Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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Attorney Docket No. 7025WO
COMPOSITIONS USED TO MAKE DOUGH, AND RELATED METHODS
OF MAKING AND USING
Field of the Invention
The present invention relates to compositions having a preferment viscosity,
and related methods of making and using. In particular, the present invention
relates
to a chemical preferment composition having a preferment viscosity.
Background
Dough products can be prepared by combining ingredients including water,
flour, and a leavening system (e.g., yeast, chemical leavening agents,
combinations
of these, and the like), among others. The ingredients can be combined and
processed together to achieve desired properties in a raw or cooked dough,
such as
desired taste, aroma, texture, color, storage stability, and baking and
rheological
properties that result in one or more of these.
Useful techniques include two different methods sometimes referred to as
"straight-dough" methods and "preferment" methods, which are described in,
e.g.,
U.S. Pub. No. 2006/0083841 (Casper et al.).
According to straight-dough methods, all or substantially all of the dough
ingredients of a dough composition are combined together generally at the same
time and are mixed together to form a dough mass that can be formed to a dough
and
cooked. Straight dough methods tend to be streamlined and efficient. Some
drawbacks of straight dough methods include limited flexibility in both the
mixing
process (e.g., it can be difficult to salvage over-mixed dough) and make-up
process
(e.g., the dough tends to become unprocessable if the dough rests on the line
too
long).
According to preferment methods (or, among other terms, "sponge"
methods) ingredients can be combined in two (or more) separate steps. In a
first step
a dough "preferment" composition is prepared to include a portion of total
dough
ingredients such as flour, water, yeast, and yeast food. This preferment
portion of
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mixed ingredients is then allowed to rest or ferment. In a second step, the
balance of
the total dough ingredients is added to the fermented dough composition, after
a
certain amount of processing (e.g., "resting") of the preferment dough
composition.
According to standard methods, yeast of this dough composition is again
allowed to
ferment in a "proofing" step that leavens the finished dough composition
before
cooking. Upon cooking, the proofed dough will exhibit a recognizable flavor
and
aroma of a fresh-baked yeast-leavened dough product as well as a light
(leavened)
composition due to the leavening that took place during the proofing step.
Sponge
dough methods tend to provide superior product characteristics (e.g., baked
specific
volume, crumb texture, combinations of these, and the like). Some drawbacks
can
include relatively high labor cost, power consumption, machine wear, and
fermentation losses.
In general, there is an ongoing need to make dough compositions using more
efficient and/or user-friendly methods while providing desirable properties in
the
raw dough and/or baked product.
Summary
It has been discovered that using chemical leavening agents to generate
carbon-dioxide gas in a manner to help seed bubble nucleation sites for bubble
dispersion within a dough matrix can help provide a dough composition (raw or
baked) having similar or even superior characteristics as a dough made using a
conventional yeast preferment composition. Such product characteristics
include
baked specific volume, crumb texture, combinations of these, and the like. The
chemical leavening agents are included in a "chemical preferment composition"
that
has at least flour component and water (chemical preferment composition
discussed
below). The water hydrates at least a portion of the flour component so that
the
composition has a preferment viscosity, which viscosity allows suitable bubble
nucleation to take place as the chemical leavening agents hydrate and react to
generate carbon dioxide gas.
Advantageously, a chemical preferment composition according to the present
invention can be made with efficient mixing methodologies (e.g., more
continuous
in nature and more similar to straight dough methods) while still being able
to be
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used to make a dough composition having similar or superior characteristics
than a
dough made from a conventional yeast preferment composition. Subjecting the
chemical preferment composition to a rest period is not necessary for
acceptable
bubble nucleation to take place.
According to one aspect of the present invention, a method of making a
chemical preferment composition includes mixing ingredients including: flour
component; water; acidic chemical leavening agent; and basic chemical
leavening
agent. The ingredients are mixed in a manner to form a chemical preferment
composition having a preferment viscosity.
According to another aspect of the present invention, a chemical preferment
composition includes flour component; water; acidic chemical leavening agent;
and
basic chemical leavening agent. The chemical preferment composition has a
preferment viscosity.
According to another aspect of the present invention, a method of making a
dough composition includes mixing ingredients in a manner to form a chemical
preferment composition having a preferment viscosity and mixing one or more
additional dough ingredients with the chemical preferment composition in a
manner
to form a dough composition. The ingredients mixed in a manner to form a
chemical preferment composition include flour component; water; acidic
chemical
leavening agent; and basic chemical leavening agent.
Brief Description of the Drawings
FIG. 1 shows a graph of composition viscosity as a function of flour
component to water weight ratio (F/W).
FIG. 2 shows a graph of composition viscosity as a function of flour
component to water weight ratio (F/W) and spindle speed.
