KR19990025853A - Fermented Flavors for Bakery Products - Google Patents

Abstract

Flavored bakery products such as breads, bagels, pastries, cakes, cereals, cookies, biscuits, savory crackers and snack products are typically grown together when incubated with flour and water at about 25 ° to 37 ° C. to a pH of about 3.6 to 3.9. Lactic acid, such as a mixture of Lactobacillus and Gluconobacter species to complete a fermentation broth having a titration of about 0.04 to 0.3 meq / g, a lactic acid concentration of about 0.5 to 2%, an acetic acid concentration of about 0.1 to 1% and a viscosity of about 100 cps or less; and It was prepared using a liquid fermentation broth containing a microbial mixture producing acetic acid. The liquid fermentation broth was kept active so that the fermented taste could be continuously produced by the addition of water and flour and the discharge of the liquid such that the average retention time was 12-48 hours. Saccharomyces chevalieri was used as part of the microbial supplement in a preferred embodiment. When used to make bagels, the present fermentation broth at a concentration of about 3 to 10% was added to the dough to obtain a bagel with good texture and chewy texture without dwelling steps.

Description

Fermented Flavors for Bakery Products

The present invention relates to the addition of certain liquid fermented flavoring / texturing substances to bakery products to develop improved taste, texture and storage stability.

Dough fermentation before baking has been known since ancient times to produce bread and other bakery products with desired properties such as improved taste. The term fermentation encompasses biochemical changes caused by microorganisms and / or enzymes present in dough or mash during incubation. In fermentation, the physicochemical properties of the materials change during the process, resulting in variations in volume, texture, taste, aroma, color, storage stability and density.

Modern bakery product fermentation is typically performed in a batch kneading method that requires a chamber of time and a controlled environment, which increases manufacturing costs. This is especially true for yeast bakery products and those with some of the properties of yeast, since they generally require additional residence time in fermenters for proper taste development. In some cases, fermentation is carried out at different temperatures to develop certain taste characteristics. Historically, yeast was made by adding the inoculum inoculum to the flour / water mixture, which resulted in mixing the resulting mass of dough and fermenting for several days. The preparation was taken out and part of it was retained as a new yeast inoculum for the next batch. With several fermentation steps, the whole process can be very ineffective for commercial scale manipulation.

Various methods have been devised for the mass production of yeast dough and yeast, and the methodology varies depending on the type of bakery product being manufactured. U.S. In Patent No. 2,953,460 Baker discloses a method relating to the supply of a pre-finished, fermented sponge which is added to the pre-mixer together with flour and other ingredients at the beginning of the continuous bread dough making process. Inconvenient and tricky manipulation of making sponges can be eliminated by using fermented yeast liquor instead (column 15, lines 19 to 35). It is made by mixing yeast with water containing sugar and other yeast nutrients and fermenting for several hours. Various materials were then mixed with the brew in the premixer, i.

Doerry et al. Also described the use of liquid and yeast prefermentation solutions by many bakeries in a continuous confectionery process ( Amevican Institute fo Baking Technical Bulletin VII, issue 6, June 1985, pages 1-9). The parameters related to the process vary widely from bakery to bakery, but are typically associated with the fermentation of about 30-50% flour in recipes with some sugar, buffers, yeast and water. Fermentation temperatures lower than 86 ° F., for example 78 ° F., and long fermentation times can produce liquid prefermentation liquids useful for making good bread products.

For yeast, special dough fermentation is used. This traditionally involves the special fermentation process and the choice of the yeast or mixed microbial mixture as a fermentation agent of the dough. Fermentations involving numerous periods of maintenance in a refrigerated environment are particularly desirable for the satisfactory taste development of some products. This method often promotes lactic acid and acetic acid-producing bacteria, which are described as delayed and provide essential microbial metabolite by-products for the characteristic aroma and taste of products with yeast and yeast characteristics, because growth conditions often delay yeast development. Let's do it.

Commercial yeast production includes bulk dough fermentation, which may be batch or continuous (see Meuser, F., Cereal Foods World 40: 114-122, March 1995). Batch production not only requires many tanks, but also requires a lot of time and is difficult to automate, so continuous fermentation or a combination of batch and continuous methods is preferred. Various systems typically include two stage fermentation in at least one fermenter.

