Note: Descriptions are shown in the official language in which they were submitted.
i248~06
PILA:010
HIGH STABILITY, HIGH FLAVOR, BREAKFAST PASTRY
This invention relates to an improved pastry product
of the type which is prepared with an interior filling,
which is cooked, packaged, and frozen. The user thaws the
product and toasts it, or toasts directly from the freezer.
Such toaster pastries present numerous technical problems
in their preparation, storage and stability.
One of the primary problems for such toaster pastry
products is the development of a product which not only
has high flavor, but is also storage stable. One rather
logical method of achievin~ high flavor is to utilize a
high moisture content product with a very large quantity
of interior filling and minimal surface contact. However,
while this might maximize the flavor impact for the
consumer, it necessarily will cause product stability
problems.
For example, a larger quantity of filling means that
there is a minimization of area of interface contact
between the filling and the interior dough surface. The
~.
-2- ~ ~ ~ ~
area of this surface contact, i.e., the interface, is a
potential area of instability caused by numerous chemical
degradation reactions. Amongst the things that may often
be noted at the interface are the following: moisture
migration from the filling to the dough which develops
sogginess in the dough; acid migration from a fruit
filling to the dough which develops a loss in pH and fruit
tartness; color changes because the filling color changes
with changes in acidity; dough and filling flavor loss;
and, degradation of product structural integrity.
One commonly employed technique heretofore used to
overcome these significant stability problems, has been to
develop toaster products of very low moisture content.
Decreasing the moisture content is desirable because it
increases shelf life~ For example some products have been
sold with as low a filling moisture content as 15% to 20
by weight, and a dough moisture content of from about 8
to about 12%. While it is true that such low moisture
content products have good shelf storage, the shelf
storage is achieved at the sacrifice of product taste and
flavor quality. In other words, because the product is
dry, it is shelf stable, but it also has a very low flavor
impact and mouth feel quality.
Thus, the manufacturers of such toaster pastry
p;oducts have been faced with a dilemma. Those things
which make the product most desirable for the consumer,
namely, flaky, crispy tender exterior crust, tender and
moist interior, high percentage of filling with the pastry
crust, as well as high moisture level in the filling,
also make the product most undesirable from the standpoint
of storage and stability.
_3_ ~ 2 4 8 ~ ~ 6
It is therefore one primary objective of the present
invention to provide a breakfast pastry product which is
of excellent product quality, both from the standpoint of
flavor and structural integrity, and yet which is uniquely
stable for long period of time.
It is another objective of the present invention to
achieve the above described result with a product which
has a significantly higher moisture level than other
breakfast pastry products heretofore prepared by cooking,
freezing, thawing, and subsequent toasting.
A still ~urther object of this invention is to
prepare a breakfast pastry product which has a very high
moisture content and as well, a long shelf life stability
when frozen~
An additional object of the present invention is to
prepare a product which because of the dough composition
and the filling composition, has substantially the same
water activity level (Aw) for both the dough portion of
the composition and the filling portion of the composi-
tion, thus minimizing moisture migration at the interface
between the coo~ed dough and the filling.
Another objective of the present invention is to
prepare a toaster pastry product with a fruit or acid type
filling which has a controlled buffering pH system to
provide acid stability to minimize acid migration which in
turn controls color change and flavor loss of the filling.
An even further objective of the present invention is
to provide a toaster pastry product of good structural
integrity, that is to say, one which has good product
_4_ ~2~8406
seams, one which will not become soggy and break, and yet
one which has a tender, flaky exterior surface and a
bready interior with good cell development.
The method and manner of accomplishing each of the
above objectives, as well as others, is achieved by
careful control of filling viscosity and pH, and control
of dough Aw and filling Aw, combined with control of dough
composition and processing.
This invention relates to an improved pastry such as
a breakfast, toaster pastry product, of high moisture
content, of good storage stability, of high flavor and of
good product integrity. These beneficial results are
achieved by careful control of pastry filling viscosity
and pH, and careful control of pastry dough composition
and processing, all of which combined in the finished
product to provide a high moisture product which at the
interface of the filling and the dough has low moisture
migration, low acid migration, resistance to color change
and flavor loss, and which still provides a product of
good structural integrity, flaky, tender exterior crust,
and bready interior with good cell development and absence
of visible layering.
According to one aspect of this invention, there is
provided a high moisture, shelf stable and product stable
filling, especially for toaster brea~fast pastries,
comprising: a flavored pastry filling material having a
viscosity of from about 20,000 cps to about 60,000 cps, a
starch content of from about 3.5% by weight to about 8% by
weight, a gum content of from about .15% by weight to
about .4~ by weight, a pH of from about 2.8 to about 7.5;
and a total moisture content of from about 30% to about
50% by weight.
-5- ~24840~
The invention further extends to a high moisture
laminated dough pad, which when cooked, frozen and.later
thawed and toasted, will provide flaky, delamination
resistant exterior surface, and at the same time a bready,
well developed interior cell structure which is stable at
its most interior surface with respect to any area of
contact with filling, comprising: a laminated mixed dough
and roll in shortening pad having from about 2 to 12
substantially discreet and continuous roll-in shortening
layers per millimeter of pad thickness, said mixed dough
being from about 45% to about 60% by weight of flour and
from shortening comprising from about 4% to about 20% by
weight of said laminated dough pad, and the overall
thickness of said laminated dough pad being such that it
will, after cooking, freezing and thawing, easily fit
within a toaster.
