RU2376767C2 - Production method of dough for bakery products - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: proposed method is performed by mixing of hot water and wheat flour at ratio flour: water from 1.0:1.1 to 1.0:1.2 with generation of preliminary brewing mass at 62-65°C. After that phospholipids composition is added to the obtained mass. The mass is cooled down and acidified by pump blowing at sequentiall going of mixed brewing mass through stages of gelatinisation, saccharification, fermentation and homogenisation in continuously-operating brewing machine. After that fluid phospholipids brewed semiproduct is obtained. It is moved through cooled tube with moisture content 58-59% at 27-29°C into dough-kneading machine for dough kneading. Phospholipids composition is added by its airless spraying on brewing mass surface with following continuous mixing and homogenisation till brewed phospholipids semiproduct is supplied fro dough kneading.

EFFECT: method allows to produce dough with limit moisture content and produce bakery products with long storage life of initial freshness keeping and improved consumer properties.

3 cl, 2 tbl

Description

The claimed invention relates to the food industry, namely to baking, and can be used in the preparation of dough for bakery products.

A known method of preparing a bakery product “Diet rolls with lecithin” with the addition of kneading dough in an amount of 15% to the formulation flour “Phosphatide concentrate” containing 50% vegetable oil, as well as making 5% sugar and 8% milk powder [1, p. 110]. The disadvantages of this method are the excessive amount of oil and sugars contained in the test, as well as the insufficient duration of maintaining the initial freshness of the crumb of the products.

A known method of preparing a bakery product using a phospholipid composition with a ratio of phospholipids to flour of 0.01-2.0%, while kneading the test as a phospholipid composition make water-phospholipid emulsion prepared at a ratio of phospholipids - water from (1:10) to (1: 100), in a thin film, in the zone of a rotating alternating electromagnetic field, using phospholipids obtained from nonfat plant vegetable phospholipids by extraction with ethyl alcohol and isolation of the solid phase, and in the dough add sugar is added up to 7.0% and fat product up to 4.0% by weight of flour. [2]

The disadvantages of this method are the technical and technological complexity of preparing the emulsion from the solid phase of phospholipids in bread production, as well as the insufficient duration of preservation of the initial freshness of the crumb and the need to use additional amounts of sugar and fat in the formulation.

Closest to the claimed method, the analogue taken as a prototype is a method for preparing a dough using a phospholipid composition, in which 1.5-2.0% by weight of flour of standard or hydrolyzed lecithins containing 62-56 are added to the dough before fermentation % phospholipids and 38-44% unsaturated fatty acids. [3 - p. 6]

When implementing the prototype method, a water-insoluble, viscous, sticky mass of lecithin is added to the mass of strong dough with a temperature of 29 ± 2 ° C and humidity for loaves of 41 ± 2%, wheat bread - 45 ± 2%, rye-wheat bread - 46 ± 2%. In actual production conditions, it is impossible to achieve a homogeneous distribution of 1.0-2.5% thick sticky lecithin in a strong dough mass in 9 ± 3 minutes of kneading. With this method of administration, lecithin due to its surface-active properties can be distributed only at the "macro level" - between the layers and aggregates of the test structure, and the "useful" physico-chemical interactions of phospholipids with hydrolyzed starches and proteins at the "micro level" occur when the test is heated in furnace, when the mass of the dough is in a static state and all processes are limited by phase boundaries. In this regard, the effects of improving the test and consumer properties of bread are minimal. The introduction of phospholipids at standard test humidities does not change the amount of starch colloid formed and therefore cannot significantly increase the hydrophilicity and water-holding capacity of the test and extend the time until the beginning of the retrograde gradation of the starch gel and starch of the crumb. The lecithins introduced in this way can only slightly slow down the staling that has already begun and maintain the softness of the stale crumb (by analogy with the action of ordinary fats and sugars in bakery products).

