GB2533402A

GB2533402A - Bakery product

Info

Publication number: GB2533402A
Application number: GB1422746.6A
Authority: GB
Inventors: Kirkland Susan
Original assignee: BAKKAVOR Ltd
Current assignee: BAKKAVOR Ltd
Priority date: 2014-12-19
Filing date: 2014-12-19
Publication date: 2016-06-22

Abstract

A bakery product that comprises flour, water and glycerol. The bakery product may comprise an additional ingredient selected from yeast, vinegar, fermented wheat flour, milk, sugar, oil, salt and combinations thereof. Glycerol, malt vinegar, milk and/or fermented wheat flour is used in the bakery product to extend the safe shelf life of the product and the bakery product may be prepared by combining the flour, water, glycerol and any additional ingredients and mixing to form a mixture; moulding the mixture; optionally, proving the mixture; and baking to form the bakery product. The bakery product could be bread, a bread- like product, a roll, a pie, a cake, a pastry or any product containing flour or meal. The bakery product may comprise 1 to 5 wt% glycerol, 30 to 40 wt% water and 50 to 60 wt% flour.

Description

Bakery Product

Field

[0001] The invention relates to a bakery product, in particular to an improved safe shelf-life bakery product.

Background

[0002] Bakery products, including bread in all its various forms, are the most widely consumed foods in the world. Such products are generally regarded as an important source of carbohydrates, portable and compact, which is why bread and sweet bakery products have been an integral part of our diet for thousands of years.

[0003] However, modern food consumers and retailers are concerned about food safety and quality. One aspect of this is safe product shelf life, a longer product shelf life allows the product to be stored for longer before sale, and reduces the need for the consumer to either use the product soon after purchase, or to artificially extend safe shelf life through, for instance, freezing the product, thereby reducing waste.

[0004] The Institute of Food Science and Technology (IFST, 1993) define shelf life of a food as "the period of time during which the food product will: remain safe, be certain to retain its desired sensory, chemical, physical, microbiological and functional characteristics, where appropriate, comply with any label declaration of nutritional data, when stored under recommended conditions." Microbiological characteristics will degrade when microbial growth occurs. This could be microbes that purely degrade the quality of the bakery product through spoilage, but could also be growth of pathogenic microbes, which cause illness when consumed. A wide range of factors influence the safe shelf life of a product, including the components present in the final product, and the environment in which was manufactured, stored, distributed and used. The principal factors are summarised in Table 1 below.

Table 1

Intrinsic Factors Extrinsic Factors Other factors Raw materials Processing Interaction of intrinsic and extrinsic factors (i.e. product Product composition and formulation Hygiene composition and processing) Packaging material and Consumer handling and use Product structure system (store in a refrigerator) Product make up Storage, distribution and Commercial considerations retail display (The needed to meet Water activity value (Aw) pH value and total acidity seasonal demands) Availability of oxygen and redox potential (Eh) [0005] Water activity, temperature and pH are generally regarded as the most important factors in controlling rates of deteriorative changes and microbial growth in foods, and it 5 would be advantageous if a new bakery product could be provided which seeks to control one or more of these factors, thereby improving the safe shelf life of the bakery product.

[0006] The invention is intended to overcome or ameliorate at least some aspects of this problem.

Summary

[0007] Accordingly, in a first aspect of the invention there is provided a bakery product comprising flour, water, and glycerol. Bakery products including glycerol have been found to offer reduced water activity, resulting in reduced microbial growth, particularly of Clostridium Botulinium, Bacillus Germs, and Staphyloccocus Aureus. This in turn extends the safe shelf life for the product as product degradation is lower.

[0008] As used herein, the term "bakery product" is intended to include any product prepared from flour or meal. Such products are typically baked, often yeast containing, and could include sweet and savoury products. For instance, a bakery product could be a bread, bread-like product (such as a gluten free product), roll, pie, cake, or pastry. The term "bread" is used to describe a wide range of products with different sizes, shapes, textures, crusts, softness, eating qualities and flavours and as used herein includes any food made from dough of flour, usually raised with yeast and then baked. The character of bread depends on the formation of a gluten network in the dough which traps gas from the yeast fermentation and makes a direct contribution to the formation of a cellular crumb structure (the sponge) which, after baking, confers texture and eating qualities quite different from other baked products.

