WO2014041358A1

WO2014041358A1 - Dough production

Info

Publication number: WO2014041358A1
Application number: PCT/GB2013/052393
Authority: WO
Inventors: Robert Francis; Andrew McILWRICK
Original assignee: Baker Perkins Limited
Priority date: 2012-09-12
Filing date: 2013-09-12
Publication date: 2014-03-20
Also published as: GB201216264D0; EP2894996A1

Abstract

Method and apparatus for dough production which comprises a first phase in which during combining ingredients to produce the dough the introduction of yeast is delayed until water, ascorbic acid and flour have been combined, and a second phase in which dough produced during the first phase is subjected to a series of sheeting(14) and coiling (15) stations.

Description

DOUGH PRODUCTION

Technical Field

The present invention relates generally to dough production.

Background

Production of dough for manufacturing bread, for example, involves first preparing the dough from the requisite ingredients, and then forming dough into a suitable size/shape to be baked. We have devised significant improvements in relation to both the preparation of the dough and the forming of the dough.

Summary According to a first aspect of the invention there is provided a method of preparing dough, the method comprising a first stage of combining flour, water and a dough improver comprising ascorbic acid, but excluding the incorporation of yeast, wherein said components are combined to form a slurry or dough consistency, subjecting the mixture to above atmospheric pressure and the method further comprising a second stage of adding yeast to the slurry or dough.

The method preferably comprises providing a supply of air (or an oxygen-containing gas) for the first stage so as to allow incorporation of oxygen with the mixture whilst under above-atmosphere pressure .

The method preferably comprises, subsequent to the application of above-atmospheric pressure to the slurry, incorporating additional flour with the mixture.

Preferably, when the flour, water and dough improver are combined for the first stage, between 50% to 80% of the total flour to be used in preparing the dough is used therefor.

Preferably, when the flour, water and dough improver are combined to form a slurry or dough consistency, substantially all of the water to be used in preparing the dough is used. The method may comprise, during the first stage, subjecting the mixture to a pressure of between 1.1 to 2.5 Bar. This is preferably based on 1 Bar being atmospheric pressure, and so the 1.1 to 2.5 Bar values are absolute values. The method may comprise, during the first stage, subjecting the mixture to an above atmosphere pressure for a period of between twenty seconds and one hundred seconds.

The method may comprise, subsequent to subjecting the mixture to above atmosphere pressure, for the second stage adding yeast and the remaining flour to the mixture and combining the same.

The method preferably comprises, subsequent to the above-atmospheric pressure step and during the second stage, subjecting the mixture to an alternating cycle of pressure and vacuum, or an alternating cycle of pressure and under-pressure. The pressure may be substantially atmospheric pressure or may be above atmospheric pressure.

The method preferably comprises applying the cycle of alternating pressure and vacuum under-pressure to the mixture subsequent to the addition of the remaining flour and the yeast.

The method may comprise during the second stage (mechanically) mixing the mixture whilst it is subjected to above-atmosphere pressure .

Each of the alternating pressure cycles may have a duration (or period) of between one hundred and eighty seconds and two hundred and thirty seconds.

The alternating pressure cycle of the second stage preferably forms the mixture into a dough consistency. A method of bread making comprising the method of the first aspect of the invention.

According to a second aspect of the invention there is provided a method of forming dough comprising sheeting a dough and then coiling said sheeted dough piece during a first coiling stage allowing the coiled dough a resting time during a resting stage, then sheeting the coiled dough in an orientation which is substantially perpendicular to the initial coiling stage.

The method preferably comprises reorientating the coiled dough piece through substantially ninety degrees prior to the second coiling stage.

The reorientation of the coiled dough piece is preferably achieved during the resting stage. The duration of the resting stage is preferably up to ten minutes.

According to a third aspect of the invention there is provided apparatus for forming dough, the apparatus comprising a first dough sheeting station and a first dough coiling station, a dough resting device, a second dough sheeting station and a second dough coiling station, wherein the first dough sheeting station arranged to sheet a dough piece, the first coiling station then arranged to coil the sheeted dough piece, the dough resting device arranged to allow the sheeted dough piece to rest, and the second dough sheeting station arranged to sheet the dough piece at an orientation which is substantially perpendicular to the orientation at which the first dough sheeting station sheeted the dough, and the second dough coiling station arranged to coil the sheeted dough piece.

The dough resting device may comprise a conveyor to carry the dough for a predetermined time.

The resting device may be arranged to change the orientation of the coiled dough piece which exits the first dough coiling station through substantially ninety degrees and to present the same to the second dough sheeting station. Each of the first and second dough sheeting stations comprises a series of opposing driven rollers.