The disadvantages of the prototype method are:

- the technical and technological complexity of feeding, dosing and dispersing the viscous mass of lecithin in the dough when batch dough is kneaded, the impossibility of dosing with continuous kneading dough, as well as the limited temperature, humidity and dispersion time of lecithin for its homogeneous distribution and interaction with the components of the dough;

- insufficient hydrophilicity and form-holding ability of the obtained tests, not allowing to reach maximum humidity;

- insufficient time to maintain the initial freshness of the crumb products.

The objective of the invention is:

- ensuring optimal supply and dosing, as well as temperature, humidity and dispersion time of viscous flowing phospholipid compositions with batch and continuous methods of preparing dough for all types of bakery products;

- achieving maximum hadrophilicity and form-holding ability of tests obtained at maximum humidity;

- achieving maximum time to maintain the initial freshness of the crumb products.

This object is achieved by the fact that in the claimed method, the recipe components are mixed, a custard semi-finished product is prepared, obtained by continuously mixing 10-20% of the recipe wheat flour with hot water at a ratio of flour: water from 1.0: 1.1 to 1.0: 1.2 with the formation of a primary custard mass with a temperature of 62-65 ° C, adding a phospholipid composition to the obtained initial custard mass, with further cooling and oxidation by blowing with air during successive passage of the gelatinized, custard mass stages of gelatinization, sowing of fermentation, by fermentation with my own amylolytic enzymes and homogenization in a continuous brewing machine, after which a flowing custard phospholipid semi-finished product is obtained, which is sent through a cooled pipe with a humidity of 58-59% and a temperature of 27-29 ° C to a dough mixer for kneading the dough, moreover, phospholipid the composition is applied by airless spraying it onto the surface of the custard mass, followed by continuous mixing and homogenization until the custard phospholipid semi-finished product is fed to the substitute with the test.

As a phospholipid composition, standard sunflower lecithins, or sunflower phosphatide concentrates, or other oil solutions of sunflower phospholipids with a flowing or viscous consistency in amounts of 0.3-5.0% by weight of the recipe flour based on 62% are added to the initial custard mass dry solids content of phospholipids.

As a device for feeding, dispensing and spraying a viscous fluid phospholipid composition, a plunger or other type high-pressure pump is used that provides the pressure required for airless spraying of the composition in the discharge line and nozzle.

The essence of the proposed method consists in the manufacture and introduction into the dough of an additional amount of hydrophilic flour paste, stabilized and strengthened by surface-active phospholipids. The required characteristics of the custard phospholipid semi-finished product in terms of humidity, consistency, temperature, degree of gelatinization and saccharification are achieved by controlling the ratio of flour: water, temperature, blowing with air, the volume of the custard mass in the machine, as well as the intensity and time of mixing.

Upon achieving uniform dosing, contact and mixing of dry flour with hot water in the stated proportions, a uniform strong motionless custard mass is formed with a primary temperature of 62-65 ° C, in which amylopectin, which constitutes the outer shell of starch grains, forms a thick colloid, and amylose, which constitutes the inner part of starch grains forms soluble colloids.

The sprayed phospholipid composition in the form of ultrafine drops falls on the surface of the mixed hot custard mass and is distributed throughout its volume. In this case, optimal conditions are created for particle dispersion, mass temperature, humidity, the presence of hydrolyzed active structures that are open for contact with polar phospholipids, and homogenization and physicochemical interaction of starch gel, swollen gluten and phospholipids occur with the formation of stabilized hydrophilic structures.

Under the influence of atmospheric oxygen and activated own amylolytic enzymes of flour, partial solubilization of the soluble part of the amylose colloid occurs while maintaining the bulk of the strong amylopectin colloid. Cooling is carried out according to the evaporation principle - when warm air is blown through the developed surface of the wet mass of the welding, evaporation of up to 10% moisture occurs, accompanied by intensive cooling. The air temperature is kept within the stated limits to maintain cooling, oxidation and the optimum temperature of the custard mass for its fermentation (35-40 ° C). Saccharification stops when the temperature drops from 62 ° to 50 ° C. Further, the processes of fermentation, homogenization and cooling during oxidative strengthening of gluten and saturation of the mass with atmospheric oxygen continue. The temperature of the mass at the end of the trough is 36 ± 4 ° C.