[0009] The flour used in the bakery product will typically be wheat flour, although other flours may be used including maize, rye and rice flours. The flour provides a source of carbohydrate. Often the flour will be present in the bakery product in the range 40 to 70 wt%, often 50 to 60 wt%of the bakery product. As used herein, all references to weight percentages of an ingredient in the bakery product are to the weight percentage of that ingredient as initially added to the bakery product, as opposed to the final product.

[0010] Water will be present in any bakery product and has functions in the preparation of bakery products including, to form the gluten and give consistency to the dough, as a solvent for sugars, to facilitate fermentation in yeast products, to assist in the homogenisation of the product, to swell starch present in the flour, and to ensure even heat distribution during baking. Often, water will be present in the bakery product in the range 30 to 60 wt%, often 30 -40 wt% of the bakery product, although the skilled person would understand that the exact level of water used will depend upon a number of factors, in particular, the nature of the flour used.

[0011] Typically bakery products, and in particular breads, are prone to product degradation through microbial growth because they have a high water activity. Glycerol has been found to reduce the water activity of the bakery product, and thus inhibit the growth of microorganisms. Glycerol is not used in bakery products because it is oily, and slightly sweet (a property that can be undesirable for savoury products such as breads). Further, the activity of yeast can be inhibited by its presence. However, it has been found by the inventors that glycerol can be used, at low levels, to beneficial effect and without the expected loss in sensory profiles, product firmness, or chewiness.

[0012] Often the glycerol will be vegetable derived, as this offers a product which is suitable for a wider range of dietary requirements than animal derived glycerol, although animal and petroleum derived glycerols may be used. Often the glycerol comprises a palm derived glycerol and/or a rapeseed derived glycerol, palm derived glycerols can often be used. In many cases the glycerol will be present in the range 1-5 wt% of the bakery product. At these levels the glycerol has been found to reduce water activity without unacceptable loss in fermentation activity from the yeast or a noticeable impact on flavour characteristics of the product. In many cases the glycerol will be present in the range 2 to 4 wt%, often around 2 wt%, although lower levels may be used if balanced by the presence of yeast at levels greater than 2 wt% of the bakery product.

[0013] The bakery product may comprise at least one additional ingredient selected from yeast, vinegar, fermented wheat flour, milk, sugar, oil, salt and combinations thereof. The presence of these additional ingredients can modify the flavour, texture or safe shelf life of the product.

[0014] Often yeast (Saccharomyces cerevisiae) will be present, particularly where the bakery product is a bread. Often the yeast will comprise a sugar tolerant yeast, as such yeasts are more resilient to low water activity conditions than some other forms of yeast; and so with the use of such yeasts there is either no or only limited reduction in fermentation performance in the presence of glycerol. Often the yeast will be a fast fermenting-sugar tolerant yeast. The use of such yeasts can be advantageous for the reasons above, but also help to ensure consistency of quality in the baking as the yeast is fast acting, providing for a "no-time" dough. Often the bakery product will comprise yeast in the range 1.25 to 3 wt%, in some cases 2.2 to 2.6 wt%, or 2.5 ± 1.00 wt% of the bakery product. At these levels the optimum level of fermentation is achieved.

[0015] Vinegar is often added to reduce the pH of the bakery product. It has been found that lowering the pH of such products can reduce the growth of microorganisms, extending the safe shelf life of the product. Often, the vinegar comprises malt vinegar as malt vinegar (as opposed to spirit vinegar for instance) not only reduces the pH of the product but also provides benign flora (for instance, acetic acid bacteria) to compete with undesirable microbial growth and improve the safe shelf life of the bakery product. The best results in terms of extension of shelf life have been observed where the vinegar is present in the range 0.65 to 0.75 vvt%, often in the range 0.67 to 0.7 wt% of the bakery product. A reduction of pH, in combination with the control of water activity (for instance through the use of glycerol) has been found to offer a particularly effective extension in safe product shelf life.