Detailed Description
The embodiments of the present invention described below are not intended
to be exhaustive or to limit the invention to the precise forms disclosed in
the
following detailed description. Rather the embodiments are chosen and
described so
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that others skilled in the art may appreciate and understand the principles
and
practices of the present invention.
In the context of forming a dough composition, a chemical preferment
composition according to the present invention is formed early on in the
overall
dough making process and is formed prior to (is a precursor to) forming a
dough
composition. As used herein, a "chemical preferment composition" refers to a
composition having a preferment viscosity and that includes flour component,
water,
and chemical leavening agent (acidic and basic chemical leavening agents). In
some
embodiments, a chemical preferment composition includes flour component,
water,
and chemical leavening agent (acidic and basic chemical leavening agents),
among
other optional ingredients. In other embodiments, a chemical preferment
composition consists of or consists essentially of flour component, water, and
chemical leavening agent (acidic and basic chemical leavening agents). In
still other
embodiments, a chemical preferment composition consists of or consists
essentially
of flour component, water, yeast, yeast food or nutrient, and chemical
leavening
agent (acidic and basic chemical leavening agents). A chemical preferment
composition having a preferment viscosity can form an internal cell structure
in the
composition that is similar to an internal cell structure that is made using
conventional yeast preferment compositions that do not include chemical
leavening
agents. Such internal cell structures help form a crumb structure and baked
specific
volume of, e.g., baked bread that is made using the chemical preferment
composition. As used herein, a "preferment viscosity" refers to a viscosity of
a
chemical preferment composition that is high enough to allow the composition
to
trap at least part of the carbon dioxide gas that is evolved from the reaction
between
acidic and basic chemical leavening agents and form an acceptable internal
cell
structure (i.e., bubble nucleation) in the composition. Preferably, a
preferment
viscosity is also high enough so as to permit the formed cells to maintain
their shape.
At the same time, a preferment viscosity refers to a viscosity of the
composition that
is low enough to let some of the generated carbon dioxide gas escape from the
composition. If the composition viscosity is too high (e.g., a viscosity of a
dough),
the composition tends to be too rigid to permit formation of an acceptable
internal
cell structure and/or tends to retain too much carbon dioxide gas. Retaining
too
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much carbon-dioxide gas that is generated at such an early stage of the
overall
dough forming process can be undesirable because the resulting dough may be
very
difficult to manipulate through subsequent process machinery.
A preferment viscosity can be measured using any known method in the
dough forming arts. It is noted that the units in which viscosity is reported
can vary
depending on the particular methodology used, even for different methodologies
using the same viscometer.
One acceptable viscometer for measuring viscosity of a chemical preferment
composition according to the present invention includes the Brabender
Farinograph - E (viscosity reported in Brabender Units (BU)), which can be
commercially obtained from C.W. Brabender Instruments, Inc., South
Hackensack, New Jersey, USA. A preferred method of using the Brabender
Farinograph - E to measure viscosity includes adding flour component and water
with only one of the chemical leavening agents to a farinograph mixing bowl.
Only
one of the leavening agents is preferably added while measuring the viscosity
of the
composition so that leavening gas is not generated to an undue degree.
Otherwise, if
both the acid and base are added while measuring viscosity, leavening gas can
be
generated to an undue degree and can thereby hinder obtaining an accurate
viscosity
measurement. The leavening agent is preferably present in an amount as the
leavening agent would be in a chemical preferment composition (described
below).
The bowl jacket coolant set at 15.5 degrees Celsius and the mixing blade speed
set
to 63 rpm, and then mixing to the maximum or peak viscosity of the blend. In
preferred embodiments, the Brabender Farinograph - E can be used to measure
preferment viscosity when the weight ratio of flour component to water is from
about 1.0 to 1.4, but as the flour component to water ratio decreases below
about 1.0
the viscosity of the composition tends to become too low to be accurately
measured
with the Brabender Farinograph - E. FIG. 1 shows a graph of the viscosity of
a
chemical preferment composition measured at 15.5 degrees Celsius with a
Brabender Farinograph - E in a 300 gram bowl at 63 revolutions per minute as
a
function of flour component to water weight ratio (F/W). The point indicated
by
arrow 10 indicates the approximate maximum viscosity for a chemical preferment
composition (i.e., about 500 BU). For viscosities higher than 500 BU on this
graph,
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the viscosity is too high such that the composition becomes much more
difficult to
form bubbles and/or retains too much of the carbon-dioxide gas that is evolved
from
the reaction between acidic and basic chemical leavening agents. In certain
embodiments, a preferment viscosity can be in the range of from 50-500 BU,
preferably from 150- 450, preferably from 150-400, and even more preferably
from
200-400 BU, measured at 15.5 degrees Celsius with a Brabender Farinograph - E
in a 300 gram bowl at 63 revolutions per minute.
