Note: Descriptions are shown in the official language in which they were submitted.
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STABLE, PACKAGED, REFRIGERATED DOUGH COMPOSITIONS
FIELD OF THE INVENTION
100011 The invention relates to refrigerator-stable, raw, yeast-containing
dough
compositions, refrigerated packaged products containing the dough, and related
methods.
BACKGROUND
100021 Packaged raw dough products can provide consumers with a convenient
way to enjoy fresh-baked dough products without the need to spend significant
time preparing the dough for baking. Typically, packaged raw dough products
are
either provided as refrigerated products or frozen products. Refrigerated raw
dough products generally rely on chemical leavening systems because such
leavening systems can be easily controlled to prevent over pressurizing the
packaging due to gas release from the dough during shelf life. Even so, many
refrigerated dough products are packaged in pressurized cans to prevent the
packaging from rupturing during shelf life. However, many consumers are
looking for alternatives to both chemically leavened dough and the typical
canned
dough formats.
SUMMARY
100031 Provided herein are packaged dough products. In some embodiments, a
packaged dough product provided herein includes a yeast-leavened raw dough
enclosed in a package. The dough can include 0.1% to 5% by weight yeast (e.g.,
Mal- yeast), and can have an apparent viscosity of 1000 to about 2000
Brabender
Units (BU) and a stable density of no less than 0.950 g/cc to no more than
1.14
g/cc at refrigeration temperatures. A packaged dough product provided herein
can
additionally have at least one of, or any combination of: a) a flour component
in
the dough that includes a composite flour in an amount of from about 10% to
about 50% by weight of the flour component, the composite flour including at
least 95% isolated starch; b) an oil content in the dough of about 2% to about
6%
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by weight of the dough; or c) gas in a headspace in the package including at
least
50% inert gas.
[0004] In some embodiments, a packaged dough product can include a yeast-
leavened raw dough enclosed in a package, the dough including 0.1% to 5% by
weight yeast (e.g., Mal- yeast), and having an apparent viscosity of 1000 to
about
2000 Brabender Units (BU) and a stable density of no less than 0.950 g/cc to
no
more than 1.14 g/cc for at least 14 days at refrigeration temperatures. A raw
dough can include at least two of any combination of: a) a flour content in
the
dough that includes a composite flour in an amount of from about 10% to about
50% by weight of the flour content, the composite flour including at least 95%
isolated starch; b) an oil content in the dough of about 2% to about 6% by
weight
of the dough; or c) gas in a headspace in the package including at least 50%
inert
gas.
[0005] In some embodiments, an isolated starch in a composite flour can
include
from 30% to 70% isolated potato starch. In some embodiments, a composite flour
can include a protein concentrate or proteidisolate.
[0006] In some embodiments, a flour component can have an amylase activity
of
36 Beta amyl-3 U/g of the flour component or less. In some embodiments, a
flour
component can have a starch content that contains less than 5% damaged starch
by weight of the starch content.
[0007] In some embodiments, a dough can include an ethanol ingredient in an
amount of about 0.8% to about 1.4% by weight of the dough.
[0008] In some embodiments, a package can be non-pressurized. In some
embodiments, a package can be vented. In some embodiments, a package can be a
pouch.
[0009] In some embodiments, a packaged dough product can have a headspace
gas that contains essentially all inert gas.
[0010] In some embodiments, a packaged dough product can have a shelf life
at
refrigerated temperatures of at least 30 days. In some embodiments, the
density of
a dough in a packaged dough product can be stable over at least 30 days at
refrigeration temperatures.
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[00111 In some embodiments, a dough in a packaged dough product provided
herein can require no proofing time between removal from the package and
before
cooking.
[0012] In some embodiments, a dough in a packaged dough product can be
formed into a sheet from about 1 mm to about 6 mm thick. In some embodiments,
a dough in a packaged dough product can be sheet rolled into a scroll
configuration. In some embodiments, a dough in a packaged dough product can
be a raw pizza crust. In some embodiments, a dough in a packaged dough product
can be formed into a raw bread loaf.
[0013] Methods of making a packaged dough product are also provided herein.
In
some embodiments, a method of making a packaged dough product includes
combining dough ingredients to make a raw dough, shaping the raw dough into
pieces, and packaging the shaped raw dough pieces into a package to produce
the
packaged dough product, where the raw dough pieces have a stable density of no
less than 0.950 g/cc to no more than 1.14 g/cc at refrigeration temperatures.
A raw
dough used in a method of making a packaged dough product herein can include
0.1% to 5% by weight yeast (e.g., Mal- yeast) and can have an apparent
viscosity
of 1000 to about 2000 Brabender Units (BU), where the raw dough can include
one or both of: a) a flour component that includes a composite flour in an
amount
of from about 10% to about 50% by weight of the flour component, the composite
flour including at least 95% isolated starch; or an oil content of about 2% to
about
6% by weight of the raw dough.
[0014] In some embodiments, a method of making a packaged dough product can
include combining dough ingredients to make a raw dough, shaping the raw
dough into pieces, and packaging the shaped raw dough pieces into a package to
produce the packaged dough product, the raw dough pieces having a stable
density of no less than 0.950 g/cc to no more than 1.14 g/cc at refrigeration
temperatures. A raw dough used in a method of making a packaged dough
product herein can include 0.1% to 5% by weight yeast (e.g., Mal- yeast), and
can
have an apparent viscosity of 1000 to about 2000 Brabender Units (BU), where a
flour component in the raw dough can include a composite flour in an amount of
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from about 10% to about 50% by weight of the flour component, the composite
flour including at least 95% isolated starch, and/or the raw dough can include
an
oil content of about 2% to about 6% by weight of the raw dough.
[0015] In some embodiments, a method of making a packaged dough product can
include a step of replacing air in a headspace of the package with at least
50%
inert gas.
[0016] In some embodiments, a method of making a packaged dough product,
the
method includes combining dough ingredients to make a raw dough, shaping the
raw dough into pieces, packaging the shaped raw dough into a package, and
replacing air in a headspace of the package with at least 50% inert gas to
produce
the packaged dough product, the raw dough pieces having a stable density of no
less than 0.950 g/cc to no more than 1.14 g/cc at refrigeration temperatures.
A raw
dough used in a method of making a packaged dough product herein can include
0.1% to 5% by weight yeast (e.g., Mal- yeast) and can have an apparent
viscosity
of 1000 to about 2000 Brabender Units (BU).
[0017] In some embodiments, a method of making a packaged dough product
includes combining dough ingredients to make a raw dough, shaping the raw
dough into pieces, packaging the shaped raw dough pieces into a package, and
replacing air in a headspace of the package with at least 50% inert gas to
produce
the packaged dough product, the raw dough pieces having a stable density of no
less than 0.950 g/cc to no more than 1.14 g,/cc at refrigeration temperatures.
A raw
dough used in a method of making a packaged dough product herein can include
0.1% to 5% by weight yeast (e.g., Mal- yeast), and can have an apparent
viscosity
of 1000 to about 2000 Brabender Units (BU), where the dough has one or both
of:
a) a flour component that includes a composite flour in an amount of from
about
10% to about 50% by weight of the flour component, the composite flour
including at least 95% isolated starch; orb) an oil content of about 2% to
about
6% by weight of the raw dough.
[0018] In any method of making a packaged dough product, shaped raw dough
pieces can proof in the package.
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[0019] In some embodiments of a method provided herein, an isolated starch
in a
composite flour includes from 30% to 70% isolated potato starch. In some
embodiments of a method provided herein, a composite flour can include a
protein concentrate or protein isolate.
[0020] In some embodiments of a method provided herein, a flour component
in a
raw dough can have an amylase activity of 36 Beta amyl-3 U/g of the flour
component or less. In some embodiments of a method provided herein, a flour
component in a raw dough can have a starch content that contains less than 5%
damaged starch by weight of the starch content.
[0021] In some embodiments of a method provided herein, a raw dough can
include an ethanol ingredient in an amount of about 0.8% to about 1.4% by
weight of the raw dough.
[0022] In some embodiments of a method provided herein, a package can be
non-
pressurized. In some embodiments of a method provided herein, a package can be
vented. In some embodiments of a method provided herein, a package can have a
headspace that has essentially all inert gas. In some embodiments of a method
provided herein, a package can be a pouch.
[0023] In some embodiments of a method provided herein, a packaged dough
product can have a shelf life at refrigerated temperatures of at least 30
days. In
some embodiments of a method provided herein, a packaged dough product can
have a stable density over at least 30 days at refrigeration temperatures.
