WO2009142637A1

WO2009142637A1 - Compositions used to make dough, and related methods of making and using

Info

Publication number: WO2009142637A1
Application number: PCT/US2008/064502
Authority: WO
Inventors: Alan A. Oppenheimer; Michael A. Staeger; Madonna M. Ray; Jean L. Weber
Original assignee: General Mills Marketing, Inc.
Priority date: 2008-05-22
Filing date: 2008-05-22
Publication date: 2009-11-26
Also published as: AU2008356514A1; EP2278884A4; EP2278884A1; CA2724359A1

Abstract

The present invention includes a method of making a chemical preferment composition that mixes ingredients including flour component, water, acidic chemical leavening agent, and basic chemical leavening agent, and mixes the ingredients in a manner to form a chemical preferment composition having a preferment viscosity. The present invention also includes a chemical preferment composition having a preferment viscosity and flour component, water, acidic chemical leavening agent, and basic chemical leavening agent. Chemical preferment compositions according to the present invention can be used to make dough compositions.

Description

Attorney Docket No. 7025WO

COMPOSITIONS USED TO MAKE DOUGH. AND RELATED METHODS

OF MAKING AND USING

Field of the Invention

The present invention relates to compositions having a preferment viscosity, and related methods of making and using. In particular, the present invention relates to a chemical preferment composition having a preferment viscosity.

Background

Dough products can be prepared by combining ingredients including water, flour, and a leavening system (e.g., yeast, chemical leavening agents, combinations of these, and the like), among others. The ingredients can be combined and processed together to achieve desired properties in a raw or cooked dough, such as desired taste, aroma, texture, color, storage stability, and baking and rheological properties that result in one or more of these.

Useful techniques include two different methods sometimes referred to as "straight-dough" methods and "preferment" methods, which are described in, e.g., U.S. Pub. No. 2006/0083841 (Casper et al.).

According to straight-dough methods, all or substantially all of the dough ingredients of a dough composition are combined together generally at the same time and are mixed together to form a dough mass that can be formed to a dough and cooked. Straight dough methods tend to be streamlined and efficient. Some drawbacks of straight dough methods include limited flexibility in both the mixing process (e.g., it can be difficult to salvage over-mixed dough) and make-up process (e.g., the dough tends to become unprocessable if the dough rests on the line too long).

According to preferment methods (or, among other terms, "sponge" methods) ingredients can be combined in two (or more) separate steps. In a first step a dough "preferment" composition is prepared to include a portion of total dough ingredients such as flour, water, yeast, and yeast food. This preferment portion of mixed ingredients is then allowed to rest or ferment. In a second step, the balance of the total dough ingredients is added to the fermented dough composition, after a certain amount of processing (e.g., "resting") of the preferment dough composition. According to standard methods, yeast of this dough composition is again allowed to ferment in a "proofing" step that leavens the finished dough composition before cooking. Upon cooking, the proofed dough will exhibit a recognizable flavor and aroma of a fresh-baked yeast-leavened dough product as well as a light (leavened) composition due to the leavening that took place during the proofing step. Sponge dough methods tend to provide superior product characteristics (e.g., baked specific volume, crumb texture, combinations of these, and the like). Some drawbacks can include relatively high labor cost, power consumption, machine wear, and fermentation losses.

In general, there is an ongoing need to make dough compositions using more efficient and/or user-friendly methods while providing desirable properties in the raw dough and/or baked product.

Summary

It has been discovered that using chemical leavening agents to generate carbon-dioxide gas in a manner to help seed bubble nucleation sites for bubble dispersion within a dough matrix can help provide a dough composition (raw or baked) having similar or even superior characteristics as a dough made using a conventional yeast preferment composition. Such product characteristics include baked specific volume, crumb texture, combinations of these, and the like. The chemical leavening agents are included in a "chemical preferment composition" that has at least flour component and water (chemical preferment composition discussed below). The water hydrates at least a portion of the flour component so that the composition has a preferment viscosity, which viscosity allows suitable bubble nucleation to take place as the chemical leavening agents hydrate and react to generate carbon dioxide gas. Advantageously, a chemical preferment composition according to the present invention can be made with efficient mixing methodologies (e.g., more continuous in nature and more similar to straight dough methods) while still being able to be used to make a dough composition having similar or superior characteristics than a dough made from a conventional yeast preferment composition. Subjecting the chemical preferment composition to a rest period is not necessary for acceptable bubble nucleation to take place. According to one aspect of the present invention, a method of making a chemical preferment composition includes mixing ingredients including: flour component; water; acidic chemical leavening agent; and basic chemical leavening agent. The ingredients are mixed in a manner to form a chemical preferment composition having a preferment viscosity. According to another aspect of the present invention, a chemical preferment composition includes flour component; water; acidic chemical leavening agent; and basic chemical leavening agent. The chemical preferment composition has a preferment viscosity.

