Note: Descriptions are shown in the official language in which they were submitted.
CA 02491171 2012-01-11
A FREEZER TO RETARDER TO OVEN DOUGH
[001]
FIELD OF THE INVENTION
[002] The present invention relates generally to the field of frozen doughs
and more
particularly to a freezer to retarder to oven dough that does not require a
conventional
proofing (proofer) step. The present invention also relates to methods of
making frozen
dough. The present invention further relates to methods of making a baked
product from
the frozen dough.
BACKGROUND OF THE INVENTION
[003] Freshly-baked products are generally preferred by consumers because of
their
"fresh" taste and aroma. However, the traditional way of preparing freshly
baked products
is time-consuming. A step that requires a significant amount of time and human
care is
proofing - during which yeast produces carbon dioxide that expands the product
which
leads to further expansion during baking. Proofing requires a proofer with
temperature
and humidity control, as well as experienced personnel attending to the
proofing process
over the duration of proofing (usually > 1 hr).
[004] Many frozen doughs also require proofing. In some frozen doughs, the
dough is
proofed prior to freezing. A significant time is required for pre-proofing.
Additionally,
pre-proofed doughs do not have long storage life. In some other frozen doughs,
the dough
is not proofed but requires chemical leavening.
[005] Frozen doughs have been described that do not need a proofing step, but
such
doughs typically have chemical leavening agents which may be either very high
in level
(U.S Pat. No 5,451,417), or require more than one acid (WO 01/32023 Al). The
former
produces a product having biscuit-like taste and texture, and the latter
results in a loss of
leavening agent's gassing power during storage of the frozen doughs thereby
limiting the
storage time.
CA 02491171 2004-12-23
SUMMARY OF THE INVENTION
[006] The present invention provides a frozen dough that is substantially free
of chemical
leavening and that does not need conventional proofing prior to freezing or
after freezing
prior to baking. It comprises a high yeast content comprising one or more
yeasts with
activity in the temperature range of from 33-140 F, and a high gluten content
in the range
of from 10 to 20 wt% based on the weight of the flour. In one embodiment, the
high
gluten content for hard rolls is 12-20 wt%.
[007] The overall yeast is present at a concentration of at least about 8 wt%
compressed
yeast on flour weight basis. The frozen dough can be thawed in a retarder
which is
generally at temperatures in the range of from 33-42 OF and a humidity of 60%
to 90%
(preferably 70% to 80% and more preferably 75% to 78%), or at higher
temperatures
including ambient temperatures without using conventional proofing (proofer).
Following
baking, the specific volume reaches about 4.0 cc/g or higher. The baked
products have
desirable texture, flavor and aroma. The frozen dough of the present invention
can be
prepared into various types of rolls, sweet rolls and breads.
DETAILED DESCRIPTION
[008] The term "conventional proofing" as used herein means allowing the dough
to sit
at a temperature of from 90 to 100 F, at a relative humidity of 80% to 90%
for a time of
from 30 to 80 minutes.
[009] All weight percents given herein are based upon the weight of flour used
(taken as
100%). For example, a yeast weight percent of 8 is to be interpreted to mean
that in a
dough product in which 50 grams of flour are used, the yeast content is 4
grams. The
phrases "on flour weight basis" and "based on the weight of flour" are used
interchangeably and have the same meaning.
[010] The present invention provides a freezer-to-retarder -to-oven dough
products that
can be baked without conventional proofing, to provide baked products with a
good
texture and desirable taste. The present invention is based on the unexpected
finding that
a combination of a high level of temperature selective yeast and a gluten
content sufficient
to provide adequate gas holding ability in the dough for the gas generated by
the high level
of yeast improves the performance of the baked products when the frozen dough
is
allowed to thaw in a retarder. In one embodiment, the retarder is at
temperatures between
33-420F. In another embodiment, the retarder is at higher temperatures,
including
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ambient temperatures. By "ambient temperatures," is meant a temperature in the
range of
from about 65 F to 85 F . The dough exhibits superior performance without the
use of a
conventional proofing step. It is believed that the special formulation
contributes to
improved gas holding ability necessary for the high yeast content which in
turn results in
desirable performance.