[0024] In some embodiments of a method provided herein, a raw dough can
require no proofing time between removal from the package and before cooking.
[0025] In some embodiments of a method provided herein, a raw dough can be
formed into a sheet from about 1 mm to about 6 mm thick. In some embodiments
of a method provided herein, a raw dough sheet can be rolled into a scroll
configuration. In some embodiments of a method provided herein, a raw dough
can be a pizza crust. In some embodiments of a method provided herein, a raw
dough can be a bread loaf.
BRIEF DESCRIPTION OF THE FIGURES
[0026] Figure 1 is a graph of amylase activity for a range of dough
compositions.
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[0027] Figure 2 is a plot of experimental data relating to carbon dioxide
release
over a range of dough compositions.
[0028] Figure 3 is a plot of experimental data relating to carbon dioxide
release
rate over a range of dough compositions.
[0029] Figure 4 is a plot of experimental data relating to carbon dioxide
release
rate over a range of dough compositions.
[0030] Figure 5 is a plot of experimental data relating to specific volume
of a
dough over a range of carbon dioxide release rates.
[0031] Figure 6 is a plot of experimental data relating to dough specific
volume
versus time for doughs having different carbon dioxide release rates.
[0032] Figure 7 is a plot of experimental data relating to dough specific
volume
versus carbon dioxide release rate, over different refrigeration periods.
[0033] Figure 8 is a plot of experimental data relating to carbon dioxide
release
rate over a range of dough compositions, and MAL- yeast content.
[0034] Figure 9 is a plot of experimental data relating to dough density
over time,
comparing the effects of flour components and gluten content.
[0035] Figure 10 is a plot of experimental data relating to carbon dioxide
release
over time, comparing the effects of flour components and gluten content.
[0036] Figure 11 is a plot of experimental data relating dough density over
time,
comparing the effects of oil content and gluten content.
[0037] Figure 12 is a plot of experimental data relating dough density over
time,
comparing the effects of oil content and gluten content.
[0038] Figure 13 is a plot of experimental data relating to dough density
over
time, comparing the effects of headspace flush composition.
[0039] Figure 14 is a plot of experimental data relating carbon dioxide
headspace
over time, comparing the effects of headspace flush composition.
[0040] Figure 15 shows packaged dough compositions that have been stored in
rolled form at refrigerated conditions, then unrolled. 15A shows a dough that
had
a headspace flushed with 100% nitrogen. 15B shows a dough that had a
headspace flushed with 50% nitrogen and 50% carbon dioxide. 15C shows a
dough that had a headspace flushed with 100% carbon dioxide.
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100411 Figure 16 Figure shows concentrations of carbon dioxide in
headspaces of
a packaged dough products, some containing ethanol.
DETAILED DESCRIPTION
100421 While yeast leavened doughs can be found as frozen products, these
products generally require thawing time and leavening time before baking. This
additional preparation time before using a raw dough is inconvenient to
consumers that desire time saving products that meet their needs. Providing
yeast
leavened dough in a refrigerator-stable format, however, has proven difficult
because yeast activity is not entirely halted at refrigeration temperatures.
As a
result, unwanted dough expansion and/or gas release into the packaging during
storage can result in distortion of the packaging, such as bulging or
rupturing of
the packaging. Distortion can not only cause consumers to find the product
undesirable, and reduce the aesthetics of the package, but ruptures in the
packaging can cause contamination of raw dough, which can cause illness upon
consumption of products made with the dough. Even rigid and/or pressurized
packaging can be susceptible to distortion if there is sufficient yeast
activity.
Previous attempts at making a refrigerator stable, yeast-leavened dough were
either unsuccessful, or had a limited shelf life (e.g., less than 20 days).
100431 To meet the desires of consumers who would prefer convenient dough
options without the use of chemical leavening systems, it was discovered that
a
combination of dough characteristics could provide a packaged, yeast-leavened
dough that is stable at refrigeration temperatures (e.g., above freezing to
about 10
C) for extended periods (e.g., at least 14 days, at least 30 days, or least 45
days)
without significant packaging distortion. A packaged dough provided herein is
formulated to maintain a stable density at refrigeration temperatures. The
inventive products described herein surprisingly achieve extended,
refrigerated
shelf life stability, even in a flexible packaging, without compromising the
expected characteristics of a cooked dough-based product made from a fresh,
yeast-leavened dough.
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[0044] As used herein, the term "stable density" refers to a density that
does not
vary more than 20% over at least 14 days (e.g., at least 20 days, at least 30
days,
or at least 45 days) following packaging. For example, a stable density can
range
from 0.900 g/cc to 1.10 g/cc over the 14 days. A stable density can
alternatively
be described as having a particular density 10% over the designated time
frame.
Under this alternative description, the example above with a stable density
can be
described as having a density of 1.00 g/cc 10%. It is to be understood that
the
level of density variation can be less than 20% (e.g., less than 15%, less
than 10%,
or less than 5%), or alternatively, a particular density less than 10%
(e.g., less
than 5%, or 3%), and still be considered a stable density.
[0045] In some embodiments, a stable density can be further limited to a
particular density range, which the density does not exceed during the
designated
time frame. For example, a stable density can be limited to a range of no less
than
0.950 g/cc to no more than 1.14 g/cc over the designated time. In this
example, a
stable density is a density that both does not vary more than 20% over the
designated time frame and does not go below 0.950 g/cc nor go above 1.14 g/cc
over the designated time frame. In another example, a stable density can be
limited to a range of no less than 1.00 g/cc to no more than 1.12 g/cc over
the
designated time. In this example, a stable density is a density that both does
not
vary more than 20% over the designated time frame and does not go below 1.00
g/cc nor go above 1.12 g/cc over the designated time frame.
[0046] In some embodiments, a stable density in a dough can also be
observed as
a stable dough volume. As used herein, the term "stable dough volume" refers
to a
dough that does not vary more than 20% (e.g., no more than 10%, or no more
than
5%) over at least 14 days (e.g., at least 20 days, at least 30 days, or at
least 45
days). For example, a stable dough volume can increase by no more than 20% or
decrease no more than 20% over at least 14 days at refrigeration temperatures.
In
some embodiments, a dough provided herein can expand no more than 0.2 cubic
centimeters/gram dough (e.g., no more than 0.1 or 0.05 cubic centimeters/gram
dough) over at least 14 days at refrigeration temperatures following
packaging.
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100471 In order to maintain a stable density, a packaged dough provided
herein
can have a relatively high apparent viscosity, along with one or more
additional
features, selected from: 1) a substrate-limited yeast (e.g., a maltose
negative
yeast), 2) a flour content in the dough that includes a composite flour; 3) an
oil
content in the dough; and 4) gas in a headspace in the packaging that includes
an
inert gas. Without being bound to theory, it is believed that a relatively
high
apparent viscosity in a packaged dough provided herein can help provide a
dough
structure resistant to volume expansion, and therefore support a stable
density
under controlled carbon dioxide content in the dough. Carbon dioxide content
in
dough can be controlled (e.g., by controlling the rate of production by yeast,
by
controlling the amount produced by yeast, by controlling the amount released
from the dough, or controlling the amount absorbed by the dough) using one or
more of the additional features. It is to be understood that features useful
for
controlling carbon dioxide content in dough can be used individually to arrive
at a
packaged dough having a stable density at refrigeration temperatures, or can
be
used in any combination.
[0048] Apparent Viscosity
[0049] Apparent viscosity is a measure of dough rheology, measured in
Brabender Units (BU), as measured using an Extensiometer. Standard tests for
measuring apparent viscosity of a dough are known, including test procedure 54-
22.01, approved by the American Association of Cereal Chemists, Inc. A dough
provided herein can have an apparent viscosity of at least 1000 BU (e.g., at
least
1100 BU, or at least 1200 BU, or from 1000 BU to 2000 BU, or from 1200 BU to
1800 BU, or about 1300 BU to about 1600 BU). A dough having a higher
apparent viscosity is relatively more stiff and less flexible compared to a
dough
having a lower apparent viscosity. It has been discovered that a dough
composition that has an apparent viscosity of a least 1000 BU can exhibit a
reduced amount of expansion in volume during refrigerated storage in package
that is at about atmospheric pressure.
[0050] Surprisingly, even though a dough provided herein has a relatively
high
apparent viscosity as compared to typical doughs, which range from about 800
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BU to 1000 BU regardless of leavening type, a dough provided herein does not
produce a cooked (e.g., baked or fried) dough product that is unpleasantly
hard or
stiff.
