Note: Descriptions are shown in the official language in which they were submitted.
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DOUGH COMPRISING RYE FLOUR AND GLUTEN
The present invention relates to a composition for use in making food
products, as well
as food products made therefrom.
In particular, the present invention relates to a composition for use in
making food
products, as well as food products made therefrom, wherein the composition
comprises
(or is made from) a high percentage of a cereal grain wherein the cereal grain
is rye.
Rye flour is used to produce bakery products, such as baked products. These
products
have distinct characteristics and are quite different to bakery products (e.g.
baked
products) produced using high levels of wheat flour.
However, rye flour has characteristics which make it less suitable for use by
itself in
the production of bakery products (e.g. baked products). For example, rye
bakery
products are often more dense and compact in texture with a sour and bitter
taste.
To overcome these problems rye flour is usually used in combination with wheat
flour.
Moreover, in the case of bread making, it is typical to use only low
percentages of rye
flour in order to produce rye bread with acceptable volume. Typical recipes
recommend in a dough to use not more than 20 percent dark rye flour, or not
more than
percent medium rye flour, or not more than 40 percent light rye flour. Here,
"percent" is Bakers' percent; which is discussed later.
25 We have found that one of the characteristics of rye flour that makes it
less suitable for
use in the production of bakery products (e.g. baked products) is that it does
not contain
gluten which prevents the formation of a gluten protein network. As an example
of the
effect of the lack of a gluten protein network, loaves of bread made from
dough in
which the only flour is rye flour are small and compact
We have found that another characteristic of rye flour that makes it less
suitable for use
in the production of bakery products (e.g. baked products) is that the
formation of a
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starch network is hampered due to the high endo-amylase activity in rye flour,
which
results in starch degradation. The degree of starch degradation in dough is
correlated
with the viscosity, which can be measured by an amylograph or a Rapid
Viscosity
Analyzer (RVA). The longer the starch molecules, the better the starch network
and
the higher the viscosity. Accordingly, if starch viscosity is too low during
baking it
will influence pore structure of the baked product as air diffuses too fast or
goes all
together. Furthermore, it has an effect on the stability of the cooled
product.
Another characteristic of rye flour is that it ferments more readily than
wheat flour as it
contains a greater percentage of natural sugars, diastase and protease enzymes
and has
a slightly higher natural acidity than wheat flour.
Another characteristic of rye flour baked products is that they do not have as
high a
water content as wheat based baked products. The water content of the rye
flour baked
product also affects the distribution of water in the rye flour baked product.
Water
content can be measured by standard heating and weight loss measurements,
whilst
water distribution can be analysed by using NMR to observe water activity.
These characteristics make rye flour unsuitable for use with yeast alone.
Normally
sourdough (leaven) is used in rye flour bakery products (e.g. rye flour baked
products)
to stabilize them instead. The sourdough (leaven) works by reducing the
negative
effects of endo-amylases, which are naturally present in rye flour and break
down the
starch during the baking process. The sourdough (leaven) also lowers the pH of
the
dough. It is well known that the pH affects the starch gelatinisation
(reference: "Mig
og mit rugbrod" by Agnete Dal Thomsen ISBN 87-87436-59-2). At lower pH the
starch gelatinisation is delayed thereby giving the amylases less time to
degrade the
starch during baking due to heat denaturation of the amylases. Amylases can
only act
on the starch granules that already have been broken down or when the starch
begins to
gelatinise. So a mechanism of reduced action of the endo-amylases using
sourdough
(leaven) is that the starch gelatinises later as a consequence of reduced pH.
Therefore
the degree of starch gelatinisation and breakdown is reduced. A similar effect
can be
obtained by the use of pasteurised cultures or by addition of acids such as
citric acid
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and lactic acid. The higher starch levels and reduced pH allow the starch to
partially
gelatinize and retain gas bubbles in the dough. It is also an object of the
present
invention to provide means for preventing starch hydrolysis in spite of a pH
in the
dough of between 5 and 7.5.
US 2006/0134270 (Kunze et a/) attempts to address some of the problems
associated
in making breads from rye flour ("sometimes called rye breads"). However,
recipies in
that document do not work ¨ sometime yielding runny dough textures. We present
herein studies that show this.
The present invention alleviates the problems of the prior art.
In broad aspects, the present invention provides:
a flour composition containing a high percentage of a flour made from rye;
a bakery product containing or made from a high percentage of a flour made
from a cereal grain wherein the cereal is rye;
a baked product containing or made from a high percentage of a flour made
from a cereal grain wherein the cereal is rye.
Rye is typically classified as the species Secale cereale.
The term 'bakery product' refers to the resultant product that is baked to
make the
baked products or to the baked product itself. For example, the bakery product
of the
present invention is a dough that has been allowed to stand for a period of
time ¨ such
as for 60 minutes.
In a preferred aspect, the bakery product is a baked product.
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The term "baked product" means a product that has been baked. Typical baked
products include bread products, such as leavened bread products. Preferred
baked
products according to the present invention include: bread loaves, Pan bread,
pizza
bases, rolls, hamburger buns, tortillas, crackers, crispbread, wafers,
croutons or toast
bread; baguette, grissini (bread sticks), Danish pastries; croissants,
biscuits; cookies;
cakes such as sponge cakes, poundcakes, muffins, cake donuts, or cupcakes;
yeast
raised sweet goods such as brioche, panettone, berliner, cinnamon rolls,
yeast, raised
donuts, or pastry, muffins and extruded products.
In one aspect, preferably the baked product is toast or Pan bread
In further broad aspects, the present invention provides:
Process for making, and uses of, the flour composition containing a high
percentage of a flour made from a cereal grain wherein the cereal is rye;
Process for making, and uses of, the bakery product containing or made from a
high percentage of a flour made from a cereal grain wherein the cereal is rye;
Process for making, and uses of, the baked product containing or made from a
high high percentage of a flour made from a cereal grain wherein the cereal is
rye.
=
In one broad aspect, the present invention provides a dough for preparing a
bakery
product (e.g. a baked product), said dough comprising a high level of rye
flour,
exogeneous gluten and a leavening agent.
The term "exogeneous gluten" means gluten that is added as an additive and not
when
present in, for example, wheat ¨ such as in the endosperm thereof (which is
endogeneous gluten). In other words, the gluten is added free of naturally
associated
non-gluten proteins. For example, the gluten is typically added in a purified
state.
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Gluten is a mixture of proteins found combined with starch in the endosperm of
some
cereals, notably wheat. It constitutes about 75% of the proteins contained in
wheat, and
is composed of the proteins gliadin and glutenin. In dough made from wheat
flour
gluten proteins form a cross-linked network that is elastic and traps carbon
dioxide
5
produced in by the leavening agents. Trapped bubbles of carbon dioxide allow
the
dough to rise and result in a larger loaf-volume and better consistency of
bread.
In a preferred aspect, the exogeneous gluten is vital gluten. Vital gluten is
gluten
purified from wheat by washing out the starch fraction from wheat flour and
recovering
the insoluble protein fraction. Vital gluten is added to the flour to
strengthen it. Vital
gluten is widely commercially available.
It is to be noted that US 2006/0134270 (sometimes referred to herein as
"Kunze" or
"Kunze et al") does not teach the addition of exogeneous gluten.
In another broad aspect, the present invention provides the use of an
emulsifier in the
preparation of a dough comprising rye flour.
It is to be noted that Kunze does not teach the addition of an emulsifier.
In another broad aspect, the present invention provides a dough for preparing
a bakery
product (e.g. a baked product), said dough comprising rye flour, a leavening
agent and
an encapsulated acidifier.
The acidifier may be an acid (such as citric acid, tartaric acid, lactic acid,
ascorbic acid,
fumaric acid) or an agent that releases acid. Further examples of acidifiers
include sour
dough, gluco delta lactone (GDL). If encapsulated, the acidifier is
encapsulated to an
extent that the acidifier is not released whilst in the dough phase but that
on baking the
acidifier is released. In some instances, an acidifier is used to ¨ for
example ¨ prolong
the shelf life of the resultant baked product.
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Encapsulation is a process of surrounding or coating an ingredient with a
substance in
order to prevent or delay the release of the ingredient until a certain time
or set of
conditions is achieved. Applications for this technique have increased in the
food
industry since the encapsulated materials can be protected from moisture, heat
or other
extreme conditions, thus enhancing their stability.
A wide variety of ingredients have been encapsulated ¨ such as flavouring
agents, acids,
bases, artificial sweeteners, colourants, preservatives, leavening agents,
antioxidants,
agents with undesirable flavours, odours and nutrients, among others.
Various techniques are employed to form the capsules, including spray drying,
spray
chilling or spray cooling, extrusion coating, fluidized bed coating, liposome
entrapment,
coacervation, inclusion complexation, centrifugal extrusion and rotational
suspension
separation.
Fats, emulsifiers, starches, dextrins, alginates, protein and lipid materials
can be
employed as encapsulating materials.
Various methods exist to release the ingredients from the capsules. Release
can be site-
specific, stage-specific or signaled by changes in pH, temperature,
irradiation or
osmotic shock. For example, in baking chemical leavening agents are
encapsulated to
delay their release until the bread reaches a certain temperature during
baking.
It is to be noted that Kunze does not teach the addition of an encapsulated
acidifier.
For ease, the present invention will now be described by a first aspect, a
second aspect
and a third aspect. It is to be noted that the commentary under each
respective aspect
(e.g. discussion of specific and/or preferred embodiments, definitions,
teachings etc.) is
applicable to each of the other aspects.
The pH of the dough according to the present invention is within the range of
pH 5 to
pH 7.5. Accordingly, if an acidifier is added to the dough, it must either be
i) a delayed
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release acidifier (sometimes referred to as a slow release acidifier) and/or
ii) an
acidifier which is encapsulated to the extent that the acidifier is not/or
less released in
the dough but during baking.
By the term "delayed release acidifier" is intended to mean that the acid is a
less (not
fast) soluble acid, which will influence the pH of the dough system. Examples
of
suitable delayed release acidifiers include fumaric acid, gluco delta lactone
(GDL),
ascorbic acid.
The optimal release of the acid is around or after the denaturation of
protein/gluten, as
the negative impact on gluten development and strength will be less. During
baking
this occurs around or above 50-65 degree C.
As indicated above, acidifiers that are not sufficiently delayed in releasing
so that they
will be released in the dough can also be used, provided that they are
suitably
encapsulated. Such acidifiers include citric acid, lactic acid, tartaric acid,
maleic acid,
succinic acid.
For some aspects of the present invention, the term "x% (bakers' %)" is used.
Bakers' % amounts are amounts that are measured by taking the total flour
added as
being 100% and the remaining ingredients are quoted in relative % amounts.
Thus, in
these instances, the cereal flour is always 100% and the remaining components
are
based on the amount of cereal flour. By way of example, if the composition of
a dough
comprises 100 g cereal flour and 5 g exogeneous gluten, then the % amounts are
expressed as 100% (bakers' %) cereal flour and 5% (bakers' %) exogenous
gluten. By
way of a further example, if the composition of a dough comprises 80 g rye
cereal flour,
20 g wheat cereal flour and 5 g exogeneous gluten, then the % amounts are
expressed
as 80% (bakers' %) rye cereal flour, 20% (bakers' %) wheat cereal flour and 5%
(bakers' %) exogenous gluten.
The term "gluten strengthener" means ingredients, which are able to
influence/interact
with the gluten network and thereby stabilise the gluten system. This means
that the
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gluten system/dough system will be more tolerant towards mechanical treatment,
process variation and improve the ability to retain CO2 in the dough system.
Those
skilled in the art can readily determine if an entity (such as an emulsifier)
has gluten
strengthening properties.
The term "shortening" means a 100% fat product (plastified fat or a fat blend
or a fat
and emulsifier bland), which by definition contains no water. The shortening
is
formulated with animal and/or vegetable oil/fat that have been carefully
processed for
functionality and to remove undesirable flavour.
The term "anti-staling agent" (sometimes referred to as a "softening agent")
means an
ingredient, which is able to delay the staling rate of bread. Often staling is
related to
starch retrogradation and by use of anti-staling agents you are able to delay
the
retrogradation/recrystalisation of starch. The agent keeps the bread soft for
a longer
period.
The term "dough strengthening enzyme" means an enzyme, which is able to
influence/interact with the gluten network or flour components associated with
the
gluten network and thereby stabilise the gluten system and strengthening the
dough
system. This makes the gluten system/dough system more tolerant towards
mechanical
treatment and process variation; and improves the ability to retain CO2 in the
dough
system.
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First Aspect
According to a first aspect there is provided a dough comprising:
System (a); and
System (b);
wherein System (a) comprises
(i) cereal flour, wherein at least 80% (bakers' %) of the cereal flour is
rye flour; and
(ii) exogenous gluten, wherein the exogeneous gluten is present in an
amount of at least 5% (bakers' %) by weight of the cereal flour of
System (a)(i);
wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein if System (a)(ii) comprises from 5% (bakers' %) to 9% (bakers' %) by
weight of the cereal flour of System (a)(i) of exogeneous gluten then the
dough
additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener;
wherein if System (a)(ii) comprises more than 9% (bakers' %) by weight of the
cereal flour of System (a)(i) of exogeneous gluten then the dough optionally
comprises System (c), wherein System (c) comprises at least one gluten
strengthener.
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The term "System" has been used to denote a component of the dough
composition.
The System itself may be multi-component (such as at least System (a)). The
System
may be just one component (such as for some applications, at least System
(b)). The
5 System may be in a dry state or in a wet state ¨ depending on the
respective application.
The gluten in system (a)(ii) is exogeneous gluten ¨ namely gluten that is
added as an
ingredient in its own right, as opposed to being part of another natural
additive (which
is referred to as endogeneous gluten), such as wheat. However, System (a)(i)
and/or
10 System (d) may comprise endogeneous gluten.
The dough may contain an acidifier but the pH of the dough is always within
the pH
range of from about pH 5 to about pH 7.5. The acidifier may be a slow acting
acidifier
¨ such as fumaric acid or gluco delta lactone. In baking, however, the pH may
drop.
This may be due to the presence of encapsulated acidifiers in the dough being
released
during the baking stage.
However, preferably the dough does not contain an acidifier and/or a dough
available
acidifier. The term "dough available acidifier" means an acidifier that can
act in the
dough phase.
If the bakery product of the present invention is a dough that has been
allowed to stand
for a period of time then the bakery product is still a dough and the pH of
that dough is
still within the pH range of from about pH 5 to about pH 7.5.
Even though System (c) is an optional feature for gluten levels in System
(a)(ii) more
than 9% (bakers' %), it is still a preferred feature. Thus, preferably the
dough
comprises:
said System (a);
said System (b); and
said System (c).
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Preferably, the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives. Here, the dough additives may
be
typical dough additives, such as one or more of: water and/or milk and/or
shortening
(e.g. butter) and/or olive oil and/or margarine and/or eggs and/or at least
one enzyme;
at least one flavouring; at least one delayed release acidifier; at least one
type of kernel;
at least one fruit piece; at least one type of shortening or oil; at least one
type of cereal
grain and/or at least one hydrocolloid and/or at least one emulsifier and/or
at least one
type of fat and/or at least one sugar and/or salt and/or at least one anti-
staling agent
and/or at least one softening agent and/or another cereal flour (such as wheat
flour);
and/or at least one maltextract (enzyme and/or non enzymatic; liquid and/or
solid (e.g.
active powder)); and/or at least one syrup; and/or at least one vegetable;
and/or at least
one yeast food (such as for example, calcium sulphate and mono calcium
phosphate);
and/or at least one preservative (such as for example calcium propionate);
and/or at
least one or more oxidative agents (enzymatic and/or non-enzymatic); and/or
one or
more reducing agents (enzymatic and/or non-enzymatic).
Preferably, the dough additionally comprises System (d); wherein System (d)
comprises at least the following dough additives: water, salt and sugar.
Preferably, the dough additionally comprises System (d); wherein System (d)
comprises at least the following dough additives: water, salt, sugar,
hydrocolloid
enzyme and an emulsifier.
A preferred dough comprises:
said System (a);
said System (b); and
said System (d).
Another preferred dough comprises:
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said System (a);
said System (b);
said System (c); and
said System (d).
In component (a)(ii) of System (a) the gluten may be any suitable gluten that
can be
used as an additive. In a preferred aspect, the gluten is Vital gluten.
The leavening agent in System (b) may be any suitable leavening agent ¨ such
as
chemical and/or biological leavening agent.
Leavening agents are substances used in doughs and batters that cause a
foaming action.
The leavening agent produces gas, usually carbon dioxide, that becomes trapped
as
bubbles within the dough. When a dough or batter is baked, it "sets" and the
holes left
by the gas bubbles remain, giving breads, cakes, and other baked goods their
soft,
sponge-like textures. The main types of leavening agents are biological, such
as yeasts
and sourdoughs, and chemical, for example baking powder.
Biological leavening agents
Microorganisms that release carbon dioxide as part of their lifecycle can be
used to
leaven products.
Varieties of yeast, in particular Saccharomyces cerevisiae, but sometimes also
wild
yeasts, are the most common biological leavening agents used in baking. Yeasts
ferment the sugars present in the dough and produce carbon dioxide as a
byproduct.
This causes the dough to expand or rise as the carbon dioxide forms bubbles,
which are
trapped by the gluten network in dough. When the bread is baked it sets
leaving holes,
which give the bread a soft and spongy texture. The use of sugar in bread
dough
accelerates the growth of yeasts. Salt and fats such as butter slow down yeast
growth.
Yeast also leaves behind other metabolic byproducts that contribute to the
distinctive
flavor of yeast breads.
