Note: Descriptions are shown in the official language in which they were submitted.
393~
Background of the Invention
Commercial lactose, or milk sugar, i5 typically
obtained by a process that involves concentrating liquid
whey (from cheese-making) to about 50% solids and then
cooling the concentrated whey to produce lactose
crystallization. The crude lactose is centrifuged,
washed, redissolved in water, and dried to obtain the
final lactose product. The resulting lactose has a
sweetening power approximating 15% that of sucrose.
It is also far less soluble than either sucrose or
dextrose. Consequently, lacking desired solubility,
flavor or sweetening qualities, the use of lactose is
not generally indicated in bakery formulations requiring
sugar. Moreover, lactose is unfermentable by baker's
yeast, and thus cannot contribute (as a nutrient) to
the dough fermentation process. For these reasons, as
well as others noted hereafter, lactose is specifically
used in bakery products only as an additive, with the
proportion of use restricted to relatively low levels.
One prospect for a more widespread use of
lactose in baking is the possibility of substituting
`~ lactose-containing dried whey for the non-fat milk solids
~ customarily used in bakery formulations. As is well
. . .
- known, the commercial development of non-fat dry milk
has been one of the major developments in American
baking technology. Thus, non-fat milk solids (obtained
by the complete drying of separated or skim milk) serves
- to improve both the nutritional value and qeneral
physical qualities of bakery products in which they
- 30 are used. Because dried whey is derived as a
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by-product of cheese-rnaking, and is thus available at
relatively low cost (and is also highly nutritional), the
prospect of using dried whey as an additive or substitute
for non-fat milk solids has received considerable
S attention. However, widespread use of whey has been
prevented by the indication that whey in bread formulas
results in depressed loaf volumes, and consequent
lowerlng of bread quality. A principal factor in this
volume-depressing effect is believed to be the presence of
the lactose in the whey.* To remedy this indicated
defect, de-lactosed wheys (i.e., protein concentrates)
have been developed, and have been used as additives or
partial substitutes for non-fat milk solids. Consequently,
although numerous literature references have indicated
theoretical or potential advantages of using lactose
in baking formulations, the foregoing considerations
as well as disadvantages related specifically to the use
lactose, have prevented any actual widespread adoption
of lactose as a principal ingredient in baking formulations.
It is further noted that prodigious quantities
of liquid whey (and lactose) are available to the
industry. Thus, it is estimated that some 17 billion
pounds of liquid whey are derived annually as a
by-product of cheese-making. As only about one-fourth
to one-third of this liquid whey is utilized in food
products, the remainder presents a staggering problem
of waste disposal which, through dumping into streams,
*See "Use of Whey in Baking", by E. J. Guy, Proceedings of
Whey Products Conference, ~une 1~-15, 1972, U.S. Dept. of
Agriculture.
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L~1334
lakes, ancl sewage disposal systems, con-tributes to
pollution.
From the foregoing, it will be apparent
that any significant or improved utilization oE lactose
in the ba]cing industry, as we:Ll as elsewhere, is
greatly to be desired.
Summary of the Invention and Objects
This invention relates to edible bakery
products such as bread, rolls, sweet goods, cakes,
cookies and the like, and to processes for their
manufacture, and in particular to such products and
processes wherein lactose is incorporated as a principal
ingredient in the dough mix.
~; In general, it is an object of the present
invention to provide high-quality bakery products of ;
the above character wherein a substantial portion of the
sugar and/or fat content of the dough mix is replaced
with lactose.
It is a particular object of the invention to
provide a process utilizing lactose as a replacement
for substantial portions of the sugar or fat content, in
a dough formulation, which is adaptable to a wide variety
of bakery formulations and procedures.
Another object of the invention is to provide
baked goods based on use of lactose in the formulation
which are of substantially improved quality, particularly
- as respects increased volume, prolonged shelf-life or
"freshness"~ flavor, appearance and aroma.