According to another aspect of the present invention, a method of making a dough composition includes mixing ingredients in a manner to form a chemical preferment composition having a preferment viscosity and mixing one or more additional dough ingredients with the chemical preferment composition in a manner to form a dough composition. The ingredients mixed in a manner to form a chemical preferment composition include flour component; water; acidic chemical leavening agent; and basic chemical leavening agent.

Brief Description of the Drawings

FIG. 1 shows a graph of composition viscosity as a function of flour component to water weight ratio (FAV). FIG. 2 shows a graph of composition viscosity as a function of flour component to water weight ratio (FAV) and spindle speed.

Detailed Description

The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.

In the context of forming a dough composition, a chemical preferment composition according to the present invention is formed early on in the overall dough making process and is formed prior to (is a precursor to) forming a dough composition. As used herein, a "chemical preferment composition" refers to a composition having a preferment viscosity and that includes flour component, water, and chemical leavening agent (acidic and basic chemical leavening agents). In some embodiments, a chemical preferment composition includes flour component, water, and chemical leavening agent (acidic and basic chemical leavening agents), among other optional ingredients. In other embodiments, a chemical preferment composition consists of or consists essentially of flour component, water, and chemical leavening agent (acidic and basic chemical leavening agents). In still other embodiments, a chemical preferment composition consists of or consists essentially of flour component, water, yeast, yeast food or nutrient, and chemical leavening agent (acidic and basic chemical leavening agents). A chemical preferment composition having a preferment viscosity can form an internal cell structure in the composition that is similar to an internal cell structure that is made using conventional yeast preferment compositions that do not include chemical leavening agents. Such internal cell structures help form a crumb structure and baked specific volume of, e.g., baked bread that is made using the chemical preferment composition. As used herein, a "preferment viscosity" refers to a viscosity of a chemical preferment composition that is high enough to allow the composition to trap at least part of the carbon dioxide gas that is evolved from the reaction between acidic and basic chemical leavening agents and form an acceptable internal cell structure (i.e., bubble nucleation) in the composition. Preferably, a preferment viscosity is also high enough so as to permit the formed cells to maintain their shape. At the same time, a preferment viscosity refers to a viscosity of the composition that is low enough to let some of the generated carbon dioxide gas escape from the composition. If the composition viscosity is too high (e.g., a viscosity of a dough), the composition tends to be too rigid to permit formation of an acceptable internal cell structure and/or tends to retain too much carbon dioxide gas. Retaining too much carbon-dioxide gas that is generated at such an early stage of the overall dough forming process can be undesirable because the resulting dough may be very difficult to manipulate through subsequent process machinery.

A preferment viscosity can be measured using any known method in the dough forming arts. It is noted that the units in which viscosity is reported can vary depending on the particular methodology used, even for different methodologies using the same viscometer.

One acceptable viscometer for measuring viscosity of a chemical preferment composition according to the present invention includes the Brabender® Farinograph®- E (viscosity reported in Brabender Units (BU)), which can be commercially obtained from CW. Brabender® Instruments, Inc., South Hackensack, New Jersey, USA. A preferred method of using the Brabender® Farinograph®- E to measure viscosity includes adding flour component and water with only one of the chemical leavening agents to a farinograph mixing bowl. Only one of the leavening agents is preferably added while measuring the viscosity of the composition so that leavening gas is not generated to an undue degree. Otherwise, if both the acid and base are added while measuring viscosity, leavening gas can be generated to an undue degree and can thereby hinder obtaining an accurate viscosity measurement. The leavening agent is preferably present in an amount as the leavening agent would be in a chemical preferment composition (described below). The bowl jacket coolant set at 15.5 degrees Celsius and the mixing blade speed set to 63 rpm, and then mixing to the maximum or peak viscosity of the blend. In preferred embodiments, the Brabender® Farinograph®- E can be used to measure preferment viscosity when the weight ratio of flour component to water is from about 1.0 to 1.4, but as the flour component to water ratio decreases below about 1.0 the viscosity of the composition tends to become too low to be accurately measured with the Brabender® Farinograph®- E. FIG. 1 shows a graph of the viscosity of a chemical preferment composition measured at 15.5 degrees Celsius with a Brabender® Farinograph®- E in a 300 gram bowl at 63 revolutions per minute as a function of flour component to water weight ratio (F/W). The point indicated by arrow 10 indicates the approximate maximum viscosity for a chemical preferment composition (i.e., about 500 BU). For viscosities higher than 500 BU on this graph, the viscosity is too high such that the composition becomes much more difficult to form bubbles and/or retains too much of the carbon-dioxide gas that is evolved from the reaction between acidic and basic chemical leavening agents. In certain embodiments, a preferment viscosity can be in the range of from 50-500 BU, preferably from 150- 450, preferably from 150-400, and even more preferably from 200-400 BU, measured at 15.5 degrees Celsius with a Brabender® Farinograph®- E in a 300 gram bowl at 63 revolutions per minute.