The invention also extends to a breakfast pastry of
high moisture, excellent shelf life and product stability,
high flavor impact and which is notably resistant to
deterioriation at the interface of cooked doùgh and
filling, comprising: a cooked dough shell encasing an
interior filling, said cooked dough having a flaky exterior
surface, and at the same time a bready well developed
interior cell structure which is uniquely stable at its
most interior surface with respect to its area of contact
with said interior filling, said filling comprising a
pastry filling have a viscosity of from about 20,000 cps
to about 60,000 cps, a starch content of from about 3.5%
to about 8% by weight, a gum content of from about 0.1~ to
about .4% by weight, a pH of from about 2.8 to about 7.5,
and a total moisture content of from about 30% to about
50% by weight.
- 5a - 124~406
The subject matter of this divisional specification
relates to a method of making a cooked dough pad, which
when fried, stored, refrigerated or frozen and later
reheated, will provide a flaky, delamination resistant
exterior surface, and at the same time a bready, well
developed interior cell structure, said method comprising:
(a) forming a dough and laminating said dough and roll
in shortening forming a laminated dough pad having from
about 2 to about 12 substantially discreet and continuous
roll-in shortening layers per millimeter of pad thickness,
said dough containing flour in the range of from about
45% to about 60% by weight of dough and total water in
the range of from about 32% to about 50% by weight of
dough, said pad including roll in shortening in the range
of about 4% to about 20% by weight of said pad, and the
overall thickness of said pad being such that it will,
after frying, easily fit within a toaster, (b) frying
said pad, (c) storing said fried pad in a refrigerated
or frozen condition and thereafter (d) reheating said
pad.
-6- ~2~40~
The filling material viscosity is carefully controlled
within the range of about 20,000 cps to 60,000 cps and the
pH is controlled within the range of about 2.8 to about
7.5, and with respect to ruit fillings, about 2.8 to
S about 3.4. The preferred dough formulation is a high
moisture mixed dough and roll-in shortening laminated pad,
with the laminated pad having from about 2 to about 12
substantially discreet and substantially continuous
shortening layers per millimeter of pad thickness, with
the mixed dough portion of the pad being from about 45~ to
about 60~ by weight of a moderately strong flour, about
30% to about 45% of added or of total water by weight, and
with the roll-in shortening comprising from about 4% to
about 20% by weight of the laminated dough pad.
The product of the present invention has been espe-
cially designed to provide a cooperative relationship and
interaction between the filling of a breakfast toaster
pastry and the dough formulation. Because of this inter-
action and the equilibrium which is set up between the twoat their interface, the result is a product which can
provide unique stability, high structural integrity and
high product quality.
The term "structural integrity" as used herein,
refers to a product which can be easily handled and
prepared by the consumer without breaking apart because of
such things as weak dough seams, sogginess or the like.
The term "product quality" refers to the combination of
conditions which a consumer typically perceives as high
quality for bakery pastries. Among those conditions are
good, tender, flaky and crisp pastry surface, tender and
moist interior, higher moisture level to obtain both a
desirable mouth feel and a higher flavor impact, uniformity
~7~ ~2484~6
of exterior surface browning, uniformity of interior
filling color, and freshness.
As heretofore mentioned, there is a unique problem
with toaster products which are to be fried, frozen,
packaged and shipped, as distinguished from products fresh
made in a bakery and immediately sold, such as jelly
donuts and bismarks. The latter type products are not
concerned so much with product stability, because it is
known that they will either be eaten or discarded in a
very short time. In other words, they do not have to have
a long shelf life. Of course, it goes without saying that
long shelf life and product stability are particularly
desirable for products which are in fact going to be
shippped after cooking, freezing, and then subjected to a
subsequent thaw and toasting.
High moisture level is desirable in such filled
products, because the consumer perceives this upon tasting
as part of the initial flavor impact, and also in part as
a desirable mouth feel. Typically a product such as a
fresh made jelly donut will employ a filling having a
moisture content of from as much as 40% to 60% by weight
of the filling. Heretofore, one has not been able to
achieve moisture levels within this range for breakfast
pastry products of the type which are to be cooked, frozen
and subsequently thawed. In such products, moisture
levels of the range of from about 15% to about 20% have
been employed for the interior filling. It has been
customary to reduce the moisture levels of such products
in order to increase their shelf stability and to minimize
the interaction at the interface between the interior
filling and the encasing, interior dough surface. Doing
so will, of course, achieve the more desirable shelf
stability, but it does so only at the sacrifice of product
quality.
~ ~248406
It has now been found that primary contributors to
the problem of product stability at the interface of the
dough and the interior filling have been moisture migra-
tion from the filling to the dough, and acid migration
from the filling to the dough. The moisture migration
causes sogginess in the dough, a change of the pastry
texture and quality and increases significantly the risk
of structural integrity failure. The acid migration
causes several effects. It changes the taste and texture
of the dough. It often changes the color of the interior
filling; it often changes the color of the dough at the
interface between the dough and the filling; and as the
acidity decreases in the filling because of hydrogen ion
migrations into the dough, the tartness and flavor impact
of the filling is decreased.
