Note: Descriptions are shown in the official language in which they were submitted.
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METHOD FOR INCEASING SPECIFIC VOLUME AND BAKERY PRODUCTS RESULTING THEREFROM
Field of the Invention
This invention relates to baked products made
from leavened dough. In particular, the invention is
directed to increasing the specific volume of such baked
products. The invention teaches the addition of compounds
to the dough that effect a reduction in the moisture
content of the dough without attendant loss of dough
consistency. By reducing the moisture content of the dough
while maintaining the same dough consistency, the invention
allows the specific volume of baked goods to be maximized.
Background of the Invention
Numerous baking techniques are known which allow
the creation of a great variety of baked goods, appealing
to a variety of tastes. Specific volume (in cubic
centimeters per gram) of baked products can be increased by
using various shortenings, see Desai et al, U.S. Patent No.
5,360,627. Shortenings are also added to leavened doughs
to impart tenderness and texture to the resulting baked
goods. But other factors effect specific volume. The
various factors that effect the specific volume of baked
goods are imperfectly understood.
An improved understanding of these factors would
allow the creation of baked goods that were fluff ier, and
lighter in~weight and texture. Desai et al., U.S. Patent
No. 5,360,,627, disclose a reduced fat shortening substitute
for baked products. In developing this reduced fat
shortening, Desai observed that shortenings can increase
~35 the specific volume of baked goods by shortening the
strands of gluten, which otherwise would form a tough,
meshwork structure that did not expand during baking.
Holscher et al., U.S. Patent No. 4,818,553, likewise
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_~_
observed that substances can be added to leavened dough to
increase the specific volume of baked products.
In developing a method for producing frozen
yeast-leavened dough, Felske et al., U.S. Patent No.
S 4,743,452, similarly observed that the texture and specific
volume of frozen dough can be effected by addition of
hydrocolloids.
None of the prior art, however, teaches how to
maximize the specific volume of baked goods by reducing
dough moisture content without any attendant loss of dough
consistency. There is a continual need for compositions
and methods that maximize the specific volume of baked
goods.
Summary of the Invention
In accordance with a first aspect of the
invention there is provided a leavened dough composition
comprising flour, a protein source, a leavener, and a
processing adjuvant.
In accordance with a preferred aspect of the
invention there is provided, a leavened dough composition
comprising flour, the flour comprising starch and a gluten
protein source. Additionally, this dough comprises a
leavener and a processing adjuvant. Replacement of water
in the dough with the processing adjuvant increases the
onset temperature for starch gelatinization while also
maintaining,the dough consistency during processing.
,:.In~accordance with a further aspect of the
invention, there is provided a method of increasing
specific volume in a baked product comprising the steps of
defining a dough composition comprising flour, a protein
source, leavening agent, and water, and removing some of
the water in the dough composition and introducing a
processing adjuvant wherein the ratio of water
concentration removed to the processing adjuvant
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concentration introduced ranges from about 0.25 to 1 and
the resulting dough consistency is preferably within 1100
Brabender Units, or BU of the dough composition without the
processing adjuvant.
We have unexpectedly found that the specific
volume of a baked product can be increased by adding a
processing adjuvant that decreases dough moisture content
while maintaining the same mixed dough consistency.
Preferably, the processing adjuvant also increases the
starch gelatinization temperature and delays the onset of
starch gelatinization.
Specific volume in baked products can be defined
as the volume of the product divided by its weight.
Specific volume is affected by numerous factors.
~.5 Manipulating these factors to obtain the highest possible
specific volume from a given dough system has long been an
objective of food industry research. Some of these factors
involve the protein content of a given system.
We have observed that beyond simply the protein
content, the ratio of protein to moisture in a dough
affects the specific volume of a baked product resulting
from baking the dough. We have also observed that the
higher the ratio, the higher the specific volume in most
dough systems. Therefore, increasing the protein content
and/or decreasing the water content will positively affect
specific volumes.
While not intending to be bound by theory, we
believe that dough water content adversely affects specific
volume in~two ways. The first is an increase in the degree
of thermosetting of protein in the presence of conventional
or excess water concentrations, and therefore an increase
- ~- - in the "setting" of the protein structure of the dough.
