Kalamarz, Arkadiusz (ul. Warzywna 22, 37-200 Przeworsk, PL)
Kalamarz, Arkadiusz (ul. Warzywna 22, 37-200 Przeworsk, PL)
| 1. | A dough for wholemeal rye bread of extended shelf life containing natural rye sour, rye flour, yeast, malt extract, kitchen salt, fat and water, wherein its formula contains: sour dough leaven with pH = 20.035.0 in a quantity of 0.1940.262 parts by weight rye flour, grade 720 in a quantity of 0.361 0.277 parts by weight wheat flour, grade 750 in a quantity of 0.0900.092 parts by weight yeast in a quantity of 0.0120.010 parts by weight malt extract in a quantity of 0.0220.027 parts by weight potato flakes in a quantity of 0.0150.018 parts by weight fat in a quantity of 0.0150.018 parts by weight kitchen salt in a quantity of 0.0120.010 parts by weight improving agent in a quantity of 0.0080.009 parts by weight water in a quantity of 0.271 0.277 parts by weight. |
| 2. | Dough as claimed in Claim 1, wherein said sour dough leaven contains: a starter consisting of: rye flour, grade 2000, in a quantity of 0.0140.016 parts by wt, water in a quantity of 0.0300.033 parts by weight, kitchen salt in a quantity of 0.00080.0006 parts by weight and lactic bacteria in a quantity of 0.000020.00004 parts by weight, rye flour, grade 2000, in a quantity of 0.2400.250 parts by weight, rye flour, grade 720, in a quantity of 0.2400.250 parts by weight and water in a quantity of 0.4760.451 parts by weight. |
| 3. | Dough as claimed in Claim 1, wherein said sour dough leaven contains: a starter consisting of: rye flour of 2000 grade in a quantity of 0.0140.016 parts by wt., water in a quantity of 0.0300.033 parts by weight, kitchen salt in a quantity of 0.00080.0006 parts by weight, lactic bacteria in a quantity of 0.000020.00004 parts by weight, rye flour, grade 2000, in a quantity of 0.1280.122 parts by weight, rye flour, grade 720, in a quantity of 0.1280.122 parts by weight, crumbled wholemeal rye bread in a quantity of 0.2500.244 parts by weight, water in a quantity of 0.4500.462 parts by weight. |
| 4. | The method of making rye bread of extended shelf life consisting in dough making with the use of natural rye sour in form of a sour dough leaven, rye flour, malt extract, yeast, kitchen salt, fat and water, its maturing, formation and baking the bread at the temperature above 220°C wherein: 0.1940.262 parts by weight of sour dough leaven with pH = 2035 and 0,0540,055 parts by weight of the water to be used for the dough is poured into a kneading trough and blended while adding 0.0120.010 parts by weight of yeast and 0.0100.012 parts by weight of kitchen salt, both diluted in water, 0.0150.018 parts by weight of potato flakes previously soaked in 0.1350.107 parts by weight of water at 40°C, 0.0220.027 parts by weight of malt extract diluted in 0.0450.043 parts by weight of water at 40°C, and finally 0.0150.018 parts by weight of fat, preferably lard, at the end of ingredient blending, then 0.3610.277 parts by weight of rye flour, grade 720, is added to the resulting mixture, depending on acidity/pH of said sour dough leaven used, as well as 0.0900.092 parts by weight of wheat flour, grade 750, and 0.0350.037 parts by weight of water, then all is subjected to slowspeed blending for 810 minutes and the resulting dough is left at rest for 46 minutes and at the temperature of 2426 °C, the mature dough is divided to portions into metal moulds (tins) and the moulds, filled with the dough, are put for about 65 minutes into warm oven at the temperature of 44 46 0C and humidity of 7882 % for the dough to rise and then the bread is baked in a, preferably ceramic, baking furnace at 210 270 °C for 25 45 minutes, and once baked, said moulds with bread are removed from furnace and the bread is put onto a spongy mat, 0 then it is moved to sterile room or compartment where the bread is wrapped into polypropylene foil and sealed on the foil sides, then the bread is put into hermetic furnace at 104 106° C and pasteurized thermally with temperature within the bread going down to 92°C, and once thermally stabilized, the bread is packed into another double layer foil, preferably polyamidepolyethylene grade, and sides are sealed with subsequent check for 55 packing tightness. ■>. |
| 5. | The method of making rye bread as claimed in Claim 4, wherein said packing tightness test is performed on the apparatus equipped with a tight water chamber in which the bread is placed and vacuum is created to enable detection of even small air bubbles. |
| 6. | The method of refreshing rye bread of extended shelf life, wherein said bread, packed 60 tightly in double, preferably polyethylene and polyamidepolyethylene foil, is placed into the chamber of the apparatus at 90 100° C and left in it until warmed all through, then the bread is cooled in free, air, removed from packing foil and left to acclimatize for approx. 20 minutes, then it is subject to slicing. ' ' "7". The method of bread refreshing as claimed in Claim 6, wherein said process of bread 65 warming is conducted in an open kettle with water at temperature of 90°C for 30 minutes." 8. The method of bread refreshing as claimed in Claim 6, wherein said process of bread warming is conducted in perforated container in chamber of convectionsteam oven preheated to a temperature of approx. 100°C and humidity of 100% for approx. 30 minutes. |
| 7. | 709. The method of bread refreshing as claimed in Claim 6, wherein said process of bread warming is conducted in microwave oven at temperature of approx. 100°C for about 3 minutes. |
The object of this invention is the dough for rye bread of extended shelf life, method of making rye bread of extended shelf life and method of refreshing such bread.