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Another popular leavening agent used in bread making is sourdough, which is a
symbiotic culture of lactobacilli or acetic acid bacteria with yeasts.
Sourdough bread
has a distinctively tangy taste, due mainly to the lactic acid and acetic acid
produced by
the bacteria. Sourdoughs have been used for thousands of years, in particular
they are
the traditional leavening ingredient used in breads containing a high
percentage of rye
flour.
Some examples of products that are commonly used as biological leaveners are:
unpasturised beer, buttermilk, ginger beer, kefir, sourdough starter, yeast,
yogurt,
spontaneous sourdough, and sourdough based on starter cultures.
Chemical leavening agents
Chemical leavening agents are chemical mixtures or compounds that typically
release
carbon dioxide when they react in the presence of moisture, heat, or acidity.
Chemical
leavening agents are often used in quick breads and cakes. Chemically leavened
doughs and batters usually require light handling and must be baked very soon
after
mixing as the carbon dioxide is released quickly.
Examples of chemical leavening agents include: baking powder, baking soda
(sodium
bicarbonate), potassium bicarbonate, ammonium bicarbonate, potassium carbonate
(potash), calcium carbonate, potassium bitartrate (cream of tartar), potassium
carbonate
(pearlash), monocalcium phosphate (MCPM), monoammonium phosphate (MAP),
diammonium phosphate (DAP), sodium acid pyrophosphate (SAPP), anhydrous
monocalcium phosphate (AMCP), dicalcium phosphate dihydrate (DCPD), sodium
aluminium phosphate (SALP), sodium aluminium sulfate (SAS), glucono delta
lactone
(GDL), citric acid, tataric acid, fumaric acid, lactic acid. acidic sodium
citrate
(monosodium citrate).
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Preferably, the leavening agent is an exogeneous yeast. The term "exogeneous
yeast"
means yeast that is added as an additive in its own right, as opposed to being
a part of
another natural additive (such as endogeneous yeast on, say, the rye flour).
Preferred examples of yeasts include bakers yeast, compressed yeast, yeast
cream,
granulated yeast, dry yeast, instant yeast. Preferably, the leavening agent in
System (b)
is at least bakers yeast.
The gluten strengthener in System (c) is capable of strengthening the gluten-
gluten
protein interactions by increasing the inter-binding thereof.
Testing for gluten strengtheners is straightforward ¨ and can be done by
measuring the
theological properties of gluten with and without the strengthener. In
addition, or
alternatively, it is possible to measure the theological properties of a dough
comprising
gluten with and without the strengthener. The rheological properties can be
measured
by use of e.g. a Brabender Extensograph, a Texture Analyser Kieffer Rig, a
Chopin
Alveograph.
Preferably, the gluten strengthener in System (c) is at least a gluten
strengthener
emulsifier and/or a gluten strengthener enzyme and/or a gluten strengthener
chemical
oxidant.
Preferably, if the gluten strengthener in System (c) is an emulsifier then the
emulsifier
is typically present in an amount of from 0.1% (bakers' %) to 2% (Bakers' %).
Preferably, if the gluten strengthener in System (c) is an enzyme then the
enzyme is
. typically present in an amount of from 5 ppm to 1000 ppm, based on flour
weight
Preferably, the gluten strengthener in System (c) is at least a lipase and/or
at least a
xylanase and/or at least a hemicellulase and/or at least an oxidative enzyme
and/or at
least a chemical oxidising agent
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Preferably, if the gluten strengthener in System (c) is an emulsifier then the
emulsifier
is typically present in an amount of from 0.1% (bakers' %) to 2% (Bakers' %).
Preferably, if the gluten strengthener in System (c) is an enzyme then the
enzyme is
5 typically present in an amount of from 5 ppm to 1000 ppm, based on flour
weight.
Preferably, the gluten strengthener in System (c) is at least a lipase and/or
at least a
phospholipase and/or at least a glycolipase.
10 Preferably, the gluten strengthener in System (c) is at least a lipase.
Preferably, if the gluten strengthener in System (c) is a lipase then the
enzyme is
typically present in an amount of from 5 ppm to 500 ppm, based on flour
weight.
15 Examples of enzymes for use in the present invention include Lipopan F
(from
Novozymes), TS-E 1367 (from Danisco).
The gluten strengthener can be any suitable emulsifier. Examples include
DATEM,
SSL, CITRIM, Polysorbate, sugar ester, lecithin.
Preferably the gluten strengthener in System (c) is at least DATEM, SSL, CSL,
Polysorbate, CITRIM, glucose ester (sugar ester), lecithin, ethoxylated
monoglyceride
(EMG), succinic acid ester of monoglyceride (SMG).
System (d) may comprise one or more of: water and/or milk and/or shortening
(e.g.
butter) and/or olive oil and/or margarine and/or eggs and/or at least one
enzyme; at
least one flavouring; at least one delayed release acidifier; at least one
type of kernel; at
least one fruit piece; at least one type of shortening or oil; at least one
type of cereal
grain and/or at least one hydrocolloid and/or at least one emulsifier and/or
at least one
type of fat and/or at least one sugar and/or salt and/or at least one anti-
staling agent
and/or at least one softening agent and/or another cereal flour (such as wheat
flour);
and/or at least one maltextract (enzyme and/or non enzymatic; liquid and/or
solid (e.g.
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active powder)); and/or at least one syrup; and/or at least one vegetable;
and/or at least
one yeast food (such as for example, calcium sulphate and mono calcium
phosphate);
and/or at least one preservative (such as for example calcium propionate);
and/or at
least one or more oxidative agents (enzymatic and/or non-enzymatic); and/or
one or
more reducing agents (enzymatic and/or non-enzymatic).
Preferably System (d) comprises at least one hydrocolloid ¨ such as xanthan,
carrageenan, starch, modified starch, pectin, alginate, gelatine, locust bean
gum (LBG),
gellan, HPMC, CMC, guar gum, depolymerised guar, acacia gum, konjac gum, agar,
tamarind, tragacanth, beta-glucan, arabinoxylan, wheat fibre, apple fibre,
karaya,
curdlam, chitosan, soluble and non-soluble fibre and combinations thereof.
Preferably the hydrocolloid is xanthan.
System (d) may comprise at least one delayed release acidifier. Typical
delayed release
acidifiers include gluco delta lactone and/or acids such as fumaric acid
and/or ascorbic
acid. The delayed release acidifier may be an encapsulated acidifier ¨ such as
any one
or more of gluco delta lactone and/or acids such as fumaric acid and/Or
ascorbic acid
and/or lactic acid, and/or citric acid, and/or tartaric acid, and/or maleic
acid, and/or
succinic acid.
The delayed release acidifier will not lower the pH below pH 5 during the
dough phase.
A preferred example of a delayed release acidifier is at least one
encapsulated acid.
For some embodiments, System (d) comprises at least one emulsifier. The
emulsifier
may be selected from the group consisting of distilled monoglycerides;
monoglycerides; diglycerides; esters of mono- and diglycerides; polyglycerol
esters of
fatty acids; polyglycerol polyrincinoleate; propylene glycerol esters of fatty
acids;
sorbitan monostearates; sorbitan tristearates; sodium steamy' lactylates;
calcium
stearoyl lactylates; lecithins; and cliacetyl tartric acid esters of mono- and
diglycerides,
acetic acid ester of mono- and diglyceride, polysorbate, ethyxolated
monoglyceride
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(EMG), succinic acid ester of monoglyceride (SMG), sugar ester and
combinations
thereof.
Preferably, the emulsifier is a monoglyceride.
Preferably, the emulsifier is a crumb softening emulsifier.
Preferably, wherein may System (d) comprise at least the following dough
additives:
water, salt and sugar.
Preferably, System (a)(i) comprises at least 82% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 84% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 86% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 88% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 90% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 92% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 94% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 96% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 98% (bakers' %) rye flour.
Preferably, System (a)(i) comprises 100% (bakers' %) rye flour.
Preferably, System (a)(ii) comprises at least 6% (bakers' %) by weight of the
cereal
flour of System (a)(i) of gluten.
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Preferably, System (a)(ii) comprises at least 8% (bakers' %) by weight of the
cereal
flour of System (a)(i) of gluten.
Preferably, System (a)(ii) comprises at least 10% (bakers' %) by weight of the
cereal
flour of System (a)(i) of gluten.
Preferably, the dough is at a pH from about pH 5.2 to about pH 7.
Preferably, the dough is at a pH from about 5.4 to about pH7.
Preferably, the dough is at a pH from about 5.4 to about pH6.5.
For some aspects, preferably the dough is at a pH from about 5.5 to about
pH6.2.
For some aspects, preferably the dough is at a pH from about 5.5 to about
pH5.9.
In preparing the dough, typically System (a)(i), System (a)(ii), System (b),
System (c)
and System (d) are mixed together with remaining ingredients and water to form
a
straight dough.
In pre-dough systems (such as sponge & dough, sour dough, liquid brew) the
dough
will be prepared normally by use of a two and/or more step mixing procedure.
Addition
of System (a)(i), System (a)(ii), System (b), System (c) and System (d)
will/can be split
into two and/or more parts related to the used procedure.
The Systems (a) to (d) may be prepared according to standard procedure. Each
respective System may be prepared for admixing with the other Systems.
Alternatively,
one or more of the Systems may be formed in situ in the dough. For example,
System
(d) may be formed by sequential addition of two or more components to already
mixed
Systems (a) to (c).
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The present invention also provides a process of making a dough as defined
above
comprising admixing System (a)(i) as defined above with System (a)(ii) as
defined
above with System (b) as defined above, optionally with System (c) as defined
above
and/or optionally with System (d) as defined above to form said dough.
The present invention also provides a process comprising pre-forming System
(a)(i) as
defined above and/or System (a)(ii) as defined above and/or System (b) as
defined
above and/or System (c) as defined above and/or System (d) as defined above.
The gluten strengthener of System (c), if present in the final dough, can come
from all
or part of a discrete added System (c) and/or it can come from all or part of
a gluten
strengthener that is all of, or is one of the components of, an added System
(d).
In some preferred aspects, added System (d) does not comprise a gluten
strengthener.
The present invention also provides a kit for forming the dough of the present
invention,
wherein said kit comprises a discrete System (a)(i) as defined above and/or a
discrete
System (a)(ii) as defined above and/or a discrete System (b) as defined above
and/or a
discrete System (c) as defined above and/or a discrete System (d) as defined
above.
The process may also include baking said dough.
The present invention also provides a bakery product or a baked product made
from the
dough according to the invention or from the product of the process defined
above.
Preferably the baked product is bread.
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Second Aspect
According to a second aspect of the present invention there is provided a
dough
5 comprising:
System (a);
System (b);
optional System (c); and
10 System (d);
wherein System (a) comprises:
(i) rye flour and
(ii) gluten;
wherein System (b) comprises at least a leavening agent;
wherein if System (a)(ii) comprises from 5% (bakers' %) to 9% (bakers' %) by
weight of the cereal flour of System (a)(i) of exogeneous gluten then the
dough
additionally comprises System (c), wherein System (c) comprises at least one
gluten strengthener; and wherein if System (a) comprises more than 9%
(bakers' %) by weight of the cereal flour of System (a)(i) of exogeneous
gluten
then the dough optionally comprises System (c), wherein System (c) comprises
at least one gluten strengthener; and
wherein System (d) comprises an encapsulated acidifier.
In this aspect, preferably the rye flour is present in a high percentage.
Preferably, System (a)(i) comprises at least 50% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 55% (bakers' %) rye flour.
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Preferably, System (a)(i) comprises at least 60% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 65% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 70% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 75% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 80% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 82% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 84% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 86% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 88% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 90% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 92% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 94% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 96% (bakers' %) rye flour.
Preferably, System (a)(i) comprises at least 98% (bakers' %) rye flour.
Preferably, System (a)(i) comprises 100% (bakers' %) rye flour.
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Preferably, System (a)(ii) comprises at least 6% (bakers' %) by weight of the
cereal
flour of System (a)(i) of gluten.
Preferably, System (a)(ii) comprises at least 8% (bakers' %) by weight of the
cereal
flour of System (a)(i) of gluten.
Preferably, System (a)(ii) comprises at least 10% (bakers' %) by weight of the
cereal
flour of System (a)(i) of gluten.
Preferably the dough is at a pH from about pH 5 to about pH 7.5.
Preferably the dough does not contain an acidifier or a dough available
acidifier.
Preferably the dough comprises:
said System (a);
said System (b);
said System (c); and
said System (d).
Preferably, System (a) is as defined earlier.
Preferably, System (b) is as defined earlier.
Preferably, System (c) is as defined earlier.
Preferably, System (d) is as defined earlier.
In preparing the dough, typically System (a)(i), System (a)(ii), System (b),
System (c)
and System (d) are mixed together with remaining ingredients and water to form
a
straight dough.
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In pre-dough systems (such as sponge & dough, sour dough, liquid brew) the
dough
will be prepared normally by use of a two and/or more step mixing procedure.
Addition
of System (a)(i), System (a)(ii), System (b), System (c) and System (d)
will/can be split
into two and/or more parts related to the used procedure.
The Systems (a) to (d) may be prepared according to standard procedure. Each
respective System may be prepared for admixing with the other Systems.
Alternatively,
one or more of the Systems may be formed in situ in the dough. For example,
System
(d) may be formed by sequential addition of two or more components to already
mixed
Systems (a) to (c).
The present invention also provides a process of making a dough as defined
above
comprising admixing System (a)(i) with System (a)(ii) as defined above with
System
(b) as defined above, optionally with System (c) as defined above and/or
optionally
with System (d) as defined above to form said dough.
The present invention also provides a process comprising pre-forming System
(a)(i) as
defined above and/or System (a)(ii) as defmed above and/or System (b) as
defined
above and/or System (c) as defined above and/or System (d) as defined above.
The present invention also provides a kit for forming the dough of the present
invention,
wherein said kit comprises a discrete System (a)(i) as defined above and/or a
discrete
System (a)(ii) as defined above and/or a discrete System (b) as defined above
and/or a
discrete System (c) as defined above and/or a discrete System (d) as defined
above.
The process may comprise baking said dough.
The present invention also provides a bakery product or a baked product made
from the
dough according to the invention or from the product defined above.
Preferably the baked product is bread.
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Third Aspect
According to a third aspect there is provided the use of an emulsifier in the
preparation
of a dough comprising rye flour.
In this aspect, preferably the rye flour is present in a high percentage.
Preferably the rye flour is present in an amount of at least 50% (bakers' %).
Preferably the rye flour is present in an amount of at least 55% (bakers' %).
Preferably the rye flour is present in an amount of at least 60% (bakers' %).
Preferably the rye flour is present in an amount of at least 65% (bakers' %).
Preferably the rye flour is present in an amount of at least 70% (bakers' %).
Preferably the rye flour is present in an amount of at least 75% (bakers' %).
Preferably the rye flour is present in an amount of at least 80% (bakers' %).
Preferably the rye flour is present in an amount of at least 85% (bakers' %).
Preferably the rye flour is present in an amount of at least 90% (bakers' %).
Preferably the dough is at a pH from about pH 5 to about pH 7.5.
Preferably the dough does not contain an acidifier or a dough available
acidifier.
Preferably the dough comprises:
said System (a) as defined above;
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said System (b) as defined above;
optionally said System (c) as defmed above; and
optionally said System (d) as defined above.
5 Preferably the dough comprises:
said System (a) as defined above;
said System (b) as defined above;
said System (c) as defined above; and
optionally said System (d) as defined above.
Preferably the dough comprises:
said System (a) as defined above;
said System (b) as defined above;
optionally said System (c) as defined above; and
said System (d) as defined above.
Preferably the dough comprises:
said System (a) as defined above;
said System (b) as defined above;
said System (c) as defined above; and
said System (d) as defined above.
Other features and aspects of the present invention will now be described.
According to another aspect there is provided a bread made from flour, an
emulsifier
and/or an hydrocolloid, wherein a high percentage of the flour is rye flour.
According to another preferred aspect there is provided a bread made from
flour, an
emulsifier and/or an hydrocolloid, wherein a high percentage of the flour is
rye flour,
wherein the bread is toast or pan bread.
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In the present invention, a high percentage of a flour means at least 50%
(bakers' %),
or at least 55% (bakers' %), or at least 60% (bakers' %), or at least 70%
(bakers' %), or
at least 75% (bakers' %), or at least 80% (bakers' %), or at least 85%
(bakers' %), or at
least 87% (bakers' %), or at least 90% (bakers' %), or at least 93% (bakers'
%), or at
least 95% (bakers' %), or at least 98% (bakers' %) w/w flour, or 100% (bakers'
%)
w/w flour based on the total weight of the flour in the composition.
Preferable values
are at least 60% (bakers' %) w/w rye flour based on the total weight of the
flour in the
composition. More preferable values are at least 70% (bakers' %) w/w rye flour
based
on the total weight of the flour in the composition. More preferable values
are at least
80% (bakers' %) w/w rye flour based on the total weight of the flour in the
composition.
More preferable values are at least 90% (bakers' %) w/w rye flour based on the
total
weight of the flour in the composition. Most preferable values are 100%
(bakers' %)
w/w rye flour based on the total weight of the flour in the composition.
According to another aspect there is provided a bread made from flour, an
emulsifier
and/or an hydrocolloid, wherein about 60% (bakers' %) or more of the flour is
rye flour.
According to another aspect there is provided a bread made from flour, an
emulsifier
and/or an hydrocolloid, wherein about 60% (bakers' %) or more of the flour is
rye,
wherein the bread is toasted.
According to another aspect there is provided a bread made from flour, an
emulsifier
and/or an hydrocolloid, wherein about 70% (bakers' %) or more of the flour is
rye flour.