The second effect is the early onset of starch
gelatinization, due to the moisture content of the dough,
causing the dough to "set up" too early in the baking process.
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Wd Q~~~~~4 PCTIUS96109105
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The water level is believed to intensify both
protein thermosetting and starch gelatinization. Both of
these interactions operate to increase the viscosity and
ultimately set the structure of the product as it is baked.
These interactions therefore mimimize or adversely affect
the expansion of gas bubbles or cells within the dough
during baking. As the baking progresses, the product
structure becomes more ~~set~~ and the gas bubbles cannot
expand further.
l0 Delaying these interactions permits optimal gas
cell or bubble expansion prior to the product setting to
result in a high specific volume product. The present
approach is to reduce the amount of water in the dough,
which increases the protein: water ratio. Reducing water
content was observed to achieve a similar specific volume
relationship as increasing the protein concentration, but
merely reducing the water~content makes the dough more
difficult to process. Most of the difficulty in processing
low moisture doughs is due to the changes in dough
consistency, making the dough difficult to mix and further
process.
The invention reduces the moisture content of
Boughs without loss in dough consistency. A dough of the
present invention retains the rheological properties of a
conventional dough, but contains less water. Not only is
the water level reduced, but the water removed from the
formula is replaced with compounds that maintain the dough
consistency: The ultimate result is that the dough retains
a processable consistency while the onset of starch
gelatinization is delayed during baking, such that the '
dough, when baked, provides a baked product having a
w - - desirably high specific volume. Baking, in the context of
the invention means cooking by conventional or convection
oven as well as microwaving.
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It was surprisingly discovered that a product
baked from a dough of the present invention has a specific
volume significantly higher than obtained simply by
altering the protein: moisture ratio. Tt is believed that
the compounds added to minimize the effectiveness of water
as a plasticizer act to permit the dough to attain a
surprisingly high specific volume.
Detailed Descrit~tion of the Invention
The invention includes a dough, capable of
producing a baked product having a high specific volume,
comprising a flour, protein source, leavening agent and
processing adjuvant aid. Additionally, the invention also
comprises a method of increasing specific volume in baked
products through introduction of a processing adjuvarit into
any dough composition. Generally, the dough of the
invention will comprise a~flour to add body, texture,
consistency and mouth feel. The flour component of the
dough also functions to provide the system with starch and
a protein source. .
The flour component of the invention may be
either processed or unprocessed flour, and may be either
white or whole grain flour. Grains useful for defining the
dough of the invention include grain constituents such as
flours, germs and bran from wheat, oats, rye, sourgum,
barley, rice, millet and corn, in addition to others. The
flour constituent of the invention will be present in a
concentration ranging from about 30 wt-~ to 70 wt-%,
a
preferably~~~about 40 wt-% to 65 wt-%, and most preferably
about 45 wt-% to 60 wt-%.
The dough composition also comprises a gluten
_ .__ protein source to provide elasticity, cohesiveness, and
adhesion in the dough composition. Over a range, the
specific volume of baked goods can be increased by
increasing the protein:moisture ratio of the dough. For
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most dough systems, the higher the protein: moisture ratio,
the higher the specific volume of the finished baked goods.
Increasing the protein content of the dough composition
thus helps to maximize the specific volume of the finished
product. The protein component of the dough composition
also provides elasticity to the dough which is helpful in
mixing the dough.
The protein source functions to provide adhesive
action promoting elasticity, cohesiveness and binding
activity in the dough composition. To this end any protein
source which will provide one or more of the
characteristics may be used in accordance with this
invention. The protein source of the invention can be
derived from any cereal grain. Generally, cereal proteinx
such as wheat gluten, corn gluten, rye protein, triticale,
barley, and mixtures have been found to provide these
properties to the dough composition. Alternatively, a
combination of flours with an adequate protein level can be
used. The preferred protein source, however, is wheat
gluten. Gluten is preferred in the dough of the invention
as it provides desirable elasticity and adhesion within the
dough composition. The total protein concentration in the
leavened composition is generally present in a
concentration ranging from about 4 to 20 wt-%, preferably
from about 6 to 15 wt-%, and more preferably 8 to 12 wt-%
of the composition as a whole.