100511 In some cases, an apparent viscosity of greater than about 1600 BU
can
begin to negatively affect the handleability of a dough and/or texture of a
cooked
dough product. While some changes in handleability and/or cooked dough
product may be acceptable, it is preferred that the apparent viscosity of a
dough
be no more than 1600. In some embodiments, apparent viscosity of a dough
provided herein remains stable (e.g., within 10%, or within 5%) throughout
a
shelf life at refrigerated temperatures for at least 14 days (e.g., at least
20 days, at
least 30 days, or at least 45 days).
100521 Aside from apparent viscosity, a dough provided herein can have
additional mechanical properties, such as extensibility and maximum resistance
during extension (Rmax), that are measured using an Extensiometer. In some
embodiments, a dough provided herein can have an extensibility of at least 60
millimeters (mm) (e.g., at least 70, 80, or 90 mm). As used in the bread and
dough
arts, extensibility of a dough is a measure, in length, of how far a dough
sample can
be extended before breaking. In some embodiments, a dough provided herein can
have an Rmax of at least 1000 Brabender Units (e.g., at least 1100 BU). As
used in
the dough and bread arts, maximum resistance (Rmax) during extension is a
measure
of force that can be presented in Brabender Units (BU), or Newton-meters.
Standard
tests for measuring Rmax and extensibility of a dough are known, including
test
procedure 54-10.01, approved by the American Association of Cereal Chemists,
Inc.
100531 Apparent viscosity of a dough provided herein can be adjusted by
adjusting ingredient content, including for example, the amount of water in
the
dough; the amounts and types of flour, starch, and protein (e.g., gluten) in
the
dough; the relative amount of flour (including all sources of protein and
starch) to
water in the dough, i.e., the flour to water ratio; the presence of other
ingredients
that may affect the behavior of water (e.g., ethanol); the presence of salt
(e.g.,
sodium chloride); the amount, types, and level of development of proteins in
the
dough; etc. Generally, lower water content and/or water activity, higher flour
to
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water ratios, higher protein content, and greater protein development (e.g.,
gluten
matrix) contribute to a higher apparent viscosity, while the converse
contribute to
a lower apparent viscosity.
[0054] In some embodiments, the amount of water in a dough provided herein
can range from about 30 to 40 weight percent (e.g., from 30 to 37 weight
percent,
or 31 to 35 weight percent) based on total weight dough composition. Amounts
of
water outside of these preferred ranges could also be useful in a dough of the
present description, depending, for example, on how other ingredients present
in
the dough affect the behavior of the water, and the types of protein or flour
present in the dough.
100551 In some embodiments, the amount of flour component in a dough
provided herein can range from about 30 to about 70 weight percent (e.g., from
about 40 to about 60 weight percent, or from about 45 to about 55 weight
percent)
based on total weight dough composition. A flour component in a dough provided
herein includes all sources of flour, protein, and starch.
100561 In some embodiments, a dough provided herein can be formulated to
have
a flour to water ratio ranging from about 1.55:1 to 2:1 (e.g., from 1.6:1 to
1.9:1, or
from about 1.7:1 to about 1.9:1). As used herein flour to water ratio refers
to the
ratio of the amount of flour component to the amount of water from all sources
(e.g., added water and moisture content of other dough ingredients, such as
eggs,
ice, milk, and the like).
100571 Yeast
100581 A dough provided herein is yeast-leavened. As used herein, the term
.'yeast-leavened" refers to a dough composition that is leavened substantially
or
primarily by the production of metabolites of yeast, including carbon dioxide
produced by the yeast. The carbon dioxide can be produced at any time that the
yeast resides in the dough composition, such as during preparation of the
dough,
during storage of the dough (e.g., during refrigerated storage in a package),
after
removal of the dough from a package, or just prior to or during cooking the
dough. A dough will be referred to as "yeast-leavened" if it meets this
criterion,
regardless of the state of leavening or expansion of the dough. A dough
provided
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herein does not require and can preferably exclude the presence of chemical
leaveners that produce carbon dioxide before or during cooking.
100591 As used herein, a yeast-leavened dough includes yeast in an amount
sufficient to impart flavor and/or aroma qualities expected in yeast-leavened
dough-based foods, including flavors imparted by compounds such as carbonyls,
aldehydes, and ketones. Suitable amounts of yeast in a dough provided herein
can
range from about 0.05% to about 5% (e.g., from about 0.1% to about 2.5%, or
from about 0.5% to about 1.5%) on a dry, active yeast basis, by weight of the
dough.
100601 Any yeast suitable for making leavened dough can be used in a dough
provided herein, particularly if other dough and/or packaging features are
included to control carbon dioxide production, though a substrate-limited
yeast is
preferred. As used herein, the term "substrate-limited yeast" refers to yeast
that
are incapable of metabolizing certain types of sugars, such as maltose. One
such
strain of yeast is incapable of metabolizing maltose, and is referred to as
"maltose-negative" (or MAL-) yeast.
100611 Maltose-negative yeasts are known and commercially available.
Referred
to as "maltose-negative," or just "MAL-," these yeasts do not metabolize
maltose,
but are usually capable of metabolizing other types of sugars such as
fructosans
(e.g., sucrose, dextrose, and fructose). A number of yeasts that ferment
sucrose
but not maltose ("SUC+/MAL-") are commercially available, including the
following strains of Saccharomyces cerevisiae: DZ (CBS 109.90), DS 10638
(CBS 110.90), DS 16887 (CBS 111.90) V 79 (CBS 7045), and V 372 (CBS
7437). An example of MAL- yeast is a yeast product available commercially
under the trade name FLEXFERM, from Lallemand, Inc. See also United States
Patent Numbers 5,385,742; 5,571,544; 5,540,940; 5,744,330, the entirety of
each
of these being incorporated herein by reference.
100621 A substrate-limited yeast can be effective to control the amount of
carbon
dioxide produced in a dough composition, especially during preparation or
during
storage, because the yeast is less active due to its inability to metabolize
certain
types of sugars. In some embodiments, a substrate-limited yeast can be
included
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in a dough formulation along with a controlled amount and/or types of sugars
(e.g., by limiting the amount of damaged starch and/or limiting the amount of
carbohydrase enzymes, such as amylase, in dough) to further reduce or limit
the
amount of carbon dioxide that is produced by the yeast. For example, sugar
availability to yeast in dough can be controlled by use of a composite flour
in a
flour component and/or by use of a flour component with reduced damaged starch
content and/or carbohydrase enzyme activity.
100631 The yeast can be part of a yeast composition that may be in any one
of
various forms, such as cream yeast, compressed yeast or fresh yeast, and dried
yeast, these forms having different amounts of water present. Dried yeast is
available as active dry yeast (ADY) and as instant dry yeast (IDY) having
moisture contents of 6 to 8 percent and 3 to 6 percent, respectively.
100641 Flour Component
100651 A flour component suitable for use in a dough provided herein can
include
any flour. Various types and variations of flour are known, for example based
on
being prepared from different parts of a flour kernel (e.g., wheat kernel), or
based
on different types of flour kernels (e.g., wheat kernels) used to produce a
flour
(which can have an effect on the relative amounts of different components
present
in the flour, e.g., starch and protein). A wheat kernel contains portions
referred to
as an endosperm, germ, and bran. The endosperm contains high levels of protein
and starch. The wheat germ is rich in protein, fat, and vitamins. And the bran
portion is high in fiber. White flour is made from just the endosperm
predominantly (optionally with some minor or incidental inclusion of other
components). Brown flour additionally includes germ and bran. Whole grain
flour is prepared from the entire grain, including the bran, endosperm, and
germ.
100661 A major, generally primary, constituent of flour is starch. The term
"starch" is used in the present description in a manner consistent with its
well
understood and conventional meaning in the chemical and food arts. Consistent
therewith, starch is a nutrient carbohydrate, e.g. of glucose (C6H1005)11,
that is
found in and can be separated, in concentrated form, from biomass such as
seeds,
fruits, tubers, roots, and stem pith, of plants, notably in corn, potatoes,
wheat,
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tapioca, legumes, and rice. Starch is a collection of polymeric carbohydrate
molecules including a form referred to as amylose, which is a straight-chain
polymer, and another form referred to as amylopectin, which is a branched-
chain
polymer molecule. Starch molecules are predominantly in the form of -
particles"
or -granules" of tightly packed collections of the starch molecules, but lower
molecular weight fragments may (i.e., "damaged starch") be also present in a
flour, separate from the starch granules. In some embodiments, the amount of
damaged starch in a flour can be less than 5% (e.g., less than 3%, less than
2%, or
less than 1%) based on the total amount of starch in the flour.