Freeze-dried natural yeast fermenters may be used, as disclosed in Kline, U.S. Patent No. 4,140,800, but this is typically used in place of the parental yeast inoculum. Actual bakery product manufacturing is similar and suffers from the same disadvantages associated with the tank volume and complex fermentation steps observed in conventional sponge yeast fermentation.

Attempts have been made to make more resilient dough preparations with respect to the time and temperature shifts required for fermentation. As summarized by Meuser cited above, in some cases a mature yeast suspension (liquid fermentation broth) is used, but when closed fermentation tanks are used, this system is ineffective because yeast growth is weak under anoxic conditions. Moreover, excess foaming often forms plaques in the preparation of liquid fermentation broths. Fermentation tanks must be of sufficient size to accommodate such foaming and to prevent overflow.

Meloan and Doerry described typical bagel manufacturing as including no fermentation step before making, since fermented dough tends to produce bagels with heterogeneous grain structures that are difficult to form into rings ( American Institute of Baking). Technical Bulletin X , issue 4, April 1988, page 8). The raw bagels are placed in a sheet pan and endured, or more generally, for 12-18 hours in the retardant at 35 ° to 42 ° F. (or sometimes even frozen). Refrigeration tends to develop better taste and aroma than bagels in conventional continuous processing.

There is a need to have improved methods for the economic production of bakery products, especially those with the expected fermented properties of good bagels. There is also a need to have a fast and economical way to produce bakery products without the complex fermentation steps and foaming problems typically observed.

It is an object of the present invention to provide fermented taste / texturing materials for bagels and other bakery products.

It is a specific and more specific object of the present invention to provide a liquid fermentation broth by a continuous method.

These and other objects are achieved by the present invention, which provides a fermented flavor concentrate for yeast-inflated products, especially bagels. In a preferred embodiment, the fermentation concentrates of the present invention continuously produce balanced growth of microorganisms that provide the required acidity and aromatic compounds necessary to impart desired properties to the dough to which the fermentation broth is added. When the concentrate of the present invention is added to the dough, the residence step in the manufacture of the product can be removed without compromising product texture, aroma or taste.

In a typical implementation of the invention, the savory bakery product is prepared as follows: a) preparing a liquid fermentation broth in a fermentation tank, wherein the liquid fermentation broth is prepared from flour, water and microbially-stable, mixed cultures. The ratio of flour to water in the fermentation broth is about 1: 0.5 to 2.0 and the fermentation broth contains at least one acid-generating microorganism; b) maintaining the liquid fermentation broth in an active state so that the fermented taste occurs and the average retention time for fermentation in the tank is at least 12 hours; c) continuously adding water and flour to the fermentation tank in an amount essentially equal to the amount of liquid fermentation liquor discharged from the tank; e) adding the liquid fermentation broth to the dough composition such that the liquid fermentation broth constitutes about 1-15% per weight of the composition; And f) baking the dough.

In a preferred embodiment, the liquid fermentation broth comprises a mixture of microorganisms producing lactic acid and / or acetic acid, preferably both. For example, growing together Lactobacillus andGluconobacterThe mixture of species has a pH of about 3.6 to 3.9, more about 0.04 to 0.3 meq / g (more narrowly about 0.10 to 0.26 meq / g) when incubated at about 25 ° to 37 ° C. with flour and water for at least about 24 hours. A fermentation broth having a titratable acidity, a lactic acid concentration of about 0.5 to 2%, an acetic acid concentration of about 0.1 to 1%, and a viscosity of about 100 cps or less can be completed.Saccharomyces chevalierisameSaccharomycesYeast must be included as part of microbial supplementation to generate aromatics. In an exemplary embodiment, when used to make a bagel, a concentration of about 3 to 10% of this fermentation broth may be added to the dough resulting in a bagel with a chewy texture and good flavor without a retention step.

1 is a graph showing the rise and level of acidity with time,

FIG. 2 is a line graph illustrating titration acidity over time (for two different flours + water to fermentation agent ratio) in the preparation of the fermentation broth of the present invention,

3 is a schematic representation of a continuous process for producing a fermented taste for bakery products using the method of the present invention.