Another acceptable viscometer for measuring viscosity of a chemical
preferment composition according to the present invention includes the
Brookfield
Viscometer, model number DVIII (viscosity reported in centipoises (cP)), which
can
be commercially obtained from Brookfield Engineering Laboratories, Inc.,
Middleboro, Massachusetts, USA. A preferred method of using the Brookfield
Viscometer, model number DVIII to measure viscosity includes pre-blending a
bench scale amount of the flour component, water, and either acid or base at
the
preferment ratios of these ingredients. Only one of the chemical leavening
agents is
preferably added while measuring the viscosity of the composition so that
leavening
gas is not generated to an undue degree. Otherwise, if both the acid and base
are
added while measuring viscosity, leavening gas can be generated to an undue
degree
and can thereby hinder obtaining an accurate viscosity measurement. The
leavening
agent is preferably present in an amount as the leavening agent would be in a
chemical preferment composition (described below). Using a jacket-cooled
concentric cylinder apparatus (jacketed cup and spindle), the viscosity of
this
preferment blend is measured at 15.5 degrees Celsius {jacket coolant
temperature) at
different spindle speeds (revolutions per minute) and recorded when the
digital
reading is stable at each separate rpm setting. Then the recorded viscosity
measurements are plotted as a function of spindle speed to see shear-thinning
characteristics for the preferment composition. The Brookfield Viscometer,
model
number DVIII can be especially useful to measure the viscosity of a chemical
preferment composition when the weight ratio of flour component to water is
below
1.0 (e.g., from 0.2 to 1.0). FIG. 2 shows a graph of the viscosity of a
chemical
preferment composition measured at 15.5 degrees Celsius with a Brookfield
Viscometer as a function of flour component to water weight ratio (F/W) and
the
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speed (revolutions per minute) of a number 64 spindle. As can be seen in FIG.
2,
the flour componentlwater mixture is slightly shear thinning, and the apparent
viscosity increases as the flour component to water weight ratio increases. In
certain
embodiments, a preferment viscosity can be in the range of from 100 to 15,000
cP,
preferably from 500 to 10,000 cP, and even more preferably from 1,000 to 5,000
cP,
measured at 15.5 degrees Celsius with a Brookfield Viscometer and a number 64
spindle at a speed of 40 revolutions per minute.
As used herein, a "flour component" refers to any ingredient that at least
partially hydrates when mixed with water so as to form the structure portion
of an
internal cellular matrix indicative of that used to make dough products.
Exemplary
flour components include flour, starch, concentrated protein ingredient, and
combinations of thereof. Suitable flour includes hard wheat flour, soft wheat
flour,
corn flour, high amylose flour, low amylose flour, and the like.
Suitable starch includes any starch that is known for use in dough
compositions generally. Such starch ingredients are well known and are
described
in, e.g., U.S. Pub. No. 2006/0083841 (Casper et al.).
Suitable concentrated protein ingredient is described in, e.g., U.S. Pub. No.
2006/0083841 (Casper et al.) and includes, e.g., wheat protein isolate, vital
wheat
gluten, combinations of these, and the like.
Flour component can be present in a chemical preferment composition in an
amount in the range of from 5 to 50 percent, or from 10 to 45 percent, or from
15 to
40 percent, or from 20 to 35 percent by weight of the chemical preferment
composition.
Water can be combined with other chemical preferment composition
ingredient(s) in any suitable form such as water, ice, and combinations of
these.
Water can be present in a chemical preferment composition in an amount in the
range of from 40 to 80 percent, or from 45 to 75 percent, or from 50 to 70
percent,
or from 55 to 65 percent by weight of the chemical preferment composition.
The flour component and water can be present in a chemical preferment
composition at a weight ratio that allows a preferment viscosity to develop
within a
suitable amount of time upon mixing of the chemical preferment composition
ingredients. In certain embodiments, the weight ratio of flour component to
water is
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in the range of from 0.1 to 2, or from 0.2 to 1.75, or from 0.2 to 1.5, or
from 0.25 to
1.4, or from 0.25 to 0.5. Calculating the weight ratio of flour component to
water
for a chemical preferment composition is shown by reference to Example 1. In
Example 1, the flour component includes 6.3 weight percent, modified starch
and
4.0 percent gluten protein for a total flour component percentage of 10.3. The
water
is present at 32.5 percent. Accordingly, weight ratio of flour component to
water for
the chemical preferment composition is 10.3 divided by 32.5, which is equal to
0.3.
It is noted that the weight ratio of flour component to water for the final
dough
composition is calculated by adding all of the flour components (42.4 weight
percent
flour + 6.3 weight percent modified starch + 4.0 percent gluten protein =
52.7) and
adding all of the water (32.5) and then dividing 52.7 by 32.5, which is equal
to 1.6.