100671 Flour for use in flour component of a dough as described can be any
conventional flour (e.g., hard winter wheat flour, soft spring wheat flour,
oat
flour, and the like, or blends thereof), an analog thereof, or any flour
having a
composition that is consistent with the present description, such as a heat-
treated
flour or "fancy patent flour" adapted to contain relatively low amounts of
active
enzyme, damaged starch, or both. Examples include commercially available
wheat flours such as those referred to as "all-purpose" flour ("plain" flour),
"bread" flour ("strong" flour), whole wheat flour, and the like. Such a flour
can
include major amounts of starch and protein, and lesser amounts of fat, sugar,
vitamins, minerals, and moisture. Typical ranges of certain flour components
can
be: from 65 to 75 weight percent starch; from about 8 to 15 weight percent
protein
(e.g., gluten); less than 2 weight percent fat; and small amounts of sugar,
fiber,
enzymes, vitamins, and minerals.
100681 In some embodiments, a flour component can include a composite
flour.
As used herein, a "composite flour" includes an isolated starch and,
optionally, a
protein concentrate or protein isolate. An isolated starch in a composite
flour
includes a high concentration of starch, e.g., at least 70, 80, 90, 95, 98, or
99
weight percent starch based on total weight solids in the starch ingredient.
An
isolated starch can be mostly in granule form but can also include a low or
minor
amount of damaged starch, e.g., less than 5, 3, 2, or 1 weight percent damaged
starch based on total weight of starch isolated starch. Isolated starch can be
derived from any plant or other starch source, such as from wheat, corn,
potato,
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rice, tapioca, oat, barley, millet, bananas, sorghum, sweet potatoes, rye, as
well as
other cereals, legumes, and vegetables, or combinations thereof. A composite
flour can include an isolated starch in an amount of at least 60% (e.g., at
least
70%, at least 90%, or at least 95%) by weight of the composite flour.
[0069] In some embodiments, a starch included in a composite flour includes
a
potato starch in an amount of about 30% to about 70% (e.g., from about 40% to
about 60%, or about 50%) of the starch content in the composite flour, with
the
remaining starch being a non-potato starch (e.g., wheat starch, corn starch,
tapioca
starch, and the like). Such a combination of potato starch and non-potato
starch
can provide desired handling and aesthetic characteristics to a dough. For
example, potato starch can reduce stickiness of a dough, while non-potato
starch
can reduce visible cracking on the surface of the dough.
[0070] Isolated starch in a composite flour can help maintain a stable
density in a
dough. Isolated starch in a composite flour can also help slow the rate of
carbon
dioxide release from a dough. Without being bound by theory, it is believed
that
isolated starch reduces the availability of sugars available to yeast in a
dough, and
thus slow carbon dioxide production by the yeast, by substituting part, or
all, of
the starch in a flour component with mostly undamaged starch (e.g., less than
5%,
or less than 3%, or less than 1% damaged starch by weight of the starch
content in
the isolated starch).
[0071] A concentrated or isolated protein in a composite flour includes a
high
concentration of protein, e.g., at least 70, 80, 90, 95, 98, or 99 weight
percent
protein based on total weight solids in the concentrated or isolated protein.
The
concentrated or isolated protein may be derived from any plant or other
protein
source, such as from dairy (e.g., whey), soy, wheat (e.g., vital wheat
gluten), fish,
eggs, poultry, or legume, grain, or animal sources. Protein content in a
composite
flour can be 30% or less (e.g., less than 20%, less than 10%, or less than 5%)
of
the composite flour.
[0072] Although a concentrated or isolated protein need not be included in
a
composite flour, it can be used to simulate protein content in flour, or to
provide a
desired protein content in a packaged dough. In some embodiments, a
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concentrated or isolated protein can help produce a desired dough
functionality.
For example, a vital wheat gluten can be included in a composite flour to
provide
functionality (e.g., texture, viscosity, extensibility) normally provided by
gluten in
a wheat flour. In addition, protein in a composite flour can help stabilize
density
over time. For example, inclusion of vital wheat gluten in a composite flour
can
increase carbon dioxide release from a dough (see, Figure 10), and thus
increase
density during storage (see, Figure 9), so the amount of protein in a
composite
flour can be adjusted to achieve a stable density.
100731 Up to the entirety (i.e., up to 100%) of a flour component can be a
composite flour. However, where included in a flour component, a more
preferred
amount of composite flour is from about 15% to about 50% (e.g., from about 20%
to about 30%, or about 25%) of the flour component. In some embodiments, a
flour component contains no composite flour.
100741 In some embodiments, a flour, composite flour, and/or flour
component
can exhibit a reduced level of active amylase enzyme (e.g., have a beta
amylase
activity of not greater than 36 Beta amyl-3 U/g, not greater than 28 Beta amyl-
3
U/g, or not greater than 19 Beta amyl-3 U/g). A reduced level of active
amylase
enzyme can be measured or quantified by known methods, e.g., assay methods
(tested at room temperature), examples of which are well known or commercially
available. For example, a level of active amylase enzymes of a dough, flour,
flour
component, protein ingredient, starch ingredient, etc., can be measured or
quantified by known methods, such as assay methods, one commercially available
example being the beta-Amylase (Betamylt Method; K-BETA3) Procedure for
ChemWell0 Auto Analyser, as described at
https://secure.megazyme.com/files/Data_Booklets/K-BETA3_D-CHEMT.pdf. In
example embodiments, a dough as described can have a beta amylase activity,
(measured within 2 hours after the final step of preparing the dough, and at
room
temperature, e.g., 70 degrees Fahrenheit) of not greater than 19 Beta amyl-3
Units
per gram (U/g), e.g., not greater than 15 Beta amyl-3 U/g, or not greater than
10
Beta amyl-3 U/g. Examples of flour that is prepared to contain a relatively
low
amount of active enzyme are described in United States Patent Number
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7,258,888; and in United States Patent Publication Number 2007/0259091, the
entireties of each of these documents being incorporated herein by reference.
100751 As illustrated, in Figure 1, amylase activity of a dough can be
adjusted by
the inclusion of a composite flour in the flour component. Amylase activity in
a
dough containing hard red winter wheat flour (HRW) can be reduced with
increasing amounts of composite flour. Example doughs of the graph of Figure 1
(shown with light shading) also exhibited particularly useful shelf life
stability,
e.g., the doughs produced a sufficiently low level of carbon dioxide to allow
for
the dough to be stored at a refrigerated condition (optionally in a package)
without exhibiting an undesired change (increase) in dough volume, or an
undesirably high amount of carbon dioxide production, as described herein.
Doughs that contain a flour component having less than 20 or 25 weight percent
composite flour can also be useful in a dough product as described, for
example
when used with other features of a dough composition or dough product that
allow for controlled density of the dough during refrigerated storage, e.g.,
substrate-limited yeast, a reduced amount of damaged starch in flour,
mechanical
properties (apparent viscosity, Rmax, extensibility) of the dough, controlled
atmosphere in a package headspace, or both.
100761 Oil Content
100771 In some embodiments, an oil can be included in a dough provided
herein.
As used herein, the term "oil" refers to an edible fat that is liquid at room
temperature. Suitable oils for inclusion in a dough provided herein include
any
edible oil, such as soybean oil, olive oil, corn oil, canola oil, sunflower
oil, and
the like, or combinations thereof An oil content of from about 2% to about 6%
(e.g., from about 2% to about 4%) can contribute to a controlled release of
carbon
dioxide from a dough.
100781 Package Headspace
100791 In packaging that has a headspace between a dough and the package,
inclusion of an inert gas in the headspace can help control carbon dioxide
absorption into the dough from the headspace. In some embodiments, air in the
headspace can be replaced (i.e., flushed) with gas that contains at least 50%
(e.g.,
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at least 75%, or at least 98%) inert gas (e.g., nitrogen or argon) in order to
further
extend shelf life of the packaged dough product. During shelf life of a
packaged
dough product, inert gas content in a headspace of a package may be reduced as
carbon dioxide is released from the dough. Thus, even if a headspace had been
flushed with a gas that is essentially all (at least 99%) inert gas upon
packaging,
the headspace may contain less than 99% inert gas at 14 days following
packaging, and even less over the course of a shelf life greater than 14 days.