According to another aspect there is provided a bread made from flour, an
emulsifier
and/or an hydrocolloid, wherein about 70% (bakers' %) or more of the flour is
rye,
wherein the bread is toast or pan bread.
According to another aspect there is provided a bread made from flour, an
emulsifier
and/or an hydrocolloid, wherein about 80% (bakers' %) or more of the flour is
rye flour,
preferably wherein about 90% (bakers' %) or more of the flour is rye flour,
preferably
wherein about 100% (bakers' %) of the flour is rye flour.
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According to another aspect there is provided a bread made from flour, an
emulsifier
and/or an hydrocolloid, wherein about 80% (bakers' %) or more of the flour is
rye,
wherein the bread is toasted, preferably wherein about 90% (bakers' %) or more
of the
flour is rye flour, preferably wherein about 100% (bakers' %) of the flour is
rye flour.
For the highly preferred dough compositions, the dough comprises a high
percentage of
flour of the rye cereal grain, gluten, an emulsifier and/or an hydrocolloid
and/or at least
one enzyme.
For some embodiments, the composition comprising or made from flour, an
emulsifier
and/or an hydrocolloid, wherein a high percentage of the flour is the flour of
rye cereal
grain, may contain gluten.
The compositions of the present invention have favourable characteristics.
Other cereal grains that may be used in conjunction with the rye cereal grain
include
the grain of cereals of wheat (inc. wheat with a low falling number), barley,
oats, and
maize.
Preferred aspects of the present invention are presented in the claims and are
described
below.
For ease of reference, the preferred compositions of the present invention ¨
i.e.
compositions comprising high levels of rye ¨ are referred to as "rye
compositions".
The rye composition may be the rye flour composition of the present invention
(i.e. a
flour composition containing a high percentage of rye flour) and/or the bakery
product
of the present invention (i.e. the bakery product containing a high percentage
of rye
flour); and/or the baked product of the present invention (i.e. the baked
product
containing a high percentage of rye flour).
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In one aspect, the present invention provides a rye composition comprising
flour, an
emulsifier and/or an hydrocolloid, wherein a high percentage of the flour is
rye flour.
A typical high percentage of rye flour is a flour that is made up of at least
60% rye flour.
The rye composition may be a rye flour composition and/or a bakery product
and/or a
baked product. In the latter instance, the flour would have been baked.
In another aspect, the present invention provides a process of preparing a rye
composition comprising admixing flour with an emulsifier and/or an
hydrocolloid and
optionally also at least one enzyme, wherein a high percentage of the flour is
rye flour.
A typical high percentage of rye flour is a flour that is made up of at least
60%
(bakers' %) rye flour. The rye composition may be a rye flour composition
and/or a
bakery product and/or a baked product.
In another aspect, the present invention provides the use of a rye composition
comprising flour and an emulsifier and/or an hydrocolloid and optionally also
at least
one enzyme to prepare a baked product, wherein a high percentage of the flour
is rye
flour. A typical high percentage of rye flour is a flour that is made up of at
least 60%
(bakers' %) rye flour. The rye composition may be a rye flour composition
and/or a
bakery product.
In another aspect, the present invention provides the use of an emulsifier
and/or an
hydrocolloid and optionally also at least one enzyme in the manufacture of a
rye
composition comprising flour, wherein a high percentage of the flour is rye
flour. A
typical high percentage of rye flour is a flour that is made up of at least
60%
(bakers' %) rye flour. The rye composition may be a rye flour composition
and/or a
bakery product and/or a baked product. In the latter instance, the flour would
have
been baked.
Preferably, a high percentage of a rye flour means at least 55% (bakers' %),
or at least
60% (bakers' %), or at least 70% (bakers' %), or at least 75% (bakers' %), or
at least
80% (bakers' %), or at least 85% (bakers' %), or at least 87% (bakers' %), or
at least
90% (bakers' %), or at least 93% (bakers' %), or at least 95% (bakers' %), or
at least
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98% (bakers' %) w/w flour based on the total weight of the flour in the
composition.
Preferable values are at least 60% (bakers' %) w/w flour based on the total
weight of
the flour in the composition. More preferable values are at least 70% (bakers'
%) w/w
flour based on the total weight of the flour in the composition. More
preferable values
are at least 80% (bakers' %) w/w flour based on the total weight of the flour
in the
composition. More preferable values are at least 90% (bakers' %) w/w flour
based on
the total weight of the flour in the composition.
In another aspect the present invention provides a process for producing a rye
flour
bakery product comprising admixing one or more components comprising rye
flour;
and at least the following
(a) an emulsifier; and
(b) a hydrocolloid
wherein the rye flour constitutes a high percentage of the flour in the bakery
product.
Preferably the components are admixed with a liquid such as water.
In another aspect the present invention provides a process for producing a rye
flour
baked product comprising baking a rye flour bakery product according to the
present
invention
In another aspect the present invention provides a rye flour bakery product
prepared by
admixing one or more components comprising rye flour; and at least the
following
(a) an emulsifier; and
(b) a hydrocolloid
wherein the rye flour constitutes a high percentage of the flour in the bakery
product.
In another aspect the present invention provides for use of an emulsifier
and/or an
hydrocolloid to produce a rye flour bakery product or rye flour baked product
comprising a high percentage of rye flour, such as at least 60% (bakers' %),
or at least
70% (bakers' %), at least 80% (bakers' %), at least 85% (bakers' %), at least
90%
(bakers' %), at least 95% (bakers' %) or 100% (bakers' %), which has improved
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theological properties and/or increased specific volume and/or TPA values
similar to
those of wheat flour bakery products and wheat flour baked products. The rye
flour
bakery product may have improved rheological properties. The rye flour bakery
product may have increased specific volume relative to a rye flour bakery
product
5 produced using a rye flour composition that does not comprise an
emulsifier and/or
hydrocolloid. The rye flour bakery product may have TPA values similar to
those of
wheat flour bakery products. The rye flour baked product may have increased
specific
volume relative to a rye flour baked product produced using a rye flour
composition
that does not comprise an emulsifier and/or hydrocolloid. The rye flour baked
product
10 may have TPA values similar to those of wheat flour baked products.
The processes of the present invention describe how to produce bakery products
containing a high percentage of rye flour. Such bakery products can be used to
produce
a rye flour baked product that displays characteristics similar to those
obtained using a
15 standard wheat flour, or a mix of rye flour and wheat flour but wherein
the rye content
is less than 50% (bakers' %). For example, using rye flour bakery products
according
to the present invention makes it possible to obtain loaves with improved
characteristics similar to those produced using standard wheat flour bakery
products.
20 In another aspect the present invention provides a rye flour baked
product prepared by
baking a rye flour bakery product of the present invention.
In another aspect the present invention provides for use of a rye flour
composition
according to the present invention in the preparation of a rye flour bakery
product.
In another aspect the present invention provides for use of a rye flour
composition
according to the present invention in the preparation of a rye flour baked
product.
In another aspect the present invention provides a bakery product or a baked
product
comprising a high percentage of rye flour, such as at least 60% (bakers' %),
or at least
70% (bakers' %), preferably at least 80% (bakers' %), at least 85% (bakers'
%), at least
90% (bakers' %), at least 95% (bakers' %) or 100% (bakers' %), an emulsifier
and/or
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an hydrocolloid wherein the bakery product or baked product has improved
rheological
properties and/or increased specific volume, relative to a respective bakery
product or
baked product not comprising an emulsifier and/or an hydrocolloid, and/or TPA
values
similar to those of wheat flour bakery products or wheat flour baked products,
respectively.
In another aspect the baked product or bakery product is a rye flour
containing bread.
In another aspect the baked product or bakery product is a rye flour
containing
processed bread.
In another aspect the baked product or bakery product is a rye flour
containing toast
bread or pad bread.
In another aspect the baked product or bakery product is a rye flour
containing roll.
In another aspect the baked product or bakery product is a rye flour
containing cake.
In another aspect the baked product or bakery product is a rye flour
containing extruded
product.
In another aspect the present invention provides a baking additive comprising
an
emulsifier and/or an hydrocolloid, wherein the addition of the emulsifier
and/or an
hydrocolloid to a flour composition allow for the production of bakery
products and
baked products with increased specific volume, relative to those produced
without an
emulsifier and/or hydrocolloid, and TPA values similar to those of wheat flour
bakery
products or wheat flour baked products respectively from cereal grains or
flour which
have high endo-amylase activity.
Thus in another aspect the present invention provides a baking additive
comprising an
emulsifier and/or an hydrocolloid, wherein the addition of the emulsifier
and/or an
hydrocolloid to a flour composition allow for the production of bakery
products or
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baked products with improved rheological properties from cereal grains or
flour
wherein the cereal is rye.
The rye compositions of the present invention have a number of favourable
characteristics.
For example, rye flour bakery products of the present invention and/or rye
flour baked
products of the present invention have improved theological properties and/or
increased specific volume and/or TPA values similar to those of wheat flour
bakery
products or wheat flour baked products respectively.
In one embodiment, the present invention provides a rye flour bakery product
and/or a
rye flour baked product that has a TPA value of about 20 to 30 HPa (such as 25
HPa )
up to 1 day after production.
The rye composition (such as the flour bakery product) may have improved
rheological
properties. The rye composition (such as the flour bakery product) may yield
an
increased specific volume relative to a rye flour bakery product produced
using a rye
flour composition that does not comprise an emulsifier and/or hydrocolloid.
The rye
flour bakery product may have TPA values similar to those of wheat flour
bakery
products.
The rye composition (such as the flour baked product) may have an increased
specific
volume relative to a rye flour baked product produced using a rye flour
composition
that does not comprise an emulsifier and/or hydrocolloid. The rye flour baked
product
may have TPA values similar to those of wheat flour baked products.
The expression "rheological properties" as used herein refers particularly to
the effects
of dough conditioners on dough strength and stability as the most important
characteristics of flour doughs. According to American Association of Cereal
Chemists (AACC) Method 36-01A the term "stability" can be defined as "the
range of
dough time over which a positive response is obtained and that property of a
rounded
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dough by which it resists flattening under its own weight over a course of
time".
According to the same method, the term "response" is defmed as "the reaction
of dough
to a known and specific stimulus, substance or set of conditions, usually
determined by
baking it in comparison with a control". Typically, the control is one which
is identical
with the test dough, but which does not comprise an emulsifier and a
hydrocolloid and
dough strengthening enzymes.
Thus, the term "rheological properties" relates to the above physical and
chemical
phenomena that in combination will determine the performance of flour doughs
and
thereby also the quality of the resulting baked products.
By "improving the theological properties" or "having improved rehological
properties"
it is meant the theological properties of the bakery product or baked product
are
improved compared with a bakery product or baked product comprising the same
constituents (including the rye flour), but which does not comprise an
emulsifier and/or
a hydrocolloid.
In particular, it has been found that satisfactory baked products can be
produced from
bakery products comprising at least 50% (bakers' %) w/w rye flour based on the
total
weight of the flour in the dough, that have specific theological properties.
These
properties may be one or more of the following: improved resistance and/or
improved
extensibility and/or increased viscosity.
The rheological properties of the dough can be measured by standard methods
according to the International Association of Cereal Chemistry (ICC) and the
American
Association of Cereal Chemistry (AACC) including the amylograph method (ICC
126),
the farinograph method (AACC 54-21) and the extensigraph method (AACC 54-10).
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Thus, in a preferred aspect, the present invention provides a rye flour
composition
comprising a flour, an emulsifier and/or an hydrocolloid, wherein a high
percentage of
the flour is rye flour (such as at least 60% (bakers' %) or at least 70%
(bakers' %)) and
wherein rye flour bakery products and rye flour baked products produced using
the
composition have improved rheological properties and/or increased specific
volume
and/or TPA values similar to those of wheat flour bakery products and wheat
flour
baked products; wherein the improved rheological properties are determinable
by the
amylograph method (ICC 126) and/or the farinograph method (AACC 54-21) and/or
the extensigraph method (AACC 54-10).
Accordingly, the rye flour bakery product may have improved rheological
properties
wherein the improved rheological properties are determinable by the amylograph
method (ICC 126) and/or the farinograph method (AACC 54-21) and/or the
extensiograph method (AACC 54-10). The rye flour bakery product may have
increased specific volume relative to a rye flour bakery product produced
using a rye
flour composition that does not comprise an emulsifier and/or hydrocolloid
and/or an
enzyme.
The rye flour baked product may have increased specific volume relative to a
rye flour
baked product produced using a rye flour composition that does not comprise an
emulsifier and/or hydrocolloid.
The present invention may also result in one or more of the following other
benefits: an
improvement in the textural characteristics; an improvement in taste; an
improvement
in nutrition, an improvement in fibre content, an increase in specific volume.
The
improvements in textural characteristics may be measured by measuring firmness
and
stress values ¨ such as by way of example measuring textural profile analysis
(TPA)
which assesses hardness, fracturability, springiness, chewiness, gumminess and
resilience.
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The rye flour bakery product may have TPA values similar to those of wheat
flour
bakery products.
The rye flour baked product may have TPA values similar to those of wheat
flour
5 baked products.
It has surprisingly been found that the composition of the present invention
provides
rye flour bakery products and rye flour baked products with substantially
similar
characteristics to wheat bakery products and wheat flour baked products (in
particular
10 texture and taste). We believe that for embodiments that comprise system
(c)
(preferably being an emulsifier and/or hydrocolloid) the benefits are achieved
by
protecting the starch in the rye flour from being hydrolysed by the naturally
present
endo-amylases and/or improving the gluten network. The protection of the
starch
granules results in the formation of a better the starch network and higher
viscosity rye
15 flour bakery products, which trap more air and result in increased
volume and more
stable cooled rye flour baked products.
By preventing the breakdown of the starch in rye flour, the present invention
allows for
the use of yeast in the preparation of rye flour bakery products and rye flour
baked
20 products and removes the need for the addition of wheat flour to rye
flour compositions.
The pH is also near to neutral and so allows for the improved use of yeast.
The substitution of rye flour for wheat flour provides for numerous health
benefits as a
result of the lower GI value of rye and the increased fibre content of the
flour
25 compositions. An example of the benefits of diets rich in rye-based
foods is given in
McIntosh et al. (Am J Clin Nutr (2003) 77:967-74) whilst a possible mechanism
for
these benefits is given in Juntunen et al. (Am J Clin Nutr (2003) 78:957-64).
Preferably System (c) comprises an emulsifier and/or a hydrocolloid.
The emulsifier of the present invention may be one or more emulsifiers.
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The emulsifier of the present invention may be selected from distilled
monoglycerides;
mono- and diglycerides; esters of mono- and diglycerides; polyglycerol esters
of fatty
acids; polyglycerol polyrincinoleate; propylene glycerol esters of fatty
acids; sorbitan
monostearates; sorbitan tristearates; sodium stearoyl lactylates; calcium
stearoyl
lactylates; lecithins; diacetyl tartric acid esters of mono- and diglycerides;
SMG; EMG;
polysorbate; CITRIM; ACETEM.
Preferably the emulsifier is selected from mono- or diglycerides, diacetyl
tartaric acid
esters of mono- and diglycerides of fatty acids, lecithins, SSL, CSL, SMG,
EMG,
polysorbate.
More preferably the emulsifier is a monoglyceride such as Dimodan RHR
Monoglycerides can also interact with the amylose to reduce degradation and
following
retrogradation.
The emulsifier is present at sufficient concentration to protect the starch
granules of the
rye flour from the endo-amylases from the amylases. The concentration of
emulsifier
may be between 0.2% (bakers' %) and 4% (bakers' %), between 0.4% (bakers' %)
and
4% (bakers' %), between 0.5% (bakers' %) and 3% (bakers' %), between 0.7%
(bakers' %) and 2.5% (bakers' %), between 0.8% (bakers' %) and 2.2% (bakers'
%), or
between 0.9% (bakers' %) and 2% (bakers' %). Preferably the concentration of
emulsifier is between 0.9% (bakers' %) and 2% (bakers' %). All percentages of
emulsifiers given herein are based on the weight of the total rye flour
composition
unless otherwise stated.
The hydrocolloid of the present invention may be one or more hydrocolloids.
The hydrocolloid of the present invention may be selected from carrageenan,
starch,
pectin, alginate, gelatine, locust bean gum (LBG), gellan, xanthan, CMC, guar
gum,
depolymerised guar, acacia gum, konjac gum, agar, tamarind, tragacanth, beta-
glucan,
arabinoxylan, wheat fibre, apple fibre, HPMC, karaya, curdlam, chitosan and
combinations thereof. For some preferred aspects of the present invention, the
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hydrocolloids are one or more of alginates, xanthan, carrageenans, pectins,
vegetable
gums including e.g. guar gum and locust bean gum.
The hydrocolloid may be present at a concentration between 0.01 and 2.5%
(bakers' %),
0.05 and 2% (bakers' %), 0.07 and 1% (bakers' %), or 0.1 and 0.7% (bakers' %).
Preferably the concentration of hydrocolloid is between 0.1 and 0.7% (bakers'
%). All
percentages of hydrocolloids given herein are based on the weight of the total
rye flour
composition unless otherwise stated.
An additional benefit of adding hydrocolloids is that they create a
hydrocolloid network
and maintain the water in the baked product, which can contribute to softness
over
storage time.
The rye composition of the present invention comprises (or is made from ¨ such
as
baked from) flour comprising a high percentage of rye; an emulsifier and/or a
hydrocolloid. Additional components of the rye composition include one or more
of:
water and/or a leavening agent.
Preferably, the rye composition of the present invention comprises (or is made
from ¨
such as baked from) at least flour comprising a high percentage of rye; an
emulsifier
and/or a hydrocolloid; water; and a leavening agent.
The leavening agent may be yeast and/or a chemical leavening agent (such as a
conventional chemical leavening agent).