[0016] Fermented wheat flour will also often be present (additionally or alternatively to vinegar), to provide benign flora to compete with undesirable microbial growth, and so improve the safe shelf life of the product. Fermented wheat flour is produced via the controlled fermentation of wheat flour with Propionibacterium.freudenreichii. The fermentation products include lactic acid, propionic acid and other organic acids, and so an additional benefit of including the fermented wheat flour is a lowering of the pH of the product, which as described above, also helps improve safe shelf life by reducing the growth of microorganisms. Often the fermented wheat flour will be present in the range 0.5 to 1.75 wt%, often 1.6 -1.65 wt% of the bakery product. These levels are sufficient to provide the benefits described, without reducing the pH too far and so inhibiting fermentation of any yeast present.

[0017] It has been found, that where vinegar or fermented wheat flour are used, in some cases less yeast can be used, as pH conditions are better suited to its growth. Further, it is possible to market the bakery products as being free of chemical preservatives.

[0018] Often the bakery product will contain milk as an emulsifier and to assist in lowering of the pH of the product. The milk may be powdered, or in liquid form. Often the milk will comprise buttermilk, often cultured buttermilk. Cultured buttermilk is low fat or skimmed milk which has been fermented with lactic acid-producing bacteria. It is acidic and imparts a soft texture to baked goods. It also helps quick breads rise. Buttermilk is a good emulsifier and is often used because of its positive impact on flavour. Often the milk will be present in the range 0.75 to 1.5 wt%, often 0.9 to 1.1 wt% of the bakery product.

Above these levels, it has been found that the buttermilk causes the dough to shrink, making kneading (and hence product preparation) difficult.

[0019] Sucrose and other sugars are often added to bakery products to enhance the sweet flavour, increase crust browning and in some cases to provide food for the yeast. Sugars include, glucose, fructose, galactose, sucrose, lactose, maltose dextrins, lactose (lactose will not give a sweeter product but it will influence the crust colour and delay staling due to its hygroscopic nature). The addition of sugars also lowers the water activity of the bakery product, helping to reduce microbial growth and improve safe shelf life. Often sugar will be present in the range 0.8 to 1.0 wt% of a savoury bakery product, and in the range 1.0 (often 1.2) to 20 wt% of a sweet bakery product, although levels will be adapted, primarily for taste.

[0020] Oil may also be present, any form of oil may be used, although olive oil, often extra virgin olive oil may be used as this type of oil reduces total and low-density lipoprotein (LDL or "bad") cholesterol levels in the bloodstream, while raising high-density lipoprotein (HDL or "good") cholesterol levels (Oliveoil source, 2014). Bakery oils are used to increase volume and softness of the product and to replace the water content in the dough. Typically, they will be present at levels in the range 0.5 to 1.5 wt%, often 0.8 to 1.2 wt% of the bakery product. However, for some products, levels can be as high as 6%, for instance in Focaccia style breads.

[0021] Salt (sodium chloride generally although potassium chloride can be used) is often included in the bakery product as a flavour enhancer. A further benefit is that, like sugar, salt lowers the water activity of the bakery product. However, levels have to be controlled, not only because high salt intake is to be avoided, but also because salt inhibits the activity of yeast, where this is present. As a result, salt will generally be present at low levels, for instance in the range 0.75 to 1.2 wt%, often 0.75 to 0.85 wt% of the bakery product.

However, it is possible that lower levels of salt may be present, particularly if government guidelines are amended to require this.

[0022] In a second aspect of the invention there is provided a process for preparing a bakery product according to any preceding claim, comprising the steps of a. combining the flour, water, glycerol and any additional ingredients and mixing to form a mixture; b. moulding the mixture; c. optionally, proving the mixture; and baking to form the bakery product.