[0080] Other Carbon Dioxide Controlling Features
[0081] In some embodiments, ethanol included in a dough provided herein can
contribute to maintaining a stable density by reducing carbon dioxide release
from
the dough. In some embodiments, ethanol can also function by reducing the
amount of carbon dioxide production and/or the rate of carbon dioxide
production
of yeast in a dough. Ethanol can be included in a dough in an amount of from
about 0.7 to about 1.1 moles ethanol per liter water (e.g., from 0.75 to 1.0,
or from
0.8 to 0.95 moles ethanol per liter water) in the dough composition. In some
embodiments, ethanol can be included in an amount ranging from 0.8 to 1.4,
e.g.,
from 1.0 to 1.2 weight percent ethanol based on total weight of a dough
composition.
[0082] In addition, packaging characteristics described herein can also
contribute
to a yeast leavened dough that has a stable density at refrigeration
temperatures.
[0083] In some embodiments, a package used to package a dough can be non-
pressurized. As used herein, "non-pressurized" refers to a package that is not
positively pressurized (i.e., having pressure at, or less than, about
atmospheric
pressure). In some embodiments, a non-pressurized package can have a headspace
at about atmospheric pressure (e.g., 1 atm 0.2 atm (absolute)). A non-
pressurized package, particularly with a headspace that includes an inert gas,
can
contribute to control of carbon dioxide absorption by a dough in the package.
[0084] In some embodiments, a dough provided herein can be packaged in
packaging that includes a headspace at about atmospheric pressure (e.g., 1 atm
0.2 atm, or 1 atm 0.1 atm), where the packaging material is permeable or
vented
to provide gas communication between the inside of the packaging and the
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outside of the packaging. In some embodiments, a vent in a vented package can
be a pressure relief (e.g., one-way) valve that can release carbon dioxide or
other
gases generated by the dough within the package. Such a valve can be set to
allow
for an interior pressure that is about I atm (e.g., 13-17 psia). A vented or
permeable package material can help maintain a lower carbon dioxide level in
the
headspace than if the packaging was not permeable or vented, so less carbon
dioxide is available for absorption by a dough in the package.
[0085] In some embodiments, a dough provided herein can be packaged in a
package that is pressurized (i.e., headspace having a pressure of greater than
1
atm). A pressurized package can contribute to less carbon dioxide release from
a
dough the package, especially if the headspace contains at least a portion of
air
that is an inert gas.
[0086] Other Dough Ingredients
[0087] A dough provided herein can contain additional appropriate
ingredients, so
long as a stable density is maintained. Ingredients suitable for including in
a
dough composition include egg products (e.g., whole egg or egg components),
dairy products (e.g., milk, buttermilk, or other milk products or components,
such
as sugars, minerals or proteins, in liquid or dried form), solid fats,
flavorants
and/or colorants (e.g., salt, spices, extracts, or other natural or artificial
flavorants
and/or colorants), particulates (e.g., chocolate pieces, confections, nuts,
dried
fruits, and the like), emulsifiers (e.g., lecithin, mono-and diglycerides,
polyglycerol esters, and the like), strengtheners (e.g., ascorbic acid),
preservatives, and conditioners.
[0088] In some embodiments, a dough provided herein excludes one or more
ingredients, or includes them in not more than insignificant amounts (e.g.,
less
than 1%, or less than 0.5%, or less than 0.1%) by weight of a dough.
Ingredients
that can be excluded, include, for example, emulsifiers, strengtheners,
conditioners, artificial colorants, or artificial flavorants.
[0089] Other Packaged Dough Product Features
[0090] A dough provided herein can be portioned and/or shaped into pieces
prior
to packaging. Pieces can be shaped into any suitable shape, such as a sheet or
a
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loaf. For example, a dough can be shaped into a standard bread loaf, or mini
loaves before packaging.
[0091] In another example, sheet of dough can be formed to be from about 1
mm
to about 6 mm thick (e.g., from about 1.5 mm to about 5 mm thick) and shaped
as
desired (e.g., into a pizza crust or a dough strip that can be cooked as-is or
rolled
into, e.g., a cinnamon roll). In some embodiments, a dough can be flattened
into a
sheet on a flexible substrate (e.g., parchment paper, a slip sheet, or a
polymeric
analog, or the like), the dough can be sheeted and then placed on a flexible
substrate before packaging. In some embodiments, a sheet of dough on a
flexible
substrate can be rolled up into a spirally-wound, or scroll-like
configuration,
before packaging.
[0092] In some embodiments, a flexible substrate suitable for use in a
packaged
dough product can be permeable to carbon dioxide or other gases that evolve
from
a packaged dough during refrigerated shelf life, which can help prevent the
formation of bubbles or separation of the dough from the substrate as gas
escapes
the dough. An example of a commercially available flexible substrate includes,
without limitation, 27# Bleached Silicone Genuine Vegetable Parchment (West
Carrollton Parchment & Converting, West Carrollton, Ohio). Other suitable
flexible substrates are known and commercially available.
[0093] Packages suitable for use in a packaged dough product provided
herein
can be any packaging suitable for refrigerated storage. Examples include
tubes,
pouches, boxes, and the like. Particularly suitable, are packages that include
at
least a portion of the exterior of the package that is a flexible polymeric
(non-
cardboard, non-metal) material, such as plastic tubes, polymeric chubs,
polymeric
sleeves, polymeric form-fill (e.g., thermoplastic) containers, polymeric
pouches,
and the like. In some embodiments, a package can be entirely flexible and
polymeric, without requiring any exterior portions that are metal or carboard.
In
some embodiments, a package can act as an oxygen barrier to promote shelf life
and freshness. Suitable polymeric materials for packaging include, without
limitation, polyesters (e.g., PET), nylons, polyolefins (e.g., polyethylene),
vinyls,
polyalcohols, and the like.
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[0094] In some embodiments, a package can be sized to accommodate dough
when inserted into the package (e.g., sized to fit a dough piece shaped as a
bread
loaf, or sized to fit a scroll-like sheet), and to contain a small amount of
headspace
(i.e., space within the volume of the package, but not used by the dough). A
useful
amount of headspace can be no more than 100% (e.g., up to about 50%, up to
about 40%, up to about 20%, or up to about 10%) the volume of the dough. In
some embodiments, a package is sized to leave no headspace.
100951 Methods
[0096] Methods of making a packaged dough product are provided herein. A
dough provided herein can be produced by combining dough ingredients
described above using standard equipment and methods. For example, a flour
component, water (as liquid water and/or ice), yeast, and optional
ingredients,
such as oil, salt, sugar, and the like, can be combined in a spiral mixer and
mixed
to produce a dough. In some embodiments, mixing can be done in more than one
stage. For example, a flour component, yeast, and water can be mixed, followed
by the addition of other ingredients and further mixing.
[0097] Following dough production, the dough can be shaped into pieces
using
standard equipment and methods. For example, a dough provided herein can be
directed through rollers to form a sheet, which can then be cut into
rectangles or
circles.
[0098] Shaped dough pieces can then be placed into the desired packaging,
and
the package sealed, with the exception of optional venting. In some
embodiments,
headspace in a package can be flushed with air containing inert gas. A
flushing
step can be performed by replacing regular air by displacement with air
containing inert gas, or can be performed by removing regular air (e.g., by
vacuum) then replacing it with air containing inert gas. In some embodiments,
a
package can be vacuum sealed, rather than leaving headspace. In some
embodiments, a package can be pressurized with air containing inert gas. In
embodiments where the package is pressurized, a rigid package is preferred to
prevent deformation of the package.
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[0099] In some embodiments, a dough can be rested or proofed prior to
packaging. However, it is preferred that at least some proofing occurs in the
package, or more preferably, most or substantially all proofing occurs in the
package.
[0100] In some embodiments, a dough can be frozen prior to packaging. A
frozen
dough can be easier to package than a fresh dough. However, a dough provided
herein can be readily packaged without freezing.
[0101] A packaged dough product can be frozen, or can remain refrigerated,
during transportation for sale. A packaged dough product provided herein can
have a shelf life of at least 14 days (e.g., at least 30 days, at least 45
days, or at
least 60 days) following packaging at refrigerated temperatures. However,
shelf
life can be extended by freezing a packaged dough product provided herein.
[0102] Methods of preparing and cooking a dough are also provided. A
packaged
dough product provided herein, after a period of refrigerated storage in the
package, can be removed from the package and cooked (e.g., baked or fried). A
dough provided herein can advantageously be removed from the package and
cooked directly, without requiring a resting or proofing step.