Another object of the invention is to provide
an improvement in bakery processing, in which optimum
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dough and product characteristics are developed in a
novel manner through lactose replacement of the sugar and
fat content in the dough.
As a general statcment, the presen-t invention
is predicated on our discovery that lactose can be
used as a replacement for up to 60~ of either the sugar
content (e.g., sucrose or dextrose) or the fa-t content
(e.g., shortening), or both, in dough processes for
producing a variety of baked goods (viz., bread, rolls~
sweet goods, cake or cookies), with significant and
unexpected improvements in the quality of the resulting
baked products.
Specifically, we have found that yeast leavened
products such as bread, rolls, sweet goods, yeast raised
donuts and the like can be processed on the basis of
the indicated lactose subtitution with significant
increases in the volume of the resulting products (10 to
15%) and with substantially improved keeping qualities
(50~ to as high as 400%). Similar results have been
obtained with chemically leavened products such as cakes,
cookies and the like. For example~ in making cookies,
essential "cookie spread" (normally attributed to the
sugar content), is equal or better than that obtained
with conventional formulations. 5ignificant improvements
in dough qualities, in the form of improved workability,
and machining of the dough, and in baking qualities,
represented by improved tenderness, flavor, color, and
aroma of the finished products, are also obtained. These
results are unusual and unexpected, not only because of the
lack of sweetness and flavor and the unfermentable character
33~
of the lactose, but because of the inherent lack of
plasticity and known volume-depressing characteristics
of the lactose ingredient, which would lead one away
from substitution of lactose for either the sugar or
shortening content of conventional dough formulas.
We have specifically found that lactose is capable
of functioning as a direct replacement for 10 -to 60% of
the sugar or fat without any deterioration in product
qualities, which are generally more satisfactory than
obtained with conventional dough formulations.
Specifically, in the case of bread, values for internal
and external appearance, tenderness and shelf-life are
; substantially better than control breads, using normalamounts of sugar and shortening. Similar results are
obtained with cake doughs and baked products.
Moreover, when used as a replacement for the sugar
and shortening in the bakery formulas, the separate
components (sugar, shortening and lactose~ additionally
cooperate with one another to provide cumulative or
synergistic effects which provides measurable improvements
in process and product characteristics, as compared to
such processes and products where lactose is omitted.
Finally, the addition of amounts of lactose ranging from
10 to 100% of the proportion of substituted lactose,
achieves further quality improvements of the type
- described.
Other objects and features of the invention
will appear from the following description in which
preferred embodiments are set forth.
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Description of the Preferred Embodiments
Sugars and fats play an important role in the
production of virtually every type of bakery product.
Based on the weight cf the flour, the sugar and fat
content may range from a low of about 10~ in bread and
rolls to 30 or 40~ in sweet goods, and as high as 150 to
200% or higher in cakes and cookies. Although the
functions of these ingredients in the various dough
mixes are diverse, they are well known and important
to the co~ercial baker.
Sugar (sucrose) and corn sugar (dextrose) are
primary ingredients in a wide variety of bakery products,
for sweetenina and flavorin ar.d as a fermentation source
-for leavening. Sucrose, as obtained from sugar cane or
sugar beets, is by far the most important of the commercial
sugars, being used in bread formulations at levels ranging from
2 to 14% (average about 8~. Although adequate carbon
dioxide production for leavening can be obtained with
about 2 to 3~ sucrose, the higher le~el is commonly used
to achieve accelerated fermentation rates as well as
desired product characteristics, viz., crust color, volume,
flavorO keeping quality, etc. Sugar plays a similar role
in other yeast leavened products such as rolls, sweet
goods, yeast raised donuts, and similar products. In
chemically lea~ened products such as cakes, cookies and
the like, sugar plays a principal role as a flavoring or
sweetening ingredient. However, in cookie production
the hygroscopic qualities of sugar are important to
obtaining a uniorm "cookie spread". Thus, as is well
known, any dough component or condition that tends to reduce
- , . . , , ~ . . , ~ . ~ , . . .