[0023] Often, where yeast is present a bread will be formed, in such cases the mixture will be a dough, and the proving step will generally (although not always) be used.

[0024] In a third aspect of the invention there is provided the use of one or more of glycerol, malt vinegar, milk, and/or fermented wheat flour in a bakery product for the extension of safe product shelf life.

[0025] There is therefore provided a bakery product comprising: a. 50 to 60 wt% of the bakery product flour, b. 30 to 40 wt% of the bakery product water, c. 1 to 5 wt% of the bakery product rapeseed or palm derived glycerol, and d. at least one additional ingredient selected from, in the range 1.25 to 3.0 wt% fast fermenting-sugar yeast, 0.65 to 0.75 wt% of the bakery product malt vinegar, in the range 0.5 to 1.75 wt% fermented wheat flour, in the range 0.75 to 1.5 wt% buttermilk, in the range 0.75 to 1.2 wt% salt, in the range 0.8 to 1.0 wt% sugar, in the range 0.5 to 1.5 wt% oil, and combinations thereof. Processes for making this product and the use of one or more of rapeseed derived glycerol, malt vinegar, and/or fermented wheat flour in a bakery product of this type for the extension of safe product shelf life are also described.

[0026] Unless otherwise stated each of the integers described may be used in combination with any other integer as would be understood by the person skilled in the art.

Further, although all aspects of the invention preferably "comprise" the features described in relation to that aspect, it is specifically envisaged that they may "consist" or "consist essentially" of those features outlined in the claims. In addition, all terms, unless specifically defined herein, are intended to be given their commonly understood meaning in the art.

[0027] Further, in the discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, is to be construed as an implied statement that each intermediate value of said parameter, lying between the smaller and greater of the alternatives, is itself also disclosed as a possible value for the parameter. Where described, all weight percentages are of an ingredient in the bakery product are to the weight percentage of that ingredient as initially added to the bakery product, as opposed to the final product.

[0028] In addition, unless otherwise stated, all numerical values appearing in this application are to be understood as being modified by the term "about"

Examples

Methodology [0029] Theoretical salt content in the final product The theoretical salt content (% NaC1) in the final product was calculated using the McCance and Widdowson's book "The compositions of foods book". The calculation made using a proportional calculation, to obtain the % NaC1 and % Na in the final new 15 product.

[0030] Water Activity Measurement * Make sure that the product is at ambient temperature.

* Calibrate the equipment before use.

* Cut pieces from the crust and crumb (separately). Piece dimensions are 3.9 cm x 3.9 cm x 0.5 cm.

* Put the sample (crust or crumb) into the device (Novasina) to read the water activity.

* Match the thermoconstanter to the ambient temperature before use.

* Wait the same time for every sample to be read, it is recommended more than 30 minutes.

[003 I] pH Measurement * Make sure that the product is at ambient temperature.

* Calibrate the equipment (Mettler Toledo pH Meter) before use.

* Find the thickest part of the bread and cut in a way that the electrode can have direct contact with the crumb.

* Wait until the pH meter shows a constant number for more than 15 seconds.

* To measure the pH of the crust, make sure that the electrode has contact with the bread surface.

[0032] Theoretical Shelf Life Measurement [0033] Predictive models can predict microbial survival for changes in new product formulation without the need for extensive laboratory analysis. The water activity, pH and theoretical salt content are the intrinsic parameters of the bakery product that influence the safe shelf life of the product. These intrinsic parameters were used in Combase to predict the rate of spoilage and pathogenic microbial growth in the product. The predictive microbiology capability provided by Combase predictive growth model will be useful to judge more easily the effect of production and storage regimes and changing product formulations on the possible growth of pathogens or spoilage organisms.