It has now been found that these undesirable effects
of a high ~oisture filling can be controlled through
control of filling viscosity and filling acid stability,
and if so controlled, a high filling moisture level, i.e.,
as high as from about 30% to 50~ by weight can be utilized,
and still a stable product will be provided.
The fillings typically comprise sweeteners, water,
viscosifiers, flavors and when appropriate, accidulants
and their salts. It is to be understood that other
fillings can be used in the pastry such as pizza flavored
filling or the like. A wide variety of jelly, or filling,
compositions and flavors can be used in the present
invention. There is no specific limitation on many of
the ingredients of the filling composition, each of those
being used to develop the desired sweetness-tartness
combination one chooses, as well as the specific flavors,
such as grape, strawberry, cinnamon, cherry, blueberry,
:
-g- i2484~)6
etc. Shown in Table 1 is a typical filling formulation
which might be utilized in the pastry industry.
TABLE 1 - FRUIT FILLING FORMULATION
In~redient Percent by Weight
Sugar 15-204
Water 40-70%
Fruit 5-10
Corn Syrup 5-10%
Artifical Flavoring 1-2%
Coloring Less than .25%
Modified Starches 2-3%
Preservatives (Potassium Sorbate,
Sodium Benzoate) Up to 1%
Gum up to .1%
What has been discovered, i5 that the significant
normally occurring interactions between the filling and
the dough can be minimized and brought into equilibrium
such that there is good product guality and stability,
providing that one carefully controls both the viscosity
of the filling composition and particularly for fruit
fillings, the pH, by employing a pH buffering system.
5
Providing that both riscosity and pH are controlled
within the ranges hereinafter specified, it has been found
that the filling formulation of this invention, in combina-
tion with the dough composition of this invention, will
achieve a product of both high product quality and high
moisture content, and yet one of good shelf stability and
product stability. This is particularly so at the inter-
face between the filling and the interior surface of the
fried dough.
_, o ~2~8~6
It is not known precisely what causes this unique
interaction and the resulting high product quality and
high stability. But it is known that typical prior art
products such as fried fruit pies and the like, have a
very short shelf life, as low as a week or so at ambient.
The product of this invention can be successfully stored,
frozen at least as long as three months, and at times up
to six to nine months. Stability after subsequent thawing
is in excess of two weeks in the refrigerator, all without
any significant effect upon product stability or quality.
The viscosity of the filling utilized in combination
with the dough formulation of this invention should be
within the range of from about 20,000 centipoises (cps) to
about 60,000 cps, preferably from about 30,000 cps to
about 50,000 cps, and most preferably about 40,000 cps.
For completeness, it should be mentioned that the viscosity
ranges as mentioned herein are measured on a Brookfield*
Viscometer RVT No. 7 spindle at 50 rpm, and a temperature
Of 72F.
The desired viscosity control can be accomplished by
control of the starch level in the filling composition,
and the gum level, with sufficient amounts being added to
achieve the specified viscosity ranges. The modified
starch level in conventional fillings is from about 2~ to
about 3% by weight, as shown in the table above. In the
present invention, the moclified starch level ranges from
about 3.5% by weight of the filling to about 8% by weight
of the filling, more preferably from about 4% by weight of
the filling to about 6% and most preferably, from about 4%
to about 5% by weight.
In addition to the modified starch level being higher
than normal, the gum content differs considerably. ~ums,
*Trade Mark
248406
such as Xan~han gum, guar gum, and locust bean gum are
commonly employed in fillings, as indicated in the table.
However, the level typically used is very low, being 0.1%
by weight or less. In this invention, the gum level is
increased to within the range of from about .15% up to as
high a 0.4% by weight of th~ filing, with a preferred
range of from 0.15% by welght to about 0.25% by weight,
with the most preferred level being about 0.2% by weight.
The gum can be any of the typical gums used, such as those
mentioned above.
As heretofore mentioned, in addition to controlling
the viscosity of the filling composition, the pH is
carfully controlled in acidified or fruit type fillings.
In non-fruit fillings, the pH may vary over a wider range
of from 2.8 to 7.5. pH control is provided in the inven-
tion formulation for fruit containing, fruit flavored, and
other acidic type fillings hereinafter referred to as
acidic fillings, to provide a pH within the range of from
about 2.8 to 3.4, most preferably within the range of from
about 3.0 to 3.1. These are fairly high acidity levels,
resulting in a high titratable acid level when compared
with conventional fillings. For example, the titratable
acidity of the fruit fillings of this invention is within
the range of from 0.5% to about 2% titratable acid, as
citric acid.
The pH and titratable acidity of the acidic fillings
are controlled within the ranges previously mentioned in
order to assure that when hydrogen ions migrate into the
dough, there is a sufficiently high level of acidity left
to maintain both tartness and product color. Also, the
employment of a buffering system, as described below, does
maintain some of the hydrogen ion concentration which
-12- ~2484~6
might otherwise decrease during cooking, and the subse-
quent subjection of product to freezing, storage, thawing
and toasting.
In applicant's filling composition, the pH range
previously specified is achieved by adding an edible acid,
along with a salt of the edible acid to provide a p~
buffering system. Typical edible acids which may be
employed along with their typical salts, are citric
acid/sodium tartarate, and the corresponding dicarboxylic
acids such as adipic acid~ and succinic acid. The amount
will, of course, vary depending upon the other filling
composition ingredients, with the amount being whatever is
necessary to achieve a pH within the ranges specified.