The dough composition of the invention may also
comprise a leavening agent. Leavening agents useful in the
invention include air, steam, yeast, and baking powders
such as those containing sodium bicarbonate, as well as
combinations of one or more baking acids with sodium
bicarbonate. Baking acids useful for leavening include
monocalcium phosphate monohydrate, sodium aluminum sulfate,
sodium acid pyrophosphate (SAPP), sodium aluminum phosphate
(sALP), dicalcium phosphate, glucono-delta-lactone, and
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pa~~~~iuen hydrogen ~ar~~r~~; anc~ mi~c~ures ~h~reot. One or
more of these baking acids may be combined with a
bicarbonate or encapsulated bicarbonate. Preferably, a
leavening system comprises sodium acid pyrophosphate,
sodium aluminum phosphate, glucono-delta-lactone, and
mixtures thereof with a bicarbonate such as sodium, or
ammonium, or potassium bicarbonate. The dough preferably
comprises from about 0.5 to 2 wt-% sodium bicarbonate, and
preferably about 0.75 to 1.5 wt-%. The dough preferably
comprises about 0.5 to 2 wt-%, and more preferably about 1
to 1.8 wt-%, total leavening acids.
The dough composition also comprises a processing
adjuvant. Addition of the processing adjuvant increases
the specific volume of the finished baked goods. The
adjuvant increases the specific volume of the finished
product by reducing the amount of moisture in the dough.
This, in turn, delays the~onset of starch gelatinization,
and ultimately results in a desirably high baked product.
specific volume.
The processing adjuvant is added to the dough
composition in place of water which would otherwise
normally be present in the dough. The processing adjuvant
functions to replace part of the water and part of the
flour. In doing so, the processing adjuvant maintains or
the consistency of the dough composition. Those processing
adjuvants which are useful can replace between 0.25 to 1%
of dough moisture, described herein as X, per % added
processing adjuvant, described herein as Y.
~~Generally, compositions useful as processing
adjuvants in accordance with the invention include any
water soluble compounds such as carbohydrates, hydrolyzed
- --. _ proteins, as well as mixtures thereof.
Starch hydrolysates of any molecular weight
(maltodextrin, corn syrup solids, dextrins) are suitable
for use as processing adjuvants, such as, polydextrose,
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_g_
polyfructose, suorose, lactose, hydrogenated starch
hydrolysates, and lactitol. Hydrolyzed proteins suitable
for use in the present invention include hydrolyzed sodium
caseinate, hydrolyzed gelatin, hydrolyzed milk proteins,
and other hydrolyzed proteins all function as processing
adjuvants. The processing adjuvants polydextrose,
hydrolyzed gelatin, 20 DE corn syrup solids, 1 DE
maltodextrin and sorbitol are preferred as processing
adjuvants.
The processing adjuvant is added to the dough
composition in a range of 2 to 20 wt-% of the dough
composition. To maximize specific volume of the final
product, the processing adjuvant is preferably added in the
amount of 3 to 9 wt-% of the dough composition. Addition
of the adjuvant in the 4-8 wt-% range of the dough
composition is especially. preferred.
Table 1
(wt-%)
MORE
USEFUL PREFERRED PREFERRED
FLOUR 30-70 40-65 45-60
TOTAL PROTEIN 4-20 6-15 8-12
LEAVENER 1-4 1.25-3.3 1.5-2.5
ADJUVANT 2-20 3-15 4-10
WATER 20-50 21-48 22-46
B. THE~~METHOD OF USE
Generally, the invention is applicable any
leavened dough or batter composition. Examples of
_. __ .30 compositions include breads, biscuits, rolls, pastry, etc.
Dough using the invention may comprise those
constituents provided above. In formulating the
composition of the invention any means known to those
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_g_
skilled in the art may be used. For example, in
formulating the composition of the invention mixing is
initiated by adding all solids except for leaveners and
salt to the water and flavors used in the composition of
the invention. The composition may then be mixed in any
appropriate mixing vessel for about 30 seconds. The
composition is then mixed until 30 seconds past peak
consistency. The second stage ingredients may then be
added including those solids and liquids not previously
introduced.