[011] Accordingly, the frozen dough of the present invention comprises a high
yeast
content comprising one or more yeast with activity in the temperature range of
from 33-
140 F, and sufficient gluten to provide gas holding ability during the thawing
process such
that upon baking, the specific volume of the baked product is about 4.0 cc/g
or higher.
Other ingredients, which are normally found in dough, such as water,
emulsifiers,
stabilizers and salt are present. Optional ingredients, such as sweeteners,
flavors and
colorants may also be present.
[012] It should be understood that the term gluten generally refers to the
group of
proteins which give dough adequate gas-holding ability. High levels of these
proteins can
result in superior specific volume in baked products. Although referred to
collectively as
"gluten," a number of different proteins are responsible. Examples are
glutenin and
gliadin. However, "gluten" as used here is meant to encompass all structure-
promoting
proteins, whether or not normally considered to be part of the gluten group,
introduced
into the dough in any way (for example as part of the flour ingredient, or
added as a
supplement). It is thought that high gluten content of doughs contributes to
the strength of
the dough.
[013] The gluten content of the dough of the present invention may also
provide texture
to the baked product. Accordingly, the gluten content of the dough can be
varied to
provide not only the desired gas holding power but also desired texture.
[014] In one embodiment, the flour used in the present invention maybe a high
gluten
flour (HG flour). High gluten flours generally have a gluten content in the
range of from
12.5 to 15% by weight of the flour. Alternatively, it may be convenient to use
a flour
which is not high-gluten. However, if a flour is used that is not high-gluten,
it may be
necessary to supplement the dough mix with gluten to form a dough which has
the ability
to hold gas such that when the dough is baked, a product having a specific
volume of 4
cc/gm is obtained. For example, the gluten can be added to the dough mix, or,
if
convenient, one or more of the flours used in preparing the mix can be pre-
supplemented
with gluten.
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[015] The gluten content of the dough should be in the range of from 10 to 20
wt%, with
higher gluten levels generally giving a dough with better gas-holding ability.
For hard
rolls, the gluten content is in the range of from 12-20%.
[016] Typically, flour sold as "high gluten" generally contains about 12.5 to
15% gluten.
However, it is to be understood that gluten levels can fluctuate from product
to product or
season to season. If desired, high-gluten flour can be used as the only flour
in the dough,
or it can be used with other flours.
[017] Flours which can be used in the doughs of the present invention include,
but are
not limited to, wheat flour, potato flour and bread flour, or combinations and
mixtures
thereof. The flour of the present invention may be enriched flour, i.e., flour
that contains
federally mandated amounts of flour, niacin, ferrous sulfate, riboflavin,
enzyme, and
thiamine mononitrate folate. Other types of flours may be substituted for the
enriched
flour or used in combination with enriched flour.
[018] The dough of the present invention also preferably comprises additional
gluten or
gluten hydrolytes. As mentioned above, gluten is known to contain gliadin and
glutenin.
Accordingly, these individual components or combinations thereof may be used
instead of
gluten. The gliadin may be alpha, beta, gamma or omega gliadin or combinations
thereof.
[019] The dough of the present invention may include flour from one or more
grains
(such as oats, corn, barley, wheat, rye and the like). The dough may include
particulate
materials from the grains (such as crushed wheat particles). Further, the
dough may also
include whole seeds or crushed seeds. Useful seeds are well known in the art
and include
sunflower seeds, caraway seeds, flax seeds, sesame seeds and the like. Thus,
multigrain
products can be prepared to improve the taste and/or to add nutritional value.
[020] Sufficient water may be added to the present doughs to achieve the
desired
consistency. The precise amount of water depends on factors known to those
skilled in the
art, including the type of yeast used, the desired final product, and the
amount and type of
other ingredients. Water is typically added in an amount of about 45 wt% to
about 70
wt%, on flour weight basis.
[021] The frozen dough the present invention comprises one or more types of
yeast. The
yeasts may be active within specific temperature ranges. The active
temperature ranges of
the different yeasts may overlap, or they may be distinct. A type of yeast
suitable for this
invention is the cold tolerance yeast, which is typically active at
temperatures between 33
to 60 F. Another type of suitable yeast is the regular Baker's yeast which
is optimally
active at between 80 -110 F. If desired, two or more types of yeast which are
active at
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CA 02491171 2004-12-23
different temperatures between freezing temperature and the temperature of
baking can be
used to generate gas essentially throughout the process of thawing, i.e.,
after removal of
the dough from the freezer until its transfer to the oven for baking.
