NL1011763C2 - Partially baked bread. - Google Patents

Description

Title: Partially baked bread 5 Description

Bread doughs and breads made therefrom are well known in the art. At the same time, it is also well known that the storage time under ambient conditions of 10 partially baked bread doughs and breads is limited due to problems that occur with regard to the food quality and microbiological stability of the bread products. For example, the products will age easily during storage and show a greater degree of microbiological spoilage, resulting in products that are no longer acceptable after a storage time of approximately 5 days.

A solution offered in the prior art (cf. e.g., EU 353 366) consists of making a frozen, partially baked dough. Freezing (freezing), however, results in baked products with a more firm crumb structure, which is of lesser quality. In addition, freezing complicates the manufacturing process for a baker because bakers generally do not have freezing devices and, if they have them, the process is more complicated and expensive than without freezing. Therefore, a freeze-avoiding method is much more preferred compared to a freeze method.

WO 95/30333 provides a solution to the above-mentioned problems, wherein a method for the preparation of a bread dough is provided, which comprises a multistage process, comprising the steps of: - making a bread dough partially baking a molded piece of dough exposing the partially baked bread product, while still hot, to a sub-atmospheric environment in order to quickly remove moisture and develop the structure and strength of the crust of the product.

subjecting the product thus obtained to further heating.

We have found that the above processing results in partially baked bread products that have a slightly longer shelf life (up to about 7 days) at ambient temperature. However, this shelf life is still inadequate for many bakery purposes, including logistics, and the quality of the baked product is insufficient to meet customer requirements.

US 3 597 223 discloses a method for the preparation of non-browned, sliced bread, in which the dough contains an emollient, while Ca propionate can also be present as a preservative. During the preparation of the product, conditions are used that ensure that the product is pasteurized. The baking and handling conditions described are insufficient to ensure that the product has a shelf life of more than the usual 5-7 days.

Therefore, we studied how to obtain partial baked dough products which, after processing with a novel process, could result in products with a shelf life under ambient conditions of at least 8, preferably at least 9, more preferably at least 10 days, and further, once fired, they are of a quality that can meet customer requirements. Shelf life is defined here as the storage time under ambient conditions (ie about 25 ° C) during which the bread dough products can be stored without a negative effect on the quality and / or microbiological condition and on the eating properties of the products once they have been baked.

The above study resulted in our 1011763 3 invention. This invention primarily relates to novel partially baked, environmentally stable bread doughs as available by a method comprising cooling and packaging in an aseptic environment (s), which includes bread doughs, water and a fermentation-causing agent, and in addition to the the above also 0.1 1.3%, based on flour weight, of a preservative and 0-5% by weight, preferably 0.05-3% by weight, of one or more anti-aging agents, preferably a combination of 10 0.1-2% fatty acid monoglycerides and at most 300 ppm alpha amylases produced by a bacterium and / or genetically modified bacterium, while the dough is partially baked, preferably to more than 70% of its total baking conditions, such that the crumb of each piece is fully baked, but the crusting and color are incomplete and the partially baked bread dough is preferably 10 to 109 fewer microorganisms, including mold and bacterial spores n contains a partially baked bread dough stable under ambient conditions, manufactured without cooling to ambient temperature and cooling and packaging in aseptic environments.

It was found that the shelf life was influenced by 2 separate factors: 1. in particular by the number of fungi present on the bread crust or bread dough product. When controlling this amount of fungi as set forth in claim 1, we found that the shelf life under ambient conditions for the compositions as claimed could be extended to 10 days.

2. in particular due to the presence of bacterial spores in the bread dough crumb, i.e. by the addition of preservative used to suppress the growth of bacterial spores.

The anti-aging agents are used to further reduce the aging properties of the doughs and the partially baked dough and of the fully baked bread.

Partial baking also has a major influence on the final properties of the baked dough products. Therefore, we prefer to bake the 5 types of dough to more than 80%, even more preferably to more than 90% of their total baking conditions, such that the crumb of each piece is fully baked, but the crusting and color are incomplete.