Another acceptable viscometer for measuring viscosity of a chemical preferment composition according to the present invention includes the Brookfield Viscometer, model number DVIII (viscosity reported in centipoϊses (cP)), which can be commercially obtained from Brookfield Engineering Laboratories, Inc., Middleboro, Massachusetts, USA. A preferred method of using the Brookfield Viscometer, model number DVIII to measure viscosity includes pre-blending a bench scale amount of the flour component, water, and either acid or base at the preferment ratios of these ingredients. Only one of the chemical leavening agents is preferably added while measuring the viscosity of the composition so that leavening gas is not generated to an undue degree. Otherwise, if both the acid and base are added while measuring viscosity, leavening gas can be generated to an undue degree and can thereby hinder obtaining an accurate viscosity measurement. The leavening agent is preferably present in an amount as the leavening agent would be in a chemical preferment composition (described below). Using a jacket-cooled concentric cylinder apparatus (jacketed cup and spindle), the viscosity of this preferment blend is measured at 15.5 degrees Celsius (jacket coolant temperature) at different spindle speeds (revolutions per minute) and recorded when the digital reading is stable at each separate rpm setting. Then the recorded viscosity measurements are plotted as a function of spindle speed to see shear-thinning characteristics for the preferment composition. The Brookfield Viscometer, model number DVIII can be especially useful to measure the viscosity of a chemical preferment composition when the weight ratio of flour component to water is below 1.0 (e.g., from 0.2 to 1.0). FIG. 2 shows a graph of the viscosity of a chemical preferment composition measured at 15.5 degrees Celsius with a Brookfield Viscometer as a function of flour component to water weight ratio (FAV) and the speed (revolutions per minute) of a number 64 spindle. As can be seen in FIG. 2, the flour component/water mixture is slightly shear thinning, and the apparent viscosity increases as the flour component to water weight ratio increases. In certain embodiments, a preferment viscosity can be in the range of from 100 to 15,000 cP, preferably from 500 to 10,000 cP, and even more preferably from 1 ,000 to 5,000 cP, measured at 15.5 degrees Celsius with a Brookfield Viscometer and a number 64 spindle at a speed of 40 revolutions per minute.

As used herein, a "flour component" refers to any ingredient that at least partially hydrates when mixed with water so as to form the structure portion of an internal cellular matrix indicative of that used to make dough products. Exemplary flour components include flour, starch, concentrated protein ingredient, and combinations of thereof. Suitable flour includes hard wheat flour, soft wheat flour, corn flour, high amylose flour, low amylose flour, and the like.

Suitable starch includes any starch that is known for use in dough compositions generally. Such starch ingredients are well known and are described in, e.g., U.S. Pub. No. 2006/0083841 (Casper et al.).

Suitable concentrated protein ingredient is described in, e.g., U.S. Pub. No. 2006/0083841 (Casper et al.) and includes, e.g., wheat protein isolate, vital wheat gluten, combinations of these, and the like. Flour component can be present in a chemical preferment composition in an amount in the range of from 5 to 50 percent, or from 10 to 45 percent, or from 15 to 40 percent, or from 20 to 35 percent by weight of the chemical preferment composition.

Water can be combined with other chemical preferment composition ingredient(s) in any suitable form such as water, ice, and combinations of these. Water can be present in a chemical preferment composition in an amount in the range of from 40 to 80 percent, or from 45 to 75 percent, or from 50 to 70 percent, or from 55 to 65 percent by weight of the chemical preferment composition.

The flour component and water can be present in a chemical preferment composition at a weight ratio that allows a preferment viscosity to develop within a suitable amount of time upon mixing of the chemical preferment composition ingredients. In certain embodiments, the weight ratio of flour component to water is in the range of from 0.1 to 2, or from 0.2 to 1.75, or from 0.2 to 1.5, or from 0.25 to 1.4, or from 0.25 to 0.5. Calculating the weight ratio of flour component to water for a chemical preferment composition is shown by reference to Example 1. In Example 1, the flour component includes 6.3 weight percent, modified starch and 4.0 percent gluten protein for a total flour component percentage of 10.3. The water is present at 32.5 percent. Accordingly, weight ratio of flour component to water for the chemical preferment composition is 10.3 divided by 32.5, which is equal to 0.3. It is noted that the weight ratio of flour component to water for the final dough composition is calculated by adding all of the flour components (42.4 weight percent flour + 6.3 weight percent modified starch + 4.0 percent gluten protein = 52.7) and adding all of the water (32.5) and then dividing 52.7 by 32.5, which is equal to 1.6.