3~
the moisture available for -the solution of sugar will
restrict cookie spread, as sugar represen-ts the
principal spreading ingredient. The proportion of sugar
also tends to effect the moisture content and retention
of the final product and consequently the shelf-life
of the product.
The importance of fat or shortening in
bakery formulations is related primarily to two
characteristics, plasticity and organoleptic quality
(viz., flavor, aroma, mouth feel). In yeast leavened
products such as bread and rolls, shortening contributes
to plasticity or lubrication of the dough and softness
of the end product. The plasticity or so-called
shortening effect insures film forming qualities for
gas retention during proof and early bake. The quality
of lubrication is necessary during development and
machining to avoid stickiness of the dough. In chemically
. leavened products such as cakes and cookies, the
plasticity imparted by the shortening facilitates the
mixing or creaming process to entrap and retain
considerable quantities of air. This insures an
important leavening effect, particularly in cakes of
high sugar content. The fat or shortening can also
provide a moistening effect through emulsification to
retain water and a tenderizing effect to provide softness
of the final product.
In general, there is little reason to replace
. sugar in the typical baking formula. Thus, sugar is
not only ideally suited for its purpose, but has
30 been readily available. Although recen-t advances in
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33~
world sugar prices might suggest some reason for
re-evaluating the use of sugar, there has been no
appreciable effort in this direction. In contrast,
a highly specialized shortening industry has developed
since the turn of the century. Principal emphasis has
been to develop desired consistencies or plastic
qualities while retaining commercially acceptable
flavor. In ~eneral, the principal sources of commercial
shortenings are vegetable oils and animal fats (e.g.,
lard). Again, apart from technological improvements,
there has been little reason to replace the existing
fat sources with other sources, but rather the emphasis
has been to modify the characteristics of existing
- shortenings through use of various surfactants as
"emulsifiers", "bread softeners", and the like.
According to the present invention dried
crystalline lactose is substituted in specific dough
formulation in proportions equivalent to 10 - 60% of the
sugar, corn sugar and/or shortening ingredients referred
to above. In this regard "sugar" is used in the customary -
dictionary sense as defining the substance consisting -
entirely or essentially of sucrose, as derived principally
from sugar cane and sugar beet but also from sugar maple, -
sorghum and like sources. "Corn sugar" is also used in
the dictionary sense of identifying specifically dextrose,
although the substitution of lactose for corn syrup is
clearly contemplated.
The terms "fat" and "shortening" as used herein -
are intended to cover the various commercially available
plastic shortenings, of animal and/or vegetable origin, as ;
~: .
~ ;
_ g~
, . . : . .
il33~
used in the bakery trade. Particular types of shortenings
include lard, plastic animal and vegetable shortenings,
plastic emulsified animal and vegetable shortening, plastic
vegetable shortenin~, plastic emulsified vegetable shorten-
ing, and fluid aerating shortenings, among others. Includedalso are the so called "compound" and "general-purpose"
shortenings, as well as all-hy~rogenated shortenings, and
in particular, specialized shortening products such as
butter and margarines. In conventional baking formulations,
lQ the ~unctions of such fats and shortenings are, generally,
to produce shortness and tenderness, to aid in the aeration
and to improve the eating quality of the product, to stabi-
lize batters such as cake batters, and to improve the keeping
qualities of the product. Additionally, in the case of
butter and lard, the shortening ingredient imparts a
distinct flavor.