Accordingly, in one
embodiment, a combination of cold tolerance yeast and regular baker's yeast is
used such
that gas can be generated when the thawing process is carried out over a
temperature range
of 33 F to 140 F. Yeast active at temperature ranges which are higher than
those for
regular baker's yeast may be used if thawing is to be carried out at
temperatures higher
than 140 F. Other types of yeast such as sugar tolerance yeast, or sweet dough
yeast, may
also be used.
[022] Yeast can be purchased and used in different forms. The driest commonly
used
yeast, sometimes referred to as "instant" yeast, contains 3.5-6.0% moisture.
Cream yeast
contains about 80-85% moisture; compressed yeast contains about 66-73%
moisture; and
active dry yeast contains about 6-8% moisture. Other examples include baker's
yeast,
protected active dry yeast, frozen yeast and the like.
[023] In the dough of the present invention, yeast is used in amounts which
are greater
than 8 wt%, based on the weight of the flour. Preferably, the yeast is present
in
proportions in the range of from 8 to 15 weight percent. It has been found
that yeast
proportions lower than about 8 weight percent can result in a baked product
with a specific
volume which is less than 4 cc/gm. Yeast proportions greater than about 15
weight
percent can result in a baked product with a poor appearance. Unless otherwise
stated, as
used herein, quantities of "yeast" refer to quantities of compressed yeast.
However, the
invention is in no way limited to compressed yeast. For a given quantity of
compressed
yeast, one of ordinary skill in the art could easily determine "compressed
yeast
equivalent," i.e., the quantity of another form of yeast having a different
degree of
hydration than compressed yeast, but containing the same amount of yeast as
the given
quantity of compressed yeast. For example, 1 lb compressed yeast is generally
equivalent
to about 0.3125-4 lbs. instant yeast. Similarly, 1% compressed yeast is
equivalent to about
1.5-1.8% cream yeast, which is equivalent to about 0.375-0.5% active dry,
which is
equivalent to about 0.3125-0.4% instant yeast. The amount of yeast may be
chosen to
correspond to the desired density of the final baked product and the flavor
profile.
[024] The dough of the present invention preferably comprises salt. Salt is
generally
added to promote better mixing, enhance flavoring, control moisture content
within the
dough, and/or to control yeast activity. Any commercially available fine-
blending salt
may be used.
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CA 02491171 2004-12-23
[025] The dough of the present invention also comprises an effective amount of
a lipid
source. In one embodiment, oil is used. In general, most edible oils are
suitable, but
vegetable oil is preferred due to its taste and lubrication properties, as
well as its lack of
trans fat. Examples of vegetable oils that may be used in accordance with the
present
invention, include, but are not limited to, soybean oil, cottonseed oil,
peanut oil, canola oil,
corn oil, olive oil and sunflower oil. Soybean and/or cottonseed oils are
preferred.
Certain oils, including sunflower and corn oils, potentially adversely affect
the overall
flavor profile of the dough and are therefore, less preferred. Flavored oils
may also be
used in addition to or in place of the oil of the present invention. Non-
limiting examples
of flavored oils include olive, sesame, ginger and the like.
[026] Lipid sources may include emulsified oils. Examples of such emulsified
oils are
shortening, butter or margarine. Glyceride shortenings derived from animal or
vegetable
fats and oils including synthetically prepared shortenings are suitable for
use herein. The
glyceride may contain saturated or unsaturated long chain acyl radicals having
from about
12 to about 22 carbon atoms generally obtained from edible oils and fats such
as corn oil,
cottonseed oil, soybean oil, coconut oil, rapeseed oil, peanut oil, olive oil,
palm oil, palm
kernel oil, sunflower seed oil, wall flower oil, lard, tallow and the like.
Examples of
preferred shortenings according to the present invention, include vegetable
shortenings,
soybean based shortenings or oils, hydrogenated soybean-based shortening or
oil, corn oil,
palm oil, hydrogenated palm oil, lard and tallow oils.
