GB2194126A - Method of producing baked goods - Google Patents

Description

SPECIFICATION Baked goods and method of manufacturing same The invention relates to a method of producing baked goods containing sugar, flour and or alternatively other starch components, egg powder and fat components initially being based on an aqueous sugar solution, as well as said baked goods. In particular, the invention relates to a process of producing so-called "Viennese Mass" on a large-scale industrial basis.

In common practice, "Viennese Mass' is industrially produced in a process where, initially, sugar is dissolved in water and the aqueous sugar solution thus obtained is used to dissolve the protein-containing ingredients particularly egg powders. The mass thus obtained is then mixed with the fat or the shortening as well as with the flour. This process. requires relatively long mixing periods of some 5 minutes at temperatures between 30 and 33"C in order to get the sugar dissolved in the water. Then the admixture of protein carriers such as egg powders requires another stirring period of some 10 minutes whereupon the additional ingredients such as fats, wheat flour, Lactovit are admixed with the mass and the whole dough is kneaded again for another 10 to 15 minutes. This way a total stirring time of at least 25 minutes is required.

One advantage of this process is that flour and other starch components will absorb quite an amount of water when being mixed and thus make it difficult for the resulting dough to be kneaded thoroughly. In more recent time the nutritional aspects have made it desirable to enrich baked goods with ingredients such as wheat bran. Wheat bran, however, is especially inclined to absorb any present water in large quantities only to release it rather slowly in the subsequent baking process.

Wheat bran furthermore contains lipolytic enzymes which normally precludes such bran from being used in connection with fat-containing baked goods such as "Viennese Mass". It is necessary, therefore, to eliminate to a considerable degree the water adsorption of the wheat bran in order to eliminate also the bran's lipolytic activity.

It is the object of the present invention to make available baked goods produced by means of a process requiring significantly less stirring/kneading periods than the ones encountered heretofore; it is furthermore desirable to be able to use starch components such as wheat bran in the mass without having said bran taking up too much water i.e. moisture in the process; the sequence of the production steps required for the production of the baked goods is also designed to eliminate to a considerable degree the lipolytic activity of said bran. Furthermore it is intended to make available baked goods offering a shelf life over extended periods of time without the need of any preservatives being added.

The object described above are attained, according to the invention, by means of a method which follows the following sequence of production steps: (a) Preparation of a solution of water, sugar and salt (using conventional techniques); (b) Dry premixing of flour and or alternatively other starch components, egg powder, raising agents such as leaven and flavouring materials, and (c) Addition of the premix of (b) to the solution of (a) while, at the same time, adding the fat components with constant stirring until a homogeneous dough mass is obtained, and (d) Baking the dough at temperatures between 150 C and 220"C until it is done, showing a residual moisture content from 18% to 22% by weight.

According to the invention the step (a) of producing the baked goods involves a stirring of 5 minutes in order to dissolve, by conventional techniques, the sugar and common salt in the amount of water needed for the dough, which is done preferably at a temperature of 40"C.

In contrast to the production steps used heretofore the method of the invention specifies the dry premixture of the flour and the other possible starch components, the egg powder, the raising agent and the flavouring materials. Production step (c) requires this dry premix to be admixed to the solution obtained under production step (a) while, at the same time, stirring the fat components into the mixture. Said stirring is continued until a homogeneous dough is obtained. This stirring, as a rule, will require periods of 10 to 15 minutes at a preferred temperature of from 30 to 35"C.

The homogeneous dough thus obtained is then placed on a baking plate and, in production step (d), baked to finish at temperatures of from 150"C to 220"C until a residual water content of 18 to 22%-preferredly 18% to 20%. by weight. It is recommended to carry out this baking process by means of having the dough pass through at least one and up to four different temperature zones.

According to the invention it is preferred to substitute part of the contents of flour by starch components. The components especially suited for this process are wheat bran, preferredly toasted wheat bran, and rye malt powder. Said share of wheat bran and/or rye malt powder may go up to 100%; the preferred range is from 30% to 80% and especially preferred is a share or 50%, by weight.