It is, however, within the scope of the present invention that further
optional
components may be present in the rye composition. Typically, such further
optional
components include salt, sweetening agents such as sugars, syrups or
artificial
sweetening agents, lipid substances including shortening, margarine, butter or
an
animal or vegetable oil, glycerol, one or more typical dough additives such as
starch,
flavouring agents, lactic acid bacterial cultures, vitamins, minerals, enzymes
and
dietary fibre substances.
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In another aspect, the rye flour composition further comprises yeast.
The use of yeast - instead of sourdough (leaven) - simplifies the production
of rye flour
bakery products and rye flour baked products and allows for the production of
rye flour
bakery products, rye flour baked products or extruded products which lack the
sour/bitter taste usiiAlly associated with rye flour products.
In another aspect, the rye flour composition further comprises a chemical
leavening
agent. Preferably the leavening agent is baking powder or a functional
equivalent
thereof.
In another aspect, the rye flour composition further comprises ascorbic acid.
In another aspect the rye flour composition further comprises gluten
(endogeneous
gluten and/or exogeneous gluten). Gluten may form more than 0%, at least 1%,
at least
5%, at least 10%, at least 15%, at least 20%, at least 25% or at least 30% of
the total
composition.
In an aspect the rye flour composition further comprises at least one enzyme.
The
enzyme may be selected from the group consisting of xylanases, starch
degrading
enzymes like exogenic amylases, mddoreductases, lipases including
phospholipases
and glycolipase, and acyl transferases. Preferably at least xylanase is
present. Other
enzymes may also be present. More preferably the xylanase has no or
substantially no
endo-amylase or glucanase activity. Most preferably the xylanase is a
bacterial
xylanase, such as the bacterial xylanase Grindsted PowerBake 900. It is
important that
the used products do not contain higher levels of endo-amylase side
activities. Other
suitable xylanases can be readily identified from the art, see for instance
Maat et al
(Xylans & Xylanases,1992, aylanases and their application in bakery' p349-360,
ISBN 978-044894779).
Preferably the rye flour composition comprises one or more xylanolytic enzyme.
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In an aspect the rye flour composition further comprises an anti-staling
enzyme.
Addition of anti staling enzyme can improve softness over storage time. The
anti-
staling enzyme may be the same as one of the enzymes mentioned above or may be
an
additional enzyme.
In some aspects lipases, oxidative enzymes (hexose oxidase, maltose oxidase,
carbohydrate oxidase and glucose oxidase) can also improve gluten structure as
well as
DATEM or other standard strengthening emulsifiers and oxidising agents such as
ascorbic acid, bromate, and azodicarbonamide (ADA).
The oxidative enzyme may be one or more of the following enzymes: glucose
oxidase,
pyranose oxidase, sulfhydryl oxidase, maltose oxidase, a carbohydrate oxidase
(such as
one that oxidises maltose, e.g. hexose oxidase (HOX)). For some aspects, the
carbohydrate oxidase is at least HOX.
Furthermore the addition of ingredients that can increase pH (such as
bicarbonate) can
contribute to improved gluten network formation. The pH value in the
composition
and the rye flour baked product may be increased as compared to a traditional
rye bread
made with a sourdough. Preferably the pH of the composition is above at least
one of
the following pH values: 4, 4.5, 5, 5.1, 5.2, 5.3, 5.4, 5.5, and 5.6.
Sourdough (leaven) is defined for the purposes of the present application as a
dough
which has microorganisms (for example lactobacillus or yeast) from sourdough
or
sourdough starters, which are active or can be reactivated. With the addition
of grain
products and water, they are capable of continuous acid generation. Parts of a
sourdough may be used as storage leaven for new sourdoughs. The vitality of
the
microorganisms is only terminated with baking or hot-extrusion. The increase
in
acidity of sourdough is based exclusively on fermentation. Preferably, other
ingredients influencing acid contents - except sourdough bread - are not used.
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EXAMPLES
The present invention will now be described in further detail by way of
examples. The
5 Examples are split into the following parts:
In Part A of the Examples, reference is made to Figures 1 to 31. Details on
those
Figures now follow.
10 Fig 1 shows the effect of acid treatment on specific volume and pH of
bread crumbs.
GRINSTEDTm Pro Tex TR 100 is encapsulated citric acid (load 60%). The left
hand
(orange) columns show the pH and right hand (green) columns show specific
volume in
ccm/g. (Typically bigger breads are measured in ccm/g and smaller breads are
measured in ml/g.)
Fig. 2 shows that soluble acids such as citric acid makes dough stiff. Use of
GRINSTEDTm Pro Tex TR 100 (encapsulated acid) minimises negative effect on
dough
rheology.
Fig. 3 shows the effect of treatment on bread softness. The higher the stress
value the
less soft the bread is.
Fig. 4 presents examples of rye toast (91% rye, 9% gluten) produced with or
without
citric acid, encapsulated citric acid (GRINDSTEDO ProTex TR 100) and 2%
journal
1652/86. Straight dough procedure with proofing time of 55 min at 35 C.
Fig 5 presents data for the exact rye toast procedure as described in example
2 and
claim 12 (Kunze et al.). Method A.
Fig. 6 presents data for the recipe of Kunze at al's Claim 12, but adjusted in
water
addition to a realistic level. Farinograph consistency 470 BU. Method B
(specific
volume 2.1). Example 2.
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Fig. 7 presents rolls using the procedure and recipe from Kunze et al. (right)
and the
same procedure but using the Basic recipe (left). Proofing time 3 hrs at 36 C.
Sample 1
(trial 2): 11,5% gluten, 2.6% Journal 1652/86 2,6% (without addition of
hemicellulase
and olive oil). Sample 2 (Trial 3): Kunze et al. 2% olive oil 50% wheat and
hemicellulase (472 ppm Grindamyl PowerBake 900). Example 3.
Fig 8 presents rolls using the procedure and recipe from Kunze et al. (right)
and the
same procedure but using the Basic recipe (left). Proofing time 55 mm at 36 C.
Fig. 9A presents the results of the laboratory trials described in example 3
with two
different fermentation times of 55 min and 180 min (50 g dough/roll).
Fig 9B presents a section of the rolls from example 3.
Fig 10. presents results that demonstrate that the specific volume achieved
from the
Basic method without hemicellulase is 27,3% larger when comparing the product
from
Kunze et al using 2% olive oil and hemicellulase on top, after 3 hours
proofing as
described in claim 12. Comparing the samples without hemicellulase the Basic
specific
volume is 35,5% larger. Lefthand columns: 55 min. proofing time, righthand
columns:
180 min. proofing time. (example 3).
Fig 11 presents Trials 1B and 2, as described in Example 4, table 2. Dough
handling
(rounding/moulding) can be performed by machine using journal 1652/86 at 2,6%,
without hemicellulase and olive oil, as it is less sticky than the dough
produced by the
method from Kunze et al using 50% wheat, 2% olive oil and hemicellulase.
Fig 12 presents a comparison of rye toast products produced in a standard
toast
procedure using claim 12 (Kunze et al.) with and without the water adjusted
method ¨
see example 2 (Method A and B). 1A: a recipe of Kunze et al. (2% olive oil,
50%
wheat flour and hemicellulase) using ingredients from example 2A. 1B: a recipe
of
Kunze et al. (2% olive oil, 50% wheat flour and hemicellulase) using
ingredients from
example 2B. 1A and 1B are optimized on all process parameters using the toast
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procedure of the present invention. 2: the basic recipe (Journal No. 1652/86
but without
hemicellulase (GRINDAMYLTm POWERBake 900) and procedure of the present
invention. Specific volumes are: 1A: 2,1 ml/g, sample 1B: 2,1m1/g and sample
2: 4,2
ml/g. Basic procedure gives and increase of 100% in comparison to Kunze et al.
using a
standard toast procedure. Bread pH for samples lA and 1B are 6,1 and 5,9.
Sample 2
has pH of 5,7.
Fig 13. shows the effect of gluten addition and addition of Journal No.
1652/86
containing DATEM (gluten strengthening emulsifier) on specific volume of
rolls.
Recipe according to the present invention with no olive oil, no acid/sour
dough, 55 min
proofing time at 35 C. Specific volume is based on rolls of 50 g dough.
Lefthand
columns: with journal no. 1652/86. Righthand columns: without journal no.
1652/86.
Fig 14 presents the specific volume (ml/g) measurements on rye toast/pan bread
produced either using the Kunze recipe and procedure (claim 12), the recipe of
Kunze
et al. but Basic process (including 2% olive oil, wheat flour 33% and
hemicellulase, no
acid) or the Basic recipe (rye, gluten, with or without emulsifier containing
ingredient
(Journal No. 1652/86 at 2,6%) and process. The first written number below the
columns refers to the amount of gluten (and not rye) used.
Fig 15 presents TPA measurements conducted on rye toast/pan bread slices on
day 7.
The first number is the % of gluten (and not rye). The first six columns
(blue) are
according to Basic method. The last two columns (Pink) are recipe of Kunze
according
to claim 12 (1 and 8) containing 2-3% olive oil and hemicellulase (wheat flour
up to
100%). The lower the stress values, the softer is the bread crumb.
Fig 16 presents a comparison of ingredients affecting specific volume in rye
toast. The
specific volumes are calculated as reduction compared to the recipe of Kunze
but using
the process of the present invention (set to zero - reference). The method
according to
claim 12 from Kunze adjusted to realistic water level in orange (dough
consistency
adjusted to 470 BU using farinograph ¨ comparable to Basic dough consistency).
The
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remaining trials are all conducted using Basic recipe (88,5% rye, 11,5%
gluten, no
olive oil) and process.
Fig. 17 presents softness measurements conducted on day 7. The same rye toast
breads
as used fig. 16.
Fig 18 presents rye toast samples. Show effect of DATEM in combination with
acid
(dough pH < 4,7). From left to right: 1) 0,3% DATEM + acid, 2) 0,3% DATEM, 3)
0,3% DATEM + phospholipase, 4) 0,3% DATEM + phospholipase + acid, 5) Basic
reference without ingredients or acid.
Fig 19 presents rye toast samples. Show effect of SSL in combination with acid
(dough
pH <4,7). From left to right: 1) 0,3% SSL, 2) 0,3% SSL + acid, 3) Basic
reference
without acid (which is better than the optimal using Kunze et al. procedure).
Fig. 20 shows the effect of phospholipase in basic recipe. To the left
reference sample
without ingredients to the right a rye toast produced as reference but with
additional
phospholipase (TS-E 1008 dosed at 400 ppm on rye flour basis). Lipase gives
some
improvements on volume and crumb structure and texture (see comparative data
in fig.
16-17).
Fig. 21 presents stress measurements. The higher the value the less soft the
bread is and
the more force is required to compress the bread slice. Light blue (no. 1, 3,
4, 5, 6, 7,
16, 19, 20) is commercial products containing above 50% rye flour. Darker blue
is this
invention containing rye flour above 90% (no. 21,18). Yellow is pure wheat
bread (no.
8, 9, 10), while orange less than 50% is rye flour (no. 11, 12, 13, 14, 15,
17).
Fig. 22 uses the same colours as fig. 21. Measurement on crumb resilience. How
well
structure is maintained after compression.
Fig. 23 Uses the same colours as fig. 21. The figure presents the meaurement
of pH.
The product of the present invention with low pH was produced using
encapsulated
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citric acid (GRINDSTED ProTex TR 100 ¨ can be obtained from Danisco). The
product of the present invention with higher pH was produced as standard wheat
bread
without the use of acids/acidifiers.
Fig 24 presents a comparison of specific volume of rye and wheat based
products.
From left to right - 1) commercial product comprising 80% rye, 2) commercial
product
comprising 50% rye, 3) product according to the present invention, 4) and 5)
two
different commercial wheat products.
Fig.25 presents rye rolls produced with Journal No. 1652-88 (Example 11).
Fig 26 presents rye hamburger buns produced with Journal No. 1652/78-2
(Example
12).
Fig . 27 presents rye brioche toast produced with Journal No. 1652/93 (Example
13).
Fig. 28 presents rye baguette produced with Journal No. 1652/87. (Example 14).
Fig. 29 presents rye grissini/bread stick produced using Journal No. 1652/95.
(Example
15).
Fig. 30 presents rye pizza produced using Journal No. 1652/92. (Example 17).
Fig. 31 presents rye tortilla produced using Journal No. 1652/89. (Example
18).
Fig 31 b presents the data as Table 2 for Ex. 8 ¨ rye toast Chorleywood
process using
Journal No.1652/86.
Fig 31 c presents the data as Table 3 for Ex. 9¨ rye toast Straight dough
process using
Journal No.1652/85.
Fig 31 d presents the data as Table 4 for Ex. 10 ¨ rye toast Sponge & dough
process.
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Fig 31 e presents the data as Table 5 for Ex. 16 ¨ rye pita using Journal No.
1652/90.
In Part B of the Examples, reference is made to Figures 32 to 37. Details on
those
5 Figures now follow.
Figure 32 presents the effect of TS-B 1111 and Enzyme 1 in rye flour
containing
systems.
10 Figure 33 presents the effect of Enzyme 1 in wheat flour containing
systems.
Figure 34 presents rye bread made without sourdough using a Chorleywood
procedure
(example 3B).
15 Figure 35 presents the effect on firmness (HPa) in rye bread straight
dough 1: control,
2: TS-B 1132 and 3: control with liquid sour (example 4B).
Figure 36 presents the effect on volume in rye bread straight dough 1:
control, 2: TS-B
1132 and 3: control with liquid sour (example 4B).
Figure 37 presents photographs of baked rye products straight dough 1:
control, 2: TS-
B 1132 and 3: control with liquid sour (example 4B).
More in particular:
Figure 32 shows the results on of analysis using a Rapid Visco Analyser:
'Curve 1 shows the results of a first control using rye flour
Curve 2 shows the results of a second control using rye flour treated with
phospholipase
Curve 3 shows the results for a rye flour composition according to the
invention
Curve 4 shows the temperature profile
Figure 33 shows comparative results of analysis using a Rapid Visco Analyser
for
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wheat flour compositions. Wheat flour compositions to which various
concentrations
of phospholipase have been added are curves 1 to 3, curve 4 is a control with
no
phospholipase, and curve 5 is the temperature profile.
Figure 34 shows a slice of rye toast breads produced using the procedure of
Example
3B.
Figure 35 shows a plot of the firmness of the sample from Example 4B.
Figure 36 shows a plot of the volume of the sample from Example 4B.
Figure 37 shows a picture of the samples from Figure 34.
Dough Recipes
For the dough application studies (baking baked products), the amounts are
present as
bakers % amounts. These amounts are measured by taking the total flour added
as
being 100% and the remaining ingredients are quoted in relative % amounts.
The term "Basic" as used herein (e.g. with respect to Basic reference, Basic
procedure,
Basic process, Basic method, Basic dough, Basic trial, Basic recipe, Basic
specific
volume etc.) means in relation to the present invention. For example, Basic
reference
means a recipe falling within the scope of the present invention, Basic
procedure means
the procedure falling within the scope of the present invention, Basic dough
means a
dough falling within the scope of the present invention etc. "Basic" does not
mean the
essential basics of the invention.
Materials
In the Examples, reference is made to the following ingredients:
GRlNDAMYLTm MAX-LIFE U4 ¨ supplied by Danisco A/S
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Enzyme complex of fungal xylanase: Aspergillus tubingensis GH11 Endo-beta-
(1,4)-xylanase (EC 3.2.1.8) (Accession No P55331) and bacterial amylase:
Bacillus subtilis (EC 3.2.1.1).
Novamyl 1500 BG equal Enzyme 2 in the examples ¨ supplied by Novozyrnes
Bacterial amylase of Bacillus stearothermophilus (EC 3.2.1.133)
GRINDAMYLTm POWERBake 900 (sometimes referred to as GRINDAMYL TM
PB900) ¨ supplied by Danisco A/S
Bacterial xylanase of: Bacillus subtilis GH11 Endo-beta-(1,4)-xylanase (EC
3.2.1.8) (G13F/R122D variant of Accession No P18429)
TS-E 1367 ¨ supplied by Danisco A/S
Lipase of Fusarium heterosporum triacylglycerol acylhydrolase (EC 3.1.1.3
and the CAS number is 9001-62-1)
GRINDAMYL TM S758 ¨ supplied by Danisco A/S
Fungal glucose oxidase of Aspergillus niger (EC 1.1.3.4)
Lipopan F BG equals Enzyme 1 in the examples ¨ supplied by Novozymes
Enzyme 1 is the lipase described in EP 869167 - Fusarium oxysporum (EC-
class 3.1.1.3)
TS-E 1514¨ supplied by Danisco.
Bacterial amylase of Pseudomonas saccharophila, Glucan 1,4-alpha-
maltotetrahydrolase (EC. 3.2.1.60)
GRINDAMYLTm SUREBake 800 supplied by Danisco.
Hexose oxidase of Chondrus crispus (EC. 1.1.3.5)
DIMODAN RT (DIMODAN R-T PEL/B KOSHER) ¨ supplied by Danisco A/S
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DIMODAN R-T PEL/B KOSHER is a distilled monoglyceride made from
edible, partially hydrogenated rapeseed oil with the following antioxidants
added:
Alpha-tocopherol (E 307) max. 200 ppm
Ascorbyl palmitate (E 304) max. 200 ppm
The antioxidants are dissolved in:
Citric acid ester (E 472c) max. 400 ppm
Total monoglyceride min. 90%
Iodine value approx. 60
Free glycerol max. 1%
Acid value max. 3
Dropping point approx. 57 C
Form pellets
DIMODAN HP75/B ( DIMODANe HP 75/B KOSHER) ¨ supplied by Danisco A/S
DIMODAN HP 75/B KOSHER is a distilled monoglyceride made from edible,
fully hydrogenated palm based oil.