The final stage of extrusion homogenization and plasticization is used for the most uniform dispersion and interpenetration of the components of the semi-finished product and to give it the necessary fluidity during final cooling.

Fermentation that occurs throughout the duration of the process also leads to a significant deoxidation and weakening of the mass of the semi-finished product.

The result is a homogeneous mass of custard cake mix, with a final moisture content of 58-59%, a temperature of 29 ± 2 ° C, containing a stabilized hydrophilic colloid, reduced sugars, activated enzymes, fortified gluten, phospholipids and polyunsaturated fatty acids. The finished fluid semi-finished product is fed into the batch, where its components are evenly distributed in the mass of the dough.

The introduction of additional amounts of starch colloid stabilized by phospholipids in the dough delays the onset of the starch retrograde process for a long time, and the presence in the mass of fatty acid and hydrophilic radicals of phospholipids and unsaturated fatty acids inhibits the onset of staling process in the future. The stabilized colloid has an increased water retention and allows you to save the structure of the dough and the shape of bakery products at extreme humidity of the dough.

Prepared according to the claimed method, a custard phospholipid semi-finished product can be used in the preparation of tests for any type of bakery products: wheat and rye-wheat breads and bread and bakery products, providing a form holding at extreme humidity, long-term preservation of the initial freshness of the crumb and superior flavoring properties.

The inventive method is intended for the manufacture of custard phospholipid semi-finished product in a continuous (in a continuous vane machine) method. At the same time, the continuous method of manufacturing a semi-finished product allows you to knead the dough in a continuous mode (with simultaneous supply of the semi-finished product to the dough mixing machine), as well as in a batch mode, feeding the semi-finished product through the batcher to the bowl.

Examples of the manufacture of semi-finished products, tests and products are shown in tables 1 and 2.

In all examples

- the temperature of hot water in the range of 75-98 ° C was set depending on the actual temperature of the brewed flour so that the total temperature of the flour and water was within 105 ± 3 ° C;

- the time of formation of the initial custard mass until dry flour completely disappeared in it was maintained within 20-60 seconds depending on the productivity of brewing flour, by changing the ratio of flour to scalded water and its temperature in the stated limits;

- the initial temperature of the custard mass was maintained within 61-65 ° C depending on the actual temperature of the air in the production room and its flow rate in the range of 0.01-0.03 l / s;

- the temperature of the final infusion in all cases was maintained within 27-29 ° C by changing the intensity of cooling of the pipe that feeds the infusion for kneading the dough.

In the examples of Table 1, the semi-finished product was prepared continuously in a continuous bladed machine, and the tests were kneaded both by continuous and batch methods.

In the examples of Table 2, the semi-finished product was prepared continuously, and the dough was kneaded by the batch method.

As the phospholipid composition in the examples of Table 1, we used sunflower lecithin of the FPL-1 brand produced by the Labinsky oil extraction plant with a phospholipid content of 62%, in the examples of Table 2 we used a solution of lecithin of the LecIPR090 brand in vegetable oil, also brought to the content of phospholipids 62%.

When applying a custard cake mix to the dough, the necessary adjustments were made to the loading of flour and water for the quantities of bound water and flour contained in the cake mix; the remaining dosages were left unchanged according to the formulations.

In the manufacture of loaf tests containing oils in the formulation, their supply was reduced by the amount of oil contained in the phospholipid compositions introduced, mixed and added together in a custard cake mix.