The present invention is based on the preparation of liquid concentrates with the desired properties that can be used as dough additives to save fermentation steps in the production of bagels and similar bakery products. When used in the manufacture of savory bakery products, the fermentation concentrate can eliminate the retention step during manufacture, but can provide a bakery product having the characteristics of the product produced with the retention step. By preparing the liquid fermentation broth in the continuous form described in this case, foaming is eliminated. Fermentation of some flour, some water plus microbial mixtures in a batch system will result in the actual foaming of the highly viscous emulsion. In contrast, the liquid medium present during the continuous fermentation process of the present invention has no carbon dioxide released, and hence little foaming is produced.

In the practice of the present invention, the savory bakery product is prepared as follows;

a) preparing a liquid fermentation broth in a fermentation tank, where the liquid fermentation broth contains flour, water and microbiologically-stable, mixed culture, wherein the ratio of flour to water in the fermentation broth is at least 1: 0.5-2.0 and the fermentation broth is at least It contains one acid-generating microorganism. b) maintaining the liquid fermentation broth in an active state so that the fermented fragrance is generated and the average retention time of fermentation in the tank is at least 12 hours; c) continuously adding water and flour to the fermentation tank in an amount essentially equal to the amount of liquid fermentation liquor discharged from the tank; e) adding the liquid fermentation broth to the dough composition such that the liquid fermentation broth constitutes about 1 to 15% per weight of the composition; And f) baking the dough.

Any microorganism commonly used in bread production can be used as the primary organism for starting liquid fermentation broth. Preferred fermentation broths contain lactic acid-generating microorganisms, acetic acid-generating microorganisms and aromatic-generating microorganisms. Examples include, but are not limited to, Lactobacillus species, Gluconobacter species, and Saccharomyces species. Microorganisms must be grown together in fermentation tanks to provide coordinated growth of microbial by-products with unexpectedly good properties. Aromatic compound-generating yeasts such as Shaccharomyces chevalieri are particularly preferred for this embodiment.

As outlined above, fermentation broth is initially prepared by mixing flour and water and adding microorganisms in a ratio of about 1: 1. At this stage, the original mixture typically has a high viscosity, for example about 40.000 cps. After fermentation, the viscosity drops below 2000 cps, preferably below 100 cps, and in some cases below 50 cps, and the fermentation broth becomes the pumpable and fluid liquid of the emulsion. As microorganisms grow, they produce carbon dioxide. Since the viscosity of the fermentation broth is lowered, carbon dioxide is not retained in the fermentation broth but is easily removed without almost resulting foaming.

The liquid fermentation broth is kept in the tank for a period of time under conditions to produce a fermented taste. This is typically accomplished by maintaining the fermentation broth at about 25-37 ° C., more narrowly about 30-35 ° C. for at least about 12 hours. Preferred retention times are at least about 24 hours, and in some cases about 48 hours for sufficient taste development. As shown in the examples below, aromatic compounds such as ethyl acetate, isoamyl alcohol, isoamyl acetate are formed during fermentation.

Acids are also formed. In a preferred embodiment, the liquid fermentation broth is self-maintained at a pH of about 3.2 to 3.9, more narrowly about 3.6 to 3.9. Titratable acidity typically varies from 0.04 to 0.3 meq / g. In some embodiments, the titratable acidity varies from about 0.15 to 0.26 meq / g, and in other embodiments it is lower, ie, about 0.1 to 0.15 meq / g. In an exemplary embodiment, the liquid fermentation broth contains about 0.5-2% lactic acid and 0.1-1% acetic acid. One embodiment contains about 1.3 to 1.4% lactic acid and about 1/10 acetic acid thereof.

Each time the fermentation broth is made and ready to be discharged, it is discharged continuously or essentially continuously, ie at short intervals of, for example, 0 to 15 minutes, preferably 5 minutes or less. Flour and water are added to the tank accordingly. Fermentation broth can be used at one location, but can also be transferred frozen or refrigerated to another bakery location for addition to the dough. The addition of water and flour to the fermentation broth can also be done in an essentially continuous manner.