The additional components admixed in production step (b) include auxiliary materials and flavouring (aromatic) substances, e.g. Colco, Nutex, Lactovit (all of which are brand names for well known materials) and raising agents (leavening agents). The fat components to be admixed may consist of shortenings commonly used in baking or butter. Especially suitable are liquid fats i.e. peanut oil in particular.

The egg powder especially suitable is whole egg powder which may be enriched by a share of egg yolk powder if desired.

The finished baked product contains a residual moisture of from 18% to 22% by weight; preferred is a range from 18% to 20% and especially preferred a content of about 19%. It shows a water activity of from 0.5 to 0.8 and yet possesses an extended shelf life from 50 up to 90 days without any preservatives being added.

The following example describes the invention but is not intended to limit the scope of this application.

Example of practical execution Production step (a): The shares by weight of sugar, water and salt are introduced into the dissolving vessel. Said vessel is double-walled, heatable by means of 801-type water heater and fitted with a stirring apparatus. All elements of this equipment consist of stainless V2A-type steel. The ingredients mentioned before are heated under stirring to a temperature of up to 40"C until sugar and salt have been completely dissolved.

Such solution may also be prepared in advance as stock for subsequent mixing.

The quantity of this solution prescribed by the receipe is then pumped into the actual mixing vessel. This mixing vessel is also double-walled, heatable with 801-type water heater, fitted with a planetary paddle mixer and made entirely from stainless steel including all input and output pipes. The planetary paddle mixer may be set at two different speeds, i.e. a) 35/87.5 RPM and b) 70/175 RPM, respectively.

Production step (b): The powdered dry ingredients such as flour, egg yolk powder, whole egg powder, toasted wheat bran (Cruschello medio), Lactovit, rye malt powder, baking powder, ammonium carbonate and vanillin are premixed without any liquids.

Production step (c): The dry premix obtained in production step (b) is then stirred into the solution prepared in production step (a). Immediately after the dry components are added there will also be the admixture of the weight-defined portions of Colco, Nutex and orange essence; the entire dough is continued to be kneaded by means of the planetary paddle mixer until a smooth and lump-free mixture is obtained. At the same time the fat components i.e. preferredly peanut oil are admixed. The stirring period of this production step takes about 10 to 15 minutes.

The stirring is set at a suitable speed to avoid the forming of lumps. The temperature of the mixed dough thus obtained will be about 32"C +/- 2"C. Said temperature is the accumulated result of the temperature of the solution prepared at production step (a) and of the temperature of the ingredients admixed at production step (c). Depending on the temperature of these ingredients the final temperature of the dough is determined by means of the solution temperature from step (a). Minor adjustments may be achieved with the help of the indirect heating system of the mixing vessel.

Production step (d): The dough thus obtained has a specific gravity between 0.95 and 1.10 and is subsequently pumped into the buffer vessel in front of the baking oven. This buffer vessel is of identical design as the mixing vessel but is fitted with a slower mixing paddle which keeps the dough in motion. Here again the temperature is kept at 32"C.

From the buffer vessel the dough is pumped into the backing trough as needed. The input pipe is provided with a sieve to remove any lumps or foreign matter. The end piece of the input pipe is moving constantly from the left to the right of the baking trough providing an even distribution of the dough over the entire width and thus eliminating the forming of excess dough on the outer flanks of the trough. The thickness of the layer of the dough thus applied is about 2 mm and may be preset manually by means of a finely adjustable skimming system. Said thickness is determined in accordance with the desired thickness of the finished product.

The dough thus applied to the steel conveyor is then run through the baking oven the interior of which has been subdivided into two zones of temperature which may be preset separatedly.

The heating of the baking oven follows the well-known hot air circulating system. On principle it is possible to subdivide the baking oven into up to four different baking zones; the individual temperatures and number of zones depend on the passage speed of the dough.

The interior temperature of the product in the baking process must reach a minimum of 95"C.

