosened due to the expansion of the leavening gas pores due to the heating, which is caused by the formed water vapor further increase. Towards the end of the baking process, the color characteristic of pretzel biscuits is created on the outside of the shaped body. The aqueous sodium hydroxide solution applied to the outer skin of the raw dough pieces reacts with the dough ingredients of the dough pieces during the baking process, which creates the characteristics, such as color and taste, that are characteristic of pretzel pastries. The sodium hydroxide solution increases the reaction of sugars with proteins, the so-called Maillard reaction. A reaction that occurs in every baking process, especially in the crust.

Baked goods known as pretzels have a moisture content of up to 12%. They are made from shaped pieces of dough that have been treated on the outside with mostly hot, aqueous sodium hydroxide solution, which has a concentration of up to 4%. When baking, the raw dough pieces treated with lye then produce biscuits with the characteristics characteristic of lye biscuits such as the texture of the outer layer (color, consistency of the crust) and taste. The biscuits usually have the shape of pretzels or sticks. They can be sprinkled with salt, caraway or other spices

A system for the production of pretzels is known from US Pat. No. 4,738,861. Pretzel dough is continuously prepared and shaped into pretzel-shaped pieces of dough, which are treated with lye before baking.

A continuous process for producing crispy salt pretzels is known from US Pat. No. 5,238,693. In this case, dough pieces shaped into pretzels are treated twice with lye before baking. First in an immersion bath and then by spraying.

The production of brittle, low-fat pretzel pastries is known from US Pat. No. 6,352,732. Pretzels are first produced in a normal process. This includes the steps: shaping the dough pieces, eyeing on the shaped dough pieces, baking the lye-coated dough pieces and drying the baked goods resulting from the baking. These are made with a sugar containing carbohydrate solution coated and dried to taste,

Improve the texture and aroma of the pretzel without losing the color and shine of the

Losing surface.

A method for producing pretzel bags is known from US Pat. No. 4,795,652. A pretzel dough is rolled out and cut into individual pies. The dough patties are wrapped around bags and the protruding parts of the dough patties are separated. The bags formed from the raw dough are poured with pretzel eye, sprinkled with salt and then baked.

The production of a filled product from pretzel dough is also known from US Pat. No. 5,185,167.

Eying is usually only used for the raw shaped dough pieces for the production of long-life and fresh pastries. The combined heat and alkali treatment and the moist oven climate stabilize and close the outer skin of the dough pieces by gelatinizing starch. The subsequent thermal dextrinization of the outer skin results in a smooth, shiny surface for the end product. In the baking process, the alkaline pH increases the Maillard and caramelization reactions that lead to a deep brown pastry color and typical flavor components. Pastry browning is promoted by the following factors: high temperature, monosaccharides (especially fructose), alkaline pH, higher water content due to pastry moisture or oven atmosphere, catalysts such as NH3 etc. In the case of sugar-rich doughs, the Maillard and Caramelization reactions come; which can be corrected within limits by lowering the pH.

The high temperatures prevailing during baking and the high pH value generated by the alkali treatment lead to a rapid acceleration of the chemical reactions during the baking process. That is why only dough pieces made from simple, low-ingredient doughs are treated with lye contain only small amounts of fat, sugars and protein-rich additives. The lye treatment of raw dough pieces made from doughs rich in ingredients would, because of the strong acceleration of the chemical reactions during the baking process, lead to a rapid premature darkening of the outer skin and to the development of off-flavors.

Summary of the Invention:

The present invention proposes a method for producing at least partially shiny brown objects, in which, in a first method step, an at least partially baked, dimensionally stable molded body is produced, which is treated as a dimensionally stable preliminary product in a second method step, at least partially with lye. The resulting intermediate product can be sprinkled with grit in a further process step. The last process step provides that the intermediate product is subjected to a new heat treatment in order to brown its spots treated with alkali and, if necessary, to reduce the depth of moisture.

According to the invention, an at least largely dimensionally stable molded body is first produced in a baking process, in which at least the outer skin is stabilized and largely solidified. This molded body is treated with lye at least in places and subjected to a new heat treatment, which creates a shiny brown top layer at its lye-treated areas. The surface details fixed in the outer skin of the molded body during the baking process are not lost during the alkali treatment and the new heat treatment and are also contained in the shiny brown top layers resulting from the new heat treatment.

The method according to the invention allows the production of baked objects with detailed surface structures in the glossy, browned top layers, as was previously only the case with lettering, steam chimneys, embossed edges etc. or biscuit sheets with a smooth or finely corrugated surface are known.

When carrying out the method according to the invention with biscuits not previously treated with alkali as a preliminary product, it has surprisingly been found - contrary to a prejudice existing so far - that these biscuits, too, are provided with smooth, shiny, browned top layers at the areas treated with alkali by means of eye-heating and brief heating can be.

According to the above-mentioned prejudice, all the swelling and pasting processes relevant for achieving a smooth, closed surface should have been completed when the baked goods were baked, and the pastry moisture that favors the Maillard reactions should also be largely removed, so that these processes or reactions when heated again of subsequently leached biscuits would no longer be sufficient to form a smooth, closed surface.

The method according to the invention can be used not only to produce objects, which have not previously been treated with alkali, on the surface, at least in places, with smooth, glossy, browned top layers, but also from doughs in which the sugar, fat or protein content during the baking of Lye treated, raw dough pieces would lead to useless results.

With the method according to the invention, objects provided with smooth, shiny, browned cover layers can also be produced for the first time from more substantial recipes in which the baking of raw dough pieces treated with lye would lead to unusable results, either because - due to the occurrence during baking strong maillard and caramelization reactions - biscuits with a dark, scalloped and burnt-looking surface that would no longer be tastable would be the result, be it because the baked to an attractive surface color Some of the pastries inside would still be raw, unbaked and therefore inedible and also not storable.