The method of making bread of extended shelf life is known from Polish patent application P-3398 ' 17 wherein the ingredients in form of natural rye sour, wholemeal
5 flour, rye andAy wheat bran, graham wheat flour, water, salt and yeast starter or a known white dough/ to which roasted buckwheat groats, suitably prepared, are added in a quantity of up to four parts by weight, depending on the dough quantity.
Polish patent specification for invention No. 187326 reveals also a wholemeal bread and the method of making it, containing rye flour, additions of wheat flour, yeast, kitchen 0 salt and caramel, as well as prunes in a quantity of 25% of the total dough weight before baking. The method of making the bread with the use of above mentioned ingredients consists in f using natural sours with a five-step fermentation method and adding destoned
• • prunes ia the- last stage of dough making. Then the dough is formed to portions and left for a secondary dough growth. Then it is baked at 240 °C. 5 In turn, a ready-to-use bakery leaven is revealed in the Polish application for invention No. P-332534. It contains at least one kind of non-malt cereal flour, one kind of amylase- supplying malt cereal flour and water, an inoculant in form of a preparation of hetero- fermentation lactic bacteria and yeast and is characterized by the content of dry matter from 12 to 50 % by weight, preferably 13 to 20 % by weight, with pH value of the leaven 0 between 4 and 4.3.
Polish patent specification for invention No. 151099 reveals also a method of making dough for wholemeal bread wherein water-soaked grains of bread cereals, in a ratio 60-70 kg of water at 28-46 °C to 100 kg of grains, then the water is drained off, the grain is kneaded and then the yeast is diluted in water from grain soaking with kefir and 5 buttermilk additions and left at the temperature of 32 °C for 20 minutes to achieve their maximum activity. Soaked and kneaded grain is joined with yeast, activated with grain- soaking water, and with the rest of that water while introducing improving ingredients, as powdered herbs, fruit additions, vegetable oil, or seeds of oil-bearing plants, during kneading. Correct dough consistency and elasticity is reached in the kneading process by 0 adding mineral water, kefir or buttermilk as well as wheat or rye flour. So prepared dough is put into metal moulds (tins) and put away for 40-60 minutes at 32° C to finish the fermentation and maturing processes. Wholemeal bread baking starts at initial temperature of 220°C and finishes at the temperature of 170°C after 45-50 minutes.
Dough for wholemeal rye bread of extended shelf life of this invention contains 5 in its formula: sour dough leaven with pH = 20.0-35.0, in a quantity of 0.194-0.262 parts by weight, rye flour, grade 720, in a quantity of 0.361-0.277 parts by weight, wheat flour, grade 750, in a quantity of 0.090-0.092 parts by weight, yeast in a quantity of 0.012-0.010 parts by weight, malt extract in a quantity of 0.022-0.027 parts by weight, potato flakes in a quantity of 0.015-0.018 parts by weight, fat in a quantity of 0 0.015-0.018 parts by weight, kitchen salt in a quantity of 0.012-0.010 parts by weight, improving agent in a quantity of 0.008-0.009 parts by weight and water in a quantity of
0.271-0.277 parts by weight.
The recipe for the sour dough leaven contains a starter that consists of rye flour, grade 2000, in a quantity of 0.014-0.016 parts by weight, water in a quantity of 0.030-
0.033 parts by weight, kitchen salt in a quantity of 0.0008-0.0006 parts by weight and lactic bacteria in a quantity of 0.00002-0.00004 parts by weight, as well as rye flour, grade 2000, in a quantity of 0.240-0.250 parts by weight, rye flour, grade 720, in a quantity of 0.240-0.250 parts by weight and water in a quantity of 0.476-0.451 parts by weight. It is also advantageous when the sour dough leaven contains in its formulation a starter that consists of rye flour, grade 2000, in a quantity of 0.014-0.016 parts by weight, water in a quantity of 0.030-0.033 parts by weight, kitchen salt in a quantity of 0.0008-0.0006 parts by weight and lactic bacteria in a quantity of 0.00002-0.00004 parts by weight, as well, as rye flour, grade 2000, in a quantity of 0.128-0.122 parts by weight, rye flour, grade 720, in a quantity of 0.128-0.122 parts by weight, crumbled wholemeal rye bread in ^quantity of 0.250-0.244 parts by weight and water in a quantity of 0.450- 0.462 parts by weight
The method of making rye bread of extended shelf life of this invention consists in the following: Pouring of 0.194-0.262 parts by weight of sour dough leaven with pH = 20-35 and 0.054-0.055 parts by weight of the water to be used for the dough into a kneading trough and, blending that while adding 0.012-0.010 parts by weight of yeast,
0.010-0.012 parts by weight of kitchen salt diluted in water, 0.015-0.018 parts by
■ -weight of -potato flakes previously soaked in 0.135-0.107 parts -by weight -of water -at
40°C, 0.022-0.027 parts by weight of malt extract diluted in 0.045-0.