IES930342A2 - Frozen bakery products and method of manufacture - Google Patents

Abstract

A method of manufacturing frozen chemically aerated bakery products which can be taken from a freezer and fully baked in an oven, the method comprising the steps of: (a) mixing product ingredients which include a chemical 10 aerating agent comprising bicarbonate of soda, cream of tartar or equivalent and lactic acid in appropriate proportions so that chemical reaction between the acids and alkali of the aerating agent does not occur until the product is being baked in the oven; 15 (b) forming and cutting the dough into product shapes; (c) freezing the product shapes. 20 The ratio of bicarbonate of soda : cream of tartar (or equivalent) is in the range 1.5-2:1-0. The preferred ratio used is 2:1 and lactic acid is included in the form of buttermilk powder at an acidity level of 0.8%. 25 The invention also relates to frozen chemically aerated bakery products manufactured using the above described process.

Description

A method of manufacturing frozen chemically aerated bakery products which can be taken from a freezer and fully baked in an oven, the method comprising the steps of: (a) mixing product ingredients which include a chemical 10 aerating agent comprising bicarbonate of soda, cream of tartar or equivalent and lactic acid in appropriate proportions so that chemical reaction between the acids and alkali of the aerating agent does not occur until the product is being baked in the oven; (b) forming and cutting the dough into product shapes; (c) freezing the product shapes.

The ratio of bicarbonate of soda : cream of tartar (or equivalent) is in the range 1.5-2:1-0. The preferred ratio used is 2:1 and lactic acid is included in the form of buttermilk powder at an acidity level of 0.8%.

The invention also relates to frozen chemically aerated bakery products manufactured using the above described process.

FROZEN BAKERY PRODUCTS AND METHOD OF MANUFACTURE The present invention relates to frozen chemically aerated 5 bakery products and method of manufacture.

Bakery products are aerated by introducing air or gas (carbon dioxide) into the mixture. Carbon dioxide may be introduced either biologically using yeast or chemically .jq using baking powder which contains an alkali and an acid. On commercial scale production in a bakery, the baking powder used contains approximately one part bicarbonate of soda (alkali) and approximately two parts cream of tartar or equivalent (acid). The acid and alkali react when moistened to produce carbon dioxide. Conventionally, once the dough is moistened, this chemical reaction takes place immediately and the dough aerates at approximately 15°C (room temperature). Thus, conventional teaching recommends that the dough should be placed in an oven for 2θ baking as soon as possible after mixing.

The term cream of tartar when used throughout the specification will be understood to mean potassium hydrogen tartrate (tartaric acid).

The term cream powder is a term used in the commercial bakery industry to described various acids or mixtures of acids equivalent to cream of tartar. Cream powder comprises acid Calcium Phosphate or acid sodium phosphate mixed with starch. Starch is included to make the powder equivalent, weight for weight, to cream of tartar as regards acidity level.

The Applicant found that there was a huge demand for products such as brown soda bread in its bakery shops.

IE 930342 OPEN TO PUBLIC INSPECTION UNDER SECTION 23 AND RULE 23 JNL. No. /77/ ,-. 17/11Π3 IE 930342 - 2 However, there was a problem in trying to maintain consistency of the product since the bread was being baked by different bakers in different shops. Furthermore each shop had to have at least one qualified baker and baking was labour intensive. In an effort to overcome these problems, the applicant attempted to freeze conventionally produced bread.

However, attempts to freeze the conventionally produced 10 chemically aerated bakery products were unsuccessful. The dough was too soft and furthermore a thick skin developed during thawing of the frozen product.

The present invention seeks to alleviate this disadvantage 15 The present invention accordingly provides a method of manufacturing frozen chemically aerated bakery products which can be taken from a freezer and fully baked in an oven, the method comprising the steps of: (a) mixing product ingredients which include a chemical aerating agent comprising bicarbonate of soda, cream of tartar or its equivalent and lactic acid in appropriate proportions so that chemical reaction between the acid and alkali constituents of the aerating agent does not occur until the product is being baked in an oven; (b) forming and cutting the dough into product shapes; (c) freezing the product shapes.

Advantageously, the proportion of bicarbonate of soda to cream of tartar or its equivalent is in the ratio of approximately 1.5-2:1-0.

IE 930342 - 3 Because of the balance of the components of the chemical aerating agent, reaction resulting in aeration does not occur until the product is placed in an oven at the appropriate temperature.

Preferably, the proportion of bicarbonate of soda to cream of tartar or equivalent is in the ratio of approximately 2:1 .