In the process according to the invention, the doughs with the more substantial recipes are produced in a baking process with largely dimensionally stable moldings with a stabilized and largely consolidated outer skin. When the aqueous lye is applied to the baked molded articles, the pastry moisture which favors the Maillard reactions is increased before the new heat treatment, so that the baked molded articles develop luster and brown color at the places treated with lye.

According to the invention, the dimensionally stable preliminary products can be produced in different ways in the first process step.

For the manufacture of the preliminary products, the shape of the raw dough pieces corresponding to the objects to be produced can be baked as moldings up to a residual moisture content of 1 to 29% by weight, preferably 1.5 to 18% by weight. The raw dough pieces can their shape corresponding to the objects z. B. obtained by punching or cutting. However, portioned dough pieces can also be mechanically shaped into the respective shape before they are baked as shaped dough pieces into dimensionally stable shaped bodies.

To produce the preliminary products, raw dough or baking masses can be prepared, portioned and baked in portions in baking tins, which determine the shape of the object to be produced, to form dimensionally stable shaped bodies which have a residual moisture content of 1-5% by weight, preferably 1 Have 5 - 4 wt .-%.

To produce the preliminary products, raw dough or baking masses can be prepared, portioned and baked in portions between the opposing baking surfaces from closed wafer baking tins to dimensionally stable moldings with a residual moisture content of 1-5% by weight, preferably 1.5-4% by weight become. In the method according to the invention, semi-baked or ready-baked pastries, which can also be filled, can also be used as intermediate products for freshly baked or long-baked pastries. Biscuits, crackers, pretzels, shortbread biscuits and waffle biscuits can be used as preliminary products. In addition, cooled intermediate or deep-frozen intermediate, filled or unfilled biscuits can also be used as intermediate products.

The method according to the invention can be used to produce objects which have a shiny brown surface on at least one side and objects which have a shiny brown surface on both sides. This also includes the application of lye solutions as lettering or decorative samples.

In order to produce objects with a shiny brown surface on one side, only one side of the intermediate product is treated with lye in the process according to the invention in the production of the intermediate product and the intermediate product is subjected to a final heat treatment. This procedure is advantageous in the production of objects designed as hollow bodies that are open on one side. Bags or cups can be produced with an optically effective, shiny, browned outside. Or bags, cups or bowls intended for use as food containers can be produced with a largely moisture-resistant, smooth, shiny, tanned inside.

To produce shiny brown objects on both sides, the preliminary product is first treated with lye on one side and then subjected to a first heat treatment and then the intermediate product, which has already been browned on one side, is also treated with lye on the opposite side and subjected to a second heat treatment. This procedure allows the development of color and gloss on the two sides of the objects to be designed differently. In the production of the objects which shine brown on both sides, a shielding of the already browned side of the intermediate product can be provided for the second heat treatment, in order to avoid the subsequent browning of the first browned side during the second heat treatment. For this purpose, the intermediate product can be accommodated in a holder covering its shiny brown side and can be heat-treated with hot air on the side last treated with lye in order to also develop gloss and color on this side

According to the invention, the heat treatment of the intermediate product treated with alkali can be carried out in an oven which heats the outer skin of the intermediate product to a temperature producing gloss and browning at the locations treated with alkali. This heat treatment can be done with hot air.

The intermediate treated with lye can also be subjected to a two-phase heat treatment consisting of a baking phase and a post-drying phase. In the baking phase, the outer skin of the intermediate product is heated by hot air or infrared radiation to a temperature at which the areas treated with lye are shiny and color. In the post-drying phase, the interior of the intermediate z. B. heated by microwaves or dielectrically to lower the moisture content there and to reduce the moisture difference to the outer skin. This has a favorable effect on the moisture balance within the baked molded article and reduces the risk of the molded article possibly tearing later.

In the lye treatment of the preliminary products which have already been baked, a lye solution can be used according to the invention, which is mixed with modified starch and / or modified cereal flour.

According to the invention, the preliminary products can be allowed to cool before the alkali treatment. In the case of freshly baked intermediate products, in particular in the case of thin-walled moldings, residual moisture can still be evaporated.

According to the invention, the preliminary products can be stored refrigerated before the lye treatment. This is advantageous in the case of a larger temporal and spatial separation between the first and second process step

In order to be able to bridge longer periods between the production of the preliminary products and their processing into intermediate products, the preliminary products can be stored frozen until the lye treatment.

In the process according to the invention, an at least partially baked, largely dimensionally stable molded body is first produced and only this is treated with lye and subjected to a new heat treatment. This makes it possible to design both the lye treatment of the shaped body and the heat treatment of the shaped body at its locations treated with lye and color, regardless of the baking process required for its production. The browning factors, such as dosing of lye, concentration of the moisture present, and the duration and amount of the temperature required for the development of the lye color, can each be specifically matched to the nature of the baked molded article to be treated with lye.

A baked molded article is considered to be dimensionally stable if, in contrast to the previous dough phase, it no longer changes shape due to gentle automatic removal from the baking mold or gentle automatic removal from the baked goods carrier (endless baking tray, baking tray, etc.), because at least on the surface gelatinization of the molded body and extensive drying and thus solidification and stabilization of its shape has taken place.

