Note: Descriptions are shown in the official language in which they were submitted.
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INERT-GAS BASED UNLEAVENED DOUGH SYSTEM
Background of the Invention
The present invention relates to packaged food articles and to their
methods of preparation. More particularly, the present invention relates to
articles
comprising a gas-impermeable container and an unleavened dough for baked goods
or other unleavened fried or dried food products that are storage stable at
room
temperature.
Preparing consistently high quality unleavened baked goods such as
pie crusts, lefsa, fila dough, tortillas and unleavened bread such as pita
bread from
"scratch" has always been a difficult task to perform. Preparing dried dough
products such as pasta has been particularly difficult and has required
special
equipment. Reproduction of good product quality has been an elusive feat in
many
households. Furthermore, with other options available, such as purchasing pre-
prepared pasta, unleavened bread, pie crusts and frozen pie crust dough,
homemakers do not have to make.these products from "scratch." One problem with
pre-prepared pasta, crusts, tortillas, and unleavened bread, however, is that
these
products do not have the fresh organoleptic properties of home-made baked
goods.
Several products have been developed iwan attempt to accommodate
time restraints of homemakers and to provide a freshly baked product. These
products include dry' mixes and refrigerated doughs. For instance, EP
Application
No. 868,850, filed April 4,1997, describes a shelf stable cake dough that has
a water
activity below 0.85. The dough is packed in a gas-impermeable pouch in an
atmosphere of an inert gas containing preferably less than 2% oxygen by
volume. A
high concentration of sugar is used to lower the water activity.
U.S. patent No. 5,178,893, which issued January 12,1993, describes
a ready to bake dough, used tb make bread, cookies, biscuits, and pastries.
The
dough includes water in a concentration of 8-20% by weight. The dough is
prepared
by making a premix comprising flour and fat and heating the premix. If water
is
added, the premix is heated under pressure.
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Another shelf stable dough is described in U.S. Patent No.'4,904,493;
which issued February 27,1990. This patent describes a biscuit dough with a
water
activity within a range of 0.6 to 0.8. The dough is made with inactivated
flour. EP
Application 443 219 A1 describes extending shelf Iife of a dough by
sterilizing each
of an aqueous phase, and oil phase, prior to mixing.
The Vasseneix patent, U.S. No. x,384,139, which issued January 24,
199S, describes a method for rendering a food composition shelf stable. The
method includes separating wet and dry components in compartmentalized
packaging.
Summan,~f the Invention
In, its product aspect, the present invention resides in a ready to use
unleavened dough article that provides a baked product, such as a pie crust,
tortilla,
lefsa~ file dough, or pits bread or a dried product such as pasta or a fried
product
such as a vegetable or soy-based meat analog. The dough article comprises a
substantially gas-impermeable container. The dough article also comprises an
unleavened dough having a water activity that is less than about 0.85. The
dough is
disposed within the container. The dough comprises flour, ~ a fat and
optionally
sugar wherein the ratio of sugar to flour is 0 to 0.2S:I. The dough article
also
comprises an inert gas that is disposed within the container. The dough
article
contains less than about 2% residual oxygen.
In one method aspect, the present invention resides in a method for
making a ready-to-use dough article. The method comprises preparing a dry
blend
comprising flour, and optionally sugar in a ratio of 0 to 0.25:1 and preparing
a wet
blend comprising fat. The wet blend and the dry blend are mixed to form a
dough
that has a water activity that is no greater than 0.85.
Detailed Description
The present invention relates to packaged, ready to bake unleavened
doughs for unleavened food products such as pits bread, file dough, lefsa,
tortillas,
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pasta, pie crust, as well as unleavened carbohydrate-based foods such as
protein-
based foods such as textured soy protein, characterized by shelf stability at
mom
temperature and to their methods of preparation. Each of the unleavened doughs
and unleavened food product components as well as product use and attributes
and
methods of preparation are described in detail herein.
Throughout the specification and claims, percentages are by weight
and temperatures and degrees Fahrenheit unless.ofiherwise indicated.
The unleavened food products comprise a gas impermeable
container; a low water activity, unleavened dough or other unleavened food
disposed within and partially filling the container; and an unpressurized,
inert low
oxygen gas atmosphere in the unfilled head space.