[0103] In some embodiments, where a packaged dough product is a sheet of
dough rolled into a scroll configuration, the dough can be unrolled prior to
cooking. In some embodiments, a dough sheet rolled with the inclusion of a
flexible substrate can be unrolled so that the sheet remains on top of the
flexible
substrate and the dough can be cooked while on top of the substrate.
[0104] In some embodiments, a dough provided herein can be shaped and/or
portioned by a consumer prior to cooking. For example, a dough provided herein
can be flattened, separated into smaller pieces, or otherwise shaped or
portioned
as desired by the consumer.
[0105] In some embodiments, additional ingredients can be added to a
packaged
dough product before or after cooking. For example, a consumer can top a raw
pizza dough with pizza toppings, such as a sauce and/or cheese prior to
cooking.
In another example, a consumer can add an icing to a dough after cooking.
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[0106] A packaged dough product provided herein can be cooked to produce a
cooked dough product having a volume that is from about 1.4 to about 2.2 times
that volume of the raw dough. In some embodiments, a cooked dough product
made from a packaged dough product provided herein can have a bake specific
volume ranging from about 1.5 to about 2.5 cubic centimeters per gram.
EXAMPLES
[0107] EXAMPLE 1, shows advantageous refrigerated storage properties and
reduced carbon dioxide production of a dough based on the use of a dough
formulation that contains one or more of substrate-limited yeast, reduced
carbohydrase enzyme activity in the dough composition, and a reduced amount of
damaged starch in the composition.
[0108] Effect of MAL- Yeast Concentration, Pre-fermentation Step, and
Percent
Composite Flour in Dough on CO2 Release Rate and Bake Performance.
[0109] This Example is designed to observe how different factors affect
carbon
dioxide production in a dough composition during refrigeration, namely, to
observe the effects of the following on carbon dioxide production: 1) the
concentration of MAL- yeast, 2) the use of a pre-fermentation step to exhaust
feimentable substrate sugars, and 3) the use of partial to complete
replacement of
a control flour with a composite flour (combination of isolated wheat starch
and
vital wheat gluten inherently low in amylase enzymes). The effects of these
factors on bake performance were also considered.
101101 Procedure, Materials and Methods:
101111 Assess various combinations of flour and composite flour, over a
range of
MAL- yeast concentrations, to determine leavening rate upon refrigeration (+/-
preferment step).
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Table 1. Design: 5x3x2 = 30 treatments
Composite % Mal- Yes/No
Treatment Flour (/o) Flour CYO yeast Preferment*
1 100 0 , 0.5 No
2 75 25 0.5 No
3 50 50 0.5 No
4 25 75 0.5 No
0 100 0.5 No
6 100 0 0.5 Yes
7 75 25 0.5 , Yes
8 50 50 0.5 Yes
9 , 25 75 0.5 Yes
0 100 0.5 Yes
_,.
11 100 0 1 No
,
12 75 25 1 No
13 50 50 1 No
14 25 75 1 No
0 100 1 No
16 100 0 1 Yes
17 75 25 1 Yes
18 50 50 1 Yes
¨
19 25 75 1 Yes
0 100 1 Yes
21 100 0 1.5 No
22 75 25 1.5 No
23 50 50 1.5 No
24 25 75 1.5 No
0 100 1.5 No
26 100 0 1.5 Yes
,
27 75 25 1.5 Yes
28 50 50 1.5 Yes
29 25 75 1.5 Yes
0 100 1.5 Yes
*Dough held at ambient for ¨20 hours prior to final shaping and freezing.
24
Table 2 - 0.5% Mal- Yeast (Treatments 1-10)
0
o
1-,
Batch gm 4000
T4/T9 T5/TIO cie
-a-,
50% Flour - 50% 25% Flour - 75% Composite
100% 75% Flour - 25%
Composite Flour 25% Flour - 75% (...)
o
Flour Composite Flour
Composite 4=.
(...)
Ingredient % , Grams % , Grams %
Grams % Grains % Grains
Cycle I
FLOUR, HARD WINTER, BL ENF 52.955 2118.2 39.841 1593.64
26.4775 1059.1 13.11375 524.55 0 0
HRW LE Flour 0 0 0 0 0
0 0 0 0
WATER (-32 F) 37.044 1481.76 37.306
1492.24 37.5655 1502.62 37.81825 1512.73 38.233 1529.32
OLIVE OIL 2 80 2 80 2
80 2 80 1.962 78.48
VITAL WHEAT GLUTEN 2 80 3.285 131.4 4.571
182.84 5.865 234.6 7.141 285.64 P
,.,
WHEAT STARCH 0 11.567 , 462.68
23.385 935.4 , 35.202 1408.08 46.769 1870.76 c,
,.,
.
c,
w
...3
u,
(A POTATO STARCH 4 160 4 160 4
160 4 , 160 3.923 156.92 , 1-
s,
MAL- YEAST thy 0.5 20 0.5 20 0.5
20 0.5 20 , 0.5 20 c,
1-
1
SAF Instant yeast 0 0 0 0 0
0 0 0 0 0 c,
1-
1
1-
GLUCOSE OXIDASE 0.001 , 0.04 0.001 0.04 0.001
0.04 , 0.001 0.04 0.001 0.04 , 1-
Cycle 2
,
SODIUM CHLORIDE 1.5 60 , 1.5 60 1.5
60 1.5 60 1.471 58.84
GRANULATED SUGAR 0 0 0 0 0 ,
0 0 0 0 0
DEXTROSE 0 0 0 0 0
0 0 0 0 0
TOTAL 100 4000 , 100 4000 100
4000 100 4000 100 4000
IV
4000 n
,-i
cp
w
=
-.1
=
.6.
c7,
u,
w
Table 3 - 1% Mal- Yeast (Treatments
11-20)
0
TI 1/116 112/117 T13/T18 114/119 T15/T20
t.)
75% Flour - 25%
50% Flour- 50% 25% Flour - 75% Composite 100% composite o
1-,
100% Flour Composite Flour
Composite Flour Flour co:
-a-,
Ingredient % Grams % Grams
% Grams % Grams % , Grams (....)
cA
4=.
Cycle 1
13.11375 524.55 0 0 t....)
. .
FLOUR, HARD WINTER, BL ENF 52.455 2098.2 39.341
1573.64 26.2275 1049.1 0 0 0
HRW LE Flour 0 0 0 0 0
0 _ 37.81825 1512.73 38.233 1529.32
WATER (-32 F) 37.044 1481.76 37.306
1492.24 37.5655 , 1502.62 2 80 1.962 , 78.48
OLIVE OIL 2 80 2 80 2 ,
80 5.865 234.6 7.141 285.64
VITAL WHEAT GLUTEN 2 80 3.285 131.4 4.571
182.84 34.702 1388.08 46.269 1850.76
WHEAT STARCH 0 , 11.567 462.68
23.135 925.4 , 4 160 3.923 156.92
P
POTATO STARCH 4 160 4 160 4
160 , 1 40 1 40 0
i,
0
MAL- YEAST dry 1 40 1 40 1 ,
40 0 0 0 0
0
ts.)
...3
cA
u,
SAF Instant yeast 0 0 0 0 0
0 0.001 0.04 0.001 0.04 1-
1.,
0
GLUCOSE OXIDASE 0.001 0.04 0.001 0.04 0.001
0.04 1-
0
1
0
Cycle 2
1.5 60 1.471 58.84 1-
,
.
1-
1-
SODIUM CHLORIDE 1.5 60 , 1.5 60 1.5
60 0 0 0 , 0
GRANULATED SUGAR 0 0 0 0 0
0 0 0 0 0
DEXTROSE 0 0 0 0 0
0 100 4000 100 4000
TOTAL _ 100 4000 100 4000 100
4000 4000
IV
n
,-i
cp
w
-.1
.6.
c7,
u,
w
Table 4 - 1.5% Mal- Yeast (Treatments
21-30) T21/T26 122/T27 T23/T28
T24/129 T25/T30 0
r=.)
75% Flour - 25%
50% Flour - 50% Composite 25% Flour - 75% Composite o
1-,
100% Flour Composite Flour Flour
100% composite pe
-a-,
Ingredient % , Grams % Grams %
Grams % Grams % Grams
(....)
cA
Cycle 1
4=.
(....)