The method according to the invention permits industrial production of parts each provided with smooth, shiny surfaces or partial surfaces. Pieces of baked goods or freshly baked goods such as sticks, pretzels, cookies, bags, mugs etc. It is also possible to use baked goods made of plastic dough, such as pastries, corresponding to the known pretzel products with shiny, browned top layers. B. pretzel dough, are produced by the method according to the invention. Likewise, dimensionally stable molded articles produced with other dough shaping and baking techniques can be used as a preliminary product in the process according to the invention, in order to produce baked goods with shiny, browned top layers. It is also possible to use dimensionally stable molded articles produced from recipes which are richer in sugar and / or rich in protein and / or rich in fats as a preliminary product in the process according to the invention, in order to produce baked goods with shiny, browned top layers. Furthermore, different types of biscuits can also be used as a preliminary product in the process according to the invention, in order to produce baked goods with shiny, browned top layers. This applies in particular to baked biscuits which have a closed, smooth surface so that they can be treated with lye without the amount of lye required to achieve the shiny, browned top layers leading to a negative taste or nutritional influence on the finished biscuits.

If baked goods with solidified but still soft crumb are used as a preliminary product in the process according to the invention, the lye treatment combined with the subsequent heat treatment of the leached intermediate product can lead to a "refreshing" of the crumb.

The inventive method allows the production of precisely shaped pastries with a smooth, shiny surface, in which the z. B. designed as a hollow body open on one side together with the wall thickness is determined by the opposing baking surfaces of closed baking tins. The same applies to pastries in the form of flat baked goods, in which the outline shape and surface shape of the top and bottom sides of the baked goods are determined by conventional biscuit molding techniques such as pastry shapes, embossing, cutting out, pressing out and cutting. Applications for articles produced by the method according to the invention are, for example, edible vessels which are resistant to moisture for a certain time and can therefore be used for drinks, sauces, moist fillings and other dishes in the catering trade or for ice cream.

Description of exemplary embodiments:

The invention is explained in more detail below using exemplary embodiments.

The process according to the invention can be carried out in a single production line in which the preliminary product with its dimensionally stable moldings is produced in a first baking process in the first section of the plant, the preliminary product is treated with lye in the second section of the plant and sprinkled with grit in a further section of the plant and the leached resulting Intermediate product is subjected to a new heat treatment in the last section of the plant, in which the surface of the molded body is browned and the interior of the molded body is optionally dried.

The process according to the invention can also be carried out in two separate production lines, the preliminary product being baked in the first production line and the addition of the preliminary product and the renewed heat treatment of the leached intermediate product taking place only in the second production line.

With regard to the water content of the baked goods used as the preliminary product, it has proven to be advantageous that baked goods, such as long-cured biscuits, savory biscuits, hard biscuits, shaped articles made from pretzel and hard biscuit crates etc., are usually largely baked out dry, preferably to a residual moisture of less than 6% in particular should be baked below 4% in order to minimize the risk of cracking. These restrictions do not apply to baked goods that are usually more water-rich, see the exemplary embodiments. The baking process for the manufacture of the preliminary products places no additional or special demands on the person skilled in the art. If the preliminary products are not eyed, the lack of an alkali layer results in minor adjustments that are within the experience of the skilled person, which relate to the control of the oven, the baking time or the possible coating of the preliminary products with water.

Most known baking processes are suitable for the production of the preliminary products with their partially or fully baked shaped bodies, such as. B. baking in conventional ovens or deck ovens on baking trays, or baking on endless, rotating baking belts in conventional continuous ovens for bread, pastries, biscuits and savory biscuits, or baking baking masses or batter in conventional, two-part or multi-part baking tins in accordance with Art of baking waffles.

In the manufacture of the intermediate products, all of the dimensionally stable molded articles with little porous surface can be used as a preliminary product, which are produced in a baking process from a dough or baking mass. The dough or baking masses used in the production of the preliminary products can have any other composition in addition to the compositions specified in the exemplary embodiments, as long as the dough or baking masses are accessible to a baking process and the quality of the preliminary products (surface structure, taste) with the In the last step of the process, the appearance and taste of the end product resulting from the heat treatment of the leached intermediates harmonize.

In the production of the intermediate products, the task falls to the person skilled in the art, depending on the desired properties of the end product, such as color depth, gloss and taste intensity of the surface and of the entire end product, for the addition of the precursors to the concentration and viscosity of the alkali solution and the amount applied per surface unit to coordinate the relevant preliminary product and one of the known application techniques such as spraying, painting, pouring, dipping, printing.

The lye concentration and the lye application are matched to the type and nature of the baked goods to be used as a preliminary product and their places or surface areas to be treated with lye. This coordination enables the person skilled in the art to specifically control the properties to be imparted to the end product, such as depth of color, gloss and taste intensity of the surface and of the entire baked goods.

To produce the end product, the intermediate product - this is the dimensionally stable molded article that has already been treated with lye and has already undergone a baking process during its manufacture - is subjected to a new heat treatment, which creates a shiny, browned top layer at the exposed parts of the intermediate product. This heat treatment of the intermediate product can be a further baking process, by means of which a shiny, browned top layer is formed at the exposed areas of the intermediate product. The intermediate product can also be heat-treated in two phases. The intermediate product is treated with hot air on the outside in a heat treatment phase in order to produce a shiny, browned top layer at its exposed areas. In the other heat treatment phase, the intermediate is heat-treated with microwaves or dielectrically in order to reduce moisture differences between its outer skin and its center.

With the methods according to the invention, a glossy, browned surface or top layer is obtained at the spots or surface areas of the intermediate products treated with alkali, in which the measurable depth of color of the browning and the measurable gloss increase compared to a surface browning already present in the baked, dimensionally stable molded body of the intermediate product are.

Depending on the basic taste of the baked preliminary products, the method according to the invention can also be used to produce new, interesting taste combinations in the end products, for example a sweet one tasting pastries with a leached surface.