However, generally the amount of added acid will be an
amount sufficient to achieve a final titratable acidity
within the broad range of from about 0.5% to about 2% by
weight of the filling composition, preferabley from .7% to
about 1.5~ by weight. It should be emphasized that these
amounts are offered not as absolutes of edible acids/salt
buffering system levels, but merely as guidelines. The
important and critical features, the amount added, and the
pH that is achieved. The most preferred combination
because of its availability, and common use with fruit
compositions, is citric acid/sodium citrate.
When both the viscosity and the pH as mentioned
herein are employed, it has been found that the filling
composition is particularly stable; and in spite of high
moisture content, does not detract either from product
quality, appearance or flavor, even during long storage
conditions and even during frying, freezing and subsequent
thawing and toasting. Thus, the filling composition, both
because of the unique combination of physical conditions
-13- ~248406
as well as its chemical composition, provides a filling of
high shear resistance, high temperature resistance, good
freeze-thaw resistance, and a filling of long shelf life,
and of high flavor quality. Moreover, the filling compo-
sition, particularly when employed in combination with thedough composition of this invention, has the proper water
activity level (Aw) to allow the filling to act as a
moisture sink to absorb moisture from the dough during
frying, without subsequent return of that moisture to the
dough. Also, the composition does not leak at the dough
shell seams during frying or subsequent toasting, even
though the dough may be a docked one.
We turn now to a description of the dough composition,
which is most preferably used in combination with the
above described filling. In developing the product
described herein a problem with the cooked dough product
quality and attributes arose. In the manufacture of dough
products which are non-laminated and fried the product is
acceptable from a greasiness standpoint but, such products
are not flaky and crispy on the exterior. To make a
flaky/crispy fried product, laminated dough having layers
of flour/water matrix alternating with layers of shorten-
ing is used. However, because of the higher level of
shortening in the laminated product, the products are
considered to be greasy by a consumer. A fried non-
laminated product does not exhibit the desirable flaky/
crispy exterior. Thus the problem was to provide a method
of producing a product which exhibits all three character-
istics of flaky, crispy, and non greasy which heretoforeto our knowledge, has not been achievable. It was thought
that fried products would either be non greasy and have a
non flaky non crispy exterior or would have a flaky/crispy
exterior but would be greasy. Because consumers would
_14- ~2~8~06
more readily accept a non greasy product without the
flakiness or crispness than one exhibiting flakiness and
crispness with greasiness conventional wisdom would direct
one to the use of a non-laminated fried product. It was
unexpectedly found that by controlling the formulation, as
hereinafter described, and certain dough properties that
all three characteristics could be achieved by frying
laminated dough.
One of the objectives of this product is to achieve a
pastry product which utilizes a leavened dough . Leavened
doughs are desirable because the leavening provides good
product volume, and aids greatly in tenderness and crisp-
ness. It is what one would expect to purchase in a
bakery, and what the consumer normally expects in a high
quality product. The fact that a product is to be a
leavened one, increases the problems encountered in pre-
paring a stable toaster product. Of course, an unleavened
product which does not have nearly the porous cellular
struc~ure of a leavened product is generally more stable
for several reasons. First , it can be highly compressed
and made with a very crumbly, dried dough-like appearance;
secondly, the lack of a well developed cell structure will
mean that moisture migration and acid migration from the
filiing to the dough composition will be less; and third,
the area of surface contact between the filling and the
dough is minimized.
However, while there are some desirable stability
factors achieved in such a compressed, dry, low moisture
content dough composition, it also necessarily involves
extreme sacrifices in product quality. In accordance with
the present invention, the dough formulation, when used in
combination with the filling previously described, pro-
vides a high moisture content dough of excellent exterior
~15- 1 2 4 8 4 O 6
fla~iness, which is tender and crisp, and has a well
develped interior cell structure, like freshly purchased
fried pastries.
.
To achieve the desirable objectives of the present
invention, one should employ a moderately strong, or
stronger flour hereinafter referred to as strong flour.
As those skilled in the art know, the strength of a flour
refers to its protein content. Such moderately strong
flours are typically high in gluten content, with the
flour having a flour protein content of from about 9% to
about 15% by weight of flour preferably from about 10% to
about 13% by weight of flour, and most preferably from
about 11% to about 12.8% by weight of flour. Such flours
can be bleached flours, and usually are.
The dough formulation typically comprises a mixed
dough of flour, water, leavening, dough shortening, and
optionally, sugars, salt, dough conditioners, flavors and
emulsifiers, which is combined with roll-in shortening to
form a laminated dough pad. The laminated dough pad com-
prises alternating substantially discrete and continuous
layers of mixed dough and roll-in shortening.
The mixed dough formulation of this invention, is a
leavened dough. It can be yeast leavened or chemical
leavened or a combination of the two. The yeast, which
may be typical ba~er's dry yeast, is added at a level of
from 0.5% by weight to about 4% by weight of dough,
preferably from about l~ by weight to about 3% by weight
of dough, and most preferably about l.2% by weight to
about 1.8% by weight of the mixed dough formulation. The
mixed dough formulation also has some added dough shorten-
ing, to be distinguished from hereinafter described
-16- 1248406
roll-in shortening, with the amount ranging from about .5%
to about 10% by weight of the mixed dough mix, preferably
from about 1~ to about 5% by weight, and most preferably
from about 2% to about 3% by weight.