Suitable preservatives are derived from 10 organic acids with a pK> 4.5. These preservatives are suitably used with a pH = 5-6.5 in a dough. Preferred preservatives are selected from the group consisting of Ca propionate, K sorbate and Na acetate. The latter preservative has advantages because of the smallest effect on the quality and taste characteristics of the end product. These preservatives are preferably used in amounts of 0.1-3%, most preferably 0.5-1.5% of the flour weight. In some circumstances, it may be necessary to adjust the pH of the dough in order to produce the proper conditions for the preservatives to operate.

Suitable anti-aging agents are the well-known agents based on enzymatic compositions. Preferred enzymes are alpha amylases produced by a bacterium and a genetically modified bacterium. These enzymes, depending on the activity of the enzymatic composition, are used in amounts of up to 300 ppm, preferably 5-100 ppm.

The partially baked bread dough products are preferably packaged in a suitable sterile packaging material, preferably a material that does not allow moisture or air transport, for example polypropylene or polyethylene or laminates containing them as one of the layers. The partially baked dough coming out of the oven is advantageously transferred directly from the oven to the aseptic environment. Here the dough is cooled and packaged aseptically. Our bread dough stable under ambient conditions can conveniently be obtained by a new method, which method is also part of our invention. This method comprises the steps of i) mixing flour, water, fermentation agent, preservative and anti-aging agent in the required amounts ii) kneading the dough iii) shaping the dough into suitable parts for a loaf of bread and proofing iv) partially baking the shaped dough to at least 70%, preferably at least 80%, more preferably at least 90% of its total baking conditions, addressed such that the crumb of each piece is completely is baked, but the crusting and color are incomplete, resulting in a bread dough with at least 6 log reduced plant cells of pathogenic microorganisms and fungi compared to an unbaked bread dough v) transferring the partially baked bread dough to an aseptic environment wherein the partially baked bread dough is cooled and then packed in sterile packaging material vi) collecting the packaged portion loaf baked bread, which preferably contains 10 to 109 fewer microorganisms, including fungi, than an environmentally stable, partially baked bread dough which is manufactured without cooling and packaging in an aseptic environment (s) and storing it at ambient temperature.

The partial baking used during this method is preferably carried out in a conventional oven at 180 -35 270 ° C for 5-45 minutes.

1011 T β 3 6

The aseptic environment is suitable for a room with clean air. Clean air chambers are commercially available and any of these commercially available clean air chambers could be used.

5

EXAMPLES

Product Name: - English White Bloomers (800g) Baking Ingredient List 10 Silver-King Flour 7200g

Yeast 180 g

Salt 144 g

Sodium acetate 72 g * Plus 2000 108 g 15 * Diamond 2000 94 g * Grebe 72 g

Lactic acid 36 g

Water 4400 g 20 * - Means for improving bread from Arcay

Craigmillar

Processing: 25 partial baking step 1. Knead all ingredients at speed 1 for 2 minutes and speed 5 for 5 minutes in a spiral kneading machine. Dose the lactic acid during the last 30 minutes.

2. Dough temperature - 25 ° C

3. Divide dough into 920 g portions and round off.

4. Leave to rise at 35 ° C / 85% humidity for 15 minutes. 5. Re-round pieces. 6. Leave to rise again for 15 minutes at 35 ° C / 85%, '7 humidity. 7. Form dough in a former. obtain a bloomer shape.

8. Place bloomer shapes on a baking sheet with paper 5 dusted with rice flour.

9.Last rise time - 90 minutes at 35 ° C / 85% humidity

10. Cut off the top of the bloomers and place the leaves in the oven at Top: 220 ° C

Bottom: 2 5 0 ° C

and apply steam injection for 5 seconds.