Objects produced by the method according to the invention have a modified surface texture which reduces or prevents soaking. This may be due to the fact that the clearly visible formation of a smooth, glossy surface is accompanied by a significant reduction in open pores in the baked goods. Objects produced by the process according to the invention, for example in the form of bag-shaped, cup-shaped or bowl-shaped containers, are therefore particularly suitable for the reception of freshly prepared ice cream, or for the reception of ice cream to be stored in the frozen state, but also as eating utensils which can be used at short notice or, if appropriate also edible disposable packaging for dishes, such as meat or vegetable preparations, sauces, salads, drinks etc.

Another area of application for the method according to the invention is in the decoration or labeling of baked goods and other baked, dimensionally stable moldings. These can be introduced into the process as a preliminary product and, in the manufacture of the intermediate product, for example, can only be treated with lye at the points or surface areas of the shaped bodies to be emphasized as decoration or lettering, so that the baked shaped bodies only have a shiny, browned finish when decorated or labeled Preserve surface or top layer.

When using baked preliminary products with increased porosity - open coarse pores with a diameter of more than 0.02 mm - this has to be taken into account in the application technique and the composition of the lye. When spraying the preliminary products with alkali, the amount applied can be better controlled and an alkali solution with increased viscosity - for example in accordance with the examples given below under "Alkali solutions" F, G, H - is advantageous. If too much lye solution is nevertheless sucked into the interior of the shaped body because of the too high porosity, this shaped body is not suitable for such leaching. Baked goods with less porous surfaces are preferred as baked preliminary products. In the production of the baked shaped bodies, baking is generally associated with skin formation on the surface and with the formation of closed pores.

Kneaded hard doughs for savory biscuits, such as those e.g. in "W. Seibel: Feine Backwaren, Berlin 1991, page 150 "(Rl) or" E. Bergmann: Hefebackbuch, Stuttgart 1987, page 151 "(R2). Recipe Rl R2f.

Flour 100 100

Shortening 6 3

Salt 1 2.5

Yeast 0.5 4.5

Malt 0.15 2 (malt baking agent)

Water, approx. 50 50

* Add 10 parts of pastry (batter)

Shaped bodies, such as bags or cups, are produced from such doughs in two-part or multi-part baking tins. Doughs which, due to the properties of their ingredients, especially the flour, and due to the addition of baking agents or small components, give a normal consistency of the dough even with a small amount of water added, tend to lead to uniformly baked moldings with good stability when baking, rather than doughs that with comparable ingredients and comparable manufacturing methods need a larger amount of water to get a normal consistency.

Balls or cubes with a defined weight are made from the dough. The dough pieces are formed and opened in bags and cup baking molds that can be made and made into bags or cups corresponding to the mold cavities of these baking molds. With their baking molds closed, the baking molds and the tops fix the shape of the bags or cups and, with the spacing of these baking surfaces, the wall thickness of the bags or cups. Depending on the baking pan, the wall thickness of the baked bags or cups is between 1.5 and 5 mm, preferably between 1.8 and 4 mm.

The baking temperature is in the range of 155 ° C to about 205 ° C. Depending on the dough recipe and the wall thickness of the bags or cups specified by the respective baking pan, the baking time is usually between 80 and 240 seconds. After this baking time, the bags or cups are at least largely baked, usually have a residual moisture content of below 12% and are sufficiently dimensionally stable that they are not deformed or even torn by the residual steam contained in the baked goods when the respective baking pan is opened. If the bags or cups are baked in the closed baking molds, they then only have a residual moisture of 1-6%, preferably 1-4%.

The baked bags or cups are removed from the baking molds and placed with the opening facing downwards at a distance from one another on a wire mesh belt which transports them through a leaching station. The bags or cups placed on the wire belt cool down and possibly evaporate any residual moisture. In the leaching station, a lye solution or a modified lye solution is applied to the bags or cups in a pouring or spraying process. The concentration and temperature of the lye determine the effectiveness of the leaching and thus the depth of color and gloss that occur during the heat treatment of the bags or cups on the surface areas treated with lye. The alkali concentration and the alkali temperature can be matched by the person skilled in the art to the baked bags or cups in accordance with the concentration ranges given below under "alkali solutions".

The bags or cups treated with lye can then pass through a conventional spreading device in which spreading material, such as. B. salt. Spices etc., is applied to the lye side of the bags or cups. In the leaching station, the moldings can be treated with lye on both sides or only on parts of their surface. For example, the surface areas of the shaped bodies that are not to be treated can be covered with stencils. The surface areas of the moldings to be treated can be printed with lye solution in a printing process analogously to the application of printing inks.

When applying the lye solution in the dipping process, the contact time in the lye bath - typically less than 10 seconds - is to be limited depending on the surface quality of the baked molded articles or the application of the lye solution using a cast film or spraying is necessary to leach the surface of the baked molded articles too strongly or to prevent the lye from being sucked up by the baked moldings. When applying the lye solution in the dipping process, the contact times in the lye bath are significantly shorter compared to the known biaxialization of raw dough pieces and are only 50% or less.

Dilute sodium hydroxide solutions or potassium hydroxide solutions or soda solutions alone can be used to vacuum the baked moldings.

On the one hand to control the viscosity of the leaching solution and its penetration and drainage behavior after it has been applied to the respective surface (faster viscosity increase, limited suction of lye solution in open pores) and on the other hand the adhesion of grit, such as salt or spices ( increased stickiness and film formation) on the leached surface and, if necessary, increasing the gloss and color of the treated surface - although the decisive effects probably come from the lye itself - a modified starch or a modified cereal flour can also be dissolved in the lye solution be selected from the group consisting of swelling flours, swelling starches, degraded starches and maltodextrins. The modified starches or cereal flours have an increased solubility in dilute alkali due to the degradation in the molecular mass during the modification compared to native starch or flour and form a smooth film in a known manner when dried.