Alternatively, the proportion of bicarbonate of soda to cream of tartar or equivalent is in the ratio of 1.5:1 .

Advantageously, the lactic acid is added in the form of buttermilk powder which is at an appropriate acidity level.

It has been found by experiment that production of product with optimum characteristics results if bicarbonate of soda (alkali) and cream of tartar or equivalent (acid) are included in the ratio of 2:1 and lactic acid is included in the form of buttermilk powder at an acidity level of 0.8%, In the case of production of Ginger cake, for instance, the ratio of bicarbonate of soda (alkali) to cream of tartar or equivalent (acid) may be 2:0, i.e. the cream of tartar or equivalent (acid) can be omitted from the ingredients since the ginger taste would compensate for the excess of soda in the cake. Furthermore, the acidity level of the buttermilk powder (lactic acid) would be increased to compensate for the omission of cream of tartar.

The acidity levels referred to are determined by the duration of the fermentation step used in the production of the buttermilk powder. Such buttermilk powder is IE 930342 - 4 commercially available.

Buttermilk powder has heretofore not been used in the production of bakery products. Conventionally buttermilk was added in liquid form, however, use of the powder form has the advantage that a more homogenous distribution of lactic acid results in the mixture.

Preferably, the product shapes are formed by forcing 10 the dough through a sheeting apparatus and cutting is carried out using a metal cutting blade.

Conveniently, a stabilising agent which is ideally, Panodan is included in the mixture. This stabilising agent prevents flow i.e. loss of shape while the bakery product is being manufactured.

In an alterative embodiment, the manufacturing process includes the step of partially baking the product. Thus the invention also provides a method of production of par-baked bakery products, a term used in the art to describe products which are part-baked in the bakery and subsequently sold to the customer who completes the baking process when desired. In this embodiment of the process of the invention, the chemical reaction between the acid and alkali constituents of the chemical aerating agent react and the product is fully aerated during the baking step carried out in the process.

The subsequent heating by the customer completes the baking in that it achieves colouring of the product and ensures a crusty product.

The bakery product of the invention does not include yeast IE 930342 - 5 and does not require proofing.

Ideally, the chemical aerating agent includes a mixture of cream of tartar or equivalent, lactic acid and an alkali which is preferably, bicarbonate of soda. Due to the balance of these acids and alkali in accordance with the present invention, the bakery product of the invention does not produce carbon dioxide and hence does not aerate, until the dough is placed in an oven.

The invention also provides a chemically aerated bakery product produced using the above described process.

The invention will now be described more particularly with 15 reference to the following non-limiting examples, which describe, by way of example only, several embodiments of the invention.

Example 1 is the preferred method of production of frozen 20 brown soda bread and Example 3 is employed when partially baked frozen brown soda bread is required.

IE 930342 - 6 Example 1 Production of Brown Soda Bread (Ratio of Bicarbonate of Soda : Cream of Tartar 2:1) 5 Weight Inqredient Kg 16.000 Flour Silver Crown chilled 1 0 16.000 Canadian's Best Wheatmeal Flour chilled 1 .000 Bicarbonate of Soda 0.500 Cream of Tartar 0.412 Salt 0.650 Bran 15 2.667 Buttermilk Powder at an acidity level of 0.8% 23.000 Water at a Temperature of 1°C 0.064 Panodan (stabilising agent) Method of manufacture of frozen dough product: (1) All the ingredients, other than the water, are added together and are dry mixed for two minutes; (2) the water is then added to the other ingredients and 25 the batch is mixed for three minutes; (3) the dough thus formed is forced through a Rijkaart Sheeter apparatus and emerges therefrom in the form of sheets; (4) the sheets of dough then pass onto a conveyor belt onto which flour has been spread and the top surface of the sheet of dough is dusted with flour; IE 930342 - Ί (5) the sheet of dough is cut using a cutter which has had flour applied thereto. The dough of the present invention has the advantage that it has a consistency which allows for cutting using a steel cutter. This is a surprising advance in the manufacture of a chemically aerated bakery product such as soda bread; (6) the portions of dough cut out of the sheet are then allowed to pass through a nitrogen tunnel freezer and are subjected to temperatures of -80°C for 12 minutes. The aim of this stage of the process is to reduce the core temperature of the dough portion to -18°C. Each portion of frozen dough product is tested for inclusion of metal; a standard safety test conducted following mass production of a food product to ensure that the product had not become contaminated by metal during production.