Each of the first and second dough coiling stations may comprise a chain mail curtain. According to a fourth aspect of the invention there is provided a method of dough production comprising the method of the first aspect followed by the method of the second aspect. Any of the above aspects of the invention may comprise any one or combination of features as disclosed in the detailed description and/or in the drawings.

Brief Description of Drawings Various embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Figures 1A to IF are schematic views of different stages of a dough preparation process, and

Figure 2 is a schematic view of a two-stage sheeting and coiling apparatus. Detailed Description There is now described a new and innovative apparatus and method for the production of dough. This may be viewed as a two phase operation. A first phase involves combining various ingredients in a particular method to prepare a quantity of dough. The second phase involves sheeting and coiling the dough. Although particular advantage results from combining first and second phases, each phase may nevertheless be advantageously used independently of the other.

With reference to Figure 1A there is shown the first phase of production. Initially for a first stage, fifty to eighty percent (by weight) of the total quantity of flour to be used, together with all of the water, is dropped into a mixing vessel 1. The mixing vessel 1 includes a mixing element 2. As shown in Figure IB a quantity of dough conditioner which includes ascorbic acid is then introduced into the mixture of flour and water. This produces a mixture 8 having a slurry consistency. The mixing of the first stage provides sufficient mechanical energy for a sufficient time to develop the gluten. The mixture is then subjected to a pressure of between 1.1 to 2.5 Bar for a period of twenty to one hundred seconds. During the application of high pressure, an air inlet of the vessel 1 permits air to combine with the slurry mixture 8. Advantageously, in doing so, the mixture being substantially of a slurry consistency it is amenable in oxygen more readily (as compared if the mixture had a dough-like consistency). In particular, the mixture being of a slurry consistency maximises the entrainment of oxygen. This is of particular importance in relation to the maximisation of the action of the ascorbic acid. It is in particular to be noted that introduction of yeast is delayed until the next stage, as shown in Figure ID, with yeast being an oxygen hungry ingredient, its presence during the high pressure mixing stage would limit the effectiveness of the ascorbic acid. Hence we have realised that it is advantageous to delay introduction of the same.

With reference to Figure ID, to the slurry mixture is added the remainder of the flour, together with the yeast and any other ingredient(s) to form a mixture 8. It will be appreciated that as an alternative to introducing the flour and yeast into the container 1 , the flour and yeast (together with any other ingredient) could be prepared offline in a separate vessel. The slurry mixture could then be added to the separate vessel. The slurry mixture is then combined with the remainder of the flour and the yeast. As shown in Figure IE, the mixture is then subjected to alternating cycles of high pressure and vacuum for a period of between one hundred and eighty seconds each to two hundred and thirty seconds to apply an energy set point of between 5 to 15 wh/kg.

It will be appreciated that the alternating pressure cycle need not necessarily comprise an above-atmosphere pressure and a vacuum, and may more generally comprise the cyclic alternation of a higher pressure and a lower pressure or an atmospheric pressure and an under-pressure. The use of above-atmospheric pressure or atmospheric pressure could be selected according to the final required texture of the cooked dough product. For example, some manufacturers may desire the effectiveness of the ascorbic acid but without further altering the bubble structure .

As shown in Figure IF, the mixture 8 of dough consistency is then discharged.

In a process not illustrated, the produced dough is then divided into dough pieces 10. Each dough piece is then processed by way of the apparatus shown in Figure 2. The apparatus in Figure 2 may generally be described as a two stage sheeting and coiling apparatus. During a first stage the dough pieces 10 are conveyed towards a dough resting station 12. The dough resting station 12 allows the dough to rest from zero to approximately five minutes, and comprises a conveyer. On exiting the station 12 the dough pieces are fed into a sheeting station 14 which comprises a series of pairs of driven rollers. As each dough piece 10 passes through the rollers it is flattened and formed into a sheet 17. On exiting the sheeting station 14 the dough sheet is coiled by way of a coiling device (not illustrated) so that the sheet is formed into two to four and a half coils. The coil of dough then passes through a forming station 15 which reduces the size of coil. On exiting the station 15 the dough coil, now of reduced dimensions, passes through a dough resting station 16 for a period of up to ten minutes. During resting, the orientation of the dough coil is changed through substantially ninety degrees such that the dough coil (of substantially cylindrical shape) is presented end-on to a second dough sheeting station 19. On exiting the second sheeting station the dough sheet is coiled by a dough coiling device (not illustrated) into a coil of between two to four and a half coils. The dough coil is then subjected to a forming station 20, on exiting the station the coil of dough is of (reduced), modified dimensions to suit the tin dimensions. The dough coil is then discharged into a tin 30 either as a single piece or as a four piece. The tinned dough can then be baked.