Developing lye color and shine:

The baked moldings treated with lye and optionally sprinkled form the intermediate product, which is subjected to heat treatment in order to develop gloss and color on the spots treated with lye. The browned, glossy outer layers are formed thermally at temperatures in the range between 160 ° C. and 290 ° C., the range between 200 ° C. and 250 ° C. being preferred.

The heat treatment can take place in a deck oven or in a continuous oven. The intermediate products are transferred to a baking sheet or the baking belt of the continuous oven and treated with heat in the oven.

In the continuous oven, the throughput time is typically 1 to 10 minutes, preferably 2 to 6 minutes. The throughput time depends on the mass of the respective intermediate product, the amount of lye applied, the temperature of the lye solution and the shaped body and the control of the heat generation of the oven via radiation or convection.

Both in the multi-deck oven and in the continuous oven, the oven control required for the formation of the browned, glossy top layers is within the experience of the expert, as is the selection of the alkali and its concentration.

The guideline for technical action is:

1) The proportion of water that is applied to the leached surface with the lye solution causes swelling and additional smoothing, and as a result an additional gloss on the surface. The control takes place in a known manner via the amount of alkali solution applied.

2) The concentration of the applied lye together with the temperature during the heat treatment and the composition of the intermediate product determine the degree of browning achieved. The control takes place via the concentration of the lye solution. The time required for the formation of the browned, smooth, glossy surface depends primarily on the parameters of temperature, intensity of heat transfer by convection and radiation and the amount of alkali solution applied and only secondarily on the wall thickness of the moldings.

In order to intensify the adherence of the spreading material and the shine, a cold lye process with the addition of modified starch can also be used.

The finished items are transferred to a cooling and stacking line. Depending on the type of objects, slow cooling (cooling distance of up to 40 minutes) may be necessary to prevent the objects from tearing due to the slow compensation in the residual moisture.

Examples of preliminary products which can be used in the process according to the invention

Example 1: Molded pastries made from pretzel / stick dough

Four variants of the production of shiny, browned top layers of pastry made from pretzel dough were carried out. In each case, dimensionally stable, baked molded articles were first produced as a preliminary product. The preliminary product was treated with lye and sprinkled on a case-by-case basis. The resulting intermediate product was subjected to a further heat treatment in a hot-air oven to produce the shiny, browned top layers.

Variant 1: preparing a plastic dough, shaping and rolling out one Dough sheet, cutting out pieces of dough with the help of a cutting roller, baking the cut pieces of dough in an oven with a rotating baking tape, from which they are removed as dimensionally stable, baked shaped bodies. Eyeing the still hot molds on the top and sprinkling with coarse salt. Drying the leached moldings in a hot air oven. Product: Dough pieces for cocktail pretzels were cut out of the dough sheet and baked in a hot air oven for 6 minutes. The still hot pretzels were poured with a solution of 2% sodium hydroxide solution in water, temperature 28 ° C. and sprinkled with coarse salt. The lyeed and sprinkled pretzels were dried in a hot air oven at 220 ° C to a medium depth of color.

Variant 2: Preparation of a crumbly-plastic dough, from which raw shaped dough pieces are produced in a pastry molding machine with the help of shaping rollers, which are baked in an oven with all-round baking belt and removed from it as dimensionally stable, baked moldings. Leach the moldings at room temperature by brushing with a solution of 20% maltodextrin 15 and 2% sodium hydroxide solution in water. Drying the leached moldings in a hot air oven as in variant 1. Product: Round sandwich biscuit, lyeing at room temperature (biscuit and lye).

Variant 3: Preparation of a pre-kneaded dough mass, which is kneaded further in an extruder and extruded as continuous dough strips, parts of the dough strips into individual pieces of dough, which are baked in an oven with a rotating baking belt and removed from it as dimensionally stable, baked moldings. Eyeing the still hot molded parts on the top by spraying with 1.5% sodium hydroxide solution (temperature approx. 40 ° C). Drying the leached moldings in a hot air oven,

Product: Salt sticks, extruded; Bake after manually dividing the extruded dough strips into individual dough strands, eyeing on the baked sticks right after baking. Pastries hot. Alkali approx. 40 ° C. +

Variant 4: preparing a plastic dough, portioning the dough, bring the dough portions into hot, two-part or multi-part baking molds that can be opened and closed, which shape the dough portions into the shape corresponding to the baking mold when closed, and baking the dough portions in the closed baking molds to form dimensionally stable moldings that are removed immediately after removal from the baking mold treated with cold lye after pouring over the outside. Drying the leached moldings in a hot air oven,

Product: "Pretzelcone" Eying the baked bags immediately after baking by pouring cold lye over the outside of the bag (3% sodium hydroxide solution in water, temperature 24 ° C).

Recipes for variants VI to V4.

Raw materials (s) V I V 2 V 3 V 4

Flour, low in glue 100 93 97 100

Strength 0 7 3 0

Fat 4 4.5 2 6

Salt 1 0.5 1 1

Fresh yeast * 0.38 1 2 0.5 **

Malt extract 0 0.5 2.5 0.15

Lecithin 0 0.12 0 0

Ammonium bicarbonate 0 0 0.5 0

Soda 0 0 0.35 0

Calcium phosphate 0 0 0.3 0

Water, approx. 35 32 40 50

* with less dough (10 to 30%); ** instant yeast

The moldings are largely baked dry. The residual moisture content is about 2 to 5%.