The dry ingredients of the mixed dough formulation
are added to water, with the flour and water content
within the ranges from about 45% to about 60% by weight
flour and from about 30% to about 45% by weight added
water. The most preferred flour and water content in
the mixed dough formulation are from about 54% to about
55% by weight high protein flour and an added water level
from about 34% to 36% by weight of dough. The total
moisture content of the laminated dough including water in
the shortening before frying should be within the range of
between about 32% and about 50%, preferably between about
34% and about 45% and most preferably between about
37% and about 41% by total weight of dough pad.
It has been found important to this invention that
the mixed dough flour be a high protein flour as herein-
before described, and that the flour to water ratio be
within the range as just described. It is important that
these levels are employed in the mixed dough co~position
in order to achieve the desired rheological properties,
once roll-in shortening is a~ded.
The mixed dough composition also has added sugars,
salts, and a certain low level of emulsifying agent. The
amount of sugar added may range from 0% to 10% by weight
of dough mix, depending upon the sweetness desired, with
from about 1% to about 5% being typical, and most prefer-
ably for this invention, at about 1.75%. As those skilled
in the art know, the sugar level controls the sweetness
~Z48~06
-17-
and as well, has some effect upon the controlled browning
during cooking and toasting.
The salt level may be within the range of from about
.5% to about 1.5% by weight in the mixed dough composition,
preferably from about 1% to_about 1.2% by weight. Emulsi-
fying agents, such as mono- and diglyceride emulsifiers
well known to those in the art, may be used at the level
of from about 0% to about 0.5% by weight of dough mix with
from about .1% to about 0.3% by weight being preferred,
with the most typical and most preferred level for this
invention being at about 0.1%.
In accordance with the preparation of the mixed dough
composition, the flours, ~ugars, salt, dough conditioners,
chemical leavening agents, eggs, shortening and flavorings
heretofore described are dry mixed prior to the addition
of water and yeast. After dry mixing the water and yeast
are added, and the ingredients are then fully mixed, at a
controlled temperature, in order to prevent premature
proofing. Typically such a mixer can be one which has a
cooling jacket to assure that the temperature is low
enough to prevent premature proofing.
During this initial mixing, the dough temperature
should not exceed about 66F as higher temperatures will
result in poor sheeting characteristics and may result in
premature proofing. Typically, mixing may be from about
three to about 30 minutes, preferably from about four to
about ten minutes.
One of the special features of this invention,
particularly for its preferred aspect, is that the dough
shell casing for the ultimate prepared product is a
~24B4[)6
-18-
laminated dough pad, that is to say, it involves lamina-
tions of mixed dough and roll-in shortening.
After the dough is mixed and prior to sheeting the
dough should have Farinograph values in the range of
between about 650 and about 950 Brabender*Units (B.U.),
preferably in the range of betw en about 750 and about 900
and most preferably in the range of between about 770 and
about 890 for "maximum" readings. Further, the dough
should have Extensigraph readings of at least about 100
millimeters, preferably at least about 150 and most
preferably at least about 200 for total extensibility and
should have at least about 100 B.U.s, preferably at least
about 250 and most preferably at least about 400 for
maximum resistance values. The above values are tested
as follows:
Farinograph:
This procedure is used on dough taken directly from a
mixer. The procedure is used to measure dough development
and general dough consistency. In this procedure a total
formulated dough sample is examined.
The test uses a Brabende~ Farinograph, Type FA/R-2
with mixing head model number 822,101, equipped with sigma
blade, stainless steel mixer bowl, by C. W. Brabender
Instruments. The Farinograph bowl temperature is set at
60~F (15.6 degrees C).
Obtain a 1000 gram dough sample directly from the
mixer. Avoid further mixing or kneading.
Record dough sample temperature and describe condi-
tion of dough as received. Allow dough to set at room
*Trade Mark
1248~)6
_1 9
temperature for 5 minutes prior to consistency measure-
ments. Do not work or knead sample during this relaxing
period. At end of relaxation period, remove outer dough
surface with a scissors. Weigh a ~80 gram sample of the
dough and place in a Farinograph bowl. Set Farinograph
chart at zero and begin mixing. Mix 5 minutes beyond peak
development. From the Farinogram, read and report:
A. Dough consistency in Brabender units (BU)
(center of maximum and minimum per stroke at the peak
maximum)
Allow at least one hour for equipment to adjust to
temperature. Dough consistency is used as a guide in
adjusting dough moisture. Time to peak and the difference
between the minimum and maximum consistency indicates
degree of development which has occurred in the mixer.
Results obtained on the same dough sample run on
different instruments should agree within +/- 20 BU's of
the average.
See also AACC method 54.21 and the physical evalua-
tion of flour performance, C.W. Brabender, the Bakers
Digest, April 1956.
Extensigraph:
This procedure is used on dough taken directly from a
mixer. The procedure is used to assess the stretching
properties of a dough as affected by chemical maturing
agents, dough modifiers and other additives which alter
the machineability of doughs. The method is a modifica-
tion of AACC method 54-10 especially regarding dough
preparation and dough temperature during the determination.
-20- 12 48~a 6
The test uses an Extensigraph, Type DM 90-40, C.W.
Brabender (Duisburg) instruments equipped with temperature
control bath.
Obtain a 1000 gram sample directly from the mixer.
Avoid further mixing or kneading.