The liquid fermentation broth of the present invention may be added to the dough of any bakery product, including but not limited to bread, bagels, pastries, cakes, cereals, cookies, biscuits, salty crackers, and snack products, mixtures or ingredients of which Premixed for either. This is particularly useful for providing taste and desired texture to yeast-dough products consisting of yeast, flour, water and / or milk and other materials typical of such products.

In the manufacture of bagels with chewy and weak acidity, liquid fermentation broth is added to the dough at a value of about 3 to 10% per weight. As illustrated in the examples below, in some embodiments, additional yeast, i.e., about 1.5 to 2.5 times the normal amount, is added to the dough because there is no retention step. The bagel dough is divided and formed into a bagel form, for example, endured for 30 minutes at 30 ° C./85% relative humidity, soaked in boiling water and / or cooked, and baked.

An advantage of the present invention is that this method can be used to make manufactured bakery products such as bagels having the taste, aroma, and texture of a bakery bagel, without the disruptive retention step, typically at about 4.4 ° C. for at least about 5 or 6 hours. . Thus, the method of the present invention provides a characteristic advantage over conventional bagel manufacturing. The holding vessel, the retention stage and excess foaming are eliminated.

In embodiments containing a mixture of Saccharomyces, Lactobacillus and Gluconobacter species, all three types of microorganisms grow together to produce the aromatics and acidity required for the properties of a bakery product made from dough that is normally fermented over an extended period of time. It is another advantage of the present invention to complete the desired characteristic.

A further advantage of the present invention is that the method can be applied to a continuous, semi-continuous, or batch kneading process. This is especially suitable for continuous operation.

The following examples are provided to further illustrate and illustrate the present invention and should not be construed as limiting in any way. Unless otherwise specified, all parts and percentages are by weight and based on the method step described.

(Example 1)

To simulate the continuous method of the present invention by bench-top operation, a liquid fermentation broth consisting of 1 part parent fermentation broth, 8 parts flour and 10 parts water per weight was prepared. It was mixed and fermented for a total of 8 days. At the beginning of each day half of the fermentation broth was removed for analysis and the same weight of 8:10 flour / water was added. Thus, the total weight of the fermentation broth remained constant. Fermentation was carried out at approximately 22 ° C. Fermentation was analyzed for acid composition. Acid production was related to the degree of fermentation. The results of the analysis are given below:

Date range % Lactic acid % Acetic acid pH TA (meq / g) One 1.37 0.11 3.89 0.121 2 0.94 0.05 3.86 0.109 3 1.04 0.11 3.88 0.124 4 1.01 0.12 3.85 0.128 5 1.02 0.14 3.87 0.127 6 0.87 0.14 3.92 0.110 7 0.97 0.16 3.89 0.125 8 1.07 0.19 3.85 0.144

In addition, the product was diluted to a significant extent over each 24-hour period.

(Example 2)

Batch fermentation was performed in 75 gallon containers to determine the retention time required to develop the desired acidity in the fermentation broth. This experiment was the third in a series of batch fermentations. The parent or fermentant fermentation broth was the product generated in Example 1. A 500 pound fermentation broth was made by combining 204.5 pounds of flour, 250 pounds of water and 45.5 pounds of fermentant. During the 48 hours, the pH rose as follows:

Time (H) pH TA (meq / g) 0 4.7 0.037 18 3.78 0.143 24 3.79 0.163 48 3.76 0.182

This result is shown in FIG. After 18 hours the acidity essentially reached level. Therefore, an average retention time of at least 12 hours appears to be necessary for the present invention. As can be seen from this data and FIG. 1, a retention time of 12 hours is required to generate a TA of about 0.12 meq / g corresponding to about 1% lactic acid, 0.1% acetic acid and pH 3.9.

(Example 3)

This example illustrates another analysis with the liquid fermentation broth of the present invention but with varying levels of fermentor fermentation broth. Two fermentations with flour: water: fermenters in 9: 9: 1 and 5: 5: 1 ratios were prepared and each fermentation broth was held at room temperature (about 23 ° C.) for 116.5 hours. The titratable acidity continued to rise in a similar fashion in both samples for about 16 hours and then leveled off after about 24 hours. Titratable acidity profiles are illustrated in FIG. 2. These results indicate that the initial values of fermenter fermentation broth in batches vary and still produce acceptable products.