Selection of acidic chemical leavening agent(s), basic chemical leavening agent(s), and their respective amounts depends on, e.g., when the agents are mixed in with one or more of the other chemical preferment ingredients and when a substantial portion of carbon dioxide gas is expected to be evolved. A chemical preferment composition having a preferment viscosity includes chemical leavening agents so that the composition can trap at least part of the carbon dioxide gas that is evolved from the reaction between acidic and basic chemical leavening agents and form the bubbles/cells (bubble nucleation) of an internal cell structure in the composition that is similar to an internal cell structure that is made using conventional yeast preferment compositions that do not include chemical leavening agents.

The reaction between the acidic and basic chemical leavening agents can be described as a source of bicarbonate (basic chemical leavening agent) being neutralized by an acidic chemical leavening agent so as to generate carbon dioxide gas. To facilitate the reaction, the bicarbonate source is solubilized to react with the acidic chemical leavening agent. Because the acidic chemical leavening agent and basic chemical leavening agent are solubilized to react, such chemical leavening agents can also be referred to as "moisture-activated" acidic chemical leavening agent and "moisture-activated" basic chemical leavening agent.

In general, a chemical preferment composition has a preferment viscosity early on in the overall dough making process so it is desirable to select acidic chemical leavening agent(s) and basic chemical leavening agent(s) that will react to generate a suitable amount of carbon dioxide gas during the time period that the composition has a preferment viscosity.

Acidic chemical leavening agent(s) for use in a chemical preferment composition include nucleating chemical leavening agent(s), time-release chemical leavening agent(s), combinations of these, and the like. Nucleating chemical leavening agents include organic acids that hydrate and undergo dissolution relatively fast. Nucleating chemical leavening agents tend to readily give up protons to react with the bicarbonate and evolve carbon dioxide gas during such early stage mixing and can control dough crumb structure by providing gas cell nucleation sites. Time-release acidic chemical leavening agents can be used to control the time(s) and rate(s) at which carbon-dioxide gas evolution occurs. A time-release acidic chemical leavening agent can be formulated to evolve carbon-dioxide gas at particular time(s) and/or rate(s) by varying characteristics such as particle size and/or blending with heat activated acidic chemical leavening agent(s), encapsulated acidic chemical leavening agents, combinations of these, and the like.

Useful acidic chemical leavening agents are generally known in the dough and bread-making arts, with some examples including potassium acid tartrate, fine fumaric acid, citric acid, adipic acid, sorbic acid, potassium hydrogen tartrate (creme of tartar), SAS (sodium aluminum sulfate), SALP (sodium aluminum phosphate), SAPP (sodium acid pyrophosphate), monosodium phosphate, monocalcium phosphate monohydrate (MCP), anhydrous monocalcium phosphate (AMCP), dicalcium phosphate dihydrate (DPD), dicalcium phosphate (DCP), glucono delta- lactone (GDL), and dicalcium phosphate dihydrate (DCPD). Commercially available acidic chemical leavening agents for use according to the invention can include those sold under the trade names Balchem Encapsulated Soda or Balchem Encapsulated GDI available from Balchem Chemical Leavening Agents, New Hampton, New York and/or products available from ICL Performance Products LP, St. Louis, Missouri. Of these, some have relatively lower solubilities at temperatures at which a chemical preferment composition has a preferment viscosity, and some have relatively higher solubilities at said temperatures. Accordingly, the solubility of the acidic chemical leavening agent is a factor in selecting a particular chemical leavening agent. An acidic chemical leavening agent of a given solubility reacts with basic chemical leavening agents at a time when the chemical preferment composition has a preferment viscosity.

The basic chemical leavening agent can be any material that is reactive with the acidic active ingredient to produce a bubble-nucleating gas, usually carbon dioxide gas. Useful basic chemical leavening agents are generally known in the dough and bread-making arts, with examples of useful basic chemical leavening agents including reactive basic materials such as soda, sodium bicarbonate (NaHCOa), potassium bicarbonate (KHCO₃), ammonium bicarbonate (NH₄HCO₃), etc. These and similar types of basic chemical leavening agents are generally soluble in an aqueous phase of a chemical preferment composition.

The acidic and/or basic chemical leavening agents can be encapsulated, non- encapsulated, or combinations of these. In preferred embodiments, the acidic and basic chemical leavening agents are non-encapsulated. Encapsulation of a chemical leavening agent tends to delay reaction between the acidic and basic chemical leavening agents, but if appropriately selected an encapsulated acidic chemical leavening agent and/or a basic chemical leavening agent could be used in a chemical preferment composition having a preferment viscosity so as to generate an internal cell structure in the preferment composition that can be used to make a dough. Encapsulation of chemical leavening agents is generally known in the dough and bread-making arts, e.g., as described in U.S. Pat. No. 7,250,187 (Domingues). In certain embodiments, the acidic and/or basic chemical leavening agents can be encapsulated in a material that dissolves in water and/or in the presence of other ingredients (e.g., flavors containing alcohol, enzymes, emulsifiers, combinations of these, and the like).