Example 2: Pre-products from pizza dough Variant 1: Preparation of a pre-dough, rest at room temperature for at least 45 min, final mixing of a plastic dough, portioning, shaping pizza dough sticks that are baked in a hot air oven (pizza oven) Variant 2: Prepare a pre-dough, let it rest at room temperature for at least 45 min, mix a plastic dough, portioning, inserting the dough portions into hot, two-part or multi-part baking molds that can be opened and made, which shape the dough portions into the shape corresponding to the baking mold when closed , and baking the dough portions in the closed baking tins to form stable molded articles.

Dough recipe for both variants

Pre-dough flour 16 main dough flour 108 water 16 water, approx. 48

Fresh yeast 5 fat 2

Sugar 1 salt 2

Baking agent 0.25

The pizza dough sticks are baked to approx. 12 - 16% residual moisture. The prebaked pizza sticks are leached immediately after baking. Alkali solution as in variant 2 of example 1, where the maltodextrin can also be replaced by 2.5% wheat spring meal.

The moldings in the baking tins are baked largely dry to about 2 to 5% residual moisture. With a wall thickness of 4 mm: with 170 ° C and approx. 180 seconds baking time. With a wall thickness of 2.5 mm: with 170 ° C and approx. 100 seconds baking time.

The moldings are poured over with alkali when passing through an alkali pouring veil. The concentration of the sodium hydroxide solution is 3% in water, the initial temperature of the alkali is about 28 ° C. The pizza sticks treated with lye are sprinkled with spices and baked in a hot air oven at 240 ° C for 6 minutes.

Example 3 Pre-product made from hard pretzel dough Preparation of a plastic dough, 15 minutes rest at room temperature,

Portioning the dough, introducing the dough portions into hot, two-part or multi-part baking molds that can be opened and made, which shape the dough portions into the shape corresponding to the baking mold when closed, and baking the dough portions in the closed baking molds to form dimensionally stable moldings.

recipe

Flour 20 emulsifier 0.2

Water, approx. 10 salt 0.2

Fat 2 dry yeast 0.1

Sugar 0.3 leavening 0.08

Baking agent 0.3

The moldings in the baking tins are baked to about 2 to 5% residual moisture. A basic dimensional stability is given from about 29% residual moisture, but then there are high demands on the demolding technology.

The shaped bodies are doused with lye when they pass through an alkali pouring veil. The concentration of the sodium hydroxide solution is 3% in water, and the starting temperature of the alkali is about 28 ° C. It is baked in a hot air oven at 240 ° C for 6 minutes.

Example 4: dough shells as a preliminary product

Variant 1: Prepare a plastic dough that is conventionally shaped and baked into dough shells after a 15-minute rest period in the refrigerator.

Variant 2: Preparation of a plastic dough, after 15 minutes of rest in the refrigerator, portioning the dough, introducing the dough portions into hot, two-part or multi-part baking molds that can be opened and closed, which transform the dough portions into the shape corresponding to the baking mold, and baking of the dough portions in the closed baking tins to keep their shape Moldings.

Recipes A B C

Flour 10 10 10

Sugar 5 0.5 0.4 Margarine 3 5 0

Shortening 0 0 5

Fresh egg 2 0 0

Water, approx. 2 4 5

Baking agent 0.4 0.1 0.01 Salt 0.2 0.18 0.25

Emulsifier 0.1 0 0.1

Aroma, approx. 0.01 0.01 0.01

The moldings are baked light to medium brown. The moldings produced according to recipe A must be removed from the mold with support and are only accessible after a lye treatment has cooled and solidified.

The lye is carried out with a solution of 30% maltodextrin 15, 1% sodium hydroxide in water (product according to recipe A) or 2.5% sodium hydroxide in water (products according to recipes B, C). The starting temperature of the lye is around 28 ° C. After drying in a hot air oven at 240 ° C for 4 to 6 minutes.

Shaped bodies are poured over with alkali when passing through an alkali pouring veil. The concentration of the sodium hydroxide solution is 3% in water, the initial temperature of the alkali is about 28 ° C. The pizza sticks treated with lye are sprinkled with spices and baked in a hot air oven at 240 ° C for 6 minutes.

Example 5: Pre-products from focaccia dough

Variant 1: Prepare a plastic dough that lasts at least 45 minutes at 26 fermented up to 29 ° C. Portioning the dough and forming focaccia

Flat breads, after about 15 minutes of baking the breads at 215 ° C to 230 ° C with bottom heat.

Variant 2: Prepare a plastic dough that ferments at 26 to 29 ° C for at least 45 min. Portioning the dough, introducing the dough portions into hot, two-part or multi-part baking molds that can be opened and closed, which shape the dough portions into the shape corresponding to the baking mold when closed, and baking the dough portions in the closed baking molds to form stable moldings.

dough recipe

Flour, highly adhesive 10 dry yeast * 0.3

Water, approx. 5 sugars 0.23

Reactivate olive oil 1.1 salt 0.23 * with approx. Three times the amount of warm water beforehand

The flat breads are baked to a light to light brown crust, the crumb is soft. The lye is applied while it is still hot by brushing with a 3% alkali solution and then baking for about 5 minutes.

The moldings in the baking tins, on the other hand, are baked to approx. 2 - 5% residual moisture and poured over with lye on the inside. The concentration of the caustic soda is 3% in water, the starting temperature of the caustic is around 28 ° C. It is baked in a hot air oven at 240 ° C for 6 minutes.