Selection of acidic chemical leavening agent(s), basic chemical leavening
agent(s), and their respective amounts depends on, e.g., when the agents are
mixed
in with one or more of the other chemical preferment ingredients and when a
substantial portion of carbon dioxide gas is expected to be evolved. A
chemical
preferment composition having a preferment viscosity includes chemical
leavening
agents so that the composition can trap at least part of the carbon dioxide
gas that is
evolved from the reaction between acidic and basic chemical leavening agents
and
form the bubbles/cells (bubble nucleation) of an internal cell structure in
the
composition that is similar to an internal cell structure that is made using
conventional yeast preferment compositions that do not include chemical
leavening
agents.
The reaction between the acidic and basic chemical leavening agents can be
described as a source of bicarbonate (basic chemical leavening agent) being
neutralized by an acidic chemical leavening agent so as to generate carbon
dioxide
gas. To facilitate the reaction, the bicarbonate source is solubilized to
react with the
acidic chemical leavening agent. Because the acidic chemical leavening agent
and
basic chemical leavening agent are solubilized to react, such chemical
leavening
agents can also be referred to as "moisture-activated" acidic chemical
leavening
agent and "moisture-activated" basic chemical leavening agent.
In general, a chemical preferment composition has a preferment viscosity
early on in the overall dough making process so it is desirable to select
acidic
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chemical leavening agent(s) and basic chemical leavening agent(s) that will
react to
generate a suitable amount of carbon dioxide gas during the time period that
the
composition has a preferment viscosity.
Acidic chemical leavening agent(s) for use in a chemical preferment
composition include nucleating chemical leavening agent(s), time-release
chemical
leavening agent(s), combinations of these, and the like. Nucleating chemical
leavening agents include organic acids that hydrate and undergo dissolution
relatively fast. Nucleating chemical leavening agents tend to readily give up
protons
to react with the bicarbonate and evolve carbon dioxide gas during such early
stage
mixing and can control dough crumb structure by providing gas cell nucleation
sites.
Time-release acidic chemical leavening agents can be used to control the
time(s) and
rate(s) at which carbon-dioxide gas evolution occurs. A time-release acidic
chemical leavening agent can be formulated to evolve carbon-dioxide gas at
particular time(s) and/or rate(s) by varying characteristics such as particle
size
and/or blending with heat activated acidic chemical leavening agent(s),
encapsulated
acidic chemical leavening agents, combinations of these, and the like.
Useful acidic chemical leavening agents are generally known in the dough
and bread-making arts, with some examples including potassium acid tartrate,
fine
fumaric acid, citric acid, adipic acid, sorbic acid, potassium hydrogen
tartrate (creme
of tartar), SAS (sodium aluminum sulfate), SALP (sodium aluminum phosphate),
SAPP (sodium acid pyrophosphate), monosodium phosphate, monocalcium
phosphate monohydrate (MCP), anhydrous monocalcium phosphate (AMCP),
dicalcium phosphate dihydrate (DPD), dicalcium phosphate (DCP), glucono delta-
lactone (GDL), and dicalcium phosphate dihydrate (DCPD). Commercially
available acidic chemical leavening agents for use according to the invention
can
include those sold under the trade names Balchem Encapsulated Soda or Balchem
Encapsulated GDl available from Balchem Chemical Leavening Agents, New
Hampton, New York and/or products available from ICL Performance Products LP,
St. Louis, Missouri. Of these, some have relatively lower solubilities at
temperatures at which a chemical preferment composition has a preferment
viscosity, and some have relatively higher solubilities at said temperatures.
Accordingly, the solubility of the acidic chemical leavening agent is a factor
in
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selecting a particular chemical leavening agent. An acidic chemical leavening
agent
of a given solubility reacts with basic chemical leavening agents at a time
when the
chemical preferment composition has a preferment viscosity.
The basic chemical leavening agent can be any material that is reactive with
the acidic active ingredient to produce a bubble-nucleating gas, usually
carbon
dioxide gas. Useful basic chemical leavening agents are generally known in the
dough and bread-making arts, with examples of useful basic chemical leavening
agents including reactive basic materials such as soda, sodium bicarbonate
(NaHCO3), potassium bicarbonate (KHCO3), ammonium bicarbonate (NH4HC03),
etc. These and similar types of basic chemical leavening agents are generally
soluble in an aqueous phase of a chemical preferment composition.
The acidic and/or basic chemical leavening agents can be encapsulated, non-
encapsulated, or combinations of these. In preferred embodiments, the acidic
and
basic chemical leavening agents are non-encapsulated. Encapsulation of a
chemical
leavening agent tends to delay reaction between the acidic and basic chemical
leavening agents, but if appropriately selected an encapsulated acidic
chemical
leavening agent and/or a basic chemical leavening agent could be used in a
chemical
preferment composition having a preferment viscosity so as to generate an
internal
cell structure in the preferment composition that can be used to make a dough.
Encapsulation of chemical leavening agents is generally known in the dough and
bread-making arts, e.g., as described in U.S. Pat. No. 7,250,187 (Domingues).