The container used in one embodiment of the present invention is
either flexible or rigid or semi-rigid and of any suitable shape or
configuration. For
example, one type of container suitable fox use includes the gas impermeable
container such as a pouch fabricated from flexible laminate materials having
low gas
permeability. A suitable laminate is a polyester-aluminum-polyester laminate.
.Also
useful are tubs fabricated from plastic, glass or metal. In other variations,
the
container or portions thereof serve as a disposable baking container. For
example,
the container comprises an aluminum or an ovenable plastic baking tray or tub
having an overlaying peelable foil membrane. Having the container. function as
a
baking container adds fiu-ther convenience by eliminating transfer of the
batter or
dough from the container to the baking utensil.
The food product further comprises a ready to-bake unleavened
dough disposed within the container. The dough comprises flour, fat and
moisture.
The dough optionally includes a nutritive carbohydrate sweetener.
"Dough" as used herein refers to an intermediate food product that
has a gluten-based structure. In dough, the gluten forms a continuous dough
elastic
medium into which other ingredients are embedded. A dough is typically
prepared
by mixing, and kneading and is often stiff enough to cut into various shapes.
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Doughs generally are used to make unleavened products such as pita bread,
tortillas,
fila dough, pasta, pie crust , pasta and so on.
In contrast, "Batter" as used herein refers to an intermediate food
product that comprises flour, water, eggs and salt and optionally fat and
sugars that
are a starch batter-based composition. In a batter, gluten development is
purposefully minimized. Batters are inelastic. Liquid added to make the batter
forms a continuous batter medium in which other ingredients are dispersed. A
batter
cooks into a soft, moist and sometimes cnunbly product. A batter is typically
prepared by blending, creaming, stirring or whipping and is generally thin
enough to
pour or scoop or squeeze out of container.
"Unleavened food product" as used.herein refers to carbohydrate-
based foods such as lefsa, fila dough, tortillas, pits bread, pasta, and
crusts and
protein based products such as textured soy protein. Carbohydrate-based foods
typically have a gluten component.
"Barrier system" as used herein refers to a substantially gas
impermeable container.
"Soy flour" as used herein refers to a product made by grinding
defatted soybeans. Soy flour is typically mixed with wheat flour to increase
the
protein content of baked products.
Flour
The present dough compositions comprise from about 5 to 80% of
the dough as flour. Conventionally, flour is standardized to a moisture
content of
about 14% although flour with lower moisture content can be used. Flours
useful
herein are of a conventional type and quality including cake flour, bread
flour, and
all purpose flour. Wheat flours are preferred but other flours conventionally
used in
the preparation of baked goods are also employed in full or partial
'substitution for
the wheat flour. Traditional cake flour used for layer cakes has about 8% or
less
protein by weight of the flour. Pastry flour ordinarily has a protein level of
about
10%. Other flours such as bread flour. generally have a higher protein level
of about
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11 to 13% by weigfit. One protein range for wheat flour used in the present
invention is between about 9 to 10% by weight of the flour. A general all-
purpose
flour is also usable. This type of all-purpose flour generally comprises
admixture of
both and hard and soft wheat flours, i.e., both high protein level and Iow
protein
level flours. Such flours are useful if the average protein content ranges
from about
8 to 10% by weight.
While chlorinated flours are used herein, unchlorinated flours are
also usable. Enzyme inactivated flours are also usable. In particular, flours
that are
free of alpha-amylase activity and have a very reduced lipasic and peroxidasic
activity are usable. In addition wheat flour, corn flour, rice flour,
buckwheat, potato
flakes and soy flour are used for some carbohydrate-based embodiments of the
present invention and either supplant or replace the wheat flour. Soy flour
typically
defatted. Pasta is typically prepared from wheat flour, buckwheat, rice flour
or a
combination of these flours.
Sugar
The dough compositions of the present invention also essentially ,
comprise 0-5% of.sugar or a nutritive carbohydrate sweetener ingredient in a
ratio of
about 0Ø to- 0.25 : 1Ø Typically, sucrose is used in mixes for baked goods
as the
sugar ingredient, although up to about 30% of the sugar in the present
invention
food products is supplied by dextrose or other nutritive carbohydrate
sweetening
agents such as~corn syrup solids. Commercially available milled sugar usually
contains up to about 4fo starch as an aid to maintaining its free-flowing
properties.