FLOUR, HARD WINTER, BL ENF 51.955 2078.2 38.841
1553.64 25.9775 1039.1 13.11375 524.55 , 0 0
HRW LE Flour 0 0 0 0 0
0 0 0 0
WATER (-32 F) 37.044 1481.76 37.306
1492.24 37.5655 1502.62 , 37.81825 1512.73 , 38.233 1529.32
OLIVE OIL 2 80 2 80 2
80 2 80 , 1.962 78.48
VITAL WHEAT GLUTEN 2 , 80 3.285 131.4
4.571 182.84 5.865 234.6 7.141 285.64
WHEAT STARCH 0 11.567 462.68
22.885 915.4 34.202 , 1368.08 45.769 1830.76
POTATO STARCH 4 160 4 160 4
160 4 160 3.923 156.92 P
µ.,
MAL- YEAST dry 1.5 60 1.5 60 1.5
60 1.5 60 1.5 60 0
µ.,
0
...3
--.1 SAF Instant yeast 0 0 0 0 0 ,
0 , 0 0 0 0 1-
1.,
GLUCOSE OXIDASE 0.001 0.04 0.001 0.04
0.001 0.04 0.001 0.04 0.001 0.04 0
1-
0
1
Cycle 2
1-
. 1
1-
SODIUM CHLORIDE 1.5 60 1.5 60 , 1.5
60 1.5 60 1.471 58.84 GRANULATED SUGAR SUGAR 0 ,
0 0 0 0 0 , 0 0 0 0
DEXTROSE 0 0 0 0 0
0 0 0 0 _ 0
TOTAL 100.00 4000.00 100.00
4000.00 100.00 4000.00 100.00 4000.00 100.00 4000.00
IV
n
,-i
cp
w
=
-.1
=
.6.
c7,
u,
w
CA 03030751 2019-01-11
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[0112] Mixing (all treatments)
Equipment: Spiral mixer (L'art du Melange)
1) Add glucose oxidase to iced water (use strainer to keep
ice out of formula water)
2) Add (iced) water plus enzyme to mixing bowl
3) Add oil to water in mixing bowl
4) Add combined dry first stage ingredients to water/oil in
mixing bowl
5) Mix slow for 30 sec. and fast for 5 minutes
6) Add 2nd stage dry ingredients
7) Mix slow for 30 sec. and fast for 4 minutes.
[0113] Straight Dough Process (Treatments - 1,2, 3,4, 5, 11, 12, 13, 14,
15, 21, 22, 23,
24, 25)
1) Divided dough into 200 gram pieces and sheeted into oval/round shape using
a
rolling pin (final thickness ¨4-5 mm)
2) Placed sheeted pieces onto parchment paper (8-x12") and rolled into tight
rolled-cylinder format.
3) Placed rolled pieces onto trays and then into a blast freezer set at -29 F.
4) Removed samples from blast freezer after ¨1-2 hours and stored at -10 F
until
packaging step.
[0114] Dough Measurements post-mixing
= Placed duplicate 25 gm samples into Risograph sample jars and started
collecting gas evolution data (set to collect at 10 min. intervals). The
samples
were held at ambient temperature ¨70 F). The Risograph is an electronic
instrument that measures gas generated by fermenting dough or chemical
leavening; these are commercially sold by the National Division of TMCO,
Lincoln, NE, U.S.A. The instrument rapidly and accurately determines the
amount (e.g., in milliliters) of CO2 per minute evolved (rate) from a sample,
as well as the cumulative gas released.
= Measured dough water activity (aw) and pH.
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[01151 Preferment Process (Treatments -6, 7, 8, 9, 10, 16, 17, 18, 19, 20,
26, 27, 28,
29, 30)
1) Divided dough into 200 gm pieces and rolled into ball shape.
2) Placed rounded dough pieces onto parchment lined baking sheets and covered
with a plastic bag (placed 4 inverted cups onto the tray surface to prevent
the
dough from sticking to the bag upon expansion and taped bag end closed but not
airtight).
3) Allowed dough to rest at room temperature (70 F) overnight.
4) Sheeted (and degassed) the expanded dough to 4-5 mm thickness and prepared
samples for freezing as described in steps 2-4 above for the straight dough
process.
[0116] Packaging (FFS - Form Fill Seal, unvented package)
= Dough samples packaged frozen to prevent collapse of dough structure upon
vacuum/flush process.
= Machine: Multi Vac 540
= Pouch cavity dimensions: width 2.5625", Depth 2.5", Length 14.3125-
= Film (Curwood/Bemis)
= Formable cavity material - Curlon Grade 9531-AA
= Lid Stock - Curlam Grade 18334-K
= Flushed with 60% N2/40% CO2 gas
o Packages labeled, weighed, and initial volumes recorded (volumetric
displacement process) prior to being stored at 40 F.
[0117] Analysis
[0118] Dough - (Measurements taken immediately after final mixing step):
Aw, pH, and
Risograph gas evolution for duplicate 25 gm pieces for TI -T15. Data collected
every 10
minutes at ambient -70 F.
101191 Package - (days 0, 5, and 10): Package volume change (volumetric
displacement
method)
[0120] Product Evaluation - (measured at day 9, day 20, and day 30 after
placing dough
in package)
[0121] Dough:
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Ease of un-rolling (qualitative assessment), general observations.
Dough specific volume.
Dough height (3 measurements across pad).
After baking (425 F for 13 min. in Reel oven):
Bake height (3 measurements across crust)
Minolta L*, a*, b* color measurement
Photograph
Taste (qualitative assessment)
[0122] Results:
[0123] Out Gassing Rate
[0124] For each MAL- yeast concentration evaluated; plotted slope of linear
change in
package volume for pre-fermented and non-fermented sample sets vs. storage
time as a
function of the flour (control HRW) used in formula.
[0125] Observations: Outgassing rate is a positive linear function of the
percent control
flour present in the dough. Conversely, as the percent of composite flour
increases,
outgassing declines in a linear fashion. One can infer from these observations
that the
flour is providing additional substrate to the yeast by either i) Increasing
the
concentration of hydrolytic amylase enzyme present in the dough, by providing
damaged
starch for the amylases to convert into fermentable sugars, or both. At the
low MAL-
yeast concentration of 0.5%, there is little difference in gas release rate
between the non-
fermented and fermented sample sets. The pre-fermentation (PF) step with 0.5%
MAL-
yeast did not exhaust the fermentable substrate sugar in the dough. See Figure
2 (Plot 1:
0.5% MAL- Yeast Rate vs % Control HRW Flour).
[0126] Looking at Figure 3 (Plot 2: 1.0% MAL-Yeast Rate vs % Control HRW
Flour), at
1% MAL- yeast, a positive linear increase in outgassing rate is observed as
the amount of
control HRW flour in the "no pre-ferment" sample set increases (similar to the
0.5%
MAL- yeast results described earlier). Unlike the 0.5% MAL- results, however,
when the
1% MAL- yeast sample set was subjected to a pre-fermentation step, the CO2
release rate
did not increase, but rather remained fairly low, constant, and independent of
flour
composition. One can hypothesize that the observed low baseline CO2 release
rate in the
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pre-fen-nented samples is the result of the continued hydrolysis of starch
oligosaccharides
over storage time. Lastly, the observation that the pre-fermented CO2 release
rate
remains fairly low and consistent regardless of the flour composition
indicates that a
majority of the fermentable substrate is exhausted during the pre-ferment
step.
101271 Looking now at Figure 4 (Plot 3: 1.5% MAL- Yeast Rate vs % Control
HRW
Flour), at 1.5% MAL- yeast, a positive linear increase in out gassing rate is
observed as
the amount of flour increases in the "no pre-ferment" sample set (similar to
previous
results at 0.5 and 1% MAL- yeast). As was observed with the 1.0% MAL- yeast
results,
when the 1.5% MAL- yeast sample set was subjected to a pre-fermentation step,
the CO2
release rate remained constant and independent of flour composition. One can
hypothesize that the observed low baseline CO2 release rate in the pre-
fermented samples
is the result of the hydrolysis of starch oligosaccharides over time (see
earlier discussion).
Lastly, the observation that the pre-fermented CO2 release rate remains fairly
low and
consistent regardless of the flour composition indicates that a majority of
the femientable
substrate is exhausted during the pre-ferment step.
101281 Referring now to Figure 5 (Plot 4: Dough Specific Vol. as a Function
of CO2
Release Rate ¨ Day 9): After 9 days storage, a linear increase in dough
specific volume is
observed with increasing CO2 release rates. The relationship is independent of
the means
by which CO2 release rate was achieved. That is to say, regardless of various
combinations of %MAL- yeast and %control flour, comparable CO2 release rates
resulted in comparable dough specific volumes.