- DougYis made in accordance with the invention
generally may have a water concentration less than about 50
wt-%, preferably less than about 48 wt-%, and more
preferably less than about 46 wt-%. The protein: water
ratio of the dough compositions of the present invention is
preferably less than about 0.3. A preferred range of the
protein: water ratio is between about 0.1 and 0.28, more
preferably between about 0.15 and 0.26.
Another means of quantifying the preferred
characteristics of the invention is to divide the wt-% of
water removed from the dough over the total wt-% of
processing aid in the finished dough. We have found that
this factor has to be at least about 0.25, preferably about
0.45, and more preferably about 0.65. This allows for an
increase in the onset of starch gelatinization, (see Table
3 at G'), of anywhere from about 1.15°C, preferably about
2.5°C, and more preferably about 5°C.
Further, the consistency of the dough composition
will depend on the makeup of the dough itself as well as
the amount of moisture which is removed from the dough.
However, for doughs based on wheat gluten type flours, a
- viscosity of 700 to 1400 BU is readily obtainable at 60°F.
Ultimately, the invention provides baked products
having an increase in specific volume of from about 10% to
50o when the wt-% of water removed from the system divided
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-10-
by the wt-% of total processing aid in the finished dough
is above 0.25. Generally, specific volumes obtainable with
~h~ a~mp~siti~ns of the inv~ntivn r~n~e ~~om ~b~~t 2 to 6,
preferably from about 3 to 6, and more preferably from
about 4 to 6.
Workinct Examples
The following examples are intended to be
illustrative but not limiting of the invention.
.:
CA 02219772 1997-10-28
WO 96139849 PC'T/US96/09105
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CA 02219772 1997-10-28
WO 96/39849 PCT/US96/09105
-12-
All ingredients were weighed for 480 g batch.
All solids were added except leaveners and salt to the
Farinograph mixing bowl with water. Mixing was started at
the #2 setting speed and after 30 seconds, the sides were
scraped down. The ingredients were then mixed until 30
seconds past peak. The peak consistency in BU was
recorded. The second stage ingredients were added, and
mixed for 3 more minutes.
Individual samples of 200 g dough was sheeted in
the following manner: 11/32" for 4 passes; 1/4" for four
passes; 3 fold and turn. 11/32" for 4 passes; 1/4" for
four passes. The dough was rolled tightly and pinched at
the final edge in place. The dough was placed seam side
down in greased aluminum loaf pan and stored at 90°F, 85%
relative humidity until the dough was 2.25° high. Baking
was completed in a preheated conventional oven at 375°F for
30 minutes.
The resistance, in Brabender Units (BU), of a
480 g dough to mixing is recorded on a mechanical line and
is expressed as a torque/time diagram from the start of
dough mixing in a Farinograph bowl. The mixing bowl
temperature is kept at 60°F and the shearing speed is 63
rpm. One Kg weights are added to the mechanical arm to
facilitate consistency readings above 1000 BU. The
midpoint of the peak torque is recorded as the consistency
of the dough in BU. For doughs with BU higher than 1350 or
lower than 1150 BU's, flour and water levels were adjusted
to reach,the final BU of 1250 +/- 100 BU.
Differential Scanning Calorimeter (DSC) is used
for measuring the onset temperature of starch
gelatinization in dough. About 55-75 mg of dough is placed
' ~ in a DSC pan, the dough is heated from 20°C to 150°C at the
rate of 10°C/min. At the end of the run, a heat flow-
temperature curve is generated. The commonly used
technique for determining onset temperatures is to take the
CA 02219772 1997-10-28
WO 96/39849 PC'T/US96J09105
-13-
intersections between straight lines drawn through the
baseline and the left tangent line of the first major
melta.ng peak.