In embodiments where sugar is used, ordinary granulated sugars.are
satisfactory for use in the dry mix. These sugars include sucrose, dextrose,
maltose,
fructose, lactose, brown and invert sugars, alone or in combination. The
preferred
sugar is sucrose.
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Sugar to Flour Ratio
The baker's ratio is the weight ratio of sugar to flour. The baker's
ratio is used to provide desired baked good attributes. The baker's ratio of
the food
products of the present invention range from 0% sugar to a ratio of about
0.25:1.
Fat
The dry mix compositions of the present invention, in soirie
embodiments, comprise from about 0 to about 50% of an edible fat or shortening
ingredient. A shortening component adds richness to the eating properties of
the
finished baked goods as well.as~ aids in the leavening pxocess. Tlie
particular fat
constituent level will depend particularlyupon the desired type of finished
baked
good desired and its properties.
Conventional shortening materials are suitable for use as the
shortening ingredient of the present doughs. Such conventional shortening
materials
are well known in the dough art. The conventional shortenings useful herein
include
fatty glyceridic materials classified on the basis of their physical state at
room
temperature. Liquid shortenings or oils are usable and provide an advantage of
ease
of incorporation. Solid shortening is usable and provides an advantage of
desirable
mouth feel upon consumption of the baked good. More commonly are mixtures of
liquid and solid shortenings. These mixtures are fluid or plastic depending in
part
on the level of solid fatty materials. ' Shortenings of this type comprise a
liquid oil
containing from about 2-26% normally solid fatty glycerides. That is, a solid
content index, "SFI", at 70° and 4% to 6% at 100° F.
Solid fatty glycerides include fatty monoglycerides and diglycerides
of saturated fatty acids having 16-22 carbon atoms. The liquid shortening is
animal
shortening, marine, vegetable or synthetic oil, such as sucrose polyesters,
which are
liquid at ordinary room temperature. Representative of such liquid shortenings
include coconut oil, palm kernel oil, cottonseed oil, peanut oil, olive oil,
sunflower
seed oil, sesame seed oil, corn oil, safflower oil, poppyseed oil, soybean
oil, canola
(rapeseed) oil, babassue oil, lard, tallow, and the like. Other suitable
shortening
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materials and methods of shortening preparation are described in detail in
Bailey
"Industrial Oil and Fat Products," (3rd ed. 1964) which is incorporated herein
by
reference.
Mixtures of the above oils are usable as are solid fatty materials, such
as saturated triglyceride fats. In general, from about 1.5 to 25%
triglycerides which
are solid at 70°F are added to a liquid oil.
The preferred oils are soybean oil hydrogenated to an iodine value
(I~ of from about 105 to l I5, preferably about 107, corn oil, palm oil,
hydrogenated palm oil, lard and tallow oils. Preferably, the oils used to
prepare the
shortening composition will contain only from about 1-7% hardstock. Hardstock
is
a hydrogenated triglyceride having an iodine value of 8 or less. Preferred
hardstocks include hydrogenated soybean oil, hydrogenated cottonseed oii,
hydrogenated pabn oil and hydrogenated lard or tallow.
Some embodiments of the unleavened doughs of the present
invention fiufiher comprise about 0.2 - 5% of emulsifiers. The shortening
provides
a convenient carrier for addition of emulsifiers to the dough. The emulsifiers
aid the
realization of baked goods with improved grain structure and texture. The
emulsifiers are also useful to maintain the emulsion integrity of the
dough.over
extended room temperature storage.
The emulsifier typically comprises from about 1 to 20 % of the
shortening component, preferably about 5 to 15% and in some embodiments from
about 10 to 15%. Emulsifiers may be prehydrated in an aqueous dispersion and
added to the dough. The emulsifier in other embodiments are part of au
emulsion or
dispersion with of without a fat component.