The residual moisture content of the baked product is 19% +/- 1%; the thickness of the baked-to-finish product is 3.5 mm +/- 0.1 mm, and the specific gravity is 0.37 +/- 0.01.

In the present example and at a conveyor speed of 3m/min the baking temperatures are as follows: In the first zone: 1500C at the top; 210 C at the bottom In the second zone: 220"C at the top; 220"C at the bottom In the present example the baked good thus obtained represents a semi-finished product; after having left the baking oven it is removed from the steel conveyor by means of a stripping system. In this phase of the process the bottom skin formed in the baking must remain at the steel conveyor and may not stay attached to the product. A subsequent cleaning process will remove said baking skin from the steel conveyor and discard it.

The baked product is then transported by means of a chain conveyor to a sterile-air-conditioned zone and allowed to cool off there.

After being run over a special roller to be turned over the continuous biscuit web is cut into strips of desired width which are forwarded to be applied with the desired quantity of filling creme.

The technical specifications of the finished baked product thus obtained are shown in the table hereunder: Table of Specifications 'Viennese Mass' 'Viennese Mass' Features before baking baked to finish pH-value 7.0 - 7.3 7.3 - 7.7 Water content 39.0% - 42.0% 18.0% - 20.0% Protein (total) 6.0% - 7.0% 6.5% - 8.5% Fat (total) 14.0% - 16.0 % 16.0% - 18.0% Viscosity 351 * 2.5M - 3.6M N.A.

Viscosity 251 * 3.7M - 4.2M N.A.

AW-value 0.92 - 0.95 0.75 - 0.80 Density 0.99 +/- 0.02 Saccharose 15.0 - 17.0% Penetrometrics N.A. ** 0.4 - 0.7mm Inerts N.A. 3.5% Note: * Brookfield spindle RV6; speed 50 ** Penetrometrie SUR-PNR 8 test stamp Total weight 215 g (Deutsche Prufvorschrift 18.242.1)

Claims (14)

1. A method of producing baked goods from sugar, flour and or alternatively other starch components, egg powder and fat components, and an aqueous sugar solution by means of the following sequence of production steps: (a) Preparation of a solution of water, sugar and salt; (b) Dry premixing of flour and any other starch components, egg powder, raising agents and flavouring materials, (c) Addition of the premix from (b) to the solution from (a) while, at the same time, adding the fat components with constant stirring until a homogeneous dough is obtained, and (d) Baking the dough at from 1500 to 220 C the baked product having a residual moisture content from 18% to 22% by weight.

2. Method according to Claim 1 wherein the egg powder consists of whole egg powder and or alternatively egg yolk powder.

3. Method according to either of Claims 1 and 2 wherein the starch components used in the process consist of wheat bran and or alternatively rye malt powder.

4. Method according to Claim 3 wherein toasted wheat bran is used.

5. Method according to any one of Claims 1 to 4 wherein additional process materials and flavouring ingredients are added at production step (c).

6. Method according to Claim 5 wherein Colco, Nutex and or alternatively Lactovit is added at production step (c).

7. Method according to any one of Claims 1 to 6 wherein the fat components added are in a liquid state.

8. Method according to Claim 7 wherein peanut oil is added.

9. Method according to any one of Claims 1 to 8 wherein the residual moisture content is from 18 to 20% by weight.

10. A method according to any one of Claims 1 to 9 wherein the solution of step (a) is stirred for about five minutes and the stirring period of step (c) is from 10 to 15 minutes.

11. A method according to any one of Claims 1 to 10 wherein the temperature is maintained in step (a) at about 40"C and at production step (c) from 30 to 35"C.

12. A method according to any one of Claims 1 to 11 wherein the bake-to-finish process of step (d) is carried out in two separate zones the temperatures of which are 1500 to 210"C and to 20"C, respectively.

13. A method of producing baked goods substantially as hereinbefore specifically described with particular reference to the example.

14. Baked goods when produced by a method as claimed in any one of Claims 1 to 13.