WO1996022676A1

WO1996022676A1 - Encapsulated salt particles for use in baking yeast-raised bakery products

Info

Publication number: WO1996022676A1
Application number: PCT/US1996/001142
Authority: WO
Inventors: John Richard Mclaughlin; Randall Vann Redd; Bruce Kinge Redding, Jr.; John Soltis
Original assignee: M-Cap Technologies
Priority date: 1995-01-25
Filing date: 1996-01-24
Publication date: 1996-08-01

Abstract

The invention is directed to an encapsulated salt composition comprising crystalline sodium chloride encapsulated within a water resistant thermoplastic shell in which are randomly dispersed finely divided particles of ascorbic acid and optionally a bicarbonate leavening agent and to methods for baking bromate-free, yeast-raised bakery products therefrom.

Description

ENCAPSULATED SALT PARTICLES FOR USE TN BA INO YEAST-RAISED BAKERY PRODI HTTS

Cross Refeience to Related Application

This application is a continuation-in-part of copending U.S. patent applications S.N. 08/148,712, filed November 8, 1993, and S.N. 08/206,378, filed March 7, 1994.

Field of Invention

The invention is directed to a salt composition for use in baking yeast-raised bakery products. In particular, the invention is directed to an encapsulated salt composition for use in baking bromate-free bakery products such as bread.

Background of the Invention

Most bread is made commercially in the United States by either of three basic procedures: (1) the straight-dough method; (2) the sponge-and-dough method or (3) the liquid-sponge method. In the straight- dough method, all of the essential ingredients of the bread (flour, yeast, salt and water) are mixed together in a single step to form a dough which is fermented, placed into individual pans, proofed and baked. In the sponge- and-dough method, the yeast, water and 50-70% by weight of the flour are formed into an initial dough which is referred to as the "sponge. " The sponge is fermented for 2-4 hours after which the remaining portion of the flour, salt and secondary additives are added to form a final dough. The final dough is then placed into individual baking pans, proofed and baked. The liquid- sponge method differs from the sponge-and-dough method mainly in that the sponge is of liquid consistency and contains 10-60% by weight of the total flour. [The term "proofing" or "proofed" refers to the practice of subjecting dough to storage for about one hour at a temperature of 90- OOF and high humidity (60-90% rh) in order to restore the extensibility and aeration of the dough prior to baking.] These are batch processes. In addition to the foregoing dough making methods, which are batchwise in nature, a considerable volume of breadmaking is carried out using continuous dough mixing systems. These methods are characterized by the preparation of a pumpable liquid preliminary admixture (preferment) in which the yeast is activated to its maximum degree of fermentation in the presence of part of the flour and/or sources of assimilatable nitrogen with careful adjustment of pH. The fermented admixture, which may contain as much as 90% weight of the total flour content of the bread, is mixed on a continuous basis with the remaining flour and other dough ingredients to form an homogeneous dough. The homogeneous dough is then intensively kneaded under pressure and anaerobic conditions to form a degassed dough. The kneaded dough is deposited directly into baking pans on a continuous basis. The so-called "continuous-brew method" is an example of such continuous systems in which the preferment contains no flour and the total flour content is incorporated during dough formation.

In addition to the essential four dough components, it is customary to add one or more secondary additives, which are optional. The use of these materials is in large part a function of the particular bread being made. Such secondary additives include yeast food, sweeteners, shortening, dairy blend, protease enzyme, emulsifiers, dough strengtheners, preservatives, gluten, etc. For example, a typical bread may contain as secondary additives all of the following: high fructose corn syrup, wheat gluten, soybean oil, calcium propionate, potassium bromate, vinegar, ammonium sulfate; calcium sulfate, ascorbic acid; and sodium stearoyl lactylate.

Among the most commonly used and preferred secondary additives are oxidizing agents such as potassium bromate (KBrO_β), which, when added to the dough at levels up to 75 pp by weight, reacts with the gluten, or protein, fraction of the wheat to improve the strength and resiliency of the dough. A substantial portion of this strengthening action occurs in the first several minutes the bread is in the baking oven as increased temperature accelerates the action of potassium bromate. Also during this first portion of the baking process, the dough expands considerably in volume due to accelerated gas production by the yeast and expansion of the contained gas with increasing temperature. The strengthening action of potassium bromate works in conjunction with this volume expansion to "set" the structure of the dough into a loaf of desired volume and consistency. This synergistic action is especially valued in modern automated production lines where mechanical shock can cause a reduction in dough volume prior to entering the baking oven. This is especially true for bakery products, such as hamburger buns, which have a relatively short time in the baking oven, e.g. , 7-10 minutes as compared with 25-28 minutes for pan bread. Therefore, breads which do not contain potassium bromate or an equivalent oxidizing agent tend to have poor volume, weak crust, poor symmetry and uneven grain and texture.

However, recent studies in Japan and in the United Kingdom indicate that potassium bromate may not be completely converted to harmless potassium bromide during the baking process. Moreover, it is believed that residual amounts of bromate may be carcinogenic. Therefore, the use of potassium bromate as a component of bread is being curtailed or even discontinued.

For the above reasons, there is a need for a convenient, safe and effective means of replacing potassium bromate in ycast-raiscd baked goods. In this regard, ascorbic acid (Vitamin C) has been mentioned. Though the functions of ascorbic acid in baking are the same as potassium bromate, it has the significant disadvantage that it is substantially decomposed by the moisture, oxygen, trace metals, and pH conditions present during mixing and proofing, leaving little or none remaining to work with the volume expansion that occurs in the oven. This makes it unsuitable as a total replacement for potassium bromate.