Generally useful as the emulsifiers are partially esterified polyhydric
compounds having surface-active propertiest This class of emulsifiers includes
among others mono and diglycerides of fatty acids, organic acid esters of
monoglycerides of fatty acids, organic acid esters of monoglycerides, and
fatty acid
esters. Mono and di-glycerides of fatty acids such as monostearin are commonly
used' emulsifiers. Preferably, they are added as distilled monoglycerides
because of
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their improved purity and better functionality due to decreased interference
fomn
diglycerides.
Organic acids such as acetic acid, lactic acid, citric, acid,
diacetyltartaric acids are used to form esters with monoglycerides to give
Acetem,
Lactem, Citrem, and Datem, respectively. These fall under the category of
organic
acid esters ofmonoglycerides. Some of the subclasses of emulsifiers included
in the
fatty acid ester category are: polyglycerol esters of fatty acids (PGE's)
wherein the
glycerol moiety can be up to 10 or more glycerol molecules and the fatty acids
can
be palmitic acid, oleic acid, stearic acid and so on, propylene glycol fatty
acid ester
(PGME's)~with stearic acid such as propylene glycol monostearate {PGME's) and
so on; sorbitan fatty acid ester which are esters of fatty acids with sorbitol
anhydride or sorbitan. Some examples are sorbitan rnonostearate (Span 60) and
sorbitan monooleate {Span 80). Sorbitan esters can be reacted with ethylene
oxide
to form polyoxyethylene sorbitan esters such as polysorbate 60 (polyoxy-20-
ethylene sorbitari stearate), polysorbate 80 (poly-20-ethylene sorbitan
oleate),
polyoxyethylene sorbitan monooleate (Tween 80) and so on; ~ sodium steroyl
lactylate (SSL); sorbitan tristearate {STS); sucrose ester of fatty acids.
Another class of emulsifiers call phospholipids (for e.g. Lecithin) can also
be
used.
Moisture
The unleavened Boughs of the present invention have a total moisture
content of 10-20%. The total moisture includes water provided with or
associated
with the various essential and optional ingredients. For example, total
moisture
includes the moisture associated with flour, starch, flavorings and especially
liquid
eggs, if used. The total rrioisture is determined by a vacuum oven drying of
the
Boughs herein. In some embodiments, very little or no added water is employed
to
formulate the present unleavened Boughs because moisture is provided in
pasteurized liquid eggs and the residual moisture associated with the dry
ingredients.
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In other applications, dry eggs may be used and water is added to the dough as
part
of an emulsion or emulsifier dispersion.
The particular selection of ingredients and concentration are selected
to provide Boughs having a water activity that is less than 0.85. For some
embodiments, the water activity is less than 0.50 and may be 0.25. Selection
of
such water activity value is important in achieving a balance between
microbial
shelf stability and dough handling characteristics. Water activity may also be
reduced by using polyols such as glycerol and sorbitol.
The present unleavened Boughs are preferably not acidified and thus
range in pH from about 6.0 to 8Ø The Boughs herein are preferably
essentially free
of conventional leavening acids. The combination of a low oxygen gas in the
head
space and low water activity are sufficient to maintain shelf stability at
room
temperature.
If desired, the Boughs :further comprise about 1-8% of a humectant,
preferably about 1-6%. Humectant addition is helpful in achieving the present
essential water activity level and the microbial shelf stability at room
temperature
provided by the present food products. The humectant is any commonly employed
humectant ingredient. . Preferred humectauts are selected from a group
consisting of
sorbitol, xylitol, manitol, glycerin, glycerol, propylene glycol and mixtures
thereof.
In other embodiments, the food articles of the present invention
comprise au anti-mycotic ingredient such as sodium, potassium sorbate, calcium
propionate, parabens or propionic acid. Whip not needed to maintain shelf
stability
addition of such anti-mycotic ingredients so desired from a food safety
standpoint
anti-mycotic in case the physical integrity of the food product is comprised
and.
compromised and oxygen leaks into the head space.
The food product of the present invention is specifically described in
terms of baked goods such as pits bread, tortillas, and pie crusts; dried
goods such as
pasta and fried goods, such textured soy protein. These products, are made
from an
unleavened dough with a pH of about 6 to 8. The unleavened dough products of
the
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present invention do not require a conventional acid/soda chemical leavening
system
or a yeast-based leavening system.