[027] Hydrogenated shortening is preferably used if a slight crispiness to the
outside of
the cooked dough is desired. The hydrogenated shortening provides better crust
definition, crispiness and better baked volume. Hydrogenated shortening
suitable for use
with the invention is readily available on the market, as for example the SHO-
2 product
from Central Soya. Vegetable shortening that may be used in accordance with
the present
invention is preferably in the form of shortening flakes. Hydrogenated
shortening is
preferably used at a low concentration to minimize trans fat related issues.
[028] The amount and type of fat source may be selected by those skilled in
the art based
on various factors including the ingredients of the frozen dough, and based on
the desired
taste and physical characteristics, such as maintaining a consistent internal
structure.
[029] The dough of the present invention comprises emulsifiers between 0.05%
to 0.5%
or higher as permissible under the FDA guidelines. Suitable emulsifiers
include lecithin,
hydroxylated lecithin; mono, di, or polyglycerides of fatty acids, such as
stearin and
palmitin mono and dyglycerides, polyoxyethylene ethers of fatty esters of
polyhydric
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alcohols, such as the polyoxyethylene ethers of sorbitan distearate; fatty
esters of
polyhydric alcohols such as sorbitan monostearate; polyglycerol esters of mono
and
dyglycerides such as hexaglyceryl distearate; mono- and diesters of glycols
such as
propylene glycol monostearate, and propylene glycol monopalmitate,
succinoylated
monoglycerides; and the esters of carboxylic acids such as lactic, citric, and
tartaric acids
with the mono- and diglycerides of fatty acids such as glycerol lacto
palmitate and
glycerol lacto stearate, and calcium or sodium stearoyl lactylates (SSL) and
all members
of the sucrose ester family thereof, all varieties of diacetyltartaric esters
of fatty acids,
diacetyl tartaric acid ester of monoglyceride ("DATEMS"), and the like, and
mixtures
thereof.
[030] The dough of the present invention includes one or more stabilizers
which are
typically hydrophilic colloids. These can be natural, i.e. vegetable, or
synthetic gums and
may be, for example, carrageenan, guar gum, alginate, xanthan gum and the like
or semi-
synthetic such as methylcellulose, carboxy-methylcellulose, ethylcellulose,
hydroxy-
propylmethylcellulose (METHOCEL F-50 HG), and microcrystalline cellulose.
Typically, a gum or combination of gums is employed with a sugar, e.g.
dextrose carrier.
The amount of these stabilizers for this product is between 0.2 to 1.6 or
higher, as
permissible under FDA guidelines.
[031] The dough of the present invention may also include flavoring and/or
coloring
agents. The dough may optionally contain suitable amounts of, for example 0.01
to 0.5%,
flavoring agents and/or coloring agents. When using flavorings, the amount of
water and
salt used in the dough may have to be adjusted to take into account, for
example, the
amount of salt and water already contained in the flavoring. It is believed
that "fine
tuning" of the amount of salt and water in the dough would be within the
ability of one of
ordinary skill in the art. An example of a suitable flavoring is butter flavor
and yeast
flavor. It will be appreciated by those skilled in the art that many different
individual
flavors can be used to achieve the ultimate desired flavor.
[032] Vitamin and minerals may also be added to the dough as desired.
Riboflavin is a
commonly added vitamin to the dough. Vitamins and minerals may be added as
enriched
flour or added individually. In addition, calcium in absorbable or elemental
form may also
be added.
[033] Sweeteners may be added to the present dough to provide for texture
and/or flavor.
Sweeteners such as sugars may be added for the additional purpose of providing
a source
of energy for the yeast. In one embodiment, dextrose and/or other sugars such
as sucrose,
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crystalline fructose, high fructose corn syrup (HFCS) or a combination of
these sugars
may be used. Alternatively or additionally artificial sweeteners such as
aspartame,
saccharine, sucralose, alitame, cyclamate and the like may also be used.
[034] If desired, the dough of the present invention may contain oxidants such
as
azodicarbonamide, potassium iodate and the like.
[035] The ingredients of the present invention may be included as a
combination. For
example, a dough conditioner comprising one or more of the following may be
used:
oxidants, enzymes, emulsifiers, flour and oil. A non-limiting example of such
a
conditioner is Tolerance Plus. The dough conditioner may also contain ascorbic
acid.
Dough conditioners can be used in a wide range of weight percents, as long as
their
presence and amount does not cause the specific volume of the baked product to
be less
than 4 cc/gm. An acceptable range for most conditioners is in the range of
from 0.3 to 2.1
wt%.