In the technology of baking bread, salt has the primary purposes of flavor enhancement and strengthening the gluten structure that serves to give bread its shape. However, it is well known that salt has the disadvantages of interfering with gas separation by yeast and, through its dough strengthening effect, limiting the extent to which the dough may rise. This is demonstrated in the common practice within the baking trade of waiting until the final portion of the dough mixing step to add salt as it substantially increases the energy required to achieve a uniform dough. The yeast inhibitory effect occurs at salt concentrations above approximately 1.5%, basis flour. Most commonly salt is added to a 2% concentration. For these reasons, there has been a substantial need for a potassium bromate replacement product which will (1) increase the volume of the proofed loaf by reducing the effect of salt upon the yeast and (2) add ascorbic acid and salt in such a manner that they can be released slowly during proofing and rapidly in the oven to allow the retention of the increased dough volume and (3) release the bulk of its contained salt and ascorbic acid in the early stages of baking to support the desirable volume expansion and repair the effects of mechanical shock.

In particular, it has been found that in some yeast-raised breads, which undergo rough handling before baking, greater loaf height is needed. An example of such breads is white dough bread for making buns.

Summary of the Invention

In a primary aspect, the invention is therefore directed to a paniculate composition for use in baking bromatc-frcc yeast-raised bakery products comprising a paniculate core of crystalline sodium chloride having a maximum dimension of 100-500 micrometers encapsulated with an inert, water-resistant thermoplastic shell having a thickness of 10-300 micrometers and a release temperature of 100-300F, the shell having randomly dispersed therein 1-10% by weight, basis total paniculate composition, of finely divided particles of ascorbic acid having bimodal particle size distribution in which 50-80% by weight of the particles are 200-400 micrometers in size and 50- 20% by weight of the particles are 1-100 micrometers in size. Preferably the composition also contains 1-8% by weight finely divided particles of a leavening agent selected from bicarbonates of Li, Na, K, NH and mixtures.

In a secondary aspect, the invention is directed to a dough composition for use in baking bromate-free yeast-raised bread comprising an admixture of flour, salt, yeast, water and the above-described encapsulated salt composition in which the weight ratio of unencapsulatcd salt in the dough to encapsulated salt in the paniculate composition is 1 : 1 to 9: 1 and the encapsulated ascorbic acid constitutes 2-220 ppm by weight of the flour component of the dough.

In a further aspect, the invention is directed to a method for baking a bromate-free, yeast-raised bread by the straight-dough method - 5 - comprising (1) formation of a dough comprising an admixture of flour, water, free salt and yeast, (2) fermenting the dough, (3) dividing and placing the fermented dough into individual pans, (4) proofing the fermented dough and (5) baking the proofed dough, characterized in that the above-described encapsulated salt composition is added to the dough fermenting the dough in such proportions that the weight ratio of unencapsulated salt in the dough to encapsulated salt in the particles is 1 : 1 to 9: 1 and the encapsulated ascorbic acid constitutes 2-200 ppm by weight of the flour content of the dough.

In a still further aspect, the invention is directed to a method for baking a bromate-free, yeast-raised bread by the sponge-and-dough method comprising (1) formation of a sponge comprising an admixture of flour, water and yeast, the sponge containing 10-70% by weight of the total flour content of the bread, (2) fermentation of the sponge, (3) formation of a dough by admixing salt, secondary additives and the remainder of the flour with the fermented sponge, (4) proofing the dough and (5) baking the proofed dough, characterized in that the above-described encapsulated salt composition is added to the fermented sponge or dough in such proportions that the weight ratio of unencapsulated salt in the dough to encapsulated salt in the particles is 1 : 1 to 9: 1 and the encapsulated ascorbic acid constitutes 2- 220 ppm by weight of the flour content of the dough.

Brief Description of the Drawing

The Drawing consists of two figures which are a schematic representation of the encapsulated salt composition of the invention. Figure 1 depicts the composition of the invention in which ascorbic acid alone is contained in the encapsulating shell. Figure 2 depicts the composition of the invention in which both ascorbic acid and a leavening agent are contained in the shell.

Detailed Description of the Invention

A. In General: Applicants have discovered that superior results are obtained with the product of the invention because a minor amount of the ascorbic acid contained in the encapsulating shell is released during the latter part of the proofing step while the rest of the ascorbic acid is released quite early in the baking oven. The minor amount of ascorbic acid released in the proofing box allows for additional rise to the fermenting dough, but does not perceptibly interfere with the action of the yeast so long as the release takes place later in the proofing process and is limited in quantity. However, it is essential that the remainder of the ascorbic acid be released rapidly early in the baking oven, preferably within the first four minutes In particular, the ascorbic acid must be completely released before crushing of the bread takes place. On the other hand, most of the salt release takes place after the ascorbic acid is substantially completely released into the heated dough.

The attainment of both limited release of ascorbic acid in the proofing box and rapid release of the ascorbic acid in the baking oven is realized by incorporating the ascorbic acid in two particle size modes. Basically, the ascorbic acid should be comprised of 50-80% by weight larger particles having a particle size of 200-400 micrometers and 50-20% by weight smaller particles having a particle size of 1-100 micrometers. Some of the ascorbic acid particles will in many instances be outside these ranges of size. However, so long as those within these ranges arc present in suitable amounts, the admixture of such diverse particles will be suitable for use in the invention. It is preferred that the larger sized particles constitute 60-70% by weight of the admixture and the smaller sized particles con.stitute 40-30% by weight of the admixture.

Even though the shell material is at least water-resistant and preferably water-insoluble, a small amount of the ascorbic acid is nevertheless released in the proofing box as a result of diffusion of moisture, fats and oils from the dough through defects at the interface of the large ascorbic acid particles and the shell material as well as incomplete encapsulation of some of the particles. In addition, some softening of the shell material may take place at the proofing temperature (ca. 125F).