The unleavened dough of the present invention optionally includes a
variety of ingredients suitable for rendering finished baked goods prepared
therefrom more organoleptically desirable. These optional dry mix components
include anti-oxidants, flavor/coloring agents, flavor chips, nuts and fruit
pieces or
other edible inclusions. Some embodiments of the unleavened dough of the
present
invention also may include an, ingredient such as inactivated yeast cells to
impart a
yeast flavor.
Another optional ingredient includes nonfat dry milk solids. Nonfat
dry milk solids aid the structuring of the finished baked good. Tf present,
such dry
milk solids comprise from about 0.5 to 2.0% of the present doughs.
The product of the present invention also includes a container,
unleavened dough stored within the container, with a headspace over the dough
and
inert gas within the head space. The inert gas comprises N20, C02 or NZ or
combinations of these gases. Residual oxygen content is less than 4% and for
best
results is less than 2%.
For some embodiments., the headspace comprises at least IO% (v/v)
of COa, and may be at Ieast 20%. At such levels, the CO2 provides modest
preservative properties against spoilage.
METHOD OF PREPARATION
The unleavened doughs of the present invention are prepared by
blending the essential and optional components such as flour, salt, optionally
sugar,
shortening or oil, water and glycerol or other poiyol together in such a
conventional
manner as to produce a well blended dough. The unleavened dough is prepared
from a wet emulsifier premix blend and a dry blend. The wet emulsifier premix
blend includes oil or liquid shortening, eggs, glycerol, emulsifiers and so
on. Tlie
dry blend includes flour, optionally sugar, salt and so on. The dry blend and
wet
blend are then combined under anaerobic conditions to form a dough. The
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unleavened dough is, fox example, prepared in a batch or a continuous mixing
device.
Doughs and/or other unleavened food products are then charged or
are otherwise disposed within the container to partially fill the container.
The
container is then flushed with an inert gas to insure low oxygen in the
headspace.
Oxygen is equal to or less than 4% by volume. The containers are then sealed
to
form the finished ready-to-bake container articles. The articles have an
extended
shelf stability at room temperature and do not require refrigerated storage.
The temperature of dough and other unleavened~food products during
the filling step can be at room temperature to warm temperature, e.g.,
60° to 100F°
(15.6° to 37.7° C). The packaged ready-to hake baked dough
articles and other
unleavened food articles herein do not require heat treatment such as
pasteurization
,or refrigeration in order to obtain shelf stability notwithstanding having a
relatively
high pH. The products enjoy microbial stability and retain their good baking
properties for as long as four to nine months at room temperature storage. The
articles are packaged to be substantially unpressurized, i.e. can be packaged
at
atmospheric pressure.
The present doughs are conveniently prepared into finished baked
goods by simple addition to a suitable bal~g container or pan and baking to
form a
finished baked good is charged into a baking container and baked for
sufficient
times, for example, at 160° to 218.3° C (325° to
425° F) for about 10 to 40 minutes
to form a finished baked good.
Baking time depends on the thic~ess of the dough in the pan, with a
longer bake time required for a thicker (higher) dough. Bake times range
between
about 10 to 45 minutes. The resultant finished baked goods are characterized
by a
firm texture. Some of the finished baked good embodiments are fiufiher
characterized by being somewhat expanded and typically have densities ranging
from about 0.3 to 0.6 g/cc. The finished baked goods are ready for immediate
consumption or can be prepared on a commercial scale for distribution.
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The present invention finds particular suitability for use in
connection with baked items such as pie crust, pita bread, and so forth; fried
items
such as tortilla dough, and fila dough; dried items such as pasta dough; and
other
unleavened food products such as textured soy protein. Also, while the
present.
articles do not require refrigeration, the articles can be cooled and stored
at
refrigeration temperatures.
Thus, since the invention disclosed herein may be embodied in other
specific forms without departing from the spirit or general characteristics
thereof,
some of which forms have been indicated, the embodiments described herein are
to
be considered in all respects illustrative and not restrictive. The scope of
the
invention is tv be indicated by the appended claims, rather than by the
foregoing
description, and all changes, which come within the meaning, and range of
equivalency of the claims, are intended to be embraced therein.
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