Advantageously, the bread produced by the dough has improved structure, improved resilience, greater volume and increased cell count. A further advantage is that is a reduced quantity of dough conditioner is required than would be required if all ingredients, and in particular the yeast, had been combined at the same time. Because yeast is oxygen hungry, a greater proportion of dough conditioner is required. However, by delaying the introduction of the yeast, the dough conditioner has a greater opportunity to be effective since its effectiveness relies of oxygen and so it is not competing for oxygen with the yeast.

Claims

1. A method of preparing dough, the method comprising a first stage of combining flour, water and a dough improver comprising ascorbic acid, but excluding the incorporation of yeast, wherein said components are combined to form a slurry or dough consistency, subjecting the mixture to above atmospheric pressure and the method further comprising a second stage of adding yeast to the slurry or dough.

2. A method as claimed in claim 1 which comprises providing a supply of air (or an oxygen-containing gas) for the first stage so as to allow incorporation of oxygen with the mixture whilst under above-atmosphere pressure .

3. A method as claimed in claim 1 or claim 2 which comprises, subsequent to the application of above-atmospheric pressure, incorporating additional flour with the mixture.

4. A method as claimed in any preceding claim in which, when the flour, water and dough improver are combined for the first stage, between 50% to 80% of the total flour to be used in preparing the dough is used therefor.

5. A method as claimed in any preceding claim in which, when the flour, water and dough improver are combined to form a slurry or dough consistency, substantially all of the water to be used in preparing the dough is used.

6. A method as claimed in any preceding claim which comprises, during the first stage, subjecting the mixture to a pressure of between 1. 1 to 2.5 Bar.

7. A method as claimed in any preceding claim which comprises, during the first stage, subjecting the mixture to an above atmosphere pressure for a period of between twenty seconds and one hundred seconds.

8. A method as claimed in any preceding claim which comprises, subsequent to subjecting the mixture to above atmosphere pressure, for the second stage adding yeast and the remaining flour to the mixture and combining the same .

9. A method as claimed in any preceding claim which comprises, subsequent to the above-atmospheric pressure step and during the second stage, subjecting the mixture to an alternating cycle of pressure and vacuum, or an alternating cycle of pressure and under-pressure.

10. A method as claimed in claim 9 which comprises applying the cycle of alternating pressure and vacuum under-pressure to the mixture subsequent to the addition of the remaining flour and the yeast.

1 1. A method of forming dough comprising sheeting a dough and then coiling said sheeted dough piece during a first coiling stage allowing the coiled dough a resting time during a resting stage, then sheeting the coiled dough in an orientation which is substantially perpendicular to the initial coiling stage .

12. A method as claimed in claim 1 1 which comprises reorientating the coiled dough piece through substantially ninety degrees prior to the second coiling stage .

13. A method as claimed in claim 1 1 or claim 12 in which the reorientation of the coiled dough piece is achieved during the resting stage.

14. A method as claimed in any of claims 1 1 to 13 in which the duration of the resting stage is up to ten minutes.

15. Apparatus for forming dough, the apparatus comprising a first dough sheeting station and a first dough coiling station, a dough resting device, a second dough sheeting station and a second dough coiling station, wherein the first dough sheeting station arranged to sheet a dough piece, the first coiling station then arranged to coil the sheeted dough piece, the dough resting device arranged to allow the sheeted dough piece to rest, and the second dough sheeting station arranged to sheet the dough piece at an orientation which is substantially perpendicular to the orientation at which the first dough sheeting station sheeted the dough, and the second dough coiling station arranged to coil the sheeted dough piece.

16. Apparatus as claimed in claim 15 in which the dough resting device comprises a conveyor to carry the dough for a predetermined time.

17. Apparatus as claimed in claim 15 or claim 16 in which the resting device is arranged to change the orientation of the coiled dough piece which exits the first dough coiling station through substantially ninety degrees and to present the same to the second dough sheeting station.

18. Apparatus as claimed in any of claims 15 to 17 in which the first and second dough sheeting stations each comprises a series of opposing driven rollers.

19. Apparatus as claimed in any of claims 15 to 18 in which each of the first and second dough coiling stations comprise a chain mail curtain.

20. A method of dough production comprising the method of any of claims 1 to 10 followed by the method of any of claims 1 1 to 14.