As will be appreciated by the skilled artisan, the individual chemical leavening agents can be included in the dough composition in respective amounts that are useful to form an acceptable internal cellular network in the chemical preferment composition. The amount of a chosen basic chemical leavening agent to be used in a chemical preferment composition can be sufficient to react with the included acidic chemical leavening agent to release a desired amount of gas for bubble nucleation, thereby forming the desired internal cellular network in the chemical preferment composition. Because the basic chemical leavening agent and the acidic chemical leavening agent work in cooperation, each chemical leavening agent should be included in an amount designed to work with the included amount of the other chemical leavening agent. In certain embodiments, the amounts of basic and acidic chemical leavening agents can be determined using a Neutralizing Value (N. V.) which is defined as parts by weight of a bicarbonate that 100 parts by weight of an acidic chemical leavening agent will neutralize (i.e., liberate substantially all of the carbon dioxide gas). Using a Neutralizing Value, an amount could be determined as a percent by weight of the total preferment composition for either the acidic or basic chemical leavening agents and the amount of the complementary chemical leavening agent could be dependent upon the Neutralizing Value of the chemical leavening agent chosen.

Typical amounts of basic chemical leavening agent (not including the weight of any encapsulant that may be present) can be in the range from 0.25 to 10 percent, or from 0.75 to 7 percent, or from 0.75 to 4 percent, or from 0.75 to 2 percent, or from 0.75 to 1.5 percent by weight of the chemical preferment composition. In terms of the weight percent of the basic chemical leavening agent based on the total dough composition, typical amounts of basic chemical leavening agent (not including the weight of any encapsulant that may be present) can be in the range from 0.1 to 10 percent, or from 0.5 to 7 percent, or from 0.5 to 5 percent, or from

0.75 to 2.5 percent, or from 0.75 to 1.3 percent by weight of the dough composition.

The acidic active ingredient can be added in an amount sufficient to neutralize the basic component, i.e. an amount that is stoichiometric (a Neutralizing Value percent) to the amount of basic chemical leavening agent, with the exact amount by weight being dependent on the particular acidic chemical leavening agent that is chosen. Typical amounts of acidic chemical leavening agent (not including the weight of any encapsulant that may be present) can be in the range from 0.25 to 10 percent, or from 0.25 to 6 percent, or from 0.5 to 6 percent, or from 0.75 to 6 percent, or from 1 to 6 percent by weight of the chemical preferment composition. In terms of the weight percent of the acidic chemical leavening agent based on the total dough composition, typical amounts of acidic chemical leavening agent (not including the weight of any encapsulant that may be present) can be in the range from 0.1 to 10 percent, or from 0.5 to 7 percent, or from 0.5 to 5 percent, or from 0.75 to 2.5 percent, or from 0.75 to 1.3 percent by weight of the dough composition.

A chemical preferment composition can include optional ingredients typically used in conventional yeast preferment compositions. Ingredients typically used in conventional yeast preferment compositions are well known as described in, e.g., U.S. Pub. No. 2006/0083840 (Casper et al), and include yeast (e.g., for flavor, bubble nucleation, and combinations of the these), a yeast food or nutrient, hydrocolloid (e.g., gum), combinations of these, and the like.

Also, while a chemical preferment composition according to the present invention has been described as including acidic and basic chemical leavening agents so that the composition can trap at least part of the carbon dioxide gas that is evolved to form the bubbles/cells (bubble nucleation) of an internal cell structure, a chemical preferment composition according to the present can include an additional leavening system that can provide leavening for any reason. For example, to help the chemical leavening agents to form the internal cellular network of the preferment, to proof the dough composition that is subsequently formed, to leaven the dough composition during baking, combinations of these, and the like. Such additional leavening systems can include, e.g., yeast, additional chemical leavening agents (e.g., encapsulated chemical leavening agent), combinations of these, and the like.

A chemical preferment composition according to the present invention can be made by mixing ingredients that include flour component, water, acidic chemical leavening agent, and basic chemical leavening agent, and mixing the ingredients in a manner to form a preferment viscosity. As mentioned above, such a chemical preferment composition is formed early on in the overall dough making process because the purpose is to develop a preferment viscosity that is lower than a dough viscosity so that nucleation sites can be produced in the chemical preferment composition in a manner similar to nucleation sites developed using a traditional offline yeast preferment process. The chemical leavening agents produce carbon dioxide that will eventually cause the nucleation sites formed in the chemical preferment composition to expand into bubbles in a subsequent dough composition and leaven to an expected structure and texture. The bubbles ultimately give rise to the cellular structure observed in a cooked dough product.

At least two considerations in forming a chemical preferment composition include development of a preferment viscosity and carbon dioxide evolution. The flour component and water are mixed so as to at least partially hydrate the flour component and develop a composition having a preferment viscosity (i.e., a viscosity that is high enough to allow the composition to trap at least part of the carbon dioxide gas that is evolved from the reaction between acidic and basic chemical leavening agents and form an internal cellular matrix). A preferment viscosity can develop within a certain time or energy input (e.g., as measured by temperature increase) and can be measured as described in detail above. Typically, a preferment viscosity is developed in the first one-third of the overall dough making process.