Though some softening of the shell material may take place upon contact with the fats and oils in the dough, there is nevertheless no major release of ascorbic acid during the proofing step. Because the action of the yeast is completed by the end of the proofing step and the ascorbic acid release is minor, neither the ascorbic acid nor the salt interferes with the action of the yeast. As the shell softens upon exposure to the higher temperature in the baking oven, the larger particles, more of which lie at or near the surface of the shell, are released. As the temperature of the shell rises, the large particles are completely released and are followed by slower release of the smaller particles.

The temperature of most commercial baking ovens is on the order of 375-450F. Therefore, to assure that the shell material does not melt before the oven, it should have a melting point well above the temperatures encountered in the proofing step. Therefore, a melting point of at least 150F and preferably at least 200F is required. On the other hand, the shell material must become completely molten in the front part of the baking oven. Therefore, it should having a melting point well below the baking temperature. A melting point at least 50F below and preferably 100F below the oven temperature is preferred. Thus the shell materials for use in the invention will ordinarily have a melting point of 100-300F and preferably 150- 250F. It should be noted here that the temperature within the bread does not reach the oven temperature because of the evaporation of water from the bread within the oven.

It is preferred to introduce the encapsulated particles of the invention into the dough mixture just before going to the proofing box; they can nevertheless be added to the sponge or to the dough prior to mixing together the sponge and dough before proofing since no ascorbic acid is released during mixing of the sponge and dough.

B. Bread Components and Additives: Except for the encapsulated salt composition of the invention, the components of the bakery products in which the invention can be used are conventional and thus well known in the art. For example, the basic constituents of breads are flour, yeast, salt and water. However, as discussed herein above, most breads contain one or more secondary additives such as yeast food, calcium propionate, sodium stearyl lactolate, vitamin C (ascorbic acid), sugar, honey, syrups, baker shortenings, dairy products, egg products, etc. The presence or absence of such secondary bread additives, other than those claimed herein, is not critical with respect to the operability of the invention. That is, the invention is effective in a wide variety of yeast-raised bakery products whether or not they contain any or all of such materials. In addition to bread, the invention can be used in other yeast-raised bakery products such as rolls, doughnuts, frozen doughs and Danish pastries.

C. Encapsulant Shell Material: A wide variety of organic thermoplastic shell materials can be used in the invention so long as they are suitable for direct addition to foods. Thus, the composition of the shell component of the invention must be a solid at ambient temperatures, be chemically inert in the presence of all the bread components, be suitable as a food component and have suitable melting properties so that it is released at the appropriate temperature and be water resistant at proofing temperatures. Water insolubility is still further preferred.

Such materials include vegetable fats such as mono, di- and tri- glycerides, vegetable oils and wax blends therewith, animal fats such as lard, beef tallow and blends of animal and vegetable fats and hydrogenated derivatives of such fats and oils. Also included are waxes such as beeswax, candclilla wax, paraffin wax and microcrystalline wax. Other suitable materials are poiysaccharides such as gums, gelatins, alginates and modifications thereof. These include natural polymers such as carbυxymcthylcellulose, cellulose acetate phthalatc, cthylcellulose, gelatin, gum arabic, starch, succinylated gelatin, proteins, and alginates. Other synthetic polymers which can be used as shell materials include poly(vinyl alcohol) and poly(vinyl acetate). Such materials are selected on the basis of their melting point and release characteristics in particular applications. Mixtures of such shell materials can also be used to obtain particular combinations of physical properties.

The amount of ascorbic acid or precursor thereof dispersed in the shell relative to the volume of the shell material (shell loading) is not critical with respect to the functionality of the invention in ordinary baking applications. However, it has been observed that the release of ascorbic acid at equivalent temperature conditions tends to be faster when the volume of ascorbic acid is higher than when a lesser volume of ascorbic acid is used. Thus, the loading level of ascorbic acid in the shell is likely to have an effect on release time.

D. Bicarbonate Leavening Agent: Especially in situations when the dough is subject to severe shock as it is conveyed to the oven, it is preferred that the composition of the invention contain 1-10% by weight of a leavening agent. Preferred leavening agents are the bicarboπates of Na, Li, K, NH₄ and mixtures thereof. Of these, sodium bicarbonate is preferred. Unlike the ascorbic acid, the particle size of the bicarbonate is not so critical. However, it is preferred that the bicarbonate be released entirely and quickly in the front part of the baking oven. Therefore, it will usually be preferred to have finely divided particles of bicarbonate within the range of 1-500 micrometers, and preferably 1-200 micrometers.

E. Formulation and Microencapsulation: The structure of the encapsulated salt particles of the invention is illustrated by the single figure of the Drawing, which is a schematic representation of the particles. In particular, a crystalline particle of salt (1) is encapsulated within a thermoplastic shell (3) in which are dispersed finely divided particles of ascorbic acid (5) and sodium bicarbonate (7). It is preferred that the salt particles which are used in the invention have a maximum dimension of no more than 220 micrometers so that they can be easily blended and dispersed in the fermented dough. On the other hand, it is preferred that the salt particles have a minimum dimension no smaller than 100 micrometers because such small particles arc more difficult to cncapsulalc satisfactorily. It is further preferred that the maximum dimension of the salt particles be in the range of 125-300 micrometers.

The invention has been developed primarily for use with sodium chloride because of its overwhelmingly greater use. Nevertheless, the invention is also applicable to the use of other flavoring salts such as potassium chloride and calcium chloride, as well as mixtures thereof with sodium chloride.