In
certain embodiments, the acidic and/or basic chemical leavening agents can be
encapsulated in a material that dissolves in water and/or in the presence of
other
ingredients (e.g., flavors containing alcohol, enzymes, emulsifiers,
combinations of
these, and the like).
As will be appreciated by the skilled artisan, the individual chemical
leavening agents can be included in the dough composition in respective
amounts
that are useful to form an acceptable internal cellular network in the
chemical
preferment composition. The amount of a chosen basic chemical leavening agent
to
be used in a chemical preferment composition can be sufficient to react with
the
included acidic chemical leavening agent to release a desired amount of gas
for
bubble nucleation, thereby forming the desired internal cellular network in
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chemical preferment composition. Because the basic chemical leavening agent
and
the acidic chemical leavening agent work in cooperation, each chemical
leavening
agent should be included in an amount designed to work with the included
amount
of the other chemical leavening agent. In certain embodiments, the amounts of
basic
and acidic chemical leavening agents can be determined using a Neutralizing
Value
(N.V.) which is defined as parts by weight of a bicarbonate that 100 parts by
weight
of an acidic chemical leavening agent will neutralize (i.e., liberate
substantially all of
the carbon dioxide gas). Using a Neutralizing Value, an amount could be
determined as a percent by weight of the total preferment composition for
either the
acidic or basic chemical leavening agents and the amount of the complementary
chemical leavening agent could be dependent upon the Neutralizing Value of the
chemical leavening agent chosen.
Typical amounts of basic chemical leavening agent (not including the weight
of any encapsulant that may be present) can be in the range from 0.25 to 10
percent,
or from 0.75 to 7 percent, or from 0.75 to 4 percent, or from 0.75 to 2
percent, or
from 0.75 to 1.5 percent by weight of the chemical preferment composition. In
terms of the weight percent of the basic chemical leavening agent based on the
total
dough composition, typical amounts of basic chemical leavening agent (not
including the weight of any encapsulant that may be present) can be in the
range
from 0.1 to 10 percent, or from 0.5 to 7 percent, or from 0.5 to 5 percent, or
from
0.75 to 2.5 percent, or from 0.75 to 1.3 percent by weight of the dough
composition.
The acidic active ingredient can be added in an amount sufficient to
neutralize the basic component, i.e. an amount that is stoichiometric (a
Neutralizing
Value percent) to the amount of basic chemical leavening agent, with the exact
amount by weight being dependent on the particular acidic chemical leavening
agent
that is chosen. Typical amounts of acidic chemical leavening agent (not
including
the weight of any encapsulant that may be present) can be in the range from
0.25 to
10 percent, or from 0.25 to 6 percent, or from 0.5 to 6 percent, or from 0.75
to 6
percent, or from 1 to 6 percent by weight of the chemical preferment
composition.
In terms of the weight percent of the acidic chemical leavening agent based on
the
total dough composition, typical amounts of acidic chemical leavening agent
(not
including the weight of any encapsulant that may be present) can be in the
range
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from 0.1 to 10 percent, or from 0.5 to 7 percent, or from 0.5 to 5 percent, or
from
0.75 to 2.5 percent, or from 0.75 to 1.3 percent by weight of the dough
composition.
A chemical preferment composition can include optional ingredients
typically used in conventional yeast preferment compositions. Ingredients
typically
used in conventional yeast preferment compositions are well known as described
in,
e.g., U.S. Pub. No. 2006/0083840 (Casper et al.), and include yeast (e.g., for
flavor,
bubble nucleation, and combinations of the these), a yeast food or nutrient,
hydrocolloid (e.g., gum), combinations of these, and the like.
Also, while a chemical preferment composition according to the present
invention has been described as including acidic and basic chemical leavening
agents so that the composition can trap at least part of the carbon dioxide
gas that is
evolved to form the bubbles/cells (bubble nucleation) of an internal cell
structure, a
chemical preferment composition according to the present can include an
additional
leavening system that can provide leavening for any reason. For example, to
help
the chemical leavening agents to form the internal cellular network of the
preferment, to proof the dough composition that is subsequently formed, to
leaven
the dough composition during baking, combinations of these, and the like. Such
additional leavening systems can include, e.g., yeast, additional chemical
leavening
agents (e.g., encapsulated chemical leavening agent), combinations of these,
and the
like.
A chemical preferment composition according to the present invention can
be made by mixing ingredients that include flour component, water, acidic
chemical
leavening agent, and basic chemical leavening agent, and mixing the
ingredients in a
manner to form a preferment viscosity. As mentioned above, such a chemical
preferment composition is formed early on in the overall dough making process
because the purpose is to develop a preferment viscosity that is lower than a
dough
viscosity so that nucleation sites can be produced in the chemical preferment
composition in a manner similar to nucleation sites developed using a
traditional off-
line yeast preferment process. The chemical leavening agents produce carbon
dioxide that will eventually cause the nucleation sites formed in the chemical
preferment composition to expand into bubbles in a subsequent dough
composition
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and leaven to an expected structure and texture. The bubbles ultimately give
rise to
the cellular structure observed in a cooked dough product.