Example 6: Gingerbread batter precursors

Preparation of a plastic dough in 2 stages (pre-dough with flour, syrup, sugar, water; main dough), which is formed with greasing and baked in a steel belt oven. dough recipe

Flour 10 seasoning 0.18

Syrup 4.5 pH regulator, approx 0.1

Farinzucker 3 water 0 to 2

Raising agents 2.2

The moldings are baked light to medium brown, brushed hot with lye (2.5% sodium hydroxide plus 50% maltodextrin 18 in water, approx. 30 ° C) and finished in a convection oven at 240 ° C for approx. 5 minutes.

Example 7: Pre-product - hard biscuits

Hard crackers from the market of the cracker, Petit Beurre, Marie type are brushed at the top with a lye solution (3% sodium hydroxide in water, approx. 30 ° C) and dried at 240 ° C for 6 minutes.

Example 8: intermediate product - crackers with or without yeast

Recipe with yeast without yeast

Flour 20 20

Water, approx. 6 6

Fat 1.4 1.3

Sugar 0.5 1

Invert syrup 0 0.5

Malt flour 0.5 0.3

Salt 0.3 0.2

Emulsifier 0.2 0.2

Leavening agent 0.12 0.15

Yeast 0.05 0

The dough with yeast is fermented for at least 1 hour, then it is rolled out, cut out and, after a short rest, baked in the usual way to a still bright color strength of the surfaces and a residual moisture content below 6%. The leavening agent must be adapted to the desired loosening. Spray on lye solution (2.5% sodium hydroxide solution in water, approx. 30 ° C.

After drying in a hot air oven at 240 ° C for about 6 minutes.

Example 9: Pre-product "Pretzel cones" yeast-free

recipe

Flour 20 emulsifier 0.2

Water, approx. 8 salt 0.2

Fat 2 leavening agents 0.08

Baking agent 0.3

All components are added in a kneader and a dough is kneaded (2 minutes slowly, 5 minutes quickly). After a rest period of at least 10 minutes at room temperature, a well plastic dough is obtained (approx. 35% water content). Dough portions of approx. 40 g are converted into bags with a residual moisture content of between 2% and 5% in hot, three-part bag baking molds that can be opened and made at 170 ° C (smooth bag shape, wall thickness 4 mm). baked The bags are removed from the baking pan and transferred with the bag opening down onto a wire belt. The bags cool down a bit, their surface temperature is between more than 40 ° C to just below the baking temperature. The bags are doused with lye as they pass through an alkali pouring veil. The concentration of caustic soda is 3% in water, the starting temperature of the caustic is around 28 ° C. The bags treated with lye are sprinkled with coarse salt and possibly also with sesame seeds and baked in a hot air oven at 240 ° C for 6 minutes.

Pretzel-Cone - Manufacturing

intermediate:

Ψ

Dough preparation: water, flour, small ingredients, Knead, portion

Ψ

Baking in bag baking tins

Remove the bags from the

bakeware

Handover of the bags on a wire belt

% $

intermediate

Sprinkle over the bags using the casting technique

θ

end product

Heat treatment with hot air cooling, packaging

Example 10: Pre-product - pretzels

Prepare a smooth, firm dough that rests for at least 15 minutes, divide the dough into individual dough strands, shape the dough strands into pretzels with a thick strand in the middle that tapers outwards and ends in a round end. After reaching the desired cooking, the pretzels are brushed with water and baked at 230 ° C for about 20 minutes.

The partially baked pretzels can also be cooled, stored chilled or frozen.

The pretzels are covered with 2.75% sodium hydroxide solution (room temperature coated), sprinkled with salt and baked at approx. 250 ° C until the desired color development.

dough recipe *

Flour, T 550 10 baker's yeast 0.45

Water, approx. 5 salt 0.25

Fat 0.3 malt baking agent 0.2

* If necessary, approx. 5% old dough is added.

The lye step

The precursors mentioned in the above examples are treated with an alkali solution in the next process step. In contrast to the conventional lyeing of raw dough pieces before baking, an essential function of the lyeing step does not apply here, namely the formation of a denatured, smooth surface skin as a result of the high pH value and the mostly high temperature of the lye bath.

The preliminary products mentioned in the previous examples already have a stable, solidified surface. In the case of open pores in the surface, too long or too intensive leaching is not desirable. The criterion for this is whether alkali solution can penetrate into the interior of the preliminary product. This can be done by changing the leaching technique, e.g. Spraying instead of pouring or dipping, and avoided by using a higher viscosity alkali according to Examples F to H below.

The caustic solution can be used hot until just below the boiling point of the caustic solution. However, it does not have to be used hot. Brief dipping or spraying is also sufficient to impregnate the surface of the primary product with lye solution.

During the heat treatment of the preliminary products treated with lye, a browned, shiny, often also smooth surface was achieved, which less porous pastry surfaces even gives a closed surface appearance. This surprising effect shows that the "leaching" of baked moldings is sufficient to achieve this effect and that the alkaline substances are reacted reactively.

Depending on the desired color intensity, the reactivity of the surfaces of the baked moldings determined by the recipe and the chosen alkali application technique such as dipping or spraying, the skilled worker can select the concentration of the alkali used, possibly also as a mixture of the preferred alkali formulations.

Caustic solutions:

A sodium hydroxide solution in water, concentration in the range from 0.15% to 4%, preferably in the range from 0.5% to 3%. Temperature between the refrigerator temperature (approx. 4 ° C) and at least 1 ° C below the boiling temperature, preferably between room temperature and 95 ° C. Potassium hydroxide solution can also be used with a low alkali concentration, although any bitter taste that occurs has a limiting effect here.

B sodium hydroxide solution in ethanol / water (50% / 50% v / v), concentration in the range from 0.15% to 4%, preferably 0.5% to 3%. Temperature between refrigerator temperature (about 4 ° C) and 50 ° C, preferably room temperature. Potassium hydroxide can also be used at a low alkali concentration, although any bitter taste that may occur has a limiting effect here.