It is preferred that the thickness of the organic shell in which the salt particles are encapsulated be at least 10 micrometers and preferably at least 20 micrometers to be assured that the coating is substantially continuous and that it contains few holes. However, the shell thickness should not exceed 300 micrometers, and preferably 200 micrometers, lest the encapsulated particles become less granular in character and thus are not free flowing. It is, of course, preferred that the particles be free flowing in bulk so that they can be dispersed more easily in the dough. The ascorbic acid and bicarbonate are preferred to be of particle size such they do not exceed about half the thickness of the shell and thus can be randomly dispersed throughout the shell. Though randomly dispersed ascorbic acid and bicarbonate particles can be at the outer surface of the shell, it is preferred that the ascorbic acid particles not protrude because too many protruding particles would result in too rapid release during the dough fermentation. On the other hand, it is preferred that the bicarbonate particles be of sufficient size and quantity that they protrude in order to facilitate early release. It is also preferred that the particles in the shell not be smaller than 0.5 micrometer because they are difficult to handle. Therefore, the particles dispersed within the organic shell will be 0.5-400 micrometers in size. As set out above, to obtain an optimum effect by use of the invention, it is preferred that the ascorbic acid particles be present in a bimodal particle size distribution. In particular, it is preferred that 50-80% by weight of the particles have a size of 200-400 micrometers and 50-20% by weight of the particles have a size of 1-100 micrometers. It is still further preferred that the larger size particles constitute 60-70% by weight and the smaller size particles be 40-30% by weight of the ascorbic acid particles in the shell of the encapsulated salt composition.

It will be appreciated that ascorbic acid derivatives which are similar to ascorbic acid can be used in the invention as well as ascorbic acid itself. Therefore, compounds such as sodium ascorbate, calcium ascorbate, ascorbyl palmitate, erythorbic acid and sodium erythorbate may also be useful in the practice of the invention. The term "ascorbic acid" as used in the claims is therefore intended to include such similar ascorbic: acid compounds.

The required release temperature of the organic shell material is a function of the proofing and baking temperature. Since the shell materials for use in the invention are heat-released, the melting point of the shell material must be higher than the proofing temperature. In particular, it is preferred that the shell release temperature be at least 25F higher than the proofing temperature. Thus if proofing is carried out at lOOF, the release shell temperature should be at least 125F and preferably still 150F. (As used herein, the terms "release temperature" and "melting point" are used interchangeably.) For most applications, the shell release temperature should be 125-300F and preferably 150-250F. The amount of ascorbic acid in the shell of the invention particles should be 1-10% by weight, basis total particle weight. If substantially less than 1 % is used, the oxidative effect is insufficient and the dough will lack strength and have low loaf volume. On the other hand, if more than 10% is used, the oxidative effect is excessive and loaf volume may be diminished.

The amount of metal bicarbonate in the shell should be at least 1 % by weight, basis total particle weight, to obtain a technical effect and preferably at least 2%. No more than 10% bicarbonate should be used in order to avoid adversely affecting the taste of the bread. Preferably, no more than 6% bicarbonate should be used. In white bread, 4-5% bicarbonate appears to be optimum.

The amount of bicarbonate in the shell on a molar basis should be about the same as the amount of ascorbic acid. The reason for this is that the acid moiety of the ascorbic acid serves as a reagent for decomposition of the bicarbonate with the concomitant release of CO₂. The release of CO₂ is believed to be an essential feature of the bicarbonate functionality in the invention.

Though sodium bicarbonate is the preferred bicarbonate for use in the invention because of its low cost and ready availability, it will nevertheless be realized that other bicarbonatcs and mixtures thereof such as ammonium, lithium and potassium bicarbonate can also be used in the invention with comparable results.

Though not essential for the practice of the invention, it will be recognized that the shell can have additional secondary additives dispersed therein, for example, other oxidizing agents, sodium diacetate, calcium propionate and the like. However it should be noted that use of the invention in bromate-free doughs also eliminates the need for such secondary additives as azodicarbonamide and enzymes.

Microencapsulation of the salt can be carried out by any of several conventional microencapsulation methods. A preferred method for carrying out the encapsulation involves the steps of (1) admixing the salt particles into the molten shell materials, (2) adding the ascorbic acid and bicarbonate to the admixture of salt and shell material and (3) cooling the final admixture to create coated granules which are free flowing. Another technique is use of a fluidized bed. More particularly, the ascorbic acid and bicarbonate are suspended in the molten shell material, (2) the salt particles are fluidized and (3) the molten shell material containing ascorbic acid and bicarbonate is sprayed into the fluidized salt particles. A still further technique is centrifugal extrusion, as developed by the Southwest Research Institute, San Antonio, TX.

In the Examples which follow, the encapsulated salt particles were prepared in the following manner:

(1) Hydrogenated cottonseed oil was melted in a jacketed mixing tank;

(2) Fine flake salt was added to the molten cottonseed oil with stirring to obtain a uniform dispersion of the salt in the oil;

(3) While maintaining stirring, ascorbic acid having an average particle size of 3 micrometers and U.S. P. powdered NaHCO₃ were added to the oil/salt dispersion; and

(4) The admixture of oil, salt, ascorbic acid and NaHCO₃ was slowly cooled until the product granulated. The granulated material was then removed from the vessel and screened through a 20 mesh (U.S. Standard) screen.