As follows from these tables, the claimed method allows you to:

- to provide effective dosing, supply and dispersion of viscous flowing phospholipid compositions in a custard mass with a temperature of 62-65 ° C, a moisture content of 58-59% for 8-12 minutes of hot and 20-40 minutes of general mixing, with batch and continuous methods of manufacturing custard semi-finished products , batch and continuous methods of kneading dough for all types of bakery products;

- make dough for bakery products with humidity exceeding the humidity of products by conventional technology

for wheat bread from 44.5% to 48.0%

for rye-wheat bread from 46.5% to 49.5%

for loaves from 39.5% to 42.0%

- while achieving superior taste and smell;

- increase the shelf life of the initial freshness of the crumb, relative to conventional technology:

for wheat bread from 8 to 36 hours

for rye-wheat bread from 10 to 48 hours

for loaves from 12 to 40 hours.

Preparation of the composition by brewing less than 10% flour, see example 6.3, reduces the initial freshness retention time below 24 hours, and more than 20% flour, see example 5.6, makes the semi-finished product unnecessarily strong for transportation and mixing.

When dosing boiled water to flour in a ratio of less than 1.0: 1.1 by weight, see example 1.3, the stationary mass of the semi-finished product is obtained, and more than 1.0: 1.2, the temperature and stickiness of the semi-finished product increase, see example 5.5.

Lowering the temperature of the initial custard mass below 62 ° C is impractical, since it reduces the degree of gelatinization, see example 6.3, 6.4, and above 65 ° C it makes the cake mix too sugared, sticky and immobile, see example 5.5.

A decrease in the moisture content of the semi-finished product below 58% results in a fixed, difficult to mix mass, see Example 1.3, and an increase in humidity of more than 59% is impractical, since it is difficult to “keep within” the calculated humidity of the final test.

The introduction of the phospholipid composition in the custard cake in amounts of less than 0.3% by weight of the recipe flour, see example 5.4, does not produce tangible effects, and more than 5% brings a significant amount of vegetable oils to the test, which is not typical for traditional types of bread.

Information sources

1. “Collection of recipes for bread and bakery products”, “Profession”, S.-Fri, 2001

2. RF patent No. 2233088 C1, M., 7 A21D 8/02, 2002

3. Timoshenko Yu.A., Markina V.Yu., Krasilnikov V.N. “Hydrolyzed Lecithins in Bakery Products”, p. 6, Protein Plus LLC, St. Petersburg TEI, 2007

Claims (3)

1. A method of manufacturing a dough for bakery products, characterized in that the recipe components are mixed, a semi-finished product is prepared, obtained by continuously mixing 10-20% of the recipe wheat flour with hot water at a ratio of flour: water from 1.0: 1.1 to 1.0 : 1.2 with the formation of a primary custard mass with a temperature of 62-65 ° C, introduction of a phospholipid composition into the obtained initial custard mass, with further cooling and oxidation by blowing with air during successive passage of the mixed custard mass to the stages testing, saccharification, fermentation with its own amylolytic enzymes and homogenization in a continuous brewing machine, after which a fluid phosphate lipid semi-finished product is obtained, which is sent through a cooled pipe with a humidity of 58-59% and a temperature of 27-29 ° C to a dough mixing machine, to knead the dough, moreover, the phospholipid composition is applied by airless spraying it onto the surface of the custard mass, followed by continuous mixing and homogenization until the custard phospholipid semi-finished product for kneading dough. 2. The method according to claim 1, characterized in that the standard sunflower lecithins, or sunflower, phosphatide concentrates, or other oily solutions of sunflower phospholipids with a flowing or viscous consistency in amounts of 0.3-5 are introduced into the primary custard mass as a phospholipid composition 0% by weight of prescription flour based on the 62% content of dry phospholipids in them. 3. The method according to claim 1, characterized in that as a device for feeding, dosing and spraying a viscous fluid phospholipid composition, a plunger or other type high pressure pump is used that provides the pressure required for airless spraying of the composition in the discharge line and nozzle.