At least two considerations in forming a chemical preferment composition
include development of a preferment viscosity and carbon dioxide evolution.
The flour component and water are mixed so as to at least partially hydrate
the flour component and develop a composition having a preferment viscosity
(i.e., a
viscosity that is high enough to allow the composition to trap at least part
of the
carbon dioxide gas that is evolved from the reaction between acidic and basic
chemical leavening agents and form an internal cellular matrix). A preferment
viscosity can develop within a certain time or energy input (e.g., as measured
by
temperature increase) and can be measured as described in detail above.
Typically,
a preferment viscosity is developed in the first one-third of the overall
dough making
process.
Any type of mixing equipment can be used that would help achieve a
preferment viscosity. Such equipment is well known and can include, e.g.,
straight
dough mixing equipment.
Carbon dioxide gas evolution is controlled by selecting acidic and basic
chemical leavening agents having a particular solubility and form (e.g., as
discussed
above, encapsulated, non-encapsulated, and combinations of these). Carbon
dioxide
gas evolution is also controlled by selecting an appropriate time to combine
one or
both of the acidic and basic chemical leavening agents with the other chemical
preferment composition ingredients.
In certain embodiments, the acidic and basic chemical leavening agents
substantially neutralize each other prior to the final dough composition
coming out
of a mixer. Preferably, the acidic and basic chemical leavening agents used
for
bubble nucleation react to such a substantially complete degree while the
composition has a preferment viscosity that such chemical leavening agents do
not
cause undue leavening to occur downstream of making the chemical preferment
composition (e.g., during sheeting). In certain embodiments, the acidic and
basic
chemical leavening agents substantially neutralize each other while the
composition
has a preferment viscosity because a preferment viscosity is low enough to
allow
some of the generated carbon-dioxide gas to escape from the dough composition.
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As the chemical preferment composition continues to develop, the composition
will
eventually develop a dough viscosity (e.g., a viscosity of 500 BU or more as
measured using the Brabender Farinograph - E procedure described herein)
which tends to retain too much carbon dioxide gas that is generated and/or
which
can even be too high of a viscosity for bubble nucleation to occur.
In certain embodiments, making a chemical preferment composition
according to the present invention can be described in terms of one or more
mixing
cycles. A mix cycle means a time period during which at least certain specific
ingredients are combined and mixed together. A mix cycle can be performed for
various time periods and at one or more mix speeds. In certain embodiments, a
first
mix cycle includes a mixing period in the range of from 30 seconds to 5
minutes, or
from 1 minute to 4 minutes, e.g., about 2 minutes, and at a speed in the range
of
from 20 to 50 revolutions per minute, or from 30 to 40 revolutions per minute,
e.g.,
about 36 revolutions per minute. In certain embodiments using the same mixer,
a
second mix cycle following the first mix cycle includes a first mixing period
in the
range of from 30 seconds to 5 minutes, or from 1 minute to 4 minutes, e.g.,
about 2
minutes, and at a speed in the range of from 20 to 50 revolutions per minute,
or from
30 to 40 revolutions per minute, e.g., about 36 revolutions per minute,
followed by a
second mixing period until a desired (e.g., peak) dough viscosity is reached
and at a
speed in the range of from 50 to 90 revolutions per minute, or from 60 to 80
revolutions per minute, e.g., about 72 revolutions per minute. Exemplary
mixing
equipment includes a horizontal bar, H-bar or D-bowl style mixer such as those
manufactured by The Peerless Group, Sidney, Ohio, under the trade name
Peerless
or ETMW Enterprises Ltd, Sherbrooke, Quebec Canada, under the trade name
ETMW with a stationary bar with 3 equally spaced mixing bars.
In one preferred embodiment, a method of making a chemical preferment
composition includes a first mix cycle that mixes flour component, water,
acidic
chemical leavening agent or basic chemical leavening agent, in a manner so
that the
composition has a preferment viscosity, and a second mix cycle that mixes a
complementary chemical leavening agent with the ingredients of the first mix
cycle.