Specific volume (SV) in the unit of cc/g is
defined as the volume (cc) of a given baked product per
unit weight (g). The baked product was cooled out of the
pan for 30 minutes and was weighed after cooling for 1
hour. The specific volume was measured using the rapeseed
displacement method. A measured volume of rapeseeds in a
container is poured over and around the baked product
placed in the same container. The volume increase of
rapeseeds displaced by the baked product is determined, and
divided by the weight of the baked product to give the
specific volume of the product. '
The dough evaluated in this example contains
flour, water, 1% salt, 3% shortening, and a sodium
bicarbonat, SAPP, SALP leavening system. Gluten was added
when higher levels of protein have been studied. This
model system showed that the ratio of protein to moisture
has strong influence on specific volume. The higher the
ratio of gluten to moisture, the higher the specific
volume, see Table 3 below. Table 3 shows that when the
ratio of water removed to processing adjuvant added, X/Y,
is around 0.2, no significant increase in specific volume
is observed. When X/Y is greater than or equal to about
0.5, the specific volume increases significantly, as does
the onset TG' and the maximum TG' and the gelatinization
temperature. A concomitant decrease in maximum G' is also
observed.
CA 02219772 1997-10-28
WO 96/39849 PGT/US96/09105
-14-
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CA 02219772 1997-10-28
WO 96/39849 PCT/US96/09105
-15
EXAMPLE II
Thie example damoaatratea a v~ry high gluten
prc~du~t (13.2-13.9%) . Ereads were, made from Boughs with
the following formulas:
IIA (wt-%) IIB (wt-%) IIC (wt-%)
wheat flour 37 37 40
wheat gluten 11 11 11
wheat starch 10 7 3
1 DE maltodextrin 0 3 7
water 39.51 39.51 36.51
Sodium Acid
Pyrophosphate (SAPP) 1.07 1.07
1.07
Sodium Aluminum
Phosphate (SALP) 0.32 0.32 0.32 ,
Sodium Bicarbonate (SODA) 1.1 1.1 1.1
Total 100.00 100.00 100,00
gluten(%) 13.2 13.2 13.5
wheat starch(%) 36.6 33.9 32.4
H20(%) 46.2 45.9 42.9
starch/gluten 2.8 2.6 2:4
-%H20/%added (X/Y) - 0.10 0.47
mix time(min) 7 10.5 9.5
consistency (BU) 1200 1020 1360
Proof time(Min) 2.5hr 2.5hr 2.25hr
weight loss(%) 10 10 10.4
SV (cc/g) 3 . 1 3 3 .4
The same mixing and measuring procedures were used as
in Example I. The results indicate that that X/Y less than
0.25, the specific volume was not significantly affected.
CA 02219772 1997-10-28
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WO 96139849 PCT/US96/09105
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EXAMPLE III
The following compositions were formulated in
accordance with the method of the invention as can be seen
in Table 4. This example demonstrates low protein (6.3-
6.7%) compositions.
TABLE 4
CONTROL 3A 3B
1 DE Maltodextrin - 6% 10%
Flour 61 59.51 57.01
Gluten 0 0 0
Salt 1 1
Shortening 3 3 3
Water 32.51 28 26.5
SAPP 1.07 1.07 1.07
SALP 0.32 0.32 0.32
SODA 1.1 1.1 1.1
TOTAL 100.00 100.00 100.00
Gluten (%) 6.7 6.5 6.3
Wheat starch (%) 42.7 41.7 39.9
Fi20 (%) ~ /~ 41.1 36.3 34.5
Starch/gluten 6.4 6.4 6.4
"Flour"/water 1.88 2.13 2.15
Consistency (BU) 1250 1340 1320
Mix time (min) 4.5 5.5 10.5
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WO 96/39849 PCT/US96/09105
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Proof height (in) 2.25 2.25 2.25
Weight loss (%) 12 12 12.5
Specific Volume 3.6 3.9 4.3
cc/g
X/Y Control 0.8 0.66
Example III shows that the displacement of water
in favor of processing adjuvant increases specific volume.
The above discussion, examples, and embodiments
illustrate our current understanding of the invention,
However, since many variations of the invention can b~ made
without departing from the spirit and scope of the
invention, the invention resides wholly in the claims
hereinafter appended.