[0034] Combase was used to predict the growth of C. botulinum non-proteolytic, C. botulinum proteolytic, B. cereu.s; and Staphylococcus alums. The maximum rates obtained in the products were compared. The maximum rate is the maximum slope of the "log (cell conc.) vs time" curve, in a given environment. It is expressed as the base (10) logarithm of the numbers of cells (colony forming units; cfu) per gram or millilitre per time unit (hour, h). The most important environmental parameter which influences the maximum growth rate is temperature, and the intrinsic parameters are pH and water activity (a quantification of the water available to the cells).

[0035] Combase (Combine dataBaSe for predictive microbiology) Pathogen predictions can be carried out using the Combase predictor system. This system is internet based and predictions are generated online. This system is freely available via: htp * iJivie iXf Te C.,2*01- [0036] ComBase Predictor uses the model of Baranyi and Roberts (1994) as the primary model. To create the secondary models, the logarithms of the specific growth rates were described as a function of the (possibly rescaled) environmental factors by a standard quadratic multivariate polynomial. For the models of ComBase Predictor, standard second order polynomials model the effect of temperature, pH, and Aw values on the logarithm of the growth rate. The maximum specific growth rate is the main model parameter for ComBase Predictor. The other key parameter (in place of lag) is the 'initial physiological state' (phys. state). The phys. state value is a dimensionless number between 0 and 1; if phys. state= 0, then there is no growth and the lag time is infinite; if phys. state=1, there is no lag and growth will commence immediately. It has a similar role to the inoculum size but is an initial parameter quantifying the history of the cells.

Bakery Products [0037] The invention will be illustrated through the study of bread products, in particular flat breads. The prior art product to be studied is a flat bread produced by New Primebake, described in more detail below.

Comparative Bakery Product [0038] Provided by New Primebake. Production Method [0039] The New Primebake flat bread is made using flour, water, compressed yeast, salt, sugar, spirit vinegar and extra virgin olive oil. The dough fermentation is a key in the production process to obtain a product with acceptable organoleptic properties. The flat bread is an ambient product. It is sold with a shelf life of Day Of Production (DOP) + 7 days in a Modified Atmosphere Packaging, with < 2.5 % residual oxygen. A typical product formulation for the New Primebake flat bread is as set out in Table 2 below.

Table 2 -Comparative Product Formulation Ingredients Dough g % Recipe Flour 1600 57.24 Water 1050 37.56 Block Yeast 44 1.57 Salt 23.6 0.84 Sugar 25.6 0.91 White spirit vinegar 20 0.72 Extra virgin olive oil 32 1.15 Total 2795 100 The Inventive Formulations [0040] The inventive formulations use the following ingredients: Yeast -Craftbake from DCL Yeast Fermented wheat flour -Sapore Molderator from Puratos Glycerol -from H Plus Limited Buttermilk -from St Ivel Malt vinegar -from Sarson's [0041] The specific formulations tested are as outlined below.

Table 3

Ingredients Dough Process A Process B Process C Recipe g % g % g % Flour 1600 53.93 1600 53.26 1600 52.51 Water 1050 35.39 1050 34.95 1050 34.46 Salt 23.6 0.795 23.6 0.785 23.6 0.77 Sugar 25.6 0.86 25.6 0.85 25.6 0.83 Extra virgin olive oil 32.0 1.08 32.0 1.065 32.0 1.05 Fermented wheat 48.0 1.62 48.0 1.6 48.0 1.58 flour Malt vinegar 20 0.675 20 0.665 20 0.66 Butter milk 32 1.08 32 1.065 32 1.05 Fast fermenting and 71.5 2.41 77 2.56 88 2.89 sugar tolerant yeast Rapeseed derived 64 2.16 96 3.2 128 4.2 glycerol Total 2966.7 100 3004.2 100 3047.2 100 Water Activity and pH [0042] For a food to have a useful safe shelf life without relying on refrigerated storage, it is important to control the level of water activity and the acidity level (pH). This can increase product stability and make it possible to predict its shelf life under known ambient storage conditions.

[0043] The water activity and pH data was gathered for the comparative product (the Primebake product) and from the products obtained with the Processes A, B and C.