As used herein, a "complementary" chemical leavening agent can be either an
acidic
chemical leavening agent or a basic chemical leavening agent, depending on the
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context. If the first mix cycle includes an acidic chemical leavening agent,
the
complementary chemical leavening agent that is included in the second mix
cycle is
a basic chemical leavening agent. Or, if the first mix cycle includes a basic
chemical
leavening agent, the complementary chemical leavening agent that is included
in the
second mix cycle is an acidic chemical leavening agent. Preferably, a
complementary chemical leavening agent is added during a subsequent (e.g.,
second
mix cycle) in situations where the reaction between the acidic and basic
chemical
leavening agents is so fast that a major portion of the bubbles are formed too
early in
the mixing process and tend to be broken up by mixing. In such situations
where a
complementary chemical leavening agent is added during a subsequent mix cycle,
it
is noted that the complementary chemical leavening agent is added in a manner
that
causes the desired carbon-dioxide gas evolution to occur when the composition
still
has a preferment viscosity. An example of adding a complementary chemical
leavening agent during a mix cycle subsequent to the first mix cycle is shown
below
in Example 1. In preferred embodiments, a complementary acidic chemical
leavening agent that is added during a mix cycle subsequent to the first mix
cycle
(e.g., a second mix cycle) is selected from the group consisting of citric
acid, adipic
acid, sorbic acid, sodium aluminum phosphate, sodium aluminum sulfate, fine
fumaric acid, potassium hydrogen tartrate, monocalcium phosphate monohydrate,
anhydrous monocalcium phosphate, glucono delta-lactone, sodium acid
pyrophosphate, and combinations thereof. Optionally, one or more additional
dough
ingredients can be mixed with the ingredients of the first mix cycle during
the
subsequent mix cycle that the complementary chemical leavening agent is added.
In another preferred embodiment, a method of making a chemical preferment
composition includes a first mix cycle that mixes flour component, water,
acidic
chemical leavening agent, and basic chemical leavening agent, in a manner so
that
the composition has a preferment viscosity, and a second mix cycle that mixes
one
or more additional dough ingredients with the ingredients of the first mix
cycle. In
general, acidic and basic chemical leavening agents are included in a first
mix cycle
in situations where the carbon dioxide evolution proceeds at a suitable rate.
An
example of including acidic and basic chemical leavening agents during a first
mix
cycle is shown below in Example 2. In preferred embodiments, an acidic
chemical
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leavening agent that is added during a first mix cycle along with a basic
chemical
leavening agent is selected from the group consisting of fine fumaric acid,
potassium
hydrogen tartrate, monocalcium phosphate monohydrate, anhydrous monocalcium
phosphate, glucono delta-lactone, sodium acid pyrophosphate, and combinations
thereof.
Preferably, a chemical preferment composition according to the present
invention is made according to single stage mixing. As used herein, single
stage
mixing means that all ingredients are combined in and mixed in a single mixer
while
continuously mixing the ingredients from mix cycle to mix cycle (i.e., the
mixing is
not stopped and there is no rest period between mix cycles). Preferably, there
is no
breaking of the seal of the mixer from mix cycle to mix cycle. For example,
ingredients can be loaded into a mixer in a sealed manner and the speed of the
mixer
can be adjusted. Preferably, a dough composition made from a chemical
preferment
composition according to the present invention is made according to single
stage
mixing meaning that a dough composition can be made in same mixer as the
chemical preferment composition so that a transfer from a separate chemical
preferment mixer to dough finishing mixer does not have to take place. In
preferred
embodiments, mixing does not stop from the beginning of making a chemical
preferment composition until the dough composition is made and ready for
subsequent processing (e.g., sheeting, packaging, and the like). Accordingly,
single
stage mixing is more similar to a straight dough method rather than an off-
line
conventional yeast preferment method (i.e., a sponge dough method).
Advantageously, a chemical preferment composition according to the present
invention can benefit from the process efficiencies associated with continuous
mixing methodology (e.g., as in straight dough methods), while providing the
crumb
texture and baked specific volume conventionally associated with off-line
mixing
methodology (e.g., conventional yeast preferment methods).
A chemical preferment composition according to the present invention can
be combined with one or more additional dough ingredients in a manner to form
a
dough composition. Such additional dough ingredients are well known as
described
in, e.g., U.S. Pat. No. 5,855,945 (Laughlin et al.), U.S. Pub. No.
2006/0083840
(Casper et al.), and U.S. Pub. No. 2006/0083841 (Casper et al.). Such
additional
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ingredients include flour, water, yeast, yeast food or nutrient, hydrocolloid
(e.g.,
gum), fat (e.g., soy oil), salt, emulsifier, dough-developing agents,
nutritional
supplements, flavorings (sweeteners, spices, and the like), preservatives,
mold
inhibitors, combinations of these, and the like.
A chemical preferment composition according to the present invention can
be used to make a variety of refrigerated or frozen doughs including doughs
for
bread, such as French bread, wheat bread, white bread, corn bread, rolls, such
as
cinnamon rolls, dinner rolls, caramel rolls and other assorted baked goods
such as
breadsticks, baguettes, croissants, pastries, biscuits, pizza dough, and the
like.
Additionally, the invention can be used to make non-refrigerated loughs, such
as
doughs that are immediately baked. In preferred embodiments, a chemical
preferment composition according to the present invention can be used to make
"Freezer-to-oven" (FTO) breads, which typically do not include a pre-proof,
par-
bake, thaw, or post-proof steps before being placed into the oven and baked
directly
from the frozen state.