9: 9: 1 5: 5: 1 Duration (hrs) pH TA pH TA Fermentation 3.78 0.1645 3.78 0.1645 0 5.05 0.034 4.79 0.0395 2 4.87 0.0385 4.43 0.0545 18 3.93 0.1415 3.98 0.1445 27 3.88 0.1595 3.93 0.1585 31.5 3.88 0.169 3.93 0.165 42.5 3.86 0.1925 3.90 0.1755 48.5 3.83 0.1895 3.89 0.1715 52.5 3.84 0.1905 3.89 0.186 66 3.85 0.1915 3.88 0.1823 70 3.86 0.192 3.87 0.185 116.5 3.83 0.2075 3.85 0.1905

(Example 4)

Experimental plant preparation of the continuously produced fermented flavors of the present invention is described in this example.

To begin this method, a batch of 500 pounds of fermented flavor was started by mixing together 204.55 pounds of flour, 250.00 pounds of water and 45.45 pounds of fermenter fermentation broth. This liquid fermentation broth was grown for 2 days for optimal taste and texture development. At this point, the continuous method was started. The flour was fed to the batch vessel at a rate of about 0.08 pounds per minute using a screw feeder to the vibratory feeder. Water was fed to the vessel at the same rate using a metering pump. The liquid fermentation broth was withdrawn from the bottom of the vessel at a rate of 0.16 pounds per minute using a displacement pump. The timer was placed on the scraper of the vessel and the starter of the stirrer to operate periodically (approximately 5 minutes every two hours). This method is illustrated in FIG. 3.

The physical parameters observed in time during the continuous preparation of the liquid fermentation broth of the invention were recorded. Samples were taken at regular intervals as shown in the table below. The numbers of yeast water, pH, titratable acidity,% lactic acid, and ethyl acetate, isoamyl alcohol and isoamyl acetate were measured. The following results were obtained:

Aromatic resin, ug / g Duration (hrs) pH TA (meq / gm) Yeast Water (X10 ^-6 ) % Lactic acid Ethyl acetate Isoamyl Alcohol Isoamyl Acetate 0 3.91 0.141 13 - 609 38.7 2.0 2 3.83 0.135 - 1.05 - - - 7 3.71 0.147 10 1.0 470 33.7 2.2 31 3.67 0.157 - 1.15 - - - 36 3.67 0.158 9.1 1.34 540 38.5 7.4 40 3.67 0.152 - 1.33 - - - 51 3.74 0.123 9.6 1.19 470 8.4 2.5 Viscosity at 0 o'clock to 40,000 cps After 51 hours Viscosity to 40 cps

(Example 5)

In this example, bagels made using the bagel dough of the present invention without dwelling were compared with those made using conventional forms processed with a six-hour dwell step.

About 260 bagels were made in each run. Yeast was hydrated with some water at 55 ° to 60 ° F. The material was mixed at low speed for 30 seconds before the yeast slurry was added. The dough was again mixed at low speed for 1.5 minutes and then mixed at high speed for 10 minutes until the dough developed to 80 ° F. The bagel was then shaped and endured at 80 ° F./85% R.H. The control bagels were then held at 40 ° F. for 6 hours prior to cooking, dried and baked (9.5 minutes). Experiment bagels were cooked, dried and baked under the same conditions without a 6 hour residence step.

Control dough and experimental dough were prepared as follows:

Control material Baker% gram flour 100.00 15890 water 56.00 8898 HF Corn Syrup 3.75 595 leaven 1.00 159 Salt 2.00 318 Experiment material Baker% gram flour 100.00 15110 water 56.00 8118 HF Corn Syrup 3.75 595 leaven 2.00 318 Salt 2.00 318 Fermentation broth (manufactured in Example 4) 6.00 1561

In a taste test by at least 10 bagel artisans and judges of bagel manufacturers, experimental bagels made using the fermentation broth of the present invention showed comparable aromatic composition, acidity, chewability and debris properties to control bagels.