Adjust Extensigraph temperature control bath to
maintain 60~F in the fermentation cabinet. Allow dough
sample to set at room temperature for 5 minutes from time
sample is removed from mixer. Do not work or knead sample
during this relaxation period. At end of relaxation time,
remove outer dough surface with a scissors. Weigh a 150
gram sample and dust lightly with dusting flour. Transfer
sample to the rounder-homogenizer on the Extensigraph and
round samples for 20 revolutions. Transfer sample to the
dough roller-type moulder and mould into cylinder. Place
dough cylinder evenly into dough holder so that all prongs
of holder are used and place holder in a cradle within the
60F chamber, place the holder with the dough sample on
the Extensigraph in position for stretching. Start
Kymograph with pen at zero and extend dough until it
breaks. Stop downward movement of hook immediately after
breaking. Lift pen from chart. From the curve, read and
record:
A. Total extensibility in millimeters.
B. Maximum resistance in Brabender Units (B.U.).
Allow at least one hour for equipment to adjust to
temperature the ratio of resistance divided by exten-
sibility characterizes the stability and potential baking
volume of the dough. The ratio figures reflect the
~248406
-21-
natural age of the flour and the effects of maturing
aqents and other dough modifiers. Average results on
duplicate samples should agree within +/- lO mm exten-
sibility and +/- 50 B.U.'s resistance for different
operators using different instruments.
See also ~The Physical Evaluation of Flour Perfor-
mance" by C.W. Brabender, The Bakers Digest, April 1956
and AACC Method 55-lO, Extensigraph Method, General.
After the mixed dough formulation hereinbefore
described has been prepared, it is then employed with a
hydrated or anhydrous roll-in shortening, with the amount
of roll-in shortening utilized being from about 4% to
about 20~ by weight of the total laminated dough pad
compositon after roll-in has occurred, preferably from
about 6% to about 12% by weight, and most preferably from
about 6.5% to 8% by weight. The total shortening (fat),
roll in shortening plus added dough shortening (add in),
in the dough should be in the range of between about 4.5%
and about 22%, preferably between about 6% and about 17%
and most preferably be~ween about 7% and about ll % by
total weight of dough. After frying the total shorteniny
(fat) including that picked up from the frying fat in the
cooked dough should be in the range of between about 8% and
about 30%, preferably between about 12% and about 24% and
most preferably between about 14% and about l9 % by total
weight of cooked dough pad.
The precise roll-in shortening employed in the
roll-in shortening step is not critical. It may be any of
the conventional hydrogenated vegetable oil shortenings
available on the market, commonly employed in the baking
industry. Those are plastic or hydrogenated glyceride
-22- 1248~06
shortenings derived most commonly from vegetable oils by
hydrogenation. The common oils are cottonseed oil,
soybean oil, coconut oil, rapeseed oil, peanut oil, olive
oil, palm oil, sunflower seed oil and the like.
A highly important aspect of this invention is that
the laminated dough pad, utilizing roll-in shortening at
the level hereinbefore described, has from about 2 to
about 12 substantially discrete and substantially con-
tinuous shortening layers per millimeter of laminated
dough pad thickness. The layers should be substantially
discrete and continuous, in other words, should be
substantially non-broken and should extend along the full
length of the laminated dough pad. It has been found that
when the roll-in shortening level is used at the level
hereinbefore described, providing that the layers of
roll-in shortening in the laminated dough pad are sub-
stantially discrete and continuous, one can achieve the
desired effects of the present invention.
Rolling in of the shortening is accomplished in known
and available machinery during a sheeting step. Such
typical machines may be a Rondo sheeter as well as others.
In order to achieve the desired results of this invention,
not only should there be both substantially discrete and
continous shortening layers, but it has been found most
desirable if there are from about 2 to about 12 substan-
tially discrete and continuous layers of shortening per
millimeter of dough pad thickness. Most preferably, the
whole laminated dough pad has a thickness of about two
millimeters.
When a laminated dough pad such as that described
herein is utilized, in combination with the mixed dough
~48406
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formulation herein described, and the filling hereinbefore
described, the result will be a product of high quality,
high stuctural integrity, and generally degradation
resistant during subsequent frying, freezing, thawing,
refrigeration and toasting.
It is peferred that the laminated dough pad have a
thickness not exceeding about two millimeters, because it
has been found that such a pad is dimensioned such that
after expansion during cooking, it will still easily fit
within a toaster; and ~fter expansion during toasting, it
can still easily be removed from a toaster without becom-
ing stuck.
It has heretofore been mentioned that there should be
both substantially discrete and continuous shortening
layers. If the layers are broken or are not discrete, it
has been found that the product stability is decreased
with moisture migration occurring more and the product
having a tendency to be somehwat more soggy. It has also
been found that this product reduces migration of moisture
from filling to dough compared to conventional non-lami-
nated doughs such as used for donuts and bismarks. Also,
the laminated dough pad is excellent from the standpoint
of being delamination resistant on its exterior surface,
and at the same time developing a well-developed bready
interior cell structure which is stable at its most
interior surface with respect to the area of contact with
the filling.
The preferred added moisture content of the mixed
dough is from about 34% to about 36% by weight, meaning a
high moisture dough which leads to good fried dough
quality.