Ordinarily, it is preferred that the individual particles in bulk be free flowing. However, in some instances it will be desirable to utilize the particles in the form of agglomerated particles or tablets. In those instances, a plurality of particles is agglomerated or tabletted by means of a lower melting binding agent. EXAMPLES

Example 1

A quantity of encapsulated salt particles in accordance with the invention and containing by weight 75% fine flake salt, 23% cottonseed oil flake and 2% ascorbic acid was prepared by the following procedure:

1. A jacketed vessel was loaded with the cottonseed oil flake and the vessel was heated to 90-95C to melt the oil flake;

2. The fine flake salt was added to the molten cottonseed oil and the mixture heated to 100-1 IOC for 5 minutes;

3. The heated admixture of oil and salt was mixed at 85C for

15-30 minutes after which the temperature was lowered to 60C;

4. Finely divided particles of ascorbic acid were added to the oil and salt dispersion and the admixture cooled to 30-32C with continuous agitation; and

5. The cooled admixture was screened through a 20 (U.S. Standard) mesh screen.

Figure 1 illustrates encapsulated salt particles made by the method of Example 1 in which a particle of salt (1) is encapsulated within a shell of hydrogenated cottonseed oil flake (3) and a bimodal mixture of ascorbic acid particles (5) is distributed in the cottonseed oil shell (3).

Example 2

In a commercial baking line for making whole wheat bread by the sponge-and-dough method, 845 pounds of sponge were prepared containing bromate-free whole wheat flour, wheat gluten, water, yeast food, sodium stearyl lactate, creamed yeast and ascorbic acid tablets. After fermentation, the remainder of the dough components and encapsulated particles made by the method of Example 1 were formed into a second dough, which was mixed into the sponge. The additional dough components were bromate-free whole wheat flour, water, soybean oil, sugar, unencapsulated salt, particles of the composition of the invention containing salt and ascorbic acid, honey, vinegar, calcium propionate, and wheat gluten. The encapsulated salt was equivalent to 0.5% by weight and the encapsulated ascorbic acid was equivalent to 200 ppm, basis dry flour weight. The weight of the final dough was 1461 pounds. After panning and proofing at 90F and 85 rh, the dough was baked at 450F. The resultant bread prepared in accordance with the invention was found to be fully equivalent in every property with the bread prepared by the control method for baking this bread. The control method differed from the experimental run in that the dough contained potassium bromate and free salt replaced the encapsulated salt and ascorbic acid.

Example 3

In a commercial baking line for making white bread by the sponge-and-dough method, 1 , 184 pounds of sponge were prepared containing bromate-free white wheat flour, water, yeast, shortening, softener, yeast food and ascorbic acid tablets (44 ppm by weight, basis flour). After fermentation, the remainder of the dough components and encapsulated particles made by the method of Example 1 were formed into a dough and mixed into the sponge. The additional dough components were white wheat flour, water whey unencapsulated salt, particles of the composition of the invention containing salt and ascorbic acid, dough conditioner, syrup, inhibitor, yeast and sodium stearyl lactate. The encapsulated salt was equivalent to 0.5 % by weight and the encapsulated ascorbic acid was equivalent to 140 ppm, basis dry flour weight. The weight of the final dough was 1,934 pounds. After panning and proofing at 90F and 85 rh, the dough was baked at 400-450F. The resultant bread was found to be fully equivalent in every property with the bread prepared by the control method for baking this bread. The control method differed from the experimental run in that the dough contained potassium bromate and free salt replaced the encapsulated salt and ascorbic acid.

Example 4

In a commercial baking line for making white bread by the sponge-and-dough method, 1 , 191 pounds of sponge were prepared containing bromate-free white wheat flour, water, yeast, shortening, softener, yeast food and ascorbic acid tablets (44 ppm by weight, basis flour). After fermentation, the remainder of the dough components and encapsulated particles made by the method of Example 1 were formed into a dough and mixed into the sponge. The additional dough components were white wheat flour, water, whey, encapsulated salt, dough conditioner, syrup, inhibitor, yeast sodium stearyl lactate and ascorbic acid tablets. The encapsulated salt was equivalent to 0.5% by weight and the encapsulated ascorbic acid was equivalent to 99 ppm, basis dry flour weight. The weight of the final dough was 1 ,946 pounds. After panning and proofing at 90F and 85 rh, the dough was baked at 400-450F. The resultant bread was found to be fully equivalent in every property with the bread prepared by a control method for baking the same bread. The control method differed from the experimental run in that the dough contained potassium bromate and free salt replaced the encapsulated salt and ascorbic acid.

In most commercial baking operations, the oven temperature of the baking step is 400-450F; however, the baking temperature for some baked goods may be as low as 350F, depending on the baking time and the physical characteristics of the baked products in question.

The ratio of unencapsulated salt to encapsulated salt may vary according to the particular baking operation in which the invention is used. In some instances, the weight ratio of unencapsulated salt to encapsulated salt may be as low as 1 : 1 , but is usually preferred to be at least 1.5: 1. Nevertheless, the weight ratio of unencapsulated salt to encapsulated salt should not exceed 4: 1 and preferably no higher than 3.5: 1. A particularly preferred ratio for most bread applications is 3.5: 1.

Example 5

Four batches of encapsulated salt particles in accordance with the invention were made by the following procedure:

1. A jacketed vessel was loaded with the hydrogenated cottonseed oil flake and the vessel was heated to 85-90C to melt the oil flake; 2. The fine flake salt was added to the molten cottonseed oil and the heated admixture of oil and salt was mixed at 85-90C for 15-30 minutes after which the temperature was lowed to 60C;

3. Finely divided particles of an admixture of ascorbic acid and sodium bicarbonate were added to the oil and salt dispersion and the admixture cooled to 30-32C with continuous agitation; and

4. The cooled admixture was screened through a 20 (U.S. Standard) mesh screen.

The composition of the particles in the four batches was as follows:

Example No. ≤B ≤£ 5D Component (% wϋ

Fine flake salt 71 71 71 71

Hydrogenated cottonseed oil 24 26 25 23

Ascorbic acid 1 1 2 2

Sodium bicarbonate 4 2 2 4

Figure 2 illustrates encapsulated salt particles made by the method of Example 5 in which a particle of salt (1) is encapsulated within a shell of hydrogenated cottonseed oil flake (3) and a mixture of bimodal ascorbic acid particles (5) and sodium bicarbonate particles (7) is distributed in the cottonseed oil shell (3).