Furthermore, the weight of each portion of dough is measured and checked; (7) the product is then packaged and stored in a deep freeze for twenty four hours so as to allow the temperature to equalise across the entire dough product; (8) following freezing, the product is distributed to retail outlets for supply to customers. The customers may store the product in a frozen state and remove for thawing as required.

To thaw the frozen dough product, a customer removes a dough portion from a freezer (-18°C), takes the frozen dough from its bag and places it on a tray, flat side down. The dough product may then be put in a fridge at 3°C(37°F) for a minimum of 4 hours and a maximum of 10 hours .

IE 930342 - 8 Alternatively, thawing may be carried out at room temperature, i.e. 21 °C to 25°C (70°F to 77°F), and the thawing time is 2 to 3 hours. Overnight thawing at room temperature should be for a minimum of 4 hours and a maximum of 10 hours.

To bake the frozen dough product, the customer carries out the following steps: 1. the oven is pre-heated to 243°C (500°F) and then maintained at 238°C (480°F); 2. with the fully thawed dough on a baking tray, the top 15 of the dough is dusted with white flour; 3. a cross is cut carefully into the top of the dough with a knife to about a third of the thickness of the dough; 4. the baking tray is placed in the oven and the product is baked for approximately 25 minutes.

It is important to ensure that the oven heat is evenly 25 distributed and that the dough is dusted with flour before the cross is cut. Cutting a cross in the dough results in the characteristic appearance of soda bread and also ensures the dough rises homogeneously.

IE 930342 - 9 Example 2 Alternative embodiment of method of manufacture of brown soda bread (Ratio of Bicarbonate of Soda : Cream of Tartar 1 . 5:1 ) Weight Kg 16.000 16.000 0.750 .500 .500 .500 . 41 2 .650 2.667 23.000 .064 .000 Ingredient Flour Silver Crown chilled Canadian's Best Wheatmeal Flour chilled Bicarbonate of Soda Cream of Tartar Skim Milk Powder Vegetable Oil Salt Bran Buttermilk Powder Water at a Temperature of 1°C Panodan (stabilising agent) * Trimmings from a previous batch (not more than this weight per mix).

The inclusion of the skim milk powder and vegetable oil assist in achieving a softer crumb and extending the shelf life of the product.

The method of manufacture of chemically aerated frozen brown soda bread includes the following steps: (1) All the ingredients, other than the vegetable oil and water, are added together and are dry mixed for two minutes; IE 930342 - 10 (2) the vegetable oil and water are then added to the other ingredients and the batch is mixed for two minutes; (3) trimmings taken from a previous batch, are then added and mixing continues for a further minute; (4) same as step 3 of Example 1; (5) same as step 4 of Example 1; (6) same as step 5 of Example 1; * The trimmings from this step in the process are returned to the mixing stage for use in a subsequent batch; The remaining steps in the process in this second embodiment are the same as described in steps (6) to (8) of Example 1. The instructions to the customer are also the same for Example 1.

Example 3 Method of production of par-baked brown soda bread The ingredients are as described in Example 1.

Steps (1) to (6) as described in Example 1 are carried out. After step (6), the dough is placed on baking trays and baked at 221 °C (430°F) in Deck ovens for 20-23 minutes until a temperature of 100°C is reached at the core of the dough. This temperature is measured using sampling techniques. The baking at this stage in the production process results in chemical reaction occurring between the IE 930342 - 11 acid and alkali constituents of the chemical aerating agent and so the dough is aerated fully at this stage. The aim at this step in the production is to maintain a white appearance on the exterior of the dough in order to avoid producing a crusty product. (Subsequent heating in the customer's oven is carried out to heat the product and to achieve an aesthetically pleasing coloured appearance and a crusty product).

The remaining steps (7) to (9) of the production method as described in Example 1 are then carried out.

To heat the frozen par-baked product, the customer carries out the steps as described in Example 1 except that the customers' oven should be maintained at 200°C and the product is heated for a period of 10 minutes.

In a further alternative embodiment the frozen par-baked product may be taken from a freezer at -18°C or a fridge at +3°C and placed, while still in the bag, in an oven at 160°C for approximately 23 minutes. This option of baking in the bag, a frozen par-baked product, is extremely convenient for the customer. Apart from the convenience aspect, since the bag is sealed, heat is transferred to the centre of the bread quickly. Furthermore, moisture given off from the bread during heating is retained within the bag and results in production of a tasty, moist product.