Any type of mixing equipment can be used that would help achieve a preferment viscosity. Such equipment is well known and can include, e.g., straight dough mixing equipment.

Carbon dioxide gas evolution is controlled by selecting acidic and basic chemical leavening agents having a particular solubility and form (e.g., as discussed above, encapsulated, non-encapsulated, and combinations of these). Carbon dioxide gas evolution is also controlled by selecting an appropriate time to combine one or both of the acidic and basic chemical leavening agents with the other chemical preferment composition ingredients.

In certain embodiments, the acidic and basic chemical leavening agents substantially neutralize each other prior to the final dough composition coming out of a mixer. Preferably, the acidic and basic chemical leavening agents used for bubble nucleation react to such a substantially complete degree while the composition has a preferment viscosity that such chemical leavening agents do not cause undue leavening to occur downstream of making the chemical preferment composition (e.g., during sheeting). In certain embodiments, the acidic and basic chemical leavening agents substantially neutralize each other while the composition has a preferment viscosity because a preferment viscosity is low enough to allow some of the generated carbon-dioxide gas to escape from the dough composition. As the chemical preferment composition continues to develop, the composition will eventually develop a dough viscosity (e.g., a viscosity of 500 BU or more as measured using the Brabender® Farinograph®- E procedure described herein) which tends to retain too much carbon dioxide gas that is generated and/or which can even be too high of a viscosity for bubble nucleation to occur.

In certain embodiments, making a chemical preferment composition according to the present invention can be described in terms of one or more mixing cycles. A mix cycle means a time period during which at least certain specific ingredients are combined and mixed together. A mix cycle can be performed for various time periods and at one or more mix speeds. In certain embodiments, a first mix cycle includes a mixing period in the range of from 30 seconds to 5 minutes, or from 1 minute to 4 minutes, e.g., about 2 minutes, and at a speed in the range of from 20 to 50 revolutions per minute, or from 30 to 40 revolutions per minute, e.g., about 36 revolutions per minute. In certain embodiments using the same mixer, a second mix cycle following the first mix cycle includes a first mixing period in the range of from 30 seconds to 5 minutes, or from 1 minute to 4 minutes, e.g., about 2 minutes, and at a speed in the range of from 20 to 50 revolutions per minute, or from 30 to 40 revolutions per minute, e.g., about 36 revolutions per minute, followed by a second mixing period until a desired (e.g., peak) dough viscosity is reached and at a speed in the range of from 50 to 90 revolutions per minute, or from 60 to 80 revolutions per minute, e.g., about 72 revolutions per minute. Exemplary mixing equipment includes a horizontal bar, H-bar or D-bowl style mixer such as those manufactured by The Peerless Group, Sidney, Ohio, under the trade name Peerless® or ETMW Enterprises Ltd, Sherbrooke, Quebec Canada, under the trade name ETMW® with a stationary bar with 3 equally spaced mixing bars.

In one preferred embodiment, a method of making a chemical preferment composition includes a first mix cycle that mixes flour component, water, acidic chemical leavening agent or basic chemical leavening agent, in a manner so that the composition has a preferment viscosity, and a second mix cycle that mixes a complementary chemical leavening agent with the ingredients of the first mix cycle. As used herein, a "complementary" chemical leavening agent can be either an acidic chemical leavening agent or a basic chemical leavening agent, depending on the context. If the first mix cycle includes an acidic chemical leavening agent, the complementary chemical leavening agent that is included in the second mix cycle is a basic chemical leavening agent. Or, if the first mix cycle includes a basic chemical leavening agent, the complementary chemical leavening agent that is included in the second mix cycle is an acidic chemical leavening agent. Preferably, a complementary chemical leavening agent is added during a subsequent (e.g., second mix cycle) in situations where the reaction between the acidic and basic chemical leavening agents is so fast that a major portion of the bubbles are formed too early in the mixing process and tend to be broken up by mixing. In such situations where a complementary chemical leavening agent is added during a subsequent mix cycle, it is noted that the complementary chemical leavening agent is added in a manner that causes the desired carbon-dioxide gas evolution to occur when the composition still has a preferment viscosity. An example of adding a complementary chemical leavening agent during a mix cycle subsequent to the first mix cycle is shown below in Example 1. In preferred embodiments, a complementary acidic chemical leavening agent that is added during a mix cycle subsequent to the first mix cycle (e.g., a second mix cycle) is selected from the group consisting of citric acid, adipic acid, sorbic acid, sodium aluminum phosphate, sodium aluminum sulfate, fine fumaric acid, potassium hydrogen tartrate, monocalcium phosphate monohydrate, anhydrous monocalcium phosphate, glucono delta-lactone, sodium acid pyrophosphate, and combinations thereof. Optionally, one or more additional dough ingredients can be mixed with the ingredients of the first mix cycle during the subsequent mix cycle that the complementary chemical leavening agent is added.