[036] If desired, the dough of the present invention may also comprise enzymes
. The
enzymes may be selected from a group including, but not limited to, amylase,
hemicellulase, glucose oxidase, xylanase and the like. Determination of the
amount and
type of enzyme is well within the purview of those skilled in the art. Use of
enzymes,
such as amylases may be advantageous in that they may retard staling of the
frozen dough
or the resulting rolls, breads and the like. Enzymes may also result in an
increased
strength, improved extensiblity or elasticity, stability and reduced
stickiness of the dough,
thus resulting in improved machinability during manufacture. The effect on the
dough
may be particularly advantageous when a lower content gluten flour is used.
The
improved machinability is of particular importance in connection with dough
which is to
be processed industrially. The amount and type of enzyme of the present
invention may
be determined by those skilled in the art depending on the specific desired
resulting
properties.
[037] The dough of the present invention may include reducing agents,
particularly for
more flow in retarder resulting in a better baked shape. Suitable reducing
agents include,
but are not limited to, L-cysteine and glutathione. It is believed that the
reducing agents
contribute to the high gluten dough becoming more malleable.
[038] Preferably, the dough is shaped into a desired shape prior to being
frozen, such as,
into the desired forms such as a square, other polygons, or round, or rolled
into rolls. If
desired, the dough may cut after freezing and before thawing.
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[039] The dough rheology can be modified to suit different categories of baked
products.
In contrast to relatively dense products like sheeted pizza dough and bread
sticks (2-3
cc/g), the present dough can expand such that it has a specific volume of 4.0
cc/gm or
greater.
[040] The frozen dough does not require conventional proofing. The dough can
be
prepared and frozen without proofing and after removal from the freezer, can
be thawed in
a retarder or at ambient temperatures as described herein and then transferred
to an oven
again without proofing.
[041] The dough of the present invention is a high-gluten, high-yeast dough,
wherein
leavening by yeast alone will result in a specific volume of the baked product
being at
least 4 cc/gram. The dough of the present invention does not need chemical
leavening.
Accordingly, the dough of this invention is substantially free of chemical
leavening. As
used herein, the term "substantially free" of chemical leavening indicates
that it does not
have both the acid and the base in amounts that will cause significant
leavening.
Generally, it is considered that no significant leavening will be achieved if
the chemical
leavening components are present in amounts less than 0.2% each on flour
basis. In one
embodiment, the chemical leavening components are present in amounts less than
0.1 %
each on flour basis and in another embodiment, the dough is free of chemical
leavening
system components. Since the acid or the base alone is not expected to cause
any
leavening, the dough may contain either the base or the acid alone in amounts
higher than
0.2% as long as it does not produce an undesirable taste.
METHOD OF PREPARING FROZEN DOUGH
[042] The present invention also relates to a method of making frozen dough
that
comprises combining the dough ingredients set forth herein, shaping and
freezing the
dough. The dough formed from these methods does not require conventional
proofing.
[043] The type and relative amount of ingredients (including the required,
preferred and
optional ingredients) according to these methods are as set forth above with
respect to the
frozen dough of the present invention. In particular, according to the present
invention,
the ingredients include a high level of yeast and gluten. Other ingredients
such as water
and flour, as well as optional ingredients such as, for example, sugar and
lipid source
should be used in amounts such that the baked product has a specific volume
which is
greater than 4 cc/gm. Exemplary and recommended amounts are as set forth above
with
respect to the frozen dough.
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[044] The combining step may include either combining all of the ingredients
at once or
combining different combinations of ingredients first and then combining all
of the
ingredients together. For example, according to one embodiment, certain of the
ingredients are combined to form a pre-mix, including for example, the salt,
stabilizers and
sugar. Then, the pre-mix is combined with the remaining ingredients including
the flour,
yeast, water and lipid source. The pre-mix and/or the final mixture may
include one or
more additional ingredients as set forth herein.
[045] According to a preferred embodiment of the present invention, the
combining step
includes mixing all the ingredients. The ingredients may be mixed with one
another by
mixing methods generally known in the art.
[046] After combining the ingredients, they are then mixed (or further mixed
if mixing
steps have already taken place) by any suitable mixing apparatus, such as a
Hobart mixer.