IE 930342 - 12 Example 4 Method of manufacture of maderia cake Ratio of Bicarbonate of Soda : Cream Powder (equivalent to Cream of Tartar) 2:1 Weight Ingredient Kg (lbs) 23.15 (10.5) Hi Ratio Flour 00.55 (0.25) Salt 02.21 (1-0) Ovalete 15 11.58 (5.25) Cake margarine 00.83 (0.38) Bicarbonate of Soda 00.41 (0.19) Cream Powder 15.44 (7.0) Eggs 01.76 (0.8) Buttermilk Powder 20 13.78 (6.25) Water The method of manufacture is as follows: Steps (1) and (2) of Example 1 are carried out.

Then the cake batter is placed in a hopper including weighing scales. The required weight is measured and the batter is formed into the required shape.

The product shapes are then subjected to temperatures of -80°C for 12 minutes, the aim being to reduce the core temperature of the product to -18°C. Each frozen product is tested for inclusion of metal; a standard safety test conducted following mass production of a food product.

IE 930342 - 13 Furthermore, the weight of each product is checked.

Steps (7) and (8) of Example 1 are then followed.

To bake the frozen maderia cake, the consumer thaws the cake for 1 hour at room temperature or in a fridge at +3°C overnight and the cake is baked in an oven at 215°C (420°F) for 20-23 minutes. 0 Example 5 Method of manufacture of tea brack Weight Inqredient Kg (lbs) 18.74 (8.5) Plain Flour 04.41 (2.0) Sugar 20 04.41 (2.0) Eggs 00.83 (0.38) Bicarbonate of Soda 00.41 (0.19) Cream Powder 00.41 (0.19) Spice 01.24 (0.56) Margarine 25 22.05 (10.00) Water (Tea) 02.76 (1.25) Buttermilk Powder 17.64 (8.0) Fruit The method of manufacture is as described in Example 4.

To bake the frozen tea brack, it is thawed in a fridge at +3°C and subsequently baked in an oven at 215°C (420°F) for 40 minutes.

IE 930342 - 14 Example 6 Method of manufacture of plain and fruit soda bread (white) Weight Ingredient Kg (lbs) 77.18 (35.0) Plain Flour 10 01 . 65 (0.75) Sugar 01.38 (0.63) Margarine 01 .93 (0.88) Bicarbonate of Soda 00.96 (0.44) Cream powder 50.72 (23.0) Water 15 06.34 (2.88) Buttermilk Powder 15.44 (7.0) Fruit (for fruit soda only) The method of manufacture is as described in Example 1, steps (1) to (8).

The baking'instructions are the same as given in Examples 1 and 2 which describe the manufacture of brown soda bread Example 7 25 Method of manufacture of plain and fruit scones Weight Ingredient Kg (lbs) 22.05 (10.0) Plain Flour 00.14 (0.06) Salt 03.31 (1.5) Margarine IE 930342 03.31 (1 -5) Sugar 00.83 (0.38) Bicarbonate of Soda 00.41 (0.19) Cream Powder 01 .65 (0.75) Eggs 02.21 (1.0) Buttermilk Powder 17.64 (8.0) Water 08.82 (4.0) Fruit (for fruit scones only) The method of manufacture is as described in Example 1, steps (1) to (8).

To bake the scones, they are thawed overnight at 3°C or for 30 minutes at room temperature and baked in an oven at 205°C (400°F) for 20-23 minutes.

It will further be understood that the invention is not limited to the specific details described herein which are given by way of example only, and that various alterations and modifications are possible within the scope of the appended claims.

Claims (5)

1. A method of manufacturing frozen chemically aerated bakery products which can be taken from a freezer and fully 5 baked in an oven, the method comprising the steps of: (a) mixing product ingredients which include a chemical aerating agent comprising bicarbonate of soda, cream of tartar or its equivalent and lactic acid in appropriate 10 proportions so that chemical reaction between the acid and alkali constituents of the aerating agent does not occur until the product is being baked in an oven; (b) forming and cutting the dough into product shapes; (c) freezing the product shapes.

2. A process according to claim 1, wherein the proportion of bicarbonate of soda to cream of tartar or its 20 equivalent is in the ratio of approximately 1.5-2:1-0.

3. A process according to claim 2, wherein the proportion of bicarbonate of soda to cream of tartar or equivalent is in the ratio of approximately 2:1 .

4. A chemically aerated bakery product produced using the process as claimed in any one of the preceding claims. IE 930342 - 17

5. A process for producing a chemically aerated bakery product which can be taken from a freezer and fully baked in an oven, substantially as herein described in the Examples .