~248406
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After the laminated dough pad, as previously de-
scribed, is made up, the peoduct is next ready for addi-
tion of the filling and folding of the laminated dough pad
to form the encasing shell. This operation is referred to
as "make upn. The make up operation may vary from manu-
facturing line to line, but generally it first involves
dedusting the laminated dough pad. This is simply brush-
ing off of excess flour on the laminated pad, in order to
reduce or eliminate interaction between the filling and
the loose flour at the pad surface. Dedusting can be
accomplished by rotating brush dedusters. After dedust-
ing, the laminated dough ~ad may be docked, followed by
slitting to its desired width, and deposition, such as
volumetric deposition, of the filling hereinbefore de-
scribed. Preferably the filling should be about 70F whendeposited. One may employ a water wicking or spraying
application along the edges of the sheet such that in the
following described folding and crimping operation, good
effective sealing and seam integrity are achieved.
The folders and crimpers used in the baking industry
are well known. With respect to the procuct of the type
described herein, the laminated dough pad is simply folded
upon itself, laying down the top dough layer after deposit-
ing of the filling has occurred, on the bottom layer.Folding can be accomplished by dough plows. Thereafter,
the free edges of the product are crimped, and preferably
crimped on all sides including the folded edge in order
to obtain a visually symmetrical product. After crimping,
there now exists a laminated dough pad of the type pre-
viously herein described, having from 2 to 12 discrete and
continuous layers per millimeter, which completely sur-
rounds the filling. During these basic steps of dough pad
formation and make up, there are certain things which have
~Z~34~6
-25-
been found important. First, during the formation of the
laminated dough pad, it has been found desirable to reduce
the laminated dough pad thickness for each pass through
the rollers less t~an a 50% reduction in laminated dough
pad thickness. If one attempts to achieve a greater than
50% reduction in laminated dough pad thickness per pass,
it has been found that one will not be as likely to
achieve the desirable discrete and continuous layers in
the laminated dough pad. Also, the dedusting technique
previously described is important to remove excess flour
which might cling to the laminated dough pad and inter-
action with the filling at the interior surface.
Proofing is, o~ course, known and need not be de-
scribed in detail herein. However, for the product
prepared in accordance with this invention, it has been
found desirable that proofing occur from about 20 to 40
minutes, most preferably from about 20 to 30 minutes, at
environmental temperatures within the range of from 105F
to 115F and at a relative humidity of from about 62% to
about 70%. During proofing the product will expand in
volume as much as 80%, with the laminated dough pad itself
expanding in volume as much as 100%. After proofing, the
product is now ready for cooking, such as by frying.
The product during cooking should involve some
constraint, to assure quality and to assure that it will
not expand to a thickness beyond which it will no longer
fit within a toaster. Thus, the cooking which is accom-
plished herein is a double restraint cooker. In other
words, the breakfast pastry is restrained as it passes
into the cooker by a lower conveyor screen upon which it
rests and is also at least partially constrained by an
upper conveyor screen on top. The screens are positioned
~248~06
--26--
such that the product during cooking will not achieve a
thickness greater than from about 15 to about 24 milli-
meters. In actual operation, in the applicant's process
as practiced, during the first portion of cooking, the
product is not constrained initially by the conveying
screens. As cooking time increases as the product moves
through the fryer, there does become constraint with
respect to both the upper conveying screen as well as the
lower conveying screen.
Cooking conditions are such to achieve a crisp
surface and moist but not gummy interior. Typically, this
can be achieved by frying at about 350F to 425F from 25
seconds to 180 seconds, but preferably from about 360F to
about 380F and from about 40 tO 50 seconds, typically
from 370F to 380F from ~3 to 47 seconds. Numerous
frying oils may be used, but one which has been found
especially preferable for frying of the product of this
invention is Durkee's Durkex 100.
Immediately after cooking, as the product exits from
the cooXer, the gap between the constraining conveying
screens is somewhat decreased to provide a post-cooking
thickness of from about 15 to 20 millimeters. Such a size
is especially suitable for placing in a conventional
toaster. The product is now ready for freezing and
packaging.
The heretofore presented description has been with
regard to the most important use of laminated dough pads
for preparation of the product of this invention. How-
ever, it should also be mentioned that it may be possible
for one skilled in the art to utilize the dough formula-
tion hereinbefore described having the requisite shorten-
ing level, all in combination with the required filling
-27- ~24~6
composition of this invention, with a dough shell prepared
from blitzed dough. However, it is strongly recommended
that one employ the lamination technique, for best results.
When the product is prepared as previously described
herein, it has been found during use, storage and stability
testing, that the product does not unduly exhibit undesir-
able characteristics typical of product degradation at the
interface of the filling and the interior dough surface.
In particular, even though high moisture is present in the
filling, there is no significant moisture migration;
color degradation of the filling;
or sogginess in the interior fried dough composition;
and the exterior surface of the composition remains flaky,
tender and crisp. It thus exhibits those tradi-
tional characteristics people normally like in fried or
baked pastries. Importantly structural integrity is also
preserved, with very little filling leakage ever exhibited.
Then too, the product is delamination resistant during
subsequent toasting, and is of the proper thickness and
dimensions such that it will easily fit within the toaster.
Storage te~ts have shown that the product can be
stored for period up to as long as six to nine months in
the freezer without any product degradation, and even
after such long storage, can be thawed and kept in a
refrigerator for up to two weeks.
Thus, it can be seen that the product accomplishes at
least some of the objectives heretofore stated for the
invention.