Table 4

g Data used in the preliminary theoretical safe shelf life assessment " Lowest A w values regis ered [0044] It can be seen that the water activities and pH values are lower for the inventive flat breads than for the prior art Primebake product, indicating that these breads will be less prone to microbial decay, and hence have an improved safe shelf life.

[0045] Further testing, to verify the above is shown in Table 5 below:

Table 5 CY934

6.66:6:66:6:66SSA166: sani )70 Sault 2 U. Ai e 1 The crumb samples 1 & a were eAkenfrona the fluletit part Of the fLAt bread, which were 2 2 and s. cm dna respactwely, Croyt CrgmU 6.669:1kitrettiur:rr1966.SgSg-gt gittittitir6r6titi Ike mtuthwmPle2AI A2-werc taken from rim ttltrCk<sfl6ti Of the L1K bread, which: wategi and 2.-"cintiotre-5pedWetTY 11001M11)=11P/os 131 were LtkeRLIum the ilmtkorPart of the flat bread, SYhieh We* 2.2 and 5.90 0 9% ato pH Aw Corn base Theoretical Safe Life (25°C) B. cereus St aureus C C. Botulinum Botulinum (proteolytic) (non-proteolytic) New 5 0.97 3.9 days 1.5 days No growth 4.4 days Primebake predicted Process A 4.9 0.97 4.6 days 1.7 days No growth 4.4 days without predicted Glycerol Process A 5 0.95 11.3 days 2.1 days No growth No growth predicted predicted Process B 4.9 0.95 12.2 days 2.4 days No growth No growth predicted predicted [0046] As can be seen from the evidence above correlates with Table 4 above. Water activities are lower for Processes A and B (the inventive processes), and the theoretical safe shelf life higher. Further, this data clearly shows the effect of adding glycerol on the water activity of the bakery product, and the resultant improvement in safe shelf life.

[0047] Any minor differences in the pH and water activity values between Table 4 and Table 5 are a result of minor variations in testing. Specifically, the results in Table 5 are derived from a combination of crust and crumb, rather than from separate analysis of these two components as is the case in Table 4 and Tables 7 and 8 (below).

Product Shelf Life [0048] The effect of water activity on microbial growth has been extensively studied. As microorganisms contain high levels of water within their cells, they need a supply of water to survive.

[0049] As many bakery products have water activities in the range 0.6 to 0.97, product deterioration due to microorganism growth is a problem.

[0050] The most commonly identified pathogenic microorganisms (microorganisms which release toxins during reproduction) are B. cereus, St. aureus and C. botulinium, due to their presence in the soil and farming livestock. The water activities, and pH ranges at which these microorganisms can survive are provided in Table 6 below.

Table 6

Organism Minimal water pH range Growth rate* activity (Acs') (ti) B. cereus 0.930 4.3-9.3 4 hours/generation, 8°C C. Botulinum type A and proteolytic B and F 0.953 4.6-9.0 6 hours/generation, 32°C (8 days, 10°C)** C. Botu/inum type 0.965 5.0-9.0 (8 days, 10°C)** E and non-proteolytic B and F St. aureus 0.830 4 01 0 (2.8 days) * 10°C (toxin production) 0.850 4 0-9 8 *These are only examples of doubling time (td) The values will vary according to food composition.

**Time to toxin production Clostridium botulinum growth prediction [0051] The new flat bread obtained with the Processes A, B and C, have the following water activity values: / Flat bread obtained with the Process A: Aw = 0.952 / Flat bread obtained with the Process B: Aw = 0.940 / Flat bread obtained with the Process C: Aw = 0.929 [0052] The water activity values shown above are below the water activity values given in Combase predictive model to predict the growth of: / Non-proteolytic Clostridium botulinum: Aw = 0.974 / Proteolytic Clostridium botulinum: Aw = 0.954 [0053] Based in the analysis of water activity values, it can be assumed that the Nonproteolytic Clostridium botulinum and Proteolytic Closfrichum botulinum will not grow in Processs A, B and C; they would be expected to grow in the comparative flat bread which has Aw=0.972.