101291 Referring to Figure 6 (Plot 5: Effect of CO2 Evolution Rate of Dough
Specific
Volume vs Time): A sampling of CO2 evolution rates (cc CO2/gm/day at 40 F)
shows
three distinct dough specific volume profiles vs storage time (not all
treatments shown for
ease of comparison). At higher CO2 evolution rates (>0.1821 cc/gm/day) (i.e.,
0.1821,
0.2125, 0.267 cc/gm/day), a rapid increase in specific volume over the initial
10 days of
storage to >1.05 cc/gin is observed, followed by a decline to 0.96-1.02
between days 10
and 15. For CO2 evolution rates ranging from 0.1049-0.1617 cc/gm/day, one
observes a
more moderate increase in dough specific volume through day 15 followed by a
plateau/stabilization in dough specific volume ranging from 0.96-1.04 cc/gm
between
days 15 and 25. At the lowest CO2 evolution rates observed (0.0436 cc/gm/day),
one
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observes a more linear and less rapid increase in dough specific volume over
time, with
an end specific volume of 1.05 cc/gm. Generally speaking, the less rapid the
CO2
evolution rate, the less likely dough specific volumes will decline upon
reaching a
maximum specific volume value.
101301 Referring to Figure 7 (Plot 6: Dough Specific Volume vs. CO2 Release
Rate at 0-
25 days): At time=0 all dough densities are ¨comparable (no opportunity of out
gassing
as the dough is frozen prior to packaging). After 9 days, a positive linear
relationship is
observed between dough specific volume and CO2 evolution rate (see plot 6
also). At 15
days, peak in dough specific volume is observed followed by a decline, with
increasing
evolution rate (dough structure can't maintain expanded volume at higher CO2
evolution
rates >0.14 cc/gm). At 25 days, a steady specific volume is reached at ¨1
cc/gm across
all CO2 evolution rates (expanded dough is no longer capable of increase in
volume).
101311 Referring to Figure 8 (Plot 7: CO2 Release Rate vs. %Control Flour
at 0.5-1.5%
MAL- Yeast): Combining the no preferment CO2 release rates curves from plots 1-
3, and
the CO2 release rate area (below the dashed line) that results in
minimal/reduced dough
structure collapse, identifies MAL- yeast concentration and flour combinations
that are
highly desirable for stable refrigerated dough structure. Based on this plot
and other
observations described earlier, 0.5% MAL- yeast concentration provides the
highly
desirable result over a range of control HRW flour compositions (0-75% control
flour/100-25% composite flour) resulting in CO2 evolution rates < 0.12-0.13
cc/gm
associated more stable dough specific volumes. 1 % and 1.5% MAL- yeast
concentrations can provide desired results over reduced ranges of flour per
composite
flour.
[01321 Summary:
[0133] A pre-fermentation step of >20 hours at ambient temperatures, will
exhaust a
majority of the felmentable substrate that is generated in a dough by the
enzymatic
hydrolysis of damaged starch, during preparation. As a result, CO2 gas
evolution rate
upon refrigeration is relatively flat; the pre-fermented dough systems 1) can
outgas very
little over storage time, and 2) expand only slightly upon baking due to a
lack in gas
holding capacity and collapse of nucleated structure.
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101341 When no pre-fermentation step is performed, there is a positive and
linear
relationship between MAL- yeast concentration and CO2 release rate (more yeast
=
greater CO2 evolution rate). Moreover, for a given MAL- yeast concentration,
outgassing rate is a positive linear function of the amount of control HRW
flour (on a
percentage basis) present in the dough, relative to composite flour.
Conversely, as the
amount of composite flour (concentrated protein ingredient and concentrated
starch
ingredients, replacing an amount of the flour) increases, replacing a portion
of the flour,
outgassing declines in a linear fashion. The flour appears to be providing
additional
substrate to the yeast by either i) increasing the concentration of hydrolytic
amylase
enzyme present in the dough, or ii) providing more damaged starch for the
amylases to
convert into fermentable sugars.
101351 It appears that, while pre-fermentation provides for a stable
density and volume in
the package, the end product is not able to perform well during cooking. The
data for
samples that were not pre-fermented provides insight into the variables that
can be
controlled to maintain both stable density in the package and performance of
the product
in a non pre-fermented dough.
101361 EXAMPLE 2, shows advantageous refrigerated storage properties and
stable
density of dough compositions provided herein.
101371 Referring to Figures 9-12, sample doughs were prepared and packaged
similarly,
without composite flour (100% flour) or with 25% composite flour. In addition,
flour
components either contained either no added gluten, with any added composite
flour
being only isolated starch (0% gluten), or added gluten, with any added
composite flour
containing isolated starch plus vital wheat gluten. Finally, either 2% olive
oil or 4% olive
oil was included in the dough. As can be observed, samples that contained
composite
flour generally had a higher density at early timepoints than those with 100%
flour, and a
more stable density over time than the 100% flour samples. However, samples
with
100% flour were more stable where no additional gluten was added (see, Figure
9),
and/or 4% oil were stable and between 0.95 and 1.14 g/m1 in density over at
least 6
weeks (see, Figure 11). The addition of gluten generally decreased density and
increased
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CO2 release (see, Figures 9-12), while higher oil content increased density
(compare 2%
olive oil to 4% olive oil in Figures 11 and 12). Thus, it appears that gluten
and oil content
can be balanced to support a stable density over shelf life, even in a dough
that included
no composite flour.
[0138] Referring to Figures 13-15, sample doughs were prepared and packaged
similarly,
with differing headspace air compositions (100% CO2, 50% CO2/50% N2, or 100%
N2).
As can be seen in Figure 13, increasing CO2 concentrations in the headspace
reduced
overall density. Without being bound to theory, it is believed that CO2 in the
headspace
can be absorbed by the dough and contribute to a lower density. As can be seen
in Figure
14, while the packaged dough with the 100% CO2 headspace flush remained steady
at
100%, the amount of CO2 in the headspace in the N2 flushed and 50% N2/50% CO2
flush increased over time at a similar rate as CO2 was released from the
dough. Even at 5
weeks, the sample flushed with 100% N2 had less than 50% CO2 in the headspace.
At
about 55% to 60% CO2 in the headspace, the dough became more sticky, which can
make it more difficult to handle. This is more noticeable in dough sheets that
are rolled
up in a scroll like configuration since they are more likely to stick while
unrolling,
leading to damage to the dough (see, Figure 15). Figures 15A, 15B, and I5C
show the
effects of these headspaces on an unrolled dough. Figure 15A shows the
unrolled dough
from a packaged dough product having a 100 percent N2 flush, after 5 weeks
refrigerated
storage, unrolled with no damage. Figure 15B shows the unrolled dough from a
packaged dough product having a 50/50 N2/CO2 flush, after 5 weeks refrigerated
storage, with some amount of damage to the dough surface due to being
unrolled. Figure
15C shows the unrolled dough from a packaged dough product having a 100
percent CO2
flush, after 5 weeks refrigerated storage, with substantial damage to the
dough surface
upon being unrolled. This is less of a problem in dough in a loaf format,
which needs less
handling prior to baking.
[0139] Referring to Figure 16, sample doughs were prepared and packaged
similarly,
with and without ethanol. The control formula does not contain ethanol and the
test
formula contains ethanol (sold under the trade name "TOPNOTE"). Packaged dough
products were prepared with comparable dough compositions and comparable
packaging,
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with headspace, with and without ethanol. The samples that contain ethanol
have lower
concentrations of CO2 in the headspace when measured during refrigerated
storage, are
less fermented, have a smoother surface, and are easier to unroll (from a roll
of dough
and parchment) over time. Levels of ethanol in the doughs were tested at range
from 0,
1.5 and 2.0 % of the total weight of the dough composition.
[0140] Table 5, below, shows some suitable ranges of ingredients for a
dough provided
herein.
Table 5 - Formula Ranges
INGREDIENT IDEAL LOW HIGH
Flour 44 34 60
Water 33 22 44
Oil 2 to 4 0 6
Protein 3 to 4 0 5
Ethanol 1.5 0 2
Potato Starch 4 to 6 0 12
Non-Potato
Starch 4 to 6 0 12
Xanthan Gum 0.15 0 0.25
Yeast 0.5 0.25 1.5
Glucose Oxidase 0.001 0 0.002
Salt 1.5 0.5 2
Granulated
Sugar 2 0 6