By way of example only, the ingredients are mixed for about 2 to about 4
minutes on a
first speed (low) and then for about 7 to about 19 minutes on a second speed
(high), which
is faster than the first speed. Preferably, the ingredients are mixed for
about 2 minutes on
low speed and for about 10-12 minutes on high speed. Mixing preferably takes
place so
that the dough temperature after mixing is preferably between 65 F -72 F.
[047] It is preferable to perform desired shaping of the dough prior to
freezing of the
dough. The dough can be formed into desired shapes by means such as rounding,
sheeting, cutting, or rolling the dough into the form of square, other
polygons, sphere,
cylinder etc. Typically for crusty (Italian) breads, the dough is rounded and
rolled into a
cylinder shape by using a molder. The dough may also be sheeted.
[048] The shaped dough is then frozen by methods known in the art. If the
dough is
going to be frozen for a short period of time, the mode of freezing is not
critical.
However, for prolonged stability, the dough should be frozen such that core
temperatures
of less than 30 F and preferably between about 30 F and about -13 F are
obtained within
I to 6 hours and more preferably within about 1 V2 to about 4 hours of the
time that the
dough is placed in the freezing apparatus. When freezing the dough, a uniform
cooling
rate throughout the dough is desirable. A convenient method for freezing the
shaped
dough is by using spiral freezer (-30 F to -62 F). Carbon dioxide optionally
may be used
for gradual freezing (0 F to -10 F).
[049] For prolonged stability, the frozen dough is preferably stored at a
temperature in a
range of from about -42 F to about -10 F, more preferably at a temperature in
the range of
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from about -20 F to about -12 F. Frozen dough according to the present
invention may be
stored for extended periods of time, i.e., at least about 12 weeks.
[050] Optionally, the shaped dough is topped with at least one topping and/or
flavoring
prior to freezing the dough. Non-limiting examples of suitable toppings and
flavorings
that may be used in accordance with these methods, are as set forth above.
[051] According to a preferred method herein, the process for preparing the
dough of the
present invention is as follows:
1) combining all dry ingredients, mix for 2 min on low;
2) mixing on high for about 10-12 minutes so that the final dough temperature
is a
temperature of 62 F -72 F, preferably about 65 F -69 F
3) forming the dough and cut into desired shapes;
4) freezing.
[052] The frozen dough made according to the present methods does not need to
be
proofed prior to baking. Further, for using the frozen dough, the dough may be
taken
directly from the freezer and subjected to thawing in a retarder or at ambient
temperatures.
The retarder is generally at a temperature of between about 33 F -42 F. The
thawing time
will depend upon the size and shape of the dough and the temperature of
thawing. In
general, dough forms having greater surface-area-to-volume ratios will thaw
faster than
dough forms of similar volume having lesser surface-area-to-volume ratios. For
example,
the dough can be thawed in the retarder for at least 8 hours, preferably
between 8-48 hrs,
more preferably between 12-36 hrs.
[053] In one embodiment, the frozen dough can be thawed at ambient
temperatures, such
as temperatures between 65 F and 85 F.
[054] Those skilled in the art will recognize that the time required for
optimal thawing at
ambient temperatures is generally less than that required in the retarder. The
time required
can be adjusted to provide for a baked product which has a specific volume of
about 4.0
cc/g or higher.
[055] The specific volume of the dough after freezing is typically about 1.2
to 1.3 cc/g.
The specific volume following the thawing step depends upon the temperature
and time of
thawing. For example, if the frozen dough is transferred to a retarder at a
temperature of
about 33 F -36 OF, for 12 hours or longer, the specific volume is about 1.4-
1.6 cc/g, and if
thawed at a higher retarder temperature or at ambient temperatures for several
hours, the
specific volume can be about 2.5 cc/g or higher.
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METHODS OF PREPARING FROZEN DOUGH PRODUCTS
[056] Further provided are methods of making dough products that include
removing
frozen dough (made by the above-described methods), from a freezer and without
proofing
the dough, transferring the dough to a retarder or incubating at ambient
temperature and
then transferring to an oven that is heated to a temperature sufficient to
bake the products.
In one embodiment, following removal from the retarder, the dough may be
allowed to sit
at ambient temperature for a period of time up to 2 hours-referred to herein
as the "floor
time." In another embodiment, the floor time is up to thirty minutes.