Bacillus cereus growth prediction [0054] The logarithm of the B. cereus growth was predicted using "a worst case" Combase growth model, based upon bakery product tests of the crumb, the most moist part of the bread, and hence the part most prone to microbial growth and degradation. B. cereus is an anaerobic, spore forming rod-shaped bacterium which is commonly present in soil, dust and water; from these sources wheat flour could be contaminated. The infective dose of B. cereus needed to have an emetic syndrome is 105 -108 cell s/g, and for the diarrhoea] syndrome it's 105-10' total.

[0055] The initial level of "log (cell conc.)=1" of Bacillus cereus was considered to make the Combase predictive microbial growth analysis considering the historical data that New Primebakes has regarding Bacillus cereus product contamination. The analysis was made in a given environment of 25°C. The results are shown in Table 7 below:

Table 7

[0056] After performing the predictive Bacillus cereus growth in the final products using Combase it can be assumed that: V Process A is going to give approximately 8 days of theoretical safe shelf life regarding Bacillus cereus to the final product.

10,5/g New Primebake pl4=5.90 Aw=0.972 10,5/g Process B pH=5.40 Asa-=0.940 10,5/g Process C pH=5.40 Aw=0.929 Process A pH=5.39 Aw=0.952 1W5/g WitifoaiirlOirent11 itatAlusiteteacto: -cause illness ":iningy 1.:H1.1111141req1.111r have Time required to have * O.111781 10.5fg 52.66 -2.5 194.53 _8 361.02 -15 No growth n/a / Process B is going to give approximately 15 days of theoretical safe shelf life regarding Bacillus cereus to the final product.

/ No growth is observed in Process C with Bacillus cereus.

[0057] This shows that even the worst case prediction for safe shelf life represents a clear improvement over the predicted 2.5 days for the Primebake product. Further, as shown in Table 5 above, safe shelf life is likely to be longer than this.

Staphylococcus aureus growth prediction [0058] Foods involved in Staphylococcus aureus food poisoning are commonly those 10 that have been physically handled and temperature abused prior to consumption. The amount of toxins are produced by 105 organisms per gram of product. St. aureus toxins are highly heat stable D98.9= > 2 hours.

[0059] The initial level of "log (cell conc.)=1" of Staphylococcus aureus was considered to make the Combase predictive microbial growth analysis considering the historical data that New Primebake has regarding Staphylococcus aureus product contamination. The analysis was made in a given environment of 25°C, the results are shown in Table 8 below:

Table 8

New Primebake pH=5.90 Aw=0.972 18.32 10^5/g Process A pH=5.39 Aw=0.952 -1.5 34.17 10A5/g Process B pH=5.40 Aw=0.940 10A5/g 41.72 -2.15 Process C pH-5.40 Aw=0.940 10A5/g aiattitS [0060] The theoretical safe shelf life regarding Staphylococcus aureus of the flat bread produced with the Process A is --1.5 days, with Process B is -2 and with Process C is -2.15. Humans are an important source of Staphylococcus aureus, the organism can be carried in the hair, throat and nose, on the skin, and transferred to foods via hands.

Therefore the Good Hygiene and Good Manufacture practices should be followed at all times.

[0061] As can be seen, even the worst case prediction for safe shelf life, this is a clear improvement over the estimated 0.8 days shelf life for the New Primebake product, although hygienic practices have to be maintained, as shown in Table 5 above, safe shelf life is likely to be longer than this.

Theoretical Salt Calculation [0062] Theoretical salt calculations were as follows:

Table 9

Formulation NaCl/100g Product (g) Na/100g of Product (g) Comparative 0.89 0.35 Process A 0.88 0.35 Process B 0.87 0.34 Process C 0.85 0.34 [0063] As can be seen, the theoretical salt calculations for the inventive formulations are

very similar to the prior art product.

[0064] It should be appreciated that the processes and apparatus of the invention are capable of being implemented in a variety of ways, only a few of which have been illustrated and described above.