The following example serves to illustrate, but not
limit the product and the process of this invention.
~LZfl~8406
-28-
EXAMPLE
A typical fruit flavored filling composition of the
foilowing formulation is prepared:
Amount on a
Ingredient Percent By Weight
Sugar 42
water 21
Fruit Puree' 20 20
Corn Syrup 10
Modified Starch 5
Preservatives .1
Gum .2
Citric Acid/Sodium Citrate 1.2/.5
The pH of this filling composition was measured and
found to be 3.1. Titratable acidity measured as citric
acid was 1~. The viscosity of the filling composition was
40,000 cps. Starch addition level was 5%, and the amount
of Xanthan gum added was 0.2~.
The viscosity was measured on a Brookfield Viscometer,
RVT No. 7 spindle, at 50 rpm at a temperature of 72F.
A high moisture mixed dough and laminated dough pad
were prepared in the following manner. The flour used was
a moderately strong flour having a protein content of
12.5%. The flour itself was blended in a double stained
blender for two minutes, after which dough shortening,
sugar and salt were added and additional dry blending
occurred. Thereafter, water and hydrated yeast were
added and mixing continued to provide an initial mixed
~248406
-2~-
dough having a water content of 44.5%. The total compo-
sition of the mixed dough, including all minor additives
is as follows:
.
Percent By Weight
Flour, hard wheat enriched 52.51
Ingredient water - potable 35.51
Vegetable shortening hydrogenated2.50
10 Flour, unbleached soft wheat 2.10
Sucrose granulated 1.75
Whole egg solids salmonella free 1.70
Active dry yeast 1.50
Salt, medium fine (unfilled) 1.04
15 Dextrose (coarse) 0.50
Butter flavor emulsion, (natural & artificial) 0.25
SAPP (sodium acid pyro-phosphate) 0.25
Bicarbonate of soda powdered 0.25
Mono- and Dyglycerides (all vegetable) 0.10
Yellow Color 0.04
After the mixed dough composition was prepared, a
dough pad was made involving discrete and continous
lamination of shortening and the above described mixed
dough composition to provide a laminated dough pad having
six shortening layers per millimeter of laminated dough
pad thickness. In this specific instance, the total
thickness of the laminated dough pad layer was about two
millimeters. The amount of roll-in shortening employed in
terms of percent by weight of the laminated dough pad
preparation, was 7.5%. The shortening and the mixed dough
composition were fed into a Rondo*sheeter belt.
*Trade Mark
_30_ ~ 2 4 8 ~ O 6
Specifically 20 pounds, of the mixed dough were
transferred to a lightly floured dusted Rondo belt, with
dusting flour applied to its top surface. The mixed dough
itself was sheeted and three-folded upon itself to form a
continuous pad. Thereafter, a shortening sheet of the
type earlier described was prepared having a width of
8-1/2 inches and a length of 18 inches. The shortening
sheet weighed approximatel!~ 340 grams. The shortening was
rolled-in by conventional techniques and the ultimate
laminated dough pad having six continuous and discrete
layers was sheeted down to a thickness of two millimeters.
Thereafter, the laminated dough pad having the rolled-in
discrete and continuous shortening layers as described was
fed to a make up table. At the make up table, the surface
flour on the laminated dough pad was removed by dedusters
which are two rotating brush dedusters that move over the
- top surface. The laminated dough pad is docked and
thereafter (the laminated dough pad is 20 inches wide), is
slit into three sections of uniform width.
The filling, which comprises 26.3% of the product, is
applied in three rows by spot deposition by a piston
filler, with the width of the spot deposit being about 1
3/4 inches, and the length of the spot deposit being about
3 7/8 inches. The weight of the deposit is about 13
grams. The temperature of the filling is about 70F.
A water wick next applies a fine water ribbon at each edge
of the slit laminated dough pad to assure proper dough-to-
dough crimping. The wick is approximately one-half inch
wide.
Thereafter, the laminated dough pad is passed into a
static plow which is used to fold the laminated dough pad
down the middle. The half section of the laminated dough
pad with the filling sta~s on the belt, while the other
~L2~8406
-31-
half rides up the plow and folds over and lays down over
the filling. Thereafter, a longitudinal crimper crimps
two sides of the product to provide a product of uniform
visual appearance. The width of the product after crimp-
ing is three inches. The product is then cross crimpedand cut.
The product is next transferred to a proofer, where
it is held for 25 minutes, at a relative humidity of 68%
and a temperature of llO-F.
Next, the product is moved into a large fryer con~
taining Durkee's Durkex*100 at a temperature of 375DF.
The product is conveyed through the hot frying fat by two
double constraint screens, one over the top and one upon
which the product rests. For the first portion of its
travel through the double constraint fryer, the product is
not constrained by the conveyors. Thereafter, the product
as it begins to fry is restrained such that the frying
thickness is about 15-24 millimeters. The belts are
reduced somewhat for a reduction in thickness at the
far edge of the fryer, such that post-frying the product
has a thickness of from 15-20 millimeters.
After frying, the product is now ready for freezing,
packaging and shipment.
Subsequent testing on the product has revealed
superior stability, good structure integrity, no seam
leakage, attractive appearance, flaky exterior, minimum
interaction at the interior interface between the filling
and dough, and overall high product integrity and quality.
*Trade Mark