According to the present invention, the lactose
is incorporated into dough formulations in the manner of
any dry subdivided material, such as nonfat milk solids,
2Q sugar or salt. Utility and effectiveness of the lactose
substitution is indicated for virtually any dough fcrmula-
tion making use of the functions of sugar and shortening,
ranging from low-sugar-level products such as yeast
leavened bread to high-sugar-level products such as cakes
and cookies. The indicated substitution is effective for
use in virtually any method for dough preparation including
the straight dough and sponge dough procedures and batch
or continuous mix techniques~ In general, and assuming
a dough ~or~ula and process wherein conventional dough
ingredients including flour~ water, sugar, shortenina and
~,,
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leavening are mixed to form a dough, the improvement of
the present invention comprises replacing from 10-60~
of the weight of the sugar or shortening in the dough
with lactose, followed by mixing the dough ingredients
including the lactose component to form a dough, divid-
ing the dough into units for baking, and baking the units
to provide bakery products having improved character-
istics as respects appearance, flavor, aroma and, in
particularly, increased volume, prolonged freshness and
shelf life, as indicated herein.
With particular reference to the production
of leaven bread (e.g., white bread, variety breads such
as whole-wheat, rye, raisin, honey-nut, etc.), a typical,
- generalized formulation for preparing bread dough is
set forth in the following table, in terms of operable ranges
of sugar, fat and lactose, as well as optimum proportions
of remaining essential ingredients in the bread dough
formula. Also presented in the table is a typical,
generalized formulation for yeast leavened sweet goods
(e.g., raisin and cinnamon rolls; Danish rolls). In this
table, the proportions of all ingredients are expressed as
percent of the r1Our.
.
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TABLE I
Component Bread Sweet Goods
Flour 100.0 100.0
Water 65.0 50 - 60
Yeast 3.0 4 - lO
Salt 2.25 2 - 3
Sugar 2.8 - 6r3 5.5 - 12.5
Corn Sugar 2.5 - 5.5
Shortening 1.2 - 2.7 6 - 13.5
Lactose l.0 - 6.0 3.5 - 21
In the foregoing formulations, the indicated
ranges for lactose sugar and shortening are representative
of a 10-60% substitution of the lactose for either the
sugar or shortening content. Leavening is, of couxse,
obtained by yeast fermentation of the sugar and any added
yeast-food or like ingredient.
In the following Table II, a representative
formula is presented for chemically leavened white cake,
made with an emulsifier-type shortening. Again, the
2Q proportions of ingredients are expressed as percent of
the flour.
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TAsLE II
Component Cake
Flour 100
Egg Whites 45 - 80
Milk 25 - 110
Baking Powder 6 - 7
Salt 3 - S
Flavor 2 - 3
Sugar 60 - 130
Shortening 35 - 60
Lactose 20 - 120
It will be evident that similar representative
formulas can be provided for other types of cakes such
as yellow cake, devils food cake, chocolate cake, spice
cake and the like. While typical cookie formulations
could also be presented, it is well-known that there is
almost a limitless variation in cookie formulations for
-~, the various types of cookies (viz., wire-cut cookies,
rotary machine cookies, cutting machine cookies, etc.).
Accordingly, it is impractical to attempt to provide
any generalized formula similar to the ones presented
above with respect to bread~ sweet goods, and cake.
It will be understood that a particular
lactose substitution, to provide optimum effects within
the foregoing operable ranges, will depend upon the
particular dough system and product characteristics
~ desired, although within the indicated range of 10 to
;, 60% on the weight of the sugar and/or shortening in the
~ormula.
"
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The following examples are intended to be
illustrative of the practice of the present invention
and also of the beneficial substitution of lactose for
a substantial portion of the sugar and/or shortening
content in the dough mix. In these examples, all
concentrations of ingredients are expressed as percent
of the flour.
EXAMPLE I
Dough Formula - White Bread-
__ _ __
RegularWith Lactose
Ingredient MixSu~stitution
_ _
Flour 100.0 100.0
Water 65.0 65.0
: Yeast 3.0 3.0
Yeast Food 0.5 0.5
Emulsifier 0.5 0.5
-~ Salt 2.0 2.0
. Nonfat Dry Milk 3.0 3.0
Sugar (Sucrose) 8.0 3.2 - 7.2
Shortening 3.0 1.2 - 2.7
Lactose --- 1.1 - 6.6
Procedure Regular
1. Combine all dry ingredients and mix 1 minute at low
speed.