11. Open lid after 20 minutes. 12. Cooking time 35 minutes.

15 13. Cool products and then, while wearing sterilized gloves, pack the products in a clean air supply in sterile bags.

14. Store under ambient conditions.

20

Baking: 15. Place partially baked products on a baking tray with paper.

25

16. Place products in the oven at Top: 230 ° C

Bottom: 240 ° C

with steam injection for 5 seconds 17. Open valve after 5 minutes 30 18. Baking time - 10 minutes RESULT - good quality crispy product.

1011763 35

Claims (10)

1. Under ambient conditions stable, partially baked bread dough as available by a method comprising cooling and packaging in an aseptic environment (s), which bread dough comprises flour, water and a fermentation agent and in addition to the above also 0.1- 3%, based on flour weight, of a preservative 10 and 0-5% by weight, preferably 0.05-3% by weight, of one or more anti-aging agents, preferably a combination of 0.1- 2% fatty acid monoglycerides and at most 300 ppm alpha amylases produced by a bacterium and / or 15 genetically modified bacteria, while the dough is partially baked, preferably to more than 70% of its total baking conditions, such that the crumb of each piece is fully baked, but the crusting and color are incomplete and preferably 10 to 10 times times less microorganisms, including fungi, than a partially baked bread dough stable under ambient conditions, produced without r cooling to ambient temperature and packaging in aseptic environments. Ambient stable bread dough according to claim 1, wherein the dough is baked to more than 80%, in particular more than 90% of its total baking conditions, such that the crumb of each piece is fully baked, but the crusting and color are incomplete. . *. - rv \ U? * I o Ó 35 Ambient stable bread dough according to claims 1-2, wherein the dough has a pH = 5-5.6, while the preservative is derived from an organic acid with a pk> 4.5. 5 Ambient stable bread dough according to claim 1 or claim 3, wherein the dough comprises 0.1-3.0% flour, based on flour weight, of one or more of the following preservatives: Ca propionate, K sorbate and in particular Na acetate. Ambient stable bread dough according to claims 1-4, wherein the dough contains from 10 to 10 times 15 microns of microorganisms, including swings, then an environmentally stable, partially baked bread which is prepared without cooling to ambient temperature and packaging in an aseptic environment (s). 20 6. Stable bread under ambient conditions according to claims 1-5, wherein the bread dough has a shelf life of at least 8 days, preferably more than 9 days and more preferably more than 10 days under ambient conditions. 7. Ambient stable, partially baked bread dough according to claims 1-6, wherein the bread dough is packaged in a suitable sterile packaging material, in particular a packaging material which is moisture and airtight, which packaging material can be a plastic material. 35 1011763 ψ 8. A method for preparing an environmentally stable, partially baked bread dough, wherein the composition of the bread dough is the composition of claims 1-7, the method comprising the steps of: i) mixing flour, water, fermentation causative agent, preservative and anti-aging agent in the required amounts ii) kneading the dough 10 iii) shaping the dough into parts suitable for a loaf and proofing iv) partially baking the formed dough into at least 70%, preferably at least 80%, more preferably at least 90% of its 15 total baking conditions, such that the crumb of each piece is fully baked, but the crusting and color are incomplete, resulting in a bread dough with at least least 6 log reduced cells of vegetative pathogenic microorganisms and fungi compared to an unbaked bread dough v) transferring the partially baked bread dough to a aseptic environment, in which the partially baked bread dough is cooled to ambient temperature and packaged in sterile packaging material vi) collecting the packaged partially baked bread preferably containing 10 to 10 ^ less microorganisms, including fungi, than one under ambient conditions stable, partially baked bread dough that is manufactured without cooling and packaging in aseptic environment (s) and storing it under ambient conditions. 1011763 The method of claim 8, wherein partial baking is performed in a conventional oven at 180-270 ° C for 5-45 minutes. The method of claims 8-9, wherein the aseptic environment is a clean air chamber. 10 15 20 25 30 h) 5; K D o 35