EXAMPLES
Example 1
SINGLE STAGE CHEMICAL PREFERMENT COMPOSITION
Preferment Flour Component /Water Ratio = 0.3 (calculated as described above).
Total Flour Component/Water Ratio = 1.6 (calculated as described above).
Ingredient Percent by Mix Cycle I Mix Cycle 2 Mix Cycle 1
weight of Ingredient - Ingredient - Percent Ingredient -
total dough Percent by by weight of total Percent by weight
composition weight of total dough composition of the total Mix
dough Cycle 1
composition ingredients
Flour Component 1 42.4 0.0 42.4 0.0
(Flour)
Flour Component 2 6.3 6.3 0.0 14.2
Modified Starch
Flour Component 3 4.0 4.0 0.0 9.2
(Gluten Protein)
Water 32.5 32.5 0.0 74.3
Sugars 2.2 0.0 2.2 0.0
Yeast 6.5 0.0 6.5 0.0
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Base 1.0 1.0 0.0 2.3
Acid 1.3 0.0 1.3 0.0
Hydrocolloid Blends 0.3 0.0 0.3 0.0
Oil Blends 1.7 0.0 1.7 0.0
Salts 1.0 0.0 1.0 0.0
Emulsifiers 0.5 0.0 0.5 0.0
Baking Powder 0.3 0.0 0.3 0.0
TOTAL 100.0 43.8 56.2 100.0
Note: the columns labeled "Mix Cycle 1 Ingredient - Percent by weight of total
dough composition" and "Mix Cycle 2 Ingredient - Percent by weight of total
dough
composition" add together so as to form 100% as indicated by the column
labeled
"Percent by weight of total dough composition".
"Single stage" mixing, as defined above, was performed in this experiment.
Mix cycle 1. Starch, Gluten, Water, and'/2-chem leavening system (only the
base) were added during a first mix cycle and prehydrated for 2 minutes under
low
speed (36 rpm) agitation.
Mix cycle 2. Add remaining ingredients (including acidic complementary
chemical leavening agent) to mixer and mix for 1 minute at 36 rpm, and then
mix at
72 rpm until peak development is reached. The final dough viscosity was in the
range of from 1000-1500 Brabender Units measured at 15.5 degrees Celsius with
a
Brabender Farinograph - E in a 480 gram bowl at 63 revolutions per minute.
Ex
SINGLE STAGE CHEMICAL PREFERMENT TREATMENT
Preferment Flour Component/Water Ratio = 0.3 (calculated in a manner similar
to
Example 1).
Total Flour Component/Water Ratio =1.6 (calculated in a manner similar to
Example 1).
Ingredient Percent by Mix Cycle 1 Mix Cycle 2 Mix Cycle 1
weight of Ingredient - Ingredient - Ingredient -
total dough Percent by Percent by weight Percent by
composition weight of total of total dough weight of the
dough composition total Mix Cycle
composition 1 in edients
Flour Component 42.4 0.0 42.4 0.0
1 (Flour)
Flour Component 6.3 6.3 0.0 13.8
2 (Modified
Starch)
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Flour Component 4.0 4.0 0.0 9.0
3 Gluten Protein
Water 32.5 32.5 0.0 72.2
Sugars 2.2 0.0 2.2 0.0
Yeast 6.5 0.0 6.5 0.0
Base 1.0 1.0 0.0 2.2
Acid 1.3 1.3 0.0 2.8
Hydrocolloid 0.3 0.0 0.3 0.0
Blends
Oil Blends 1.7 0.0 1.7 0.0
Salts 1.0 0.0 1.0 0.0
Emulsifiers 0.5 0.0 0.5 0.0
Baking Powder 0.3 0.0 0.3 0.0
TOTAL 100.0 45.1 54.9 100.0
Note: the columns labeled "Mix Cycle 1 Ingredient - Percent by weight of total
dough composition" and "Mix Cycle 2 Ingredient - Percent by weight of total
dough
composition" add together so as to form 100% as indicated by the column
labeled
"Percent by weight of total dough composition".
"Single stage" mixing, as defined above, was performed in this experiment.
Mix cycle 1. Starch, Gluten, Water, Acidic chemical leavening agent, Basic
chemical leavening agent, and hydrocolloid blends were added during a first
mix
cycle and prehydrated for 2 minutes under low speed (36 rpm) agitation.
Mix cycle 2. Add remaining ingredients to mixer and mix for 1 minute at 36
rpm, and then mix at 72 rpm until peak development is reached. The final dough
viscosity was in the range of from 1000-1500 Brabender Units measured at 15.5
degrees Celsius with a Brabender Farinograph - E in a 480 gram bowl at
63revolutions per minute.
19