In another preferred embodiment, a method of making a chemical preferment composition includes a first mix cycle that mixes flour component, water, acidic chemical leavening agent, and basic chemical leavening agent, in a manner so that the composition has a preferment viscosity, and a second mix cycle that mixes one or more additional dough ingredients with the ingredients of the first mix cycle. In general, acidic and basic chemical leavening agents are included in a first mix cycle in situations where the carbon dioxide evolution proceeds at a suitable rate. An example of including acidic and basic chemical leavening agents during a first mix cycle is shown below in Example 2. In preferred embodiments, an acidic chemical leavening agent that is added during a first mix cycle along with a basic chemical leavening agent is selected from the group consisting of fine fumaric acid, potassium hydrogen tartrate, monocalcium phosphate monohydrate, anhydrous monocalcium phosphate, glucono delta-lactone, sodium acid pyrophosphate, and combinations thereof.

Preferably, a chemical preferment composition according to the present invention is made according to single stage mixing. As used herein, single stage mixing means that all ingredients are combined in and mixed in a single mixer while continuously mixing the ingredients from mix cycle to mix cycle (i.e., the mixing is not stopped and there is no rest period between mix cycles). Preferably, there is no breaking of the seal of the mixer from mix cycle to mix cycle. For example, ingredients can be loaded into a mixer in a sealed manner and the speed of the mixer can be adjusted. Preferably, a dough composition made from a chemical preferment composition according to the present invention is made according to single stage mixing meaning that a dough composition can be made in same mixer as the chemical preferment composition so that a transfer from a separate chemical preferment mixer to dough finishing mixer does not have to take place. In preferred embodiments, mixing does not stop from the beginning of making a chemical preferment composition until the dough composition is made and ready for subsequent processing (e.g., sheeting, packaging, and the like). Accordingly, single stage mixing is more similar to a straight dough method rather than an off-line conventional yeast preferment method (i.e., a sponge dough method). Advantageously, a chemical preferment composition according to the present invention can benefit from the process efficiencies associated with continuous mixing methodology (e.g., as in straight dough methods), while providing the crumb texture and baked specific volume conventionally associated with off-line mixing methodology (e.g., conventional yeast preferment methods).

A chemical preferment composition according to the present invention can be combined with one or more additional dough ingredients in a manner to form a dough composition. Such additional dough ingredients are well known as described in, e.g., U.S. Pat. No. 5,855,945 (Laughlui et al.), U.S. Pub. No. 2006/0083840 (Casper et al.), and U.S. Pub. No. 2006/0083841 (Casper et al.). Such additional ingredients include flour, water, yeast, yeast food or nutrient, hydrocolloid (e.g., gum), fat (e.g., soy oil), salt, emulsifier, dough-developing agents, nutritional supplements, flavorings (sweeteners, spices, and the like), preservatives, mold inhibitors, combinations of these, and the like.

A chemical preferment composition according to the present invention can be used to make a variety of refrigerated or frozen doughs including doughs for bread, such as French bread, wheat bread, white bread, corn bread, rolls, such as cinnamon rolls, dinner rolls, caramel rolls and other assorted baked goods such as breadsticks, baguettes, croissants, pastries, biscuits, pizza dough, and the like. Additionally, the invention can be used to make non-refrigerated doughs, such as doughs that are immediately baked. In preferred embodiments, a chemical preferment composition according to the present invention can be used to make "Freezer-to-oven" (FTO) breads, which typically do not include a pre-proof, par- bake, thaw, or post-proof steps before being placed into the oven and baked directly from the frozen state.

EXAMPLES

Example 1

SINGLE STAGE CHEMICAL PREFERMENT COMPOSITION

Preferment Flour Component /Water Ratio = 0.3 (calculated as described above). Total Flour Component/Water Ratio = 1.6 (calculated as described above).

Note: the columns labeled "Mix Cycle 1 Ingredient - Percent by weight of total dough composition" and "Mix Cycle 2 Ingredient - Percent by weight of total dough composition" add together so as to form 100% as indicated by the column labeled "Percent by weight of total dough composition".

"Single stage" mixing, as defined above, was performed in this experiment. Mix cycle 1. Starch, Gluten, Water, and Vi-chem leavening system (only the base) were added during a first mix cycle and prehydrated for 2 minutes under low speed (36 rpm) agitation. Mix cycle 2. Add remaining ingredients (including acidic complementary chemical leavening agent) to mixer and mix for 1 minute at 36 rpm, and then mix at 72 rpm until peak development is reached. The final dough viscosity was in the range of from 1000-1500 Brabender Units measured at 15.5 degrees Celsius with a Brabender® Farinograph®- E in a 480 gram bowl at 63 revolutions per minute.