The above description is illustrative and is for the purpose of teaching the person of ordinary skill in the art how to practice the invention without limiting the invention. It is not intended to explain all such obvious variations and changes that will appear to those skilled in the art in connection with the present description. However, all such obvious modifications and variations are intended to be included within the scope of the invention as defined in the appended claims. The claims specifically indicate that the claimed elements and steps are in any order effective for the intended purpose unless the context indicates otherwise.

Claims (20)

In the manufacturing method of a savory bakery product, a) preparing a liquid fermentation broth in a presentation tank, wherein the liquid fermentation broth contains flour, water and microbially stable mixed culture, wherein the ratio of flour to water in the fermentation broth is 1: 0.5-2.0 and the fermentation broth is at least one Contains acid-generating microorganisms; b) maintaining the liquid fermentation broth in an active state so that the fermented taste is produced and the average retention time for the fermentation broth in the tank is at least 12 hours; c) continuously or essentially continuously adding water and wheat furniture to the fermentation tank in an amount essentially equal to the amount of liquid fermentation liquor discharged from the tank, e) adding the liquid fermentation broth to the dough composition such that the liquid fermentation broth constitutes 1-15% per weight of the composition; And f) baking the dough. The method of claim 1 wherein the liquid fermentation broth contains lactic acid-generating microorganisms and acetic acid-generating microorganisms. The method of claim 2, wherein the liquid fermentation broth is self-maintained at a pH of about 3.2 to 3.9. 4. The process of claim 3 wherein the liquid fermentation broth contains about 0.5 to 2% lactic acid and about 0.1 to 1% acetic acid. The method of claim 1 wherein the liquid fermentation broth is added to bread, bagels, pastries or cereal batter. 6. The method of claim 5, wherein the liquid fermentation broth is added to the dough at a value of about 3 to 10% by weight. 6. The method of claim 5 wherein the liquid fermentation broth contains lactic acid-generating microorganisms, acetic acid-generating microorganisms and aromatic-generating yeast. 8. The method of claim 7, wherein the liquid fermentation broth is self-maintained at a pH of about 3.2 to 3.9. 9. The process of claim 8 wherein the liquid fermentation broth contains 0.5 to 2% lactic acid and 0.1 to 1% acetic acid. 10. The method of claim 9, wherein the liquid fermentation broth has an average fermentation time of at least about 24 hours. The method of claim 10 wherein the liquid fermentation broth has a suitable acidity of about 0.04 to 0.3 meq / g. 12. The method of claim 11, wherein the titratable acidity is about 0.10 to 0.26 meq / g. The method of claim 11, wherein the liquid fermentation broth added to the dough has a viscosity of about 100 cps or less. 12. The method of claim 11, wherein the yeast is Saccharomyces Chevalieri . In the manufacturing method of a savory bakery product, a) preparing a liquid fermentation broth in a fermentation tank, wherein the liquid fermentation broth contains flour, water and microbiologically-stable, mixed culture, wherein the ratio of flour to water in the fermentation broth is about 1: 0.5-2.0 and the fermentation broth is lactic acid Contains -generating microorganisms, acetic acid-generating microorganisms and aromatic-generating yeast; b) maintaining the liquid fermentation broth in an active state at about 25 ° to 37 ° C. such that a fermented taste is produced and the average retention time for the fermentation broth in the tank is at least about 24 hours at a pH of about 3.6 to 3.9; c) continuously or essentially continuously adding water and flour to the fermentation tank in an amount essentially equal to the amount of liquid fermentation liquor discharged from the tank; e) adding the liquid fermentation broth to the dough composition such that the liquid fermentation broth constitutes 1-15% per weight of the composition; And f) baking the dough. 16. The method of claim 15, wherein the microbial culture is comprised of a mixture of Saccharomyces, Lactobacillus and Gluconobacter species. The method of claim 16, wherein the liquid fermentation broth has a suitable acidity of 0.04 to 0.3 meq / g and a viscosity of 100 cps or less. 18. The method of claim 17, wherein the fermentation broth contains about 0.5 to 2% lactic acid and about 0.1 to 1% acetic acid. 19. The method of claim 18, wherein the dough is a bagel dough, the bagel dough being divided without disturbing retention steps, formed in the form of bagels, endured, cooked and baked. 20. The method of claim 19, wherein the liquid fermentation broth is added to the bagel dough at a value of 3 to 10% by weight.