Example 6

In a commercial baking line for making white bread hamburger rolls by the sponge-and-dough method, 882 pounds of sponge were prepared containing bromate-free white wheat flour, water, yeast, emulsifier, azodicarbonamide and enzymes. After fermentation, the remaining dough components were formed into a dough and mixed into the sponge. The additional dough components were white wheat flour, water, sugar, shortening, calcium propionate, sodium propionate, calcium sulfate, dough conditioner (sodium stearyl lactylate), azodicarbonamide, emulsifier and 6 pounds of encapsulated salt particles per Example 5B (75 ppm by weight ascorbic acid, basis flour). The encapsulated salt was equivalent to 0.5% by weight, basis dry flour weight. The weight of the final dough was 1 ,424 pounds. After panning and proofing at 90-115F and 80-110 rh, the dough was baked at 440-460F. The resultant bread was found to have good height and volume, even texture, well distributed crumb and evenly spaced holes.

Examples 7-10

A series of laboratory scale tests was conducted in which bread for hamburger buns was made by the sponge-and-dough method for the purpose of observing the effect of varying concentrations of the encapsulated salt particles of the invention. Each of the tests was conducted with sponge weights of about 850 grams and total dough weights of about 1 ,300 grams. The compositions of the sponge and dough for this series of tests are given in Table 2 below:

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TABLE 2

Sponge and Dough Test Formulae

Ingredient % Wt. fhasis flour. Weight,

Sponge

White wheat flour 70 490

Compressed yeast 3 21

Water 46 322

Dough conditioner 0.5 3.5

Nonbromated yeast food 0.3 2.1

Dough

White wheat flour 30 210

High fructose corn syrup 18 126

Shortening 6 42

Unencapsulated salt 2 14

Encapsulated salt per Ex. 1A Variable Variable

Water Variable Variable

Calcium propionate 0.12 0.84

The bread compositions, including a control composition, were prepared by the sponge-and-dough method. The test compositions in the series contained 6, 8, 10 and 12 ounces of the encapsulated salt particles per hundred weight of flour. The control dough composition was the same as the Example doughs except that it contained unencapsulated salt particles and no ascorbic acid or sodium bicarbonate. The following procedure was used for preparation of the breads:

All sponge ingredients were mixed for 2 minutes at 79F and allowed to ferment in a sealed container for 3.5 hours at 87F. The dough ingredients were mixed for 30 seconds at low speed and the sponge was added to the admixture and mixed for 7.0 minutes to allow gluten development. The fully mixed dough was allowed to rest for 10 minutes at 87F in a covered container after which the dough was removed from the container and divided into 56 g dough pieces which were rounded and then panned. The panned dough was proofed at 110F and 90% rh to 3.6 cm total height and baked for 11 minutes at 435F. The weight (g) and volume (cc by rapeseed displacement) were measured 30 minutes after completion of baking. Four dough batches were prepared for each encapsulated salt level and for the control dough as well. To observe the effect of shock on the various dough, two of the dough were subject to shock by dropping the pan on a hard surface from a height of 3 inches (7.6 cm).

All of the doughs were evaluated with respect to their external properties-symmetry, crust density and color-and internal properties-grain, texture, crumb body and color, taste/aroma and mouthful-in accordance with the American Institute of Baking (AIB) Sensory Evaluation Test. All data are based on the average of duplicate dough batches.

All of the test breads prepared using the encapsulated salt particles of the invention, which had undergone shock, exhibited equal or better external properties than the control bread and better internal properties then the control bread.

In addition, as shown by the following loaf volume data, all of (he breads utilizing the invention had at least equal loaf volume and the bread containing 6 ounccs/cwt of encapsulated salt appeared to have even higher volume then the control bread composition.

Table 2

Loaf Volume of Breads Exposed to Shock

Example No. Weight of Encapsulated Salt Loaf Volume

(Oz/cwt. tec)

Control 292

Example 7 6 313

Example 8 8 296

Example 9 10 296

Example 10 12 289 Examples 11-14

A still further series of bread dough compositions for use in baking hamburger rolls was tested in which encapsulated salt particles containing different amounts of bicarbonate and ascorbic acid were used. The composition of these particles is given hereinabove (Examples 5A-D). These dough compositions were then compared with a control dough of the same composition except the encapsulated salt particles contained ascorbic acid, but no sodium bicarbonate in the hydrogenated cottonseed oil shell. The breads tested in this manner were made and evaluated in accordance with the procedure of Examples 7-10 except for the variations in the compositions of the encapsulated salt particles therein.

The AIB evaluation of these breads showed that the particles from Examples 5A-5D yielded rolls having the same or higher internal evaluations than the control and yielded uniformly higher external evaluations than the control. The breads containing the Example 5A-C particles all exhibited significantly higher load volumes. The volume of the bread containing the Example 5D particles was slightly lower than the control bread (269 v. 276 cc).

The foregoing examples show clearly the quite beneficial effect of making bread from doughs containing the encapsulated salt particles of the invention as compared with conventional breads made from unencapsulated salt or from encapsulated salt particles which contained no sodium bicarbonate. In particular, the addition of sodium bicarbonate to the encapsulated salt and ascorbic acid clearly improves the resistance of the dough to shock forces incurred during processing and handling of the dough.

The ratio of unencapsulated salt to encapsulated salt may vary according to the particular baking operation in which the invention is used. In some instances, the weight ratio of unencapsulated salt to encapsulated salt may be as low as 1: 1 , but is usually preferred to be at least 1.5: 1. Nevertheless, the weight ratio of unencapsulated salt to encapsulated salt should not exceed 9: 1 and preferably no higher than 5: 1. A particularly preferred ratio for most bread applications is 5:1.