Total monoglyceride min. 90%
Iodine value max. 2
Free glycerol max. 1%
Acid value max. 3
Dropping point approx. 69 C
Form fine powder
Particle size 75p,
DIMODAN" PH200 (DIMODAN PH 200 VEG KOSHER) ¨ supplied by Danisco
A/S
DIMODAN PH 200 VEG KOSHER is a distilled monoglyceride based on
soya bean and/or rapeseed oil with the following antioxidants added:
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Natural tocopherol (E 306) max. 200 ppm
Ascorbic acid (E 300) max. 200 ppm
Citric acid (E 330) max. 100 ppm.
Total monoglyceride min. 90%
Iodine value approx. 15
Free glycerol max. 1%
Acid value max. 3
Dropping point approx. 65 C
Form fine powder
PANODAN A2020 (PANODANC A2020 KOSHER )¨ supplied by Danisco A/S
PANODANC A2020 KOSHER is a diacetyl tartaric acid ester of mono-
diglycerides (DATEM) made from edible, fully hydrogenated rapeseed and/or
palm based oil containing calcium carbonate as carrier in the following ratio:
80% DATEM
20% Calcium carbonate
Specifications on the DATEM part:
Saponification value 430-460
Acid value 65-85
Iodine value max. 2
Form coarse powder
PANODANI1 A2020 is sometimes referred to as DATEM.
GRINDSTED SSL P 55 (GRINDSTED SSL P 55 KOSHER) ¨ supplied by
Danisco
GRINDSTED SSL P 55 KOSHER is a sodium stearoyl lactylate made from
refined, edible vegetable fatty acids.
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Ester value 150-190
Acid value 60-80
Iodine value max. 2
Lactic acid content 31-34%
5 Sodium content 3.5-5.0%
Dropping point approx. 45 C
Form beads
TS-B 1111 ¨ supplied by Danisco A/S
10 TS-B 1111 is an encapsulated Xanthan 200 in DIMODAN HR.
It is a powder with the following composition:
DIMODAN HR 70 %
GRINDSTED Xanthan 200 30 %
GRINDSTED Xanthan 200 is a food grade xanthan gum supplied by Danisco
Moisture 5 ¨ 12 %
PH (1% solution) 6.0 ¨ 8.0
Particle size min. 92% through 75[im (200 mesh)
Min. 99.5% through 1801.1m (180 mesh)
Viscosity 1,200 ¨ 1,600 inPa.s (24 degree C, 1% KC1, Brookfield
LVT, 60
rpm, spindle3)
DIMODAN HR is a distilled monoglyceride made from edible, fully hydrogenated
rapeseed oil supplied by Danisco.
Total monoglyceride min. 90%
Iodine value max. 2
Free glycerol max. 1%
Acid value max. 3
Dropping point approx. 72 C
Form beads
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TS-B 1130 ¨ supplied by Danisco A/S
Combination of
31.58% DIMODAN PH 100
5.26% Ascorbic acid
2.63% GRINDAMYLTm POWERBake 900
3.16% TS-E 1367
1.58% Enzyme 2
52.63% PANODANO A2020
3.16% GRINDAMYLTm SUREBake 800
DIMODAN PH 100 (DIMODAN@ PH 100 NS/B KOSHER) supplied by Danisco.
A distilled monoglyceride based on rapeseed and palm based oil with the
following antioxidants added:
Alpha-tocopherol (E 307) max. 200 ppm
Ascorbyl palmitate (E 304) max. 200 ppm
The antioxidants are dissolved in:
Citric acid ester (E 472c) max. 400 ppm
Total monoglyceride min. 90%
Iodine value max. 35-45
Free glycerol max. 1%
Acid value max. 3
Dropping point approx. 62 C
Form fine powder
TS-B 1131 ¨ supplied by Danisco A/S
Combination of:
32.61% DIMODAN PH 100
5.43% Ascorbic acid
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2.72% GRINDAMYLTm POWERBake 900
3.26% TS-E 1367
1.63% Enzyme 2
54.35% PANODAN A2020
TS-B 1132¨ supplied by Danisco A/S
Combination of ascorbic acid, enzyme complex, monoglyceride and
hydrocolloid.
Combination of:
94,67% TS-B 1111
1.78% Enzyme 1
1,78% GRINDAMYL TM SUREBake 800
1.78% Ascorbic acid
GRINDSTED ProTex TR 100 supplied by Danisco
GRINDSTED Pro Tex TR 100 is an encapsulated citric acid 200 in
DIMODAN HR.
Journal No. 1652/86 ¨ Danisco A/S
% of total
Product
,5
gt?:: = Ati
TS-B 1111 63.64
PANODAN A2020 29.55
GRINDAMYLTm POWERBake 900 1.82
Enzyme 2 0.91
TS-E 1367 0.68
GRINDAMYLTm S 758 1.14
Ascorbic acid 2.27
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Journal No. 1652/85 ¨Danisco A/S
% of total
Product
-GRINDAMLTm MAX-LIFE U4 0.07
PANODAN A2020 45.26
Ascorbic acid 0.70
DIMODAN HP 75 48.75
Enzym 1 0.70
GRINDAMYLTm POWERBake 900 2.79
GRINDAMYLTm S 758 1.74
Journal No. 1652/92-2 ¨ Danisco A/S
% of total
Product
PANODAN A2020 31.25
DIMODAN PH 100 14.42
TS-B 1111 48.08
Ascorbic acid 2.40
GRINDAMYLTm POWERBake 900 1.44
Enzyme 2 0.96
Enzyme 1 1.44
Journal No. 1652/88 ¨ Danisco A/S
% of total
Product
GRINDAMYLTm MAX-LIFE U4 0.07
PANODAN A2020 45.26
Ascorbic acid 0.70
DIMODAN HP 75 48.75
Enzyme 1 0.70
GRINDAMYLTm POWERBake 900 2.79
GRINDAMYLTm S 758 1.74
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Journal No. 1652-78-2 ¨ Danisco A/S
% of total
Product
Dimodan HP 76 17.33
PANODAN A2020 22.53
TS-B 1111 55.46
Enzyme 2 0.52
GRINDAMYLTm POWERBake 900 0.69
TS-E 1367 1.04
GRINDAMYLTm S-758 0.69
Ascorbinsyre 1.73
Journal No. 1652/93 ¨ Danisco A/S
% of total
Product
GRINDAMYLTm MAX-LIFE U4 0.04
PANODAN A2020 22.21
TS-B 1111 44.42
DIMODAN HP 75 31.10
Enzyme 1 0.44
GRINDAMYLTm POWERBake 900 1.78
Journal No. 1652/87 ¨ Danisco A/S
% of total
Product
GRINDAMYLTm MAX-Life U4 0.07
PANODAN A2020 46.07
DIMODAN HP 75 49.61
Enzyme 1 0.71
GRINDAMYLTmPOWERBake 900 2.83
Ascorbic acid 0.71
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Journal No. 1652/95 ¨ Danisco A/S
% of total
Product
GRINDAMYLTm MAX-Life U4 0.07
PANODAN A2020 45.26
DIMODAN HP 75 48.75
Enzyme 1 0.70
GRINDAMYLTm POWERBake 900 2.79
Ascorbic acid 0.70
GRINDAMYLTm S-768 1.74
Journal No. 1652/90 ¨ Danisco A/S
% of total
Product
GRINDAMYLTm MAX-LIFE U4 0.07
PANODAN A2020 45.26
DIMODAN HP 75 48.75
Enzyme 1 0.70
GRINDAMYLTm POWERBake 900 2.79
Ascorbic acid 0.70
GRINDAMYLTm S-758 1.74
5 Journal No. 1652/92 ¨ Danisco A/S
% of total
Product
GRINDAMYLTm MAX-Life U4 0.07
PANODAN A2020 45.26
DIMODAN HP 75 48.75
Enzyme 1 0.70
GRINDAMYLTm POWERBake 900 2.79
Ascorbic acid 0.70
GRINDAMYLTm S-758 1.74
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Journal No. 1652/89 ¨ Danisco A/S
% of total
Product
DIMODAN HP 75 21.80
TS-E 1514 1.91
TS-B 1111 54.50
GRINDSTED ProTex TR 100 10.90
Sodium Bicarbonate 10.90
=
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PART A
Introduction
In this Section reference is made to Examples 1 to 18. In these examples we
show that
if gluten is used in levels above 9% in System (a) then there is no need to
use a gluten
strengthener in System (c). We also found that if the gluten levels are
between 5-9% in
System (a) then it is preferred to use a gluten strengthener in System (c). In
each
instance, we obtained better results than those obtained by Kunze et al who
used only
66% rye flour (see fig. 12, fig 13 and fig. 10 of that document)
In particular:
Examples 1 and 7:
- Demonstrate how acid affects gluten network development in a
negative
direction, producing rye breads of low volume and poor softness compared
to products produced without the addition of acids.
- Addition of ingredients containing emulsifiers (such as journal
nr.1652/86)
can improve volume and softness to a level comparable to wheat based
products (example 7 fig 21-24) when added without acid or in combination
with encapsulated acid. Encapsulated acids have not been used before in rye
bread production.
Examples 2, 3 and 4:
- Reproduction of rye toast described in claim 12 by Kunze et al.
failed as we
believe they made a mistake in their example 4. (Example 2 Method 2A in
this patent).
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- Difference between the Basic recipe and Kunze et al. The Basic
recipe does
not need addition of shortening or oil, nor hemicellulase to obtain better
results than Kunze et al. The use of gluten makes it possible to obtain high
quality products in combination with ingredients such as emulsifier (e.g.
Datem) even using very high levels of rye flour (above 80%).
- Optimisation of Kunze et al procedure: The water addition in the
recipe of
Kunze et al. was adjusted to a standard dough consistency around 470 BU
by use of farinograph.
The resulting rye toast (proofing /maturation time of 16 hrs) was compared
to a rye toast resulting from the Basic recipe given above ¨
proofmg/maturation of only 55 min. Comparison was done in example 4.
Comparison was performed on specific volume and softness (TPA ¨ stress
measurements). The Basic recipe disclosed above produces significantly
higher volumes and better softness than the products produced using the
method disclosed by Kunze et al.
Measurements on bread pH demonstrate that pH of products obtained using
the method of Kunze et al. are between 5,9-6,2 while the pH of the bread
crumbs are between 5,5-5,7 when using the Basic recipe from this invention.
Example 5 and 6:
- Studies show that increasing gluten addition in the Basic recipe
demonstrates improved volume. If no ingredients are added then the level
should preferable be above 9% to obtain higher quality than Kunze et al.
However by further addition of ingredients containing emulsifiers as Datem
or a lipase lower amount can be used (such as above 5%) ¨ see fig. 13-15
example 5).
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- However these effects in high rye flour containing recipes are
only possible
to obtain when at pH is above 5. Preferably between 5,4-6,5. If acid is added
then the effect of both gluten and ingredient is eliminated (see fig. 15-19 in
example 6).
- Example 6 demonstrates the positive effect of emulsifiers (gluten
strengthening) on specific volume, crumb structure and texture (including
softness).
EXAMPLES 8-18
- Cover a series of different applications using the Basic recipe:
rye, gluten,
emulsifier/lipase, no acid/sourdough (alternatively encapsulated citric acid).
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EXAMPLE 1. Effect of acids and encapsulated acids on rye toast production.
Recipe.
5
100 % Rye flour
10 % gluten
2,5% g salt
5 % sugar
10 6 % yeast compressed
79 % Water
Procedure (Tweedy mixer ¨ high speed high shear mixer based on the Chorleywood
process (CBP) principles from 1960).
15 Dough temperature: 26-27 C. using 11Wh/kg.
Rest: 5 min
Scaling: 900 g/toast tin. Tin 10x9x27cm. With lid
Rest max 5 min.
Mould on Glimek: 1:4 ¨ 2:4 ¨ 3:14 ¨ 4:12. 11 in each side
20 Proofing: 55 min at 35 C, 85%RH. In proofing cabinet, Miwe GBA
Baking: 30 min at 210 C. in Miwe roll-in oven
Cooling: 1 hr. before gas packing in Komet S 501, with vacuum and CO2
Volume was determined using the rape seed displacement method.
Softness was determined at day 7 using a texture analyzer (TPA) stress
measurement.
pH of crumbs was measured using 3 g of crumb homogenized in 15 ml of deionised
water.
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Experimental set-up
1. Control
2. 0,72% citric acid
3. 1,2% GRINDSTED Pro Tex TR 100 (encapsulated citric acid)
4. 1,2% GRINDSTED Pro Tex TR 100 and 2% Journal no.: 1652/86
(emulsifier,hydrocolloid, enzyme blend according to the present invention
description)
5. 2% Journal no.: 1652/86
The results are shown in Figures 1, 2, 3 and 4.
Conclusion on example 1:
- The addition of soluble acids has negative effect on protein network
development.
- By encapsulating the acid it is possible to avoid the negative
effect of the acid
on the gluten network development.
- When dough has pH over 5 (preferably above 5,4) it is possible to
obtain
significant volume and softness improvements by addition of ingredients
improving interactions to gluten protein such as DATEM, lipase.
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EXAMPLE 2
Comparison of rye toast bread according to the present invention to prior art
from Kunze et al. 2006.
Recipe and procedure according to Kunze et al.
2A. Method A: As described in claim 12 of Kunze et al.
Sponge step:
1000 g rye flour type 997
5 g compressed yeast
7625 g water
Procedure:
Mix for 5 min. Dough temperature 30 C
Leave at RT (22 C) for 15,5 hrs.
Dough step:
1000 g rye type 997
500 g US flour (high protein)
100g olive oil
=
45g compressed yeast
50 g milk powder
50 g sugar
50 g salt
400 ppm Grindamyl PowerBake 900
7625 g water
Procedure:
Mix: in spiral mixer. 2 min at low speed and 5 mm at high speed.
Rest: 10 mm followed by moulding.
Use 850 g dough for toast tin
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Proofing: 32 C, 78%RH for 60 mm.
Baking: 35 min at 220 C
2B. Method B: As claim 12 but with water level modified by the present
inventors to
try to obtain an optimised system of Kunze et al.
Sponge step:
1000 g rye flour type 997
5 g compressed yeast
762,5 g water
Procedure:
Mix for 5 min. Dough temperature 30 C
Leave at RT (22 C) for 15,5 hrs.
Dough step:
1000 g rye type 997
500 g US flour (high protein)
100 g olive oil
45 g compressed yeast
50 g milk powder
50g sugar
50 g salt
400 ppm Grindamyl PowerBake 900 (hemicellulase, xylanase according to claim)
762,5 g water
The whole of the sponge is used.
Procedure:
Mix: in spiral mixer. 2 min at low speed and 5 mm at high speed.
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Rest: 10 min followed by moulding.
Use 850 g dough for toast tin
Proofing: 32 C, 78%RH for 60 min.
Baking: 35 min at 220 C
The results are shown in Figures 5 and 6.
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Example 3. Rolls laboratory method to evaluate differences between method from
Kunze et al. and the present invention.
5 Recipe and procedure:
Kunze Basic recipe
Kunze et Basic et al (trial 4) g
al (trial recipe (trial 3)
1) g (trial 2) g g
Rye flour type 997 200 200 200 200
wheat flour US 100 100
Yeast 9 9 9 9
Sugar 10 10 10 10
Salt 10 10 10 10
Gluten (75% protein) 20 20
Olive oil 4 4
200
200 (BU152 (BU (BU
water 470) 470) 470) 152 (BU 470)
Hemicellulase/xylanase (GRLNDAMYLTm 472ppm,
POWERBake 900) - 0,095g
2,6% but 2,6% (5,2g)
no
0,095g of
PowerBake PowerBake
Journal No. 1652-86 900 900
The units "BU" are Barbender Units ¨ namely, a unit of the water needed in
order to
10 get the right dough consistency in this example a dough consistency of
470 BU at the
Farinograph.
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Dosage of single ingredients in journal 1652/86. Dosed on basis of rye flour:
PANODANTm A2020 : 0,767% (Datem)
GRINDAMYLIm Maxlife U4: 17,7 ppm (bacterial amylase)
TSB 1111: 1,65% (monoglyceride and xanthan ¨ encapsulated)
Enzyme 2: 236ppm (exo amylase, bacterial)
TS-E 1367: 177ppm (lipase, glycolipase)
PB 900: 472 ppm (hemicellulase/xylanase, bacterial)
S758: 295 ppm (Glucose oxidase, oxidative enzyme)
Ascorbic acid: 590 ppm (oxidizing agent)
Procedure:
1) Mix in Farinograph for 7 min at 30 C (63rpm)
2) weigh 4 x 50 g dough
3) rest dough ball for 10 min after end mix
4) Rounding/moulding
5) Proofing 55 min or 3 hrs (L) in humidity chamber at 36 C, 85% RH.
6) Baking with steam in MIWE- roll-in at 18 min (prog. 1)
The results in Fig 7. show that the Basic recipe ( sample 1) without olive
oil, acid or
sour dough but containing gluten (11,5%) and 2,6% journal 1652/86 without
hemicellulase comparable to the amount used by Kunze (33% flour) result in
larger
volume than the method described by Kunze et al. with 2% olive oil, 33% wheat
flour
and hemicellulase. Even under prolonged proofing (3 hrs) as described by Kunze
et al.
The results in Fig 8 show that also under shorter proofing times sample 1
(Basic recipe)
gives higher volumes that the procedure described by Kunze et al. (sample 2).