C Mixtures of A and B. Temperature between refrigerator temperature (about 4 ° C) and 50 ° C, preferably room temperature.

D sodium carbonate (soda) in water. Concentration in the range of 0.5% to 6%, preferably 1.5% to 5%. It is monohydrate, other hydration levels are to be converted equivalent. Temperature between see refrigerator temperature (about 4 ° C) and at least 1 ° C below boiling temperature, preferably between room temperature and 95 ° C. With a low alkali concentration, potassium carbonate can also be used, with any bitter taste that may have a limiting effect here.

E Mixtures of A and D. Temperature between refrigerator temperature (about 4 ° C) and at least 1 ° C below boiling temperature, preferably between room temperature and 95 ° C.

F As A, but additionally maltodextrin (DE between 5 and 20) is dissolved in a concentration of 4 to 55%, preferably 10 to 50%. Temperature between room temperature and at least 1 ° C below the boiling temperature, preferably between room temperature and 60 ° C.

G As A, but additional wheat spring flour is dissolved in a concentration of 0.5 to 5%, preferably 1 to 4%. Temperature between room temperature and at least 1 ° C below the boiling temperature, preferably between room temperature and 60 ° C.

H Mixtures of F and G. Temperature between room temperature and at least 1 ° C below the boiling temperature, preferably between room temperature and 60 ° C.

Claims

claims

1. A method for producing baked, at least partially brown shiny objects characterized by the steps:

(1) producing an at least partially baked, dimensionally stable molded body as a preliminary product,

(2) treating the dimensionally stable intermediate with lye and producing an intermediate treated with lye,

(3) optionally sprinkling the intermediate product with scattering material, and (4) heat treating the intermediate product:

(a) at least on the surface for browning the spots of the intermediate treated with lye, and

(b) optionally also in depth to reduce moisture.

2. The method according to claim 1, characterized in that for the manufacture of a dimensionally stable preliminary product, a raw dough piece corresponding in shape to the object to be manufactured as a shaped body up to a residual moisture content of 1 to 29 wt .-% is baked.

3. The method according to claim 1, characterized in that for producing a dimensionally stable intermediate product, a portioned, raw piece of dough is mechanically formed into a shape corresponding to the object to be produced and the shaped body formed by the forming up to a residual moisture content of 1 to 29% by weight, is preferably baked from 1.5 to 18% by weight.

4. The method according to claim 1, characterized in that for the production of a dimensionally stable intermediate product, a raw dough or baking mass is baked in portions in a baking mold, which determines the shape of the object to be produced, to form dimensionally stable shaped bodies which have a residual moisture content of 1-6% by weight, preferably 1.5-4% by weight

5. The method according to claim 1, characterized in that to produce a dimensionally stable intermediate product, a raw dough or baking mass in portions between the opposing baking surfaces of a closed wafer baking mold to form dimensionally stable moldings with a residual moisture content of 1-6% by weight, preferably of 1, 5 - 4 wt .-% is baked.

6. The method according to claim 1, characterized in that the dimensionally stable intermediate product is preferably used for freshly baked or long-baked pastries, at least partially baked or ready-baked and optionally filled biscuits.

7. The method according to claim 1, characterized in that finished biscuits, such as biscuits, crackers, pretzels, pastries, waffle biscuits or the like, are used as the dimensionally stable intermediate.

8. The method according to claim 1, characterized in that temporarily stored biscuits are used as a dimensionally stable intermediate.

9. The method according to claim 1, characterized in that intermediately stored biscuits are used as a dimensionally stable intermediate.

10. The method according to any one of claims 1 to 9, characterized in that only one side of the preliminary product is treated with alkali to produce an object which at one point has a brown shine in the manufacture of the intermediate product.

11. The method according to any one of claims 1 to 9, characterized in that in order to produce an object that shines brown on both sides, at least in places, the intermediate is treated with lye only on one side and then subjected to a first heat treatment, and then the intermediate, which has already been browned on one side, is also treated with lye on the opposite side and a second Is subjected to heat treatment.

12. The method according to claim 11, characterized in that the one-sided browned intermediate product is shielded on the already browned side in the second heat treatment.

13. The method according to any one of claims 1 to 12, characterized in that the heat treatment of the intermediate product is carried out by means of hot air.

14. The method according to any one of claims 1 to 12, characterized in that the heat treatment of the intermediate product is subdivided into a baking phase and a post-drying phase, the outer skin of the intermediate product being heated up to a temperature by hot air or infrared radiation in the baking phase the areas treated with alkali are given a sheen and color, and in the post-drying phase the interior of the intermediate product is heated by microwaves or dielectrically in order to lower the moisture content there.

15. The method according to any one of claims 1 to 14, characterized in that an alkali solution is used in the alkali treatment, which is mixed with modified starch and / or modified cereal flour.

16. The method according to any one of claims 1 to 15, characterized in that the preliminary product is stored refrigerated before the treatment with lye.

17. The method according to any one of claims 1 to 15, characterized in that the preliminary product is stored frozen before treatment with lye.

18. Object with at least in places a shiny brown surface, characterized in that it is produced according to one or more of claims 1 to 17.

19. Food product with at least in places a shiny brown surface characterized by a baked and subsequently heat-treated and after the baking process at least in places treated with lye molded bodies made of dough or baking mass with a shiny, browned top layer at its locations treated with lye.

20. Container characterized by a baked, after the baking process at least partially treated with lye and subsequently heat-treated molded body made of dough or baking mass with a shiny, browned top layer at its locations treated with lye.