-~ 2. Dissol~e yeast in water, add yeast slurry to dry
ingredients and mix 1 minute at low speed to form
dough.
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3. Mix dough -to development at medium speed (about 8
minutes).
4. Ferment for 45 minutes in greased container.
5. Divide and round.
6. Proof (intermediate) for 10 minutes.
7. Mold.
8. Proof (final) for 60 minutes ~10F., 90~R.H.).
9. Bake at 400F. for 20 minutes.
Procedure - With Lactose Substitution
The procedure is the same except that lactose
is substituted for the sugar and shortening content of
the dough, within the indicated range of proportions.
The resulting baked breads are evaluated with respect to
conventional standards, tenderness, shelf lifej etc.j
in comparison to control breads made with the regular
- mix.
Results
Upon replaclng the sucrose with lactose, whlle
2Q holding the proportion of shortening constant at the
normal level, increases in loaf volume from 2500 cc. for
the regular mix are observed to an optimum loaf volume
(about 2600 cc.) at a lactose replacement approximating
two parts of lactose for each part of sucrose and sucrose
~15-
reductions o~ the order of 25 ~o 40~. ~bove the indi-
ca-ted optimum levels of replacemen-t, loa-f volumes begin
to decrease. By comparison w:Lth the control breads, it
is clearly indicated that optimum loaf volumes can be
obtained by decreasing the sucrose level while adding
lactose. Upon reducing the shortening level by one
third, with corresponding rep:Lacements of sucrose with
lactose, similar results are obtained. At reductions of
shortening up to 60%, similar results are again ob-
tained, but optimum loaf values are decreased somewhat
(i.e., to about 2500 cc or equal to the control breads).
On evaluation of the loaves by standard procedures for
external and internal appearance, optimum scores are
obtained at 25 to 35% reductions in the sucrcse with
corresponding additions of 35 to 50% lactose, when the
shortening content is held at the normal level. Sur-
prisingly, improved scores are achieved at a 33% reduc-
tion in shortening, with similar replacements of sucrose
with lactose (e.g., external score increased from 31 to
32). Tenderness scores also indicate that as lactose is
added to replace the sucrose, optimum results are ob-
tained at lower levels of sucrose (i.e., 50% replacement)
and higher levels of lactose (e.g., 60% addition). Shelf
life of the bread is also significantly increased with
the addition of lactose and reduced le~els of sucrose and
shorteniny. Specifically, as compared to a three day
shelf life for control bread, breads with only a 2%
,. .
lactose addition and a 33% reduction in sucros- and
shortening, remain fresh for four to five days, thus
indicating 30 to 60% longer shelf life. Additionally,
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exce]lent browning e~ the crust is obtained with the
lactose substitutions to provide golden brown color.
Equal or better tenderness values also occur with lactose
addition and sucrose and shortening reduction, together
with improved workability of the doughs and specific
flavor enhancement with retenticn or accentu,~-ion (-~f
color and aroma on baking.
EXAMPLE 2
Dough ]~ormula ~ Yellow Cake
Regular With Lactose
Ingredlent MiX_ Replacement
Cake Flour 100.0 100.0
Water 104.0 104.0
Liquid Eggs (whole) 33.3 33.3
Nonfat Dry Milk 12.5 12.5
Salt 2.1 2~1
Baking Powder6.25 6.25
Sugar ~Sucrose) 145.0 58.0 - 130.0
Shortening 57.0 34.0 - 51.0
Lactose -- 20.0 - 120.0
; Procedure - Regular
1. Dry blend flcur, sugar, shortening, baking powder,
salt, and nonfat dry milk.
2. Mix the eggs with half of the water.
3. Add half of the egg/water mixture to dry blended
cake rdix, and mix for 3 minutes at low speed.