In
Figure 8 rolls using the procedure and recipe from Kunze et al. (right) and
the same
procedure but using the Basic recipe (left) were prepared. The proofing time
was 55
min at 36 C
1 11,5% gluten, Journal 1652/86 2,6% (no hemicellulase).
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2 Kunze et al. 2% olive oil, 33% wheat and hemicellulase (472
ppm
Grindamyl PowerBake 900, hemicellulase/xylanase)
Studies of effect of hemicellulase addition and proofing time.
Fig. 9A shows the laboratory trials form left to right (50 g dough/roll):
1. Kunze et al (2% olive oil, 33% wheat no hemicellulase). 55 min proofing at
36 C.
2. journal 1652/86 but without hemicellulase, no olive oil, 9% gluten, 55 min
proofing at 36 C
3. Kunze et al (2% olive oil, 33% wheat with hemicellulase). 55 min proofing
at
36 C.
4. journal 1652/86 but with hemicellulase, no olive oil, 9% gluten, 55 min
proofing at 36 C
5. Kunze et al (2% olive oil, 33% wheat no hemicellulase). 180 min proofing at
36 C. (1L)
6. journal 1652/86 but without hemicellulase, no olive oil, 9% gluten, 180 min
proofing at 36 C (2L)
7. Kunze et al (2% olive oil, 33% wheat with hemicellulase). 180 min proofing
at
36 C. (3L)
8. journal 1652/86 but with hemicellulase, no olive oil, 9% gluten, 180 min
proofing at 36 C. (4L)
Cross sections of these results are shown in Fig 9B.
The result of specific volume measurements are given in fig 10.
The results in Fig 10 demonstrate that the volume achieved from the method of
the
present invention without hemicellulase is 27,3% larger when comparing the
product
from Kunze et al using 2% olive oil and hemicellulase on top, after 3 hours
proofing as
described in claim 12. Comparing the samples without hemicellulase the
specific
volume is 35,5% larger.
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Conclusion from example 3 (fig 7-10).
- Addition of gluten is important to obtain large volumes.
The higher
the gluten levels give significantly higher volumes becomes. The
effect is dominated by the development of a gluten network. The
gluten network is improved significantly by addition of gluten
strengtheners ¨ such as journal 1652/86 containing DATEM.
- From example 1 it is demonstrated that gluten can be developed
well if the dough pH levels are higher than 4,7 preferably 5,5 (that
is without addition of acid/sour dough). We also demonstrate that it
is possible to get significant improvements without the addition of
neither shortening (olive oil) nor hemieellulase.
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EXAMPLE 4 Pilot test of rye toast covering claim 1-12 (Kunze et al) compared
to
the method of the present invention.
Recipe and procedure:
Trial 1B: as described in example 2
In this example, we took the ingredients from Ex 2 method B (ingredients used
by
Kunse et al. with optimized water level) and then further tested those
ingredients in the
procedure of the present invention so as to compare the Kunze ingredients and
those of
the present invention.
Trial 1B Trial 2
rye flour 2000 2000
wheat flour US 1000
Yeast 100 100
Sugar 100 100
Salt 100 50
Gluten 260
Oil 40
Water 2000 1600
Milk powder
GRINDAMYLTm 0,95g
PowerBake 900
2,6% - without
GRINDAMYLTm PowerBake
Journal 1652-86 900
Table 2. TB: Recipe of Kunze et al. 2006 using basic procedure. 2. Basic
procedure and
recipe.
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Basic Procedure:
Mix ¨ 1 min. dry, 2 + 5 min. Using a spiral mixer from Diosna.
Dough temp. 27 C.
5 Rest: 5 min at ambient temperature (22 C)
Scaling: 750 g, toast tin. Tin dimensions 10x9x27cm. With lid
Mould on Glimek: 1:4 ¨ 2:4 ¨ 3:14 ¨ 4:12. 11 in each side
Proofing: 55 min at 35 C, 85%RH. In proofing cabinet, Miwe GBA
Baking: 30 min at 210 C. in Miwe roll-in oven
10 Cooling: 1 hr. before gas packing in Komet S 501, with vacuum and CO2
Volume was determined using the rape seed displacement method.
Softness was determined at day 7. using a texture analyzer (TPA).
The results are shown in Figure 11 and Figure 12.
Figure 11 shows Trials 1B and 2 as described in example 4.
Dough handling (rounding/ moulding) can be performed by machine using journal
1652/86 at 2,6%, without hemicellulase and shortening/oil, as it is less
sticky than the
dough produced by the method from Kunze et al using 50% wheat, 2% olive oil
and
hemicellulase.
Fig 12 presents a comparison of rye toast products produced in a standard
toast
procedure using claim 12 (Kunze et al.) with and without the water adjusted
method ¨
see example 2 (Method A and B). 1A: a recipe of Kunze et al. (2% olive oil,
50%
wheat flour and hemicellulase) using ingredients from example 2A. 1B: a recipe
of
Kunze et al. (2% olive oil, 50% wheat flour and hemicellulase) using
ingredients from
example 2B. lA and 1B are optimized on all process parameters and using the
toast
procedure of the present invention. 2: the basic recipe (Journal No. 1652/86
but without
hemicellulase (GRINDAMYLTm POWERBake 900) and procedure of the present
invention. Specific volumes are: 1A: 2,1 ml/g, sample 1B: 2,1m1/g and sample
2: 4,2
ml/g. Basic procedure gives and increase of 100% in comparison to Kunze et al.
using a
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standard toast procedure. Bread pH for samples 1A and 1B are 6,1 and 5,9.
Sample 2
has pH of 5,7.
EXAMPLE 5. Effect of gluten addition and ingredient containing strengthening
emulsifiers (Datem) ¨ comparison to Kunze et al.
Example 5A Rolls.
Recipe and procedure
Basic (trial 4)
Rye flour type 997 200
Yeast 9
Sugar 10
Salt 10
Gluten (vital) variable
Water 152 (BU 470)
Journal 1652-86 2,6% on rye flour 5,2
Type 997 (rye flour) refers to a German type system.
Procedure:
1) Mix in Farinograph for 7 mm at 30 C (63rpm)
2) weigh 4 x 50 g dough
3) rest dough ball for 10 min after end mix
4) Rounding/moulding
5) Proofing 55 min in humidity chamber at 36 C, 85% RH.
6) Baking with steam in MIWE- roll-in at 18 min (prog. 1)
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Results ¨ Specific volume of rolls
The results are shown in Fig 13 which shows the effect of gluten addition and
addition
of 1652/86 containing Datem (gluten strengthening emulsifier) on specific
volume of
rolls. Recipe according to the present invention with no olive oil, no
acid/sour dough,
55 min proofmg time at 35 C. Specific volume is based on rolls of 50 g dough.
The results demonstrate that there is a linear correlation close to 1 between
addition of
gluten in combination with 2,6% journal nr.1652/86 ingredient containing
Datem.
. There is approximately 100% increase when adding ingredient on top of
gluten. If no
ingredient is added then it is preferable to add more 9% gluten in order to
obtain
significant volume increase. Above this level it is possible to get positive
correlation
between gluten addition and specific volume even in the absence of ingredients
containing emulsifier (gluten strengthener).
Example 5B . Pilot test ¨ rye toast. Effect of gluten and Journal 1652/86 in
rye-
toast using a straight dough procedure.
Kunze recipe ¨ pink columns in the attached Figures
Trials 7 and 8
rye flour 2000
wheat flour US 1000
Yeast 100
Sugar 100
Salt 100
Oil 40
Water 2000
Hemicellulase ,PowerBake 900 0,95g
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Basic recipe - Bakers percent (dosage based on rye flour) for samples 1-6 in
blue
columns.
100% of rye flour (997 APB lot.: 2007-00044) ¨ 3000 g flour
variable gluten (10-15% on rye flour)
2,5% salt
5 % sugar on flour
yeast (6% APB)mht:23-4-07
0,3% Calcium proionate.
80% water
Basic process
Mix - Diosner: 2+6 min.
Just after mixing scale and mould 2x 900g + 2x 750g for rye toast
Proffing: 55 min. 30C.- 85%Rh.
Baking 30 min at 205 C with steam program l(Danish Toast)
Cool 1 hour before packing.
The results are presented in Figures 14 and 15.
In Fig 14: Specific volume (ml/g) measurements on rye toast produced either
using the
Kunze recipe and procedure (claim 12), the recipe of Kunze et al. but Basic
process
(including 2% olive oil, wheat flour 33% and hemicelllulase, no acid) or the
Basic
recipe (rye, gluten, with or without emulsifier containing ingredient (journal
1652/86 at
2,6%) and process. The first written number below the columns refers to the
amount of
gluten used.
Fig 14: The higher the specific volume results the larger volume is obtained.
The
largest volumes are achieved using Basic recipe and process containing higher
gluten % (that is lower rye flour % - see blue columns), addition of
ingredients
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containing gluten strengthening emulsifier (journal nr. 1652/86 at 2,6%)
improves
volumes compared to Kunze et al. even if using gluten levels comparable to 33%
wheat
flour addition (compare Kunze claim 12 in pink to that of the present
invention 9%
gluten + 1652/86 in blue).
Fig 15: TPA measurements conducted on rye toast slices on day 7. The first
number is
the % of gluten. Samples in blue are according to Basic method. Pink are
recipe of
Kunze according to claim 12 (1 and 8) containing 2-3% olive oil and
hemicellulase
(wheat flour up to 100%). The lower the stress values the softer the bread
crumb is.
The softest bread is obtained using the Basic recipe and process with
additional
ingredient (journal number 1652/86 containing gluten strengthening emulsifier-
Datem).
Conclusion: The method of the present invention without olive oil and
acid/sour dough
but containing gluten gives better specific volume and TPA results (softness),
especially when 1652/86 containing gluten strengthening emulsifier is added.
This
compared to the procedure described by Kunze et al with olive oil and
hernicellulase
whether it is short proofing/maturation (Kunze process) or long
proofing/maturation
(claim 12 of Kunze). The difference is affected by the amount of gluten added
and by
addition of ingredient containing gluten strengthener emulsifier (here Datem).
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EXAMPLE 6. Effect of single ingredients such as emulsifiers and lipases.
The recipe is given below
5
Straight dough rye-toast recipe -Bakers percent (dosage based on rye flour)
100 % Rye flour (type 997)
13 % gluten, Kroner Starke
2,5 % salt
10 5 % sugar
5 % yeast compressed (rnht:21-05-07)
% Water
Emulsifier - variable
Acid ¨ variable
15 Enzyme-variable
0,3 % Calcium Propionate (anti-microbial/molding)
Procedure:
Mix ¨ 1 min. slow dry, add water and mix 2min slow + 5,5 high speed min. Using
a
20 spiral mixer from Diosna.
Dough temp. 27 C.
Rest: 5 min at ambient temperature (22 C)
Scaling: 750 g, toast tin. Tin dimensions 10x9x27cm. With lid
Mould on Glirnek: 1:4 ¨ 2:4 ¨ 3:15 ¨ 4:14. 11 in each side
25 Proofmg: 55 min at 35 C, 85%RH. In proofing cabinet, Miwe GBA
Baking: 30 min at 210 C. in Miwe roll-in oven
Cooling: 1 hr. before gas packing in Komet S 501, with vacuum and CO2
The results are shown in Figures 16-20.
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Fig 16: Comparison of ingredients affecting specific volume in rye toast. The
specific
volumes are calculated as reduction compared to the recipe of Kunze but using
the
process of the present invention (set to zero - reference). The method
according to
claim 12 from Kunze adjusted to realistic water level in orange (dough
consistency
adjusted to 470 BU using farinograph ¨ comparable to Basic dough consistency).
The
remaining trials are all conducted using Basic recipe (100% rye, 11,5% gluten
based on
flour, no olive oil) and process.
The best results are obtained using emulsifiers which strengthen gluten such
as:
Datem, lecithin, fatty acid sugar ester, SSL, Citrem, Polysorbate. (Colums in
green.)
If the strengthening emulsifiers are added in combination with acid/sourdough
then the
positive effect is eliminated. (Columns in pink). (See fig 17 and 18.)
Phospholipase and glycolipase improve the specific volume. Comparable to the
Basic
reference without ingredients. Combination of lipase with lower levels of
Datem gives
volumes comparable to using high levels of Datem with no lipase. Column in
blue
Addition of non gluten strengthening emulsifiers such as monoglyceride gives
increase
in volume comparable to phospholipase but the crumb structure is not
acceptable
column in dark green
Softness measurements in fig 17 show that the gluten strengthening emulsifiers
also
have a positive effect on softness when used in the recipe disclosed in this
report. When
using the emulsifiers in combination low dough pH (added soluble acids or sour
dough)
then the positive effect is not recognized (pink columns compared to light
green). The
main effect on softness is obtained by increased volume and not by
complexation of
monoglyceride to amylose as normally expected (dark green column).
Fig 18: Rye toast samples. Show effect of Datem in combination with acid
(dough pH
<4,7). From left to right: 1) 0,3% Datem + acid, 2) 0,3% Datem, 3) 0,3% Datem
+
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phospholipase, 4) 0,3% Datem + phospholipase + acid, 5) Basic reference
without
ingredients or acid.
Fig 19: Rye toast samples. Show effect of SSL in combination with acid (dough
pH <
4,7). From left to right: 1) 0,3% SSL, 2) 0,3% SSL + acid, 3) Basic reference
without
acid (which is better than the optimal using Kunze et al. procedure)
The results demonstrate that no positive effect is obtained on volume (see
also fig. 16)
nor crumb structure when adding gluten strengthening emulsifiers in a gluten
containing recipe in cpmbination with acid. Therefore it is necessary to have
dough of
above 4,7, pH preferably around 5,5 in order to obtain the benefits from
ingredients,
which strengthen the gluten network ¨ such as Datem fig 18 and SSL fig 19.
Addition of emulsifiers such as Datem, SSL, Citrem, polysorbate, sugar esters
etc. can
further contribute to improve softness, however the effect is
diminished/eliminated
when used in rye dough of low pH dough ¨ if acid or sour dough is added (see
fig. 16-
19)
Fig. 20: Effect of phospholipase in Basic recipe. To the left reference sample
without
ingredients to the right a rye toast produced as reference but with additional
phospholipase (TS-E 1008 dosed at 400 ppm on rye flour basis). Lipase gives
some
improvements on volume and crumb structure and texture (see comparative data
in fig.
16-17). The Basic recipe includes rye flour, yeast, sugar, salt gluten and
water. It is
like the recipe described in example 4 trial no. 2, but without Journal 1652-
86.
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Conclusion:
The contribution of gluten proteins is important, but the effects of
ingredients such as
emulsifiers can only be obtained if pH of dough is above 4,7. Basic procedure
is
approximately pH = 5,5-5,7
By using gluten it is possible to maintain high contents of rye flour and
obtain rye toast
quality characteristics (volume, softness, crumb structure, crumb texture)
comparable
to using high content of wheat flour (such as >80%).
Without wishing to be bound by theory, we believe that the main effect on
specific
volume and softeness of journal nr. 1652/86 is derived from the gluten
strengthening
emulsifier component - Datem.
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EXAMPLE 7 ¨ comparison of rye toast (according to this invention) to standard
wheat toast and standard commercial rye based products
Here, we demonstrate that it is possible to produce bakery products similar to
standard
wheat products using more than 70% of rye (or other materials) based on total
cereal
flour content.
The products produced have similar softness as products produced using mainly
wheat
flour.
Characteristics of commercial bread products (sampled from Germany, Finland,
Sweden and Denmark) in which the majority of the cereal part is rye flour
(that is more
than 50% of the cereal flour ¨ called mainly rye flour). These are compared to
typical
characteristics of bread products mainly composed of wheat flour or mainly
wheat flour
(more than 50% of flour is from wheat).
The quality characteristics used to describe the differences are:
- TPA measurements (stress measurements - an inverse measurement of softness)
and resilience (meaurement on tolerance to compression force)).
- Acidity of bread ¨ pH measurements.
- Specific volume
To demonstrate the effect of the rye bread produced by the present invention
two
examples of rye toast were selected for comparison (diagram colour dark blue).
The results from TPA measurements (fig 21) demonstrate that the texture of the
rye
toast is comparable to the pure wheat samples. Furthermore the pH of the rye
products
of the present invention can fall into the mainly rye category or the wheat
category
depending on whether an encapsulated acid/acidifier has been used or not.
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The results are presented in Figures 21-24.
Fig. 21: Stress measurement. The higher the value the less soft the bread is.
Or the
more force is required to compress the bread slice. Light blue is commercial
products
5 containing above 50% rye flour. Darker blue is this invention containing
rye flour
above 90%. Yellow is pure wheat bread, while orange less than 50% is rye
flour.
Fig. 22: Same colours as fig. 21. Measurement on crumb resilience. How well
structure
is maintained after compression.
Specific volume depends on the bakery application. To compare specific volumes
the
same process as described in example 9 (straight dough procedure has been
used).
Fig 24: Comparison of specific volume of rye and wheat based products.
The results from fig 21-24. demonstrate that it is possible to obtain rye
toast
comparable to wheat toast using the Basic recipe.
Conclusions:
- Typical mainly wheat based products (bread) have TPA stress values
under 100.
Measured at day 7. The pure wheat breads have values under 50. The products
produced by the present invention have stress between 20-100 depending on
specific recipe.
- Pure wheat bread has pH above 5. Most rye products have pH below 5. The
products of the present invention can belong to any of these groups depending
on whether encapsulated acids/sourdough have been used or not.
- Specific volumes are higher for the rye bread produced using the
present
invention than conventional rye breads. The rye bread produced by the present
invention comparable to specific volume breads produced using high levels of
wheat flour (>80%).