In the course of several such tests, it has been observed that bun crumb quality and uniformity, as well as texture, have been improved.

Examples 15-21

A series of seven laboratory scale tests was conducted to test the effect of various encapsulated ascorbic acid compositions on the volume, grain and texture of a commercial type white bread made by the sponge-and- dough method. Each of the doughs was mixed with an equal weight of the test ascorbic acid composition. The formula and procedure for the sponge- and-dough method is given in Tables 3 and 4 below. The procedure used was typical for commercial sponge-and-dough preparations.

The finished breads were scored according to a modified AIB Universal Scoring System. The results showed that variations in the ascorbic acid compositions yielded measurable differences in internal and external bread characteristics, particularly with regard to crust color. Seven doughs were mixed producing two loaves of bread each. Three of the loaves (Examples 16-18) showed objectionable dark specs in the crust derived from the apparatus, but were not scored down therefor since the specks were not caused by any of the variables being studied. Examination of the internal characteristics of the bread showed that the various ascorbic acid compositions affected the evenness, and ellipticality of the bread cells, as well as the degree of openness. It is desirable to produce breads whose internal structure is comprised of thin-walled evenly spaced cells which are elliptical in shape.

In the following examples, the same amount of encapsulated salt and ascorbic acid was used in each. The examples differed, however, in the nature of the encapsulated material, as follows:

Example 15: The salt and ascorbic acid were encapsulated individually, the maximum particle size of the ascorbic acid was 850 micrometers; Example 16: The salt and ascorbic acid were encapsulated in the manner of Example 1, the maximum particle size of the ascorbic acid being 180 micrometers;

Example 17: The salt and ascorbic acid were encapsulated in the manner of Example 1 , the maximum particle size of the ascorbic acid being 850 micrometers;

Example 18: The salt and ascorbic acid were encapsulated in the manner of Example 1, the ascorbic acid in the shell having a bimodal particle size distribution of particles having a maximum size of 45 and 180 micrometers.

Example 19: This composition was the same as Example 21 below, except that the ascorbic acid particles were not bimodal, having a maximum particle size of 325 micrometers.

Example 20: The salt and ascorbic acid were encapsulated in the manner of Example 1 and thus the composition, proportions and particle size distribution were the same as in Example 18, except that a different grade of cotton seed oil was used as the shell material.

Example 21: The salt and ascorbic acid were encapsulated in the manner of Example 1. The composition was the same as Example 18.

The quality data for the above-described series of tests are given in

Table 5 below:

Table 5

Quality Data on Commercial White Sponge and Dough

Example No. 15 16 17 18 19 20 21

Qualities Total Possible Points

External 30 23 23 23 24 23 24.5 26

Volume 10 10 10 10 10 10 10 10

Symmetry 5 3 3 4 3 3 4.5 5

Crust Color 10 8 8 8 8 8 8 8

Break & Shred 5 2 2 1 3 2 2 3

Internal 35 23.5 25 25.5 26.5 29 29.5 31

Grain 10 6.5 7.5 7 7.5 8 8.5 9

Texture 15 9.5 10 9.5 10 12 12 13

Crumb Color 10 7.5 7.5 9 9 9 9 9

Total Score 65 46.5 48 48.5 50.5 52 54 57

Proof Height (in.) 3/4 3/4 3/4 3/4 3/4 3/4 3/4

Proof Time (min.) 80 75 77 78 79 80 75

Avg. Volume (cc) 3400 3338 3425 3350 3275 3313 3400

Dough Water Abs. (%) 59.89 59.89 59.89 59.89 59.89 59.89 59.89

Mixing Time at Medium Speed (min.) 4 4 4 4 4 4 4

It is evident from the data from Example 15 that the properties of the bread made from individually encapsulated salt and ascorbic acid was inferior to those made in accordance with the invention, that is, in which the ascorbic acid was incorporated in the shell surrounding the encapsulated salt particles. In particular, all of the internal properties-grain, texture and crumb color were inferior.

The quality data from Example 16, in which relatively small ascorbic acid particles having mono-modal distribution were used in the shell, again shows relatively poor internal properties, albeit somewhat better than those obtained in Example 15.

The data from Examples 17 and 19, in which only fine particles of ascorbic acid were used, yielded doughs which were inconsistent with respect to symmetry, grain, texture and crumb color.

The data from Examples 18, 20 and 21 , show that the use of bimodal particle size distribution is still further beneficial and high total ascores are obtained consistently. With such bimodal distribution, slow release of the large particles of ascorbic acid is obtained in the proofing step while the smaller particles are released very rapidly during the baking step.

The bread of Example 21 showed the highest grain and texture score having the most even grain and softest, smoothest texture. Breads containing other compositions showed a slight streaking of the grain and a tendency towards openness as well as more roundness of cells versus the more desirable elliptical conformation. Example 20 was also acceptable in that only a slight roundness of cells resulted when that composition was used. Sample 19 showed a slight tendency towards streaking, but was acceptable in other features.

Other breads resulted in lowered grain and texture scores; however, their total score was affected more by external crumb color. Additionally, there was a tendency for certain ascorbic acid compositions to yield breaks and shreds which were uneven or ragged on the side of the loaf. The volume on all breads was very good to excellent. A confirming experiment was run to test these conclusions in which a control ascorbic acid composition, the subject of this invention, was baked against Examples 21 and 20 of the previous bake. The resulting breads confirmed that either the original ascorbic acid composition or the ascorbic composition in which only the cotton seed oil had been changed were superior to other compositions in producing breads with desirable grain and texture. Changing the encapsulated composition resulted in cell structure properties that were slightly open and more round then elliptical in conformation. Additionally, various compositions did not allow the dough to machine as evenly as the invention, as evidenced by streaking in the grain.