Example 2

SINGLE STAGE CHEMICAL PREFERMENT TREATMENT

Preferment Flour Component/Water Ratio = 0.3 (calculated in a manner similar to Example 1).

Total Flour Component/Water Ratio = 1.6 (calculated in a manner similar to Example 1).

"Single stage" mixing, as defined above, was performed in this experiment.

Mix cycle 1. Starch, Gluten, Water, Acidic chemical leavening agent, Basic chemical leavening agent, and hydrocolloid blends were added during a first mix cycle and prehydrated for 2 minutes under low speed (36 rpm) agitation.

Mix cycle 2. Add remaining ingredients to mixer and mix for 1 minute at 36 rpm, and then mix at 72 rpm until peak development is reached. The final dough viscosity was in the range of from 1000-1500 Brabender Units measured at 15.5 degrees Celsius with a Brabender® Farinograph®- E in a 480 gram bowl at 63revolutions per minute.

Claims

Attorney Docket No. 7025WO WHAT IS CLAIMED IS:

1. A method of making a chemical preferment composition comprising: mixing ingredients comprising: a) flour component; b) water; c) acidic chemical leavening agent; and d) basic chemical leavening agent; wherein the ingredients are mixed in a manner to form a chemical preferment composition having a preferment viscosity.

2. The method of claim 1, wherein the step of mixing is a first mix cycle comprising mixing ingredients comprising: i) flour component; ii) water; iii) the acidic chemical leavening agent; and iv) the basic chemical leavening agent; and further comprising a second mix cycle comprising mixing one or more additional dough ingredients with the ingredients of the first mix cycle.

3. The method of claim 2, wherein the acidic chemical leavening agent is selected from the group consisting of fine fumaric acid, potassium hydrogen tartrate, monocalcium phosphate monohydrate, anhydrous monocalcium phosphate, glucono delta-lactone, sodium acid pyrophosphate, and combinations thereof.

4. The method of claim 2, wherein the first mix cycle and second mix cycles are performed under single stage mixing conditions.

5. The method of claim 1, wherein the step of mixing comprises: a) a first mix cycle comprising mixing ingredients comprising: i) the flour component; ii) the water; and iii) the acidic chemical leavening agent or the basic chemical leavening agent; and b) a second mix cycle comprising mixing a complementary chemical leavening agent with the ingredients of the first mix cycle.

6. The method of claim 5, wherein the fast-acting acidic chemical leavening agent is selected from the group consisting of citric acid, adipic acid, sorbic acid, sodium aluminum phosphate, sodium aluminum sulfate, fine fumaric acid, potassium hydrogen tartrate, monocalcium phosphate monohydrate, anhydrous monocalcium phosphate, glucono delta-lactone, sodium acid pyrophosphate, and combinations thereof.

7. The method of claim 5, wherein the first mix cycle and second mix cycles are performed under single stage mixing conditions.

8. The method of claim 5, wherein the second mix cycle further comprises mixing one or more additional dough ingredients with the ingredients of the first mix cycle.

9. The method of claim 1 , wherein the preferment viscosity is in the range of from 50 to 500 Brabender Units measured at 15.5 degrees Celsius with a Brabender® Farinograph®- E in a 300 gram bowl at 63 revolutions per minute.

10. The method of claim 1 , wherein the preferment viscosity is in the range of from 100 to 15,000 centipoises measured at 15.5 degrees Celsius with a Brookfield Viscometer and a number 64 spindle at 40 revolutions per minute.

11. The method of claim 1 , wherein the ingredients further comprise yeast.

12. A chemical preferment composition comprising: a) flour component; b) water; c) acidic chemical leavening agent; and d) basic chemical leavening agent; wherein the chemical preferment composition has a preferment viscosity.

13. The composition of claim 12, wherein the flour component is present in an amount in the range of from 5 to 50 percent by weight of the chemical preferment composition and wherein the water is present in an amount in the range of from 40 to 80 percent by weight of the chemical preferment composition.

14. The composition of claim 12, wherein the weight ratio of flour component to water is in the range of from 0.2 to 1.5.

15. The composition of claim 12, wherein the acidic chemical leavening agent is present in an amount in the range of from 0.25 to 6 percent by weight of the chemical preferment composition, and wherein the basic chemical leavening agent is present in an amount in the range of from 0.75 to 4 percent by weight of the chemical preferment composition.

16. The composition of claim 12, wherein the basic chemical leavening agent is non-encapsulated.

17. The composition of claim 12, wherein the acidic chemical leavening agent is non-encapsulated.

18. The composition of claim 12, further comprising yeast.

19. A method of making a dough composition comprising: a) mixing ingredients comprising: i) flour component; ii) water;

Ui) acidic chemical leavening agent; and iv) basic chemical leavening agent; wherein the ingredients are mixed in a manner to form a chemical preferment composition having a preferment viscosity; and b) mixing one or more additional dough ingredients with the chemical preferment composition in a manner to form a dough composition.