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EXAMPLE 8 . Rye toast produced using rapid mixer (Chorleywood process)
STANDARD TWEEDY RECIPE ¨ Chorleywood process
__ 100 % Rye flour
% gluten
2,5% g salt
5 % sugar
6 % yeast compressed
10 __ 79 % Water
0,3% Calcium propionate
Ingredient: 1,8% journal no. 1622/86
Procedure (Tweedy mixer ¨ high speed high shear mixer based on the Chorleywood
__ process (CBP) principles from 1960).
Dough temperature: 26-27 C. using 11Wh/kg.
Rest: 5 min
Scaling: 900 g/toast tin. Tin 10x9x27cm. With lid
Rest max 5 min.
__ Mould on Glimek: 1:4 ¨ 2:4 ¨ 3:14 ¨ 4:12. 11 in each side
Proofing: 55 min at 35 C, 85%RH. In proofmg cabinet, Miwe GBA
Baking: 30 min at 210 C. in Miwe roll-in oven
Cooling: 1 hr. before gas packing in Komet S 501, with vacuum and CO2
Volume was determined using the rape seed displacement method.
__ Softness was determined at day 7. using a texture analyzer (TPA).
The results are presented as Table 2 in Fig 3 lb.
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EXAMPLE 9. Rye toast produced by straight dough procedure.
STANDARD TOAST RECIPE
100 % Rye flour
% gluten, Kroner Starke
2,5% g salt
5 % sugar
10 6 % yeast compressed
70 % Water
0,3% Calcium propionate
1,4% journal no. 1652/85
Procedure:
Mix ¨1 min. dry, 2 + 5 min. Using a spiral mixer from Diosna.
Dough temp. 27 C.
Rest: 5 min at ambient temperature (22 C)
Scaling: 750 g, toast tin. Tin dimensions 10x9x27cm. With lid
Mould on Glimek: 1:4 ¨ 2:4 ¨ 3:14 ¨ 4:12. 11 in each side
Proofing: 55 min at 35 C, 85%RH. In proofing cabinet, Miwe GBA
Baking: 30 min at 210 C. in Miwe roll-in oven
Cooling: 1 hr. before gas packing in Komet S 501, with vacuum and CO2
Volume was determined using the rape seed displacement method.
Softness was determined at day 7. using a texture analyzer (TPA).
The results are presented as Table 3 in Fig 31c.
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EXAMPLE 10. Rye toast produced using Sponge and dough procedure.
TOAST ¨ RYE SPONGE & DOUGH
Recipe:
Dosage based on flour.
Sponge:
Ingredients
rye flour (Type 997) 60
Gluten (new German) 8
Water 51,4
Rape seed oil 2
Compressed yeast 3
PANODAN A2020 0,65
DIMODAN8PH 100 1,0
Dough:
Ingredients
Rye flour (type 997) 40
Gluten 2
Salt 1,5
Calcium Propionate 0,25
Compressed yeast 0,9
Sugar 8
Water 27,6
Ascorbic acid 500 ppm
GRINDAMYLnIP OWERBake 300 ppm
900
Enzyme 2 300 ppm
* NOTE: total amount of water is 79% - 65% in the sponge and 35% in the dough
phase
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Equipment:
Mixer: Hobart (sponge) ¨ Diosna (dough)
Proofing cabinet.:Miwe GBA
Moulder: Glimek
Oven: MIWE Roll in
Procedure:
Sponge:
1. Mix all ingredients 1 min 1st speed ¨4 min 2rld speed on Hobart
2. Sponge temp. must be app. 24 C
3. Ferment sponge 3 hours at 25 C, 85% RH
Dough:
4. Mix sponge and all remaining ingredients EXCEPT SALT for 1 min
low ¨2 min high on spiral mixer, Diosna
Add salt ¨ mix 8 min high speed
5. Scale 900 g mould (for toast tins 27x11x9 cm.)
6. Rest dough 10 min at ambient temperature
7. Mould on Glimek: 1:4 ¨ 2:3 ¨ 3:15 ¨ 4:12 ¨ width: 8 in both sides
8. Put dough into tins
9. Proof to height (about 45 min) at 38 C, 85% RH ( Miwe GBA)
10. Bake 30 min. 205 C. with steam ( Miwe roll-in oven)
11. Take breads out of tins and cool for 70 min before packing
On mixing the two components a dough according to the present invention is
formed.
The results are presented as Table 4 in Fig 31d.
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EXAMPLE 11. Rye rolls
STANDARD ROLLS RECIPE
5 100 % Rye flour
10 % gluten, Kroner Starke
2,5 % salt
5 % sugar
6 % yeast compressed
10 70 % Water
1,4% Journal no. 1652/88
Mix: 1 min. dry mix ¨2+5 min. Diosna (spiral mixer, Diosna)
Dough temperature: 26 C.
15 Rest: 5 min
Scaling: 2000g. / 30 pieces of 67 g
Proofing: 45 min at 34 C, 85%RH in proofing cabinet, Miwe GBA
Baking 18 min at 205 C with steam, in Miwe Roll-in oven
Specific volume, ccm/g
Control 2,5
1,4% Journal no. 1652/88 4,3
20 Table 8
The results are shown in Fig.25.
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EXAMPLE 12. Burger buns
RECIPE
100 % Rye flour
% gluten, Kroner St5rke
2,5 % salt
5 % sugar
6 % yeast compressed
10 79 % Water
2,88 % journal no. 1652-78-2
Mix : 1 min. dry rnix ¨ 2 + 5 min. Spiral mixer, Diosna.
Dough temperature: 26 C.
Rest: 5 min
Scaling: Dough pieces of 90 g/piece
Rest 5 min before compressing rounded dough to 80% of the area of the
hamburger tins
(4 inch.)
Proofing: 45 min at 34 C, 85%RH in proofing cabinet, Miwe GBA
Baking 12 min at 230 C in deck oven (Miwe Condo)
Specific volume, ccm/g
Control 2,05
2,88% Journal no. 1652/78-2 3,40
Table 9.
The results are shown in Fig 26.
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EXAMPLE 13. Rye brioche.
Standard Brioche recipe
100% Rye flour
10% gluten, Kroner starke
1,2% salt
% sugar
10 1,4 % yeast (Brown dry yeast- Fermipan)
20,4 % Whole eggs - fresh
19,1% Butter, unsalted
0,3% propionate
54% Water
15 Ingredient: 2.25% 1652/93
Mix ¨ Diosna spiral mixer: 1 min. dry, speed 1- add eggs and water mix 2 min.
speed 1
and 5,5 min. at speed 2¨ add butter mix 2,5 min. speedl and 1,5 min. speed 2.
Dough temp: 25 C.
Just after mixing scale and mould at 900g baked with lids ¨ toast tin (27x11x9
cm)
Proofing: 110 min. 30 C.- 75%Rh. in proofing cabinet, Miwe GBA
Baking 33 min ¨ 10 min. 210 C. + 18 min. 200 C. + 5 min. 180 C. with steam.
(Miwe
roll-in oven).
Cooling: 1 hr. before gas packing in Komet S 501, with vacuum and CO2
Volume was determined using the rape seed displacement method.
Softness was determined at day 7. using a texture analyzer (TPA).
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Specific volume, ccm/g TPA stress day 7 HPa
2,25% Journal No. 1652/93 3,28 84.8
The results are shown in Figure 27.
EXAMPLE 14. Rye baguette.
100 % Rye flour
% gluten, Kroner Stkke
2,5% salt
10 5 % sugar
6 % yeast compressed
70 % Water
1,4% Journal nr. 1652/87
Mix: 1 mm. dry mix ¨2 + 5 min. Spiral mixer, Diosna.
Dough temperature: 26 C.
Rest: 5 min
Scaling: 350g.
Mould in baguette moulder, from Glimek
Proofing: 45 min at 34 C, 85%RH in proofing cabinet, Miwe GBA
Cut 4-5 slices in the surfaces
Baking 18 min. at 205 C with steam, in Miwe Roll-in oven
Specific volume, ccm/g
Control 2,2
1,4% Journal no. 1652/87 4,3
The results are shown in Fig. 28.
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EXAMPLE 15. Rye grissini (bread sticks'
GRISSINI RECIPE
100 % Rye flour
% gluten, Kroner Starke
2,5 % salt
5 % sugar
10 6 % yeast compressed
79 % Water
1,4% journal no. 1652/95
Procedure:
Mix ¨ 1 min. dry, 2 + 5 min. spiral mixer (Diosna)
Rest: 5 min
Scale the dough pieces at 20g.
Rest: 5 min
Mould them out at 20 cm
Proofing: 55 min at 35 C, 85%RH in proofing cabinet, Miwe GBA
Baking: 12 min at 230 C (dech oven,Miwe condo) .
Cooling: 25 min. before packing
Specific volume, ccm/g
Control 2,5
1,4% Journal no. 1652/95 4,3
The results are shown in Fig. 29.
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EXAMPLE 16. Rye pita
STANDARD PITA RECIPE
5
100 % Rye flour
10 % gluten, Kroner Starke
2,5 % salt
5 % sugar
10 6 % yeast compressed
79 % Water
1,4% 1652/90
Procedure:
15 Mix ¨ 1 min. dry, 2 + 5 min. spiral mixer (Diosna)
Rest: 5 min
Sheet the dough according to: 20-15-10-5 mm. Cut the dough sheet using a
circular
cutter of 14 cm. on diameter.
Proofing: 55 min at 35 C, 85%RH in proofing cabinet, Miwe GBA
20 Baking: 12 min at 230 C (dech oven, Miwe condo) .
Cooling: 25 min. before packing
The results are presented as Table 5 in Fig 31e.
,
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EXAMPLE 17. Rye pizza
STANDARD PIZZA RECIPE
100 % Rye flour
% gluten, Kroner Starke
2,5 % salt
5 % sugar
10 6 % yeast compressed
79 % Water
1,4% Journal 1652/92
Procedure:
Mix ¨ 1 min. dry, 2+ 5 min. spiral mixer (Diosna)
Rest: 5 min
Sheet the dough according to: 20-15-10-5-3 mm. Cut the dough sheet using a
circular
cutter of 20 cm. on diameter.
Proofing: 55 min at 35 C, 85%RH in proofing cabinet, Miwe GBA
Baking: 9 min at 230 C (dech oven,Miwe condo) .
Cooling: 25 min, before packing
The results are shown in Fig. 30.
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EXAMPLE 18. Rye tortilla.
Dosage
Standard ingredients
Flour¨rye 100
Gluten 10
Water 70
Sugar 5
Shortening type: 5
Rapeseed oil
Glycerol 3
Journal no. 1652/89 2,3
Salt 2
Potassium sorbate 0,3
Calcium propionate 0,3
Procedure:
Mixing: 2 min at low speed and 4,5 min at high speed in spiral mixer.
The dough temperature was 30 C.
1350 g dough is used for moulding.
The dough pieces rest 5 minutes in a proofing chamber before baking.
The dough pieces are pressed and baked the tortilla machine (CFO 40).
Pressing plates: 200 C and 205 C
Baking process:
Top: 252 C Middle: 263 C
Bottom: 180 CSpeed: 60 rpm (30 sec)
Packing setting: 10 tortillas/plastic bag:40 vacuum
40 Gas (carbon dioxide) 78 C
The results are shown on Fig. 31.
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PART B
Example 1B. Results from Rapid Visco Analyser
Three samples were prepared according to the AACC method 76-21. The samples
were as follows:
1: Sample 1: Control containing 3.5 g rye flour and 25 ml deionised water
2. Sample 2: 2 g rye flour, Enzyme 1 and 25 ml deionised water.
3. Experimental Sample 3: 5 g rye flour, 0,07g TSB 1111 and 25 ml deionised
water
The active ingredients of TSB 1111 are a combination of distilled
monoglycerides
Dimodan RHR 70% and hydrocolloid (xanthan) no lipases are included in TSB
1111.
Samples were run in Rapid Visco Analyser using the standard profile according
to the
AACC method.
The results of the assay are shown in Figure 32.
Aside from using the TSB 1111, which is a combination of mono glyceride and
hydrocolloid, in this case xanthan, however also other ingredients such as
lipases,
monoglycerides, SSL and Diacetyl Tartaric Acid Esters can be used to avoid too
high
degradation of starch during baking process. Furthermore inhibitors or
feedback
substrates, which are known to inhibit amylases, can also contribute to this
effect.
TSB products are available from Danisco A/S
Figure 33 shows the effect of Enzyme 1 in wheat flour containing systems.
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Example 2B. Results from Kieffer measurements:
Kieffer method using the texture analyzer
A piece of dough (20 g of dough produced using the method described in Example
4)
was pressed into the Kieffer rig. Measurements were conducted after 5 min or
10 min
rest at room temperature (depending on the gas cell development). The dough
resistance gives information of the strength of the dough while the distance
gives
information on the extensibility/stretchability of the dough.
Treatment Mixing Kieffer Kieffer pH in the dough pH in the
energy force distance measured 15 end product
(Wh/kg) min after mixing
Control 9,5 8 15 5,7 6,0
TSB 1111 (1,6%), 9,5 16 23 5.7 6,0
TSB 1130(1%)
TSB 1111 (1,6%), 9,5 14 25 5.72 6,0
TSB 1131 (1%)
TSB 1111 (1,6%), 11 23 27 6.19 6,48
TSB 1130 (1%)
sodium bicarbonate
(0,3%)
The addition of Hexose oxidase in the composition increases dough resistance
(TSB
1130 contains Hexose oxidase, TSB 1131 is similar to TSB 1130 except that it
does not
contain Hexose oxidase). Furthermore the addition of ingredients that can
increase pH
(such as sodium bicarbonate) can contribute to improved gluten network
formation.
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Example 3B Rye toast application (using rye and no sourdough) in a Chorleywood
process.
5 A dough was prepared using a Tweedy mixer, which is a high speed high
shear mixer
based on the Chorleywood process (CBP) the principles of which date from the
1960s,
using the following ingredients:
2500 g of rye flour 2006009 type 997.
10 250 g gluten (vital gluten EMCEvit C)
62,5 g salt
125 g sugar on flour
150 g yeast compressed
TSB 1111 (dosage 1.6% on rye flour) and TSB 1131(1% on rye flour) and
additional
15 0,3% DIMODAN PH100.
Water addition 82% of rye flour
and the following conditions:
20 Mix with a mixing energy between 9.5-11Wh/per kg
Dough temperature 25 C
After mixing in a Tweedy mixer (CBP) the dough was allowed to rest for 10min
at
room temperature. Then 900 g dough samples were added per DK toast tin. Four
25 pieces were used for texture profile analysis (TPA) measurements (for
softness
determination over a period of 14 days storage at room temperature) and 1
piece was
used for volume measurements.
The samples were baked at 200 C for 30 minutes using a Miwe roll in oven. The
30 volume and toast weight was recorded and specific volume was recorded.
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The products were easy to slice just after cooling. Often it can be a problem
when
using high levels of rye. The specific volume for this product was 3.1 ml/g.
The firmness data was similar to standard wheat toast data produced using
GRINDAMYLTm MAXLIFE U4, PANODANTM A2020 (DATEM) and DIMODAN
HP 75/B.
Firmness measurements (low values show that the bread is soft whilst high
values show
that it is firm).
Firmness
Day 1 30 Hpa
Day 7 40 Hpa
Day 14 46 Hpa
Method used to measure pH in the end product:
1. 2.5 g is weighed and 12 ml of deionised water is added.
2. The crumbs are homogenised for 30 sec at 13500 RPM using an ultra turrex.
3. The pH is measured.
Results from rye toast bread go from pH 5.9 to 6.5 using the procedure
described in
example 3. The pH given in example 3B is when the pH is measured directly on
the
dough 15 min after mixing.
The pH meter used is a PHM 220. Meter Lab.
The samples showed taste improvements in that they were less bitter than rye
bread
baked without the above mentioned ingredients. The taste improvements were
achieved by use of the bacterial xylanase. The literature (J.A. Delcour et al.
1989
Cereal Chem. 66(2): 107-111) indicates that the insoluble pentosans can
contribute
negatively to darkness, dull gray surface and bitter taste. Therefore the
bacterial
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xylanases without endo-amylase were used. Furthermore sugar was added and the
increase of pH by the sodium bicarbonate improved crumb structure (less gummy)
and
resulted in a less bitter taste.
Figure 34 shows a slice from a rye toast produced using a Chorleywood process.
It can
be seen that the bread is similar to that produced using wheat flour.
Example 4B. Bread made without sourdough using a straight dough procedure
and 100% rye flour
Samples were prepared according to the following recipe and process:
Sample 1 Control
2000 g. Rye flour type 997
50 g. Salt
120 g. Yeast
1300 g. Water
Composition according to
Sample 2 the invention
2000 g. Rye flour type 997
50 g. Salt
120 g. Yeast
1300 g. Water
34 g TSB 1132
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Sample 3 Control
2000 g. Rye flour type 997
50 g. Salt
120 g. Yeast
1300 g. Water
Liquid sour
TSB 1132 is a combination of ascorbic acid, enzyme complex, monoglyceride and
hydrocolloid.
Add water and yeast - mix 5 min slow
Dough temp ca.25 C
Scale 800 g - rest for 15 min
Mould by hand
Proof 35 min - 35 C, 85% relative humidity
Bake for 35 min in Miwe stone deck oven (prog nr. 6)
After baking the breads were cooled for 10 minutes before wrapping in plastic
foil.
After 70 minutes 1 bread sample was unpacked and used for weighing and
evaluation
The remaining bread samples were wrapped and store for softness measurements
Dough temperature is achieved by regulating the water temperature. The water
temperature is dependant on how strong the gluten network is developed in the
dough
system. The stronger the dough the more heat the mixer generates in the dough.