A further series of commercial lite white bread doughs were baked on a laboratory scale to assess the difference between various oxidizing systems in which potassium bromate had been omitted. The encapsulated ascorbic acid composition of this invention was tested alone or in combination with an enzyme-based bromate replacer and azodicarbonamide at various salt levels. These test formulations were compared to a control oxidation system comprising unencapsulated ascorbic acid, azodicarbonamide, and an enzyme-based bromate replacer. All breads were made by a liquid ferment system and were scored for dough handling and baked volume. Fiber and minor ingredients were prehydrated prior to mixing.

In comparison to a control which contained 100% salt concentration, ascorbic acid, azodicarbonamide, and an enzyme-based oxidizing system, breads containing only the composition of the invention as a bromate replacer, maintained or increased average baked volume except in the case where salt had been reduced by 25%. The highest volume was achieved when salt was reduced 50% and the composition of the invention was the sole source of oxidation. This combination also produced the most even dough performance among divided doughs and was significantly better than when either 100% or 75% salt had been used. The doughs, however, were slightly more sticky than the control, but not as sticky as when a combination of the enzyme-based bromate replacer, the composition of the invention, and azodicarbonamide was used at a 50% salt level. In addition, the invention was able to be substituted for powdered ascorbic acid without loss of volume or dough handling characteristics. These results indicate that the invention in combination with a 50% salt reduction, is capable of producing lite white bread with greater volume than would the combination of azodicarbonamide, ascorbic acid and an enzyme-based dough condition in the presence of 100% salt concentration.

Claims

Claims;

1. A paniculate composition suitable for use in baking bromate-free yeast-raised bakery products comprising a paniculate core of crystalline sodium chloride having a maximum dimension of 100-500 micrometers encapsulated within an inert thermoplastic shell having a thickness of 10-300 micrometers and a release temperature of 125-300F, the shell having randomly dispersed therein 1-10% by weight, basis total particulate composition, finely divided particles of ascorbic acid having a bimodal particle size distribution in which 50-80% by weight of the particles are 200-400 micrometers in size and 50-20% by weight of the particles are 1 - 100 micrometers in size.

2. The particulate composition of claim 1 in which the particles in bulk are free-flowing.

3. The particulate composition of claim 1 in which a plurality of particles are agglomerated by means of an organic binder.

4. The particulate composition of claim 3 in which the agglomerated particles are tabletted.

5. The particulate composition of claim 1 in which the shell also contains 1-10% by weight, basis total particulate composition, of metal bicarbonate leavening agent.

6. The particulate composition of claim 5 in which the bicarbonate leavening agent is selected from bicarbonates of ammonium, lithium, potassium, sodium and mixtures thereof.

7. The particulate composition of claim 6 in which the bicarbonate leavening agent is sodium bicarbonate.

8. A dough composition for use in baking bromate-free yeast-raised bread comprising an admixture of flour, salt, yeast, water and the particulate composition of claim 1 in which the weight ratio of unencapsulated salt in the dough to encapsulated salt in the particulate composition is 1:1 to 9:1 and the encapsulated ascorbic acid constitutes 2-220 ppm by weight of the flour component of the dough.

9. In the sponge-and-dough method for baking a bromate-free, yeast-raised bread comprising (1) formation of a sponge comprising an admixture of flour, water and yeast, the sponge containing 10-70% by weight of the total flour content of the bread, (2) fermentation of the sponge, (3) formation of a dough by admixing salt, secondary additives and the remainder of the flour with the fermented sponge, (4) proofing the dough and (5) baking the proofed dough, the improvement comprising admixing with the fermented sponge finely divided particles of the composition of claim 1 in such proportions that the weight ratio of unencapsulated salt in the dough to encapsulated salt in the particles is 1:1 to 9:1 and the encapsulated ascorbic acid constitutes 2-220 ppm by weight of the flour content of the dough.

10. In a method for baking a bromate-free, yeast-raised bread comprising (1) formation of a preliminary admixture comprising water, yeast and up to 70% by weight of the total flour content of the bread, (2) fermentation of the preliminary admixture, (3) formation of a dough by admixing salt, secondary additives and the remainder of the flour with the fermented admixture, (4) proofing the dough and (5) baking the proofed dough, the improvement comprising admixing with the fermented preliminary admixture finely divided particles of the composition of claim 1 in such proportions that the weight ratio of unencapsulated salt in the dough to encapsulated salt in the particles is 1:1 to 9:1 , the encapsulated ascorbic acid is 2-220 ppm by weight and the metal bicarbonate is 1-10% by weight, basis flour content of the dough.

11. The method of claim 10 in which the preliminary admixture is a pumpablc liquid suitable for use in the continuous brew method for baking bread.

12. The method of claim 10 in which the preliminary admixture is a non-pumpable dough suitable for use in the sponge and dough method for baking bread.

13. In the straight-dough method for baking bromate-free, yeast-raised bread comprising (1) formation of a dough comprising an admixture of flour, water, free salt and yeast; (2) fermenting the dough; (3) dividing and placing the fermented dough into individual pans; (4) proofing the fermented dough and (5) baking the proofed dough, the improvement comprising adding to the fermented dough before step (3) finely divided particles of the composition of claim 1 in such proportions that the weight ratio of unencapsulated salt in the fermented dough to encapsulated salt in the particles is 1 : 1 to 9: 1 and the encapsulated ascorbic acid constitutes 2-220 ppm by weight of the flour content of the dough.

14. The dough composition of claim 8 in which the dough is free of azodicarbonamide.

15. The method of claims 9 through 13 in which the dough is free of azocarbonamide.