[057] The oven preferably is a thermostatically controlled oven. However, any
oven
known in the art that is suitable for baking may be used. A rack oven with
steam
application is preferred. If a convection oven is used, dough products may
need to be
placed into a cluster in a baking pan.
[058] The dough of the present invention can be fully baked when its interior
reaches a
temperature of at least about 176 OF (80 C). These interior temperatures are
typically
achieved by heating the product at a temperature in the range of from about
250 F to about
500 F, more preferably from about 325 F to about 450 F, for a corresponding
period of
time in the range of from about 10 to about 40 minutes, depending on the
weight and
shape of the baked product, as well as the type of oven used to bake the
product.
[059] In the methods of the present invention frozen dough is thawed and then
transferred to an oven without a proofing step. The oven is preferably pre-
heated to a
temperature sufficient to bake the dough prior to transferring the dough to
the oven. For
example, the oven may be pre-heated to a temperature in the range of from
about 350 F to
about 425 F, preferably about 375 F, which cooks the dough in about 11 to 25
minutes
depending on dough size. Alternatively, the dough may be transferred to an
oven that has
not been pre-heated, or has only been partially pre-heated.
[060] The exact conditions under which the dough is baked will depend upon the
type of
product, and will be apparent to one skilled in the art. For example, shapes
having greater
surface-area-to-volume ratios will cook faster than shapes having lesser
surface-area-to-
volume ratios.
[061] In one embodiment, the dough pieces are removed from the freezer and set
out in a
baking tray or dish. The tray or dish (or other similar container) is set in a
retarder at 33 F
-42 F. After about 12-48 hours, the product may be optionally rested at
ambient
temperature for a brief period (such as up to 2 hours, preferably up to 30
minutes) and then
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CA 02491171 2004-12-23
baked in an oven at 350 F -400 OF for 9-14 minutes for obtaining soft home-
style rolls and
22-30 minutes following steaming for about 15-20 seconds, for crusty surface
bread.
[062] Instead of baking, the dough of the present invention can be cooked with
steam
resulting in a freezer to steamer product. Additionally, it can also be fried
into different
products such as breakfast items, snack items, etc.
[063] The dough of the present invention can be formed in the shape of a
swirl. In swirl
product application, use of oil-based paste gives products a pleasant, golden
brown, baked
color due to oil-flying effect during baking. For water-based paste, water
activity (Aw)
matching between dough and paste is needed to minimize migration of
ingredients
between two components (dough and paste).
[064] The present invention will now be described in detail with respect to
specific
representative embodiments. The examples are intended to be illustrative only.
In
particular, the invention is not intended to be limited to the methods,
ingredients,
conditions, process parameters, apparatus and the like specifically recited
herein.
[065] The present invention provides compositions which are suitable for
preparing
baked products which have a crusty Italian bread type surface. The dough has a
high yeast
content, high gluten flour, low sugar and low fat content. Preferably,
substantially all of
the flour used to prepare the dough is high gluten flour. If desired,
additional sources of
gluten may be used. The dough is formed from ingredients in the proportions
given in the
following table.
Table 1
Range (% of Preferred
Ingredient flour) Range (% of
flour)
High Gluten Flour 100 100
Gluten 0-7.0 1.5-2.5
Compressed Yeast 6-16 10-12
High fructose corn syrup 0.5-2.5 1.0-2.0
Dextrose 0.2-2.0 0.8-1.2
Emulsifiers 0.2-1.4 0.5-1.1
Dough Conditioner 0.4-0.9 0.6-0.9
Stabilizers 0.2-0.8 0.4-0.6
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CA 02491171 2004-12-23
Lipid Source 0.5-2.5 1.0-2.0
Salt 1.0-3.0 1.5-2.5
Water 54-66 58-62
[066] In another embodiment where a softer texture is desired, a combination
of bread
flour, high yeast content, high gluten, high sugar and high fat is used. With
this
combination, the baked product has a soft surface and crumb and is similar in
appearance
and texture to soft home-style rolls. Accordingly, in this embodiment, the
dough has the
following composition.