4. Add remainder of egg/water mixture and mix 1~2
minute at low speed and 3 minutes at medium speed.
5. Add the balance o~ the water to the preceding cake
3a mix and mix for three minutes at low speed.
- .
. .
33~
6. Pour aliquo-t portion of cake batter (380 grams)
into 8-inch lined cake pan l~nd bake for 26 minutes
at 375F.
Procedure - With Lactose Replacement
The same procedure :is employed except that
lactose is substituted for sugar and/or shortening
~- within the ranges of proportions set forth above. Varied
cake batter mixes are thereby produced, baked and compa~ed.
Results
In response to approximately equal replacements
of sucrose with lactcse (while maintaining the norr,-,l le~e:l
of shortening), increased cake volumes ar~ obtained to an
optimum of 20 to 30% replacement of sucrose with lactose.
A fairly broad optimum response is indicated, with in-
creased vcl~mes being indicated up to 30~ replacement
of the sucrose with lactose. Upon reducing the shortening
level to 30%, with a similar pattern of su'~s'can~ially
- ~qual replacemen~s of suorose with lactose, similar in-
- cxeases in cake volumes are observed. Upon further re-
2a ducing the shortening content by approximately 60%, the
results indicated by cake volumes show lactose to be a
substantially direct replacement for the omitted shortening,
with the general leveJ of the res~lts be:ing only slightly
' less satisfactory than with the control bakes. As re5pect
appearance factors, the substantially equivalent substitu-
tion of lactose for sucrose pro~ides ex.ernal appearance
scores which are beyond the capability of the sucrose alone.
Similar results are also indicated at reduc~ions in the
shcrtenin~3 conte~t up to 30rO. Tenderness scores indicate
-18-
~a3 B'~33~
that lactose can be used as an approximately equal
replacemen-t for sucrose; with the tenderness values
equalling those of the contrc)l hakes. Cake tenderness
scores over a five day periocl (as a measure of shelf life),
specifically indicate optimum results with replacement
of both the sucrose and shortening (i.e., at 20 to 30%
levels), in comparison to the control bakes wherein no
lactose replacement is used. Significantly, compressability
or tenderness scores over the five day period indicate
extensions in the shelf life or "freshness" of the
lactose substituted cakes ranging to 50% or more, as
; respects the control bakes. The comparative results notonly indicate that the addition of lactose promotes ~ -
tenderizing of cakes and like baked goods, but, also,
that the use of lactose permits greater tolerances in
the dough as respects variations in ingredients, workability,
and machining qualities.
A particularly significant observation is that
merely adding lactose to the cake formulations without
any concurrent reduction in sucrose, causes a substantial ~-
reduction in cake volumes. Thus, replacement of sucrose
with lactose resulted in substantial increases in the cake
volumes, whereas merely adding lactose without replacement
of sucrose resulted in the volume-depression ef~ect
observed by previous researchers. While the reasons
for this phenomena are no-t clearly understood, one
possibility :is that the favorable result (viz., the
increase in cake volumes with replacement of sucrose and
shortening by lactose) is due to the tenderizing effects
of the lactose, with a concurrent ability of the modified
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formulation to retain the crumb structure and texture
of the cake. In contrast, at excessive lactose levels,
the greater tenderizing effect may conversely weaken
the grain structure and texture and, coupled with higher
osmotic effects, cause decreases in volume. In any event,
the positive indieations of use of the disclosed
replacement coneept are clearly contrary to the prior
research indications related simply to lactose additions.
In general, foregoing examples were chosen to
illustrate the use of lactose replaeement of sugar and
shortening in diverse bakery products (specifically, in
a low sugar, yeast lea~ened bread and in a relatively
high sugar chemieally leavened cake), under substantially
different conditions of formula and mixing procedure.
It is, of eourse, not praetical or feasible to illustrate
all possible variations by way of~specifie example, and
the diselosures and deseriptions herein should eonsequently
be eonsidered as merely illustrative and not in any
sense limiting.
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