For these samples in a Diosna mixer the water temperature was approx. 31 C
The recipe samples and their method of preparation had the following
characteristics:
a) Easy to process (non sticky and sliceable)
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b) Fine and even crumb structure and at least comparable in volume and shape
to using sourdough. However the samples had no sour taste.
c) Softness at least as when using sourdough
Bread without sourdough (samples 1 and 2) has a pH of 5.65. Bread made with
liquid
sour (sample 3) has a pH of 4.5.
As can be seen from these results, examples according to the present invention
produce
rye flour baked products with characteristics similar to those obtained for a
standard
wheat flour product. From Figures 34 to 37, it can be clearly seen that bread
made
according to the invention shows a marked improvement over the product
obtained
from conventional rye flour dough. In particular, Figure 37 shows the much
improved
pore structure of the rolls prepared in accordance with the present invention.
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Summary Aspects
Aspects of the present invention will now be described by way of numbered
paragraphs.
1. A rye cereal flour composition comprising a flour, an emulsifier and/or an
hydrocolloid, wherein a high percentage of the flour is rye cereal flour, such
as at
least 60%, and wherein rye cereal flour bakery products and rye cereal flour
baked
products produced using the composition have improved rheological properties
and/or increased specific volume and/or TPA values similar to those of wheat
flour
bakery products and wheat flour baked products.
2. A rye cereal flour composition according to paragraph 1 wherein the flour
comprises at least 60%, or at least 70%, or at least 80%, or at least 85%, or
at least
90% or at least 95%, rye cereal flour.
3. A rye cereal flour composition according to paragraph 2 wherein the flour
comprises 100% rye cereal flour.
4. A rye cereal flour composition according to any of paragraphs 1 to 3
further
comprising yeast.
5. A rye cereal flour composition according to any of paragraphs 1 to 4
further
comprising a chemical leavening agent.
6. A rye cereal flour composition according to paragraph 5 further comprising
baking
powder or a functional equivalent thereof.
7. A rye cereal flour composition according to any of paragraphs 1 to 6
further
comprising ascorbic acid.
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8. A rye cereal flour composition according to any of paragraphs 1 to 7
further
comprising gluten.
9. A rye cereal flour according to paragraph 8 comprising at least 1%
gluten, such as
at least 5%, at least 10%, at least 15%, at least 20%, at least 25% or at
least 30%
gluten as a percentage of the total composition.
10. A rye cereal flour composition according any of paragraphs 1 to 9 further
comprising at least one enzyme.
11. A rye cereal flour composition according to paragraph 10 wherein the
enzyme is
selected from the group consisting of xylanases, starch degrading enzymes like
exogenic amylases, oxidoreductases, lipases including phospholipases and
glycolipases, acyl transferases and combinations thereof.
12. A rye cereal flour composition according to paragraph 10 or 11 wherein the
enzyme
is xylanase.
13. A rye cereal flour composition according to paragraph 12 wherein the
xylanase is
free of or substantially free of endo-amylase and/or glucanase activity.
14. A rye cereal flour composition according to paragraph 12 or 13 wherein the
xylanase is a bacterial xylanase.
15. A rye cereal flour composition according to any one of paragraphs 1 to 14
wherein
the hydrocolloid is selected from the group consisting of carrageenan, starch,
pectin,
alginate, gelatine, locust bean gum (LBG), gellan, xanthan, carboxy methyl
cellulose (CMC), guar gum, depolymerised guar, acacia gum, konjac gum, agar,
tamarind, tragacanth, beta-glucan, arabinoxylan, karaya, curdlam, chitosan and
combinations thereof.
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16. A rye cereal flour composition according to paragraph 15 wherein the
hydrocolloid
is xanthan.
17. A rye cereal flour composition according to any of paragraphs 1 to 16
wherein the
hydrocolloid is present at a concentration between 0.01% and 2.5% such as
between 0.05% and 2%, between 0.07% and 1%, or between 0.1% and 0.7%, as a
percentage of the total composition.
18. A rye cereal flour composition according to any of paragraphs 1 to 17
wherein the
emulsifier is selected from the group consisting of distilled monoglycerides;
monoglycerides; diglycerides; esters of mono- and diglycerides; polyglycerol
esters
of fatty acids; polyglycerol polyrincinoleate; propylene glycerol esters of
fatty
acids; sorbitan monostearates; sorbitan tristearates; sodium stearoyl
lactylates;
calcium stearoyl lactylates; lecithins; and diacetyl tartric acid esters of
mono- and
diglycerides and combinations thereof.
19. A rye cereal flour composition according to paragraph 18 wherein the
emulsifier is
a monoglyceride.
20. A rye cereal flour composition according to any of paragraphs 1 to 19
wherein the
emulsifier is present at a concentration between 0.2% and 4% such as, between
0.4% and 4%, between 0.5% and 3%, between 0.7% and 2.5%, between 0.8% and
2.2%, or between 0.9% and 2%, as a percentage of the total composition.
21. A rye cereal flour composition according to any of paragraphs 1 to 20
further
comprises an anti-staling enzyme.
22. A rye cereal flour composition according to any of paragraphs 1 to 21
which
includes any of the following baking additives: lipases, oxidative enzymes,
DATEM, standard strengthening emulsifiers and oxidising agents such as bromate
or azodicarbonamide (ADA).
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23. A rye cereal flour composition according to paragraph 22 wherein the
oxidative
enzyme is selected from the group consisting of glucose oxidase, pyranose
oxidase,
sulthydryl oxidase, maltose oxidase, and carbohydrate oxidase, such as one
that
oxidises maltose, e.g. hexose oxidase (HOX).
24. A rye cereal flour composition according to any of paragraphs 1 to 23
having a pH
greater than 4, such as a pH greater than 4.5, a pH greater than 5, a pH
greater than
5.1, a pH greater than 5.2, a pH greater than 5.3, a pH greater than 5.3, a pH
greater
than 5.4, a pH greater than 5.4, a pH greater than 5.5 or a pH greater than
5.6.
25. A rye cereal flour composition according to any of paragraphs 1 to 24
capable of
producing rye cereal flour bakery products or rye cereal flour baked products
having theological properties substantially similar to wheat flour bakery
products or
wheat flour baked products.
26. A process for producing a rye cereal flour bakery product comprising
admixing a
composition according to any of paragraphs 1 to 25.
27. A process according to paragraph 26 wherein the composition is admixed
with a
liquid such as water.
28. A process for producing a rye cereal flour baked product comprising baking
a
bakery product prepared according to paragraph 26 or 27.
29. Use of a rye cereal flour composition according to any of paragraph 1 to
25 in the
preparation of a bakery product.
30. Use of a rye cereal flour composition according to any of paragraphs 1 to
25 in the
preparation of a rye cereal flour baked product
31. Use of an emulsifier and/or an hydrocolloid for producing a baked product
or
bakery product comprising a high percentage of rye cereal flour, such as at
least
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60%, or at least 70%, or at least 80%, or at least 85%, or at least 90%, or at
least
95% or about 100%, having improved rheological properties and/or increased
specific volume and/or TPA values similar to those of wheat flour bakery
products
and wheat flour baked products.
32. Use according to paragraph 31 wherein the emulsifier is as defined in any
of
paragraphs 18 to 20.
33. Use according to paragraph 31 to 32 wherein the hydrocolloid is as defined
in any
of paragraphs 15 to 17.
34. A rye cereal flour bakery product prepared by admixing a composition
according to
any of paragraphs 1 to 25.
35. A rye cereal flour baked product prepared by baking a rye cereal flour
bakery
product according to paragraph 34.
36. A baked product or bakery product comprising a high percentage of rye
cereal flour,
such as at least 60%, or at least 70%, or at least 80%, or at least 85%, or at
least
90%, or at least 95% or about 100%, and an emulsifier and/or an hydrocolloid,
wherein the baked product has an increased specific volume and/or TPA values
similar to those of wheat flour bakery products and wheat flour baked
products.
37. A baked product or bakery product according to paragraph 35 or 36 wherein
the
baked product is a bread.
38. A baked product or bakery product according to paragraph 35 or 36 wherein
the
baked product is a processed bread.
39. A baked product or bakery product according to paragraph 35 or 36 wherein
the
baked product is a toast bread.
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40. A baked product or bakery product according to paragraph 35 or 36 wherein
the
baked product is a roll.
41. A baked product or bakery product according to paragraph 35 or 36 wherein
the
baked product is a cake.
42. A baked product or bakery product according to paragraph 35 or 36 wherein
the
baked product is an extruded product.
43. A baking additive composition comprising an emulsifier and/or a
hydrocolloid,
wherein the emulsifier and/or the hydrocolloid allow for the production of
bakery
products and baked products having improved rheological properties from rye
cereal grain.
44. A composition substantially as described herein.
45. A process substantially as described herein.
46. A use substantially as described herein.
47. A bakery product substantially as described herein.
48. A baked product substantially as described herein.
49. A baking additive substantially as described herein.
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Further aspects of the present invention will now be described by way of
numbered
paragraphs.
1. A composition comprising or is made from flour, an emulsifier and/or an
hydrocolloid, wherein a high percentage of the flour is the flour of rye
cereal grain.
2. A method comprising admixing flour with an emulsifier and/or an
hydrocolloid,
wherein a high percentage of the flour is the flour of rye cereal grain.
3. Use of an emulsifier and/or an hydrocolloid in the preparation of a
composition
comprising or is made from a high percentage of flour that is the flour of a
rye cereal
grain.
4. The invention according to any one of the preceding paragraphs wherein the
composition is a dough product for preparing a baked product.
5. The invention according to any one of paragraphs 1 to 3 wherein the
composition is
a bakery product for preparing a baked product.
6. The invention according to any one of paragraphs 1 to 3 wherein the
composition is
a baked product.
7. The invention according to any one of the preceding paragraphs wherein the
baked
product is a bread.
8. The invention according to any one of the preceding paragraphs wherein the
baked
product is a toast bread.
9. The invention according to any one of the preceding paragraphs wherein the
high
percentage is at least 60% of the total weight of the composition.
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10. The invention according to any one of the preceding paragraphs wherein the
high
percentage is at least 65% of the total weight of the composition.
11. The invention according to any one of the preceding paragraphs wherein the
high
percentage is at least 70% of the total weight of the composition.
12. The invention according to any one of the preceding paragraphs wherein the
composition further comprises a leavening agent.
13. The invention according to any one of the preceding paragraphs wherein the
composition further comprises gluten. -
14. The invention according to any one of the preceding paragraphs wherein the
composition further comprises at least one enzyme.
15. The invention according to paragraph 14 wherein the enzyme is at least
xylanase.
16. The invention according to paragraph 15 wherein the xylanase is free of or
substantially free of endo-amylase and/or glucanase activity.
17. The invention according to any one of the preceding paragraphs wherein the
hydrocolloid is selected from the group consisting of carrageenan, starch,
pectin,
alginate, gelatine, locust bean gum (LBG), gellan, xanthan, carboxy methyl
cellulose
(CMC), guar gum, depolymerised guar, acacia gum, konjac gum, agar, tamarind,
tragacanth, beta-glucan, arabinoxylan, karaya, curdlam, chitosan and
combinations
thereof.
18. The invention according to any one of the preceding paragraphs wherein the
hydrocolloid is xanthan.
19. The invention according to any one of the preceding paragraphs wherein the
emulsifier is selected from the group consisting of distilled monoglycerides;
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monoglycerides; diglycerides; esters of mono- and diglycerides; polyglycerol
esters of
fatty acids; polyglycerol polyrincinoleate; propylene glycerol esters of fatty
acids;
sorbitan monostearates; sorbitan tristearates; sodium stearoyl lactylates;
calcium
stearoyl lactylates; lecithins; and diacetyl tartric acid esters of mono- and
diglycerides
and combinations thereof.
20. The invention according to any one of the preceding paragraphs wherein the
emulsifier is a monoglyceride.
21. The invention according to any one of the preceding paragraphs wherein the
composition has a pH greater than 4.
22. A bread made from flour, an emulsifier and/or an hydrocolloid, wherein a
high
percentage of the flour is rye flour.
23. A bread made from flour, an emulsifier and/or an hydrocolloid, wherein a
high
percentage of the flour is rye flour, wherein the bread is toasted.
24. A bread made from flour, an emulsifier and/or an hydrocolloid, wherein
about 90%
or more of the flour is rye flour.
25. A bread made from flour, an emulsifier and/or an hydrocolloid, wherein
about 90%
or more of the flour is rye, wherein the bread is toasted.
26. A bread made from flour, an emulsifier and/or an hydrocolloid, wherein
about
100% of the flour is rye flour.
27. A bread made from flour, an emulsifier and/or an hydrocolloid, wherein
about
100% of the flour is rye, wherein the bread is toasted.
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28. A bread according to any one of paragraphs 23 to 28 wherein the bread is
made
from rye flour, an emulsifier and/or an hydrocolloid, salt, yeast and water,
and
optionally sugar and/or gluten.
29. A bread according to any one of paragraphs 22 to 28 wherein the bread is
made
from rye flour, an emulsifier and/or an hydrocolloid, salt, yeast, water, and
gluten and
optionally sugar.
30. A composition substantially as described herein.
31. A process substantially as described herein.
32. A use substantially as described herein.
33. A bakery product substantially as described herein.
34. A baked product substantially as described herein.
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There now follows some preferred aspects of the present invention.
1. A dough comprising:
System (a); and
System (b);
wherein System (a) comprises:
(i) at least 80% (bakers' %) rye flour by weight of System (a) and
(ii) at least 5% (bakers' %) exogeneous gluten by weight of System
(a);
wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein if System (a)(ii) comprises from 5% (bakers' %) to 9% (bakers' %)
exogeneous gluten then the dough additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener;
wherein if System (a)(ii) comprises more than 9% (bakers' %) exogeneous
gluten then the dough optionally comprises System (c), wherein System (c)
comprises at least one gluten strengthener;
wherein the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives.
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2. A dough comprising:
System (a); and
System (b);
wherein System (a) comprises:
at least 80% (bakers' %) rye flour by weight of System (a) and
(ii) at least 5%
(bakers' %) exogeneous gluten by weight of System
(a);
wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein if System (a)(ii) comprises from 5% (bakers' %) to 9% (bakers' %)
exogeneous gluten then the dough additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener selected from an
emulsifier and/or an enzyme;
wherein if System (a)(ii) comprises more than 9% (bakers' %) exogeneous
gluten then the dough optionally comprises System (c), wherein System (c)
comprises at least one gluten strengthener;
wherein the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives.
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3. A dough comprising:
System (a); and
System (b);
wherein System (a) comprises:
(i) at least 80% (bakers' %) rye flour by weight of System
(a) and
(ii) at least 5% (bakers' %) exogeneous gluten by weight of System
(a);
wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein if System (a)(ii) comprises from 5% (bakers' %) to 9% (bakers' %)
exogeneous gluten then the dough additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener;
wherein if System (a)(ii) comprises more than 9% (bakers' %) exogeneous
gluten then the dough optionally comprises System (c), wherein System (c)
comprises at least one gluten strengthener;
wherein the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives;
wherein the gluten is vital gluten.
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4. A dough comprising:
System (a); and
System (b);
wherein System (a) comprises:
(i) at least 80% (bakers' %) rye flour by weight of System
(a) and
(ii) at least 5% (bakers' %) exogeneous gluten by weight of System
. (a);
wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein if System (a)(ii) comprises from 5% (bakers' %) to 9% (bakers' %)
exogeneous gluten then the dough additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener selected from an
emulsifier and/or an enzyme;
wherein if System (a)(ii) comprises more than 9% (bakers' %) exogeneous
gluten then the dough optionally comprises System (c), wherein System (c)
comprises at least one gluten strengthener.
wherein the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives;
wherein the gluten is vital gluten.
=
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5. A dough comprising:
System (a); and
System (b);
wherein System (a) comprises:
(i) at least 80% (bakers' %) rye flour by weight of System (a) and
(ii) at least 5% (bakers' %) exogeneous gluten by weight of System
(a);
wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein the dough additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener;
wherein the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives.
6. A dough comprising:
System (a); and
System (b);
wherein System (a) comprises:
(i) at least 80% (bakers' %) rye flour by weight of System (a) and
(ii) at least 5% (bakers' %) exogeneous gluten by weight of
System
(a);
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wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein the dough additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener selected from an
emulsifier and/or an enzyme;
wherein the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives.
7. A dough comprising:
System (a); and
System (b);
wherein System (a) comprises:
(i) at least 80% (bakers' %) rye flour by weight of System (a) and
(ii) at least 5% (bakers' %) exogeneous gluten by weight of System
(a);
wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein the dough additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener;
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wherein the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives;
wherein the gluten is vital gluten.
8. A dough comprising:
System (a); and
System (b);
wherein System (a) comprises:
(i) at least 80% (bakers' %) rye flour by weight of System (a) and
(ii) at least 5% (bakers' %) exogeneous gluten by weight of System
(a);
wherein the dough is at a pH from about pH 5 to about pH 7.5;
wherein System (b) comprises at least a leavening agent;
wherein the dough additionally comprises System (c);
wherein System (c) comprises at least one gluten strengthener selected from an
emulsifier and/or an enzyme;
wherein the dough additionally comprises System (d); wherein System (d)
comprises at least one or more dough additives;
wherein the gluten is vital gluten.
For any of these preferred aspects, preferably the leavening agent in System
(b) is at
least an exogeneous yeast.
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For any of these preferred aspects, preferably the gluten strengthener in
System (c) is at
least a lipase and/or at least a xylanase and/or at least a hemicellulase
and/or at least an
oxidative enzyme and/or at least an oxidising agent and/or an emulsifier (in
particular
DATEM).