Table 2
Range (% of Preferred
Ingredient flour) Range (% of
flour)
Bread flour 100 100
Gluten 0-5 1.5-2.5
Potato flour 2.0-6.0 3.0-5.0
Compressed yeast 10-14 11-13
High fructose corn syrup 8.0-27.0 13.0-22.0
Emulsifiers 0.2-1.6 0.5-1.2
Dough conditioner 0.4-0.9 0.6-0.9
Lipid source 4.0-16.0 8.0-12.0
Salt 1.0-3.0 1.5-2.5
Water 45-59 47-55
EXAMPLE 1
[067] This example provides a specific formulation for a crusty Italian bread.
Table 3
Ingredient Amount (% of
flour)
High gluten flour 100.0
Gluten 1.0
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CA 02491171 2012-01-11
Compressed Yeast 10.0
High fructose corn syrup 1.5
Dextrose 1.0
SSL 0.3
DATEM 0.5
Dough conditioner 0.8
Guar gum 1.0
Soybean oil 1.5
Salt 1.5
Water 60.0
[068] All ingredients were mixed together using a Hobart mixer, with a paddle
on low
speed for about 2 minutes; then on high speed for about 11 minutes. The final
dough
temperature was between about 65 F -69 OF. The dough was divided, rounded,
rested and
rolled into a cylinder shape with a molder. Individual loaves were frozen in a
blast .
freezer. After freezing (30 min), the dough pieces were transferred to a
regular freezer and
stored for at least 24 hrs. For using the products, doughs were set out in a
baking tray and
put in a retarder at 33 F - 42 F for 12-36 hrs. The thawed product was then
baked in an
oven at 375 F for 25 min with 15-20 second steam. This resulted in a
desirable baked
product with golden brown color, good appearance, and good tasting attributes.
A specific
volume of about 4.9 cc/g was obtained.
EXAMPLE 2
[069] This example provides a specific formulation and method for preparing a
soft
home-style roll.
Table 4
Ingredient Amount (% of
flour)
Bread flour 100.0
Wheat gluten 2.0
Potato flour 4.0
Compressed yeast 11.0
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CA 02491171 2012-01-11
High fructose corn syrup 17.5
SSL 0.5
DATEM 0.4
Dough conditioner 0.8
Soybean oil 10.0
Salt 1.9
Water 52.0
Methocel 1.0
[070] All ingredients were mixed together using a Hobart mixer, with a paddle
on low
speed for about 2 minutes; then on high speed for about 10 minutes. The final
dough
temperature was between about 65 F -69 F. The dough was shaped and frozen in
a blast
freezer. After freezing (30 min), the dough pieces were transferred to a
regular freezer and
stored for at least 24 hrs. The doughs were then set out in a baking tray and
put in a
retarder at 33 F -42 F for 12-36 hrs. The thawed product was then baked in an
oven at
375 OF for 11 min with 15-20 second steam. This resulted in a desirable baked
product
with golden brown color, good appearance, and good tasting attributes. A
specific volume
of about 6 cc/g was obtained.
EXAMPLE 3
[071] This embodiment provides three additional examples, one for a hard roll
and two
for a soft roll formulation. The emulsifier used was SSL. The dough
conditioners were
Tolerance Plus w/AA, Panodann 205, PBRI and ADA, and the stabilizers were guar
gum,
TM
coyote gum, and Methocel K4M. Non-fat dry milk (NFDM) and Vital wheat gluten
(VWG) were present in the composition. A specific volume of about 6.9 cc/g was
obtained
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CA 02491171 2012-01-11
Table 5
Ingredient Hard Roll Soft Roll 1 Soft Roll 2
Salt 2.00 1.90 2.00
Dough Conditioner 1.47 1.20 1.21
Emulsifier 0.40 0.40 0.38
Stabilizer 2.00 1.00 1.00
VWG 2.00 0.00 1.00
Dextrose 1.00 0.00 0.00
Deactivated Yeast 1.00 0.00 0.00
Potato Flour 0.00 1.50 0.00
Soy oil 0.00 3.50 0.00
HG Flour 100.00 100.00 100.00
Cream Yeast 17.50 19.10 19.08
Shortening 1.50 1.90 0.00
HFCS 1.50 15.00 13.50
Water 53.10 0.00 48.00
Butter 0.00 0.00 5.00
Spice Blend 0.00 0.00 0.02
Egg Powder 0.00 0.00 4.40
NFDM 0.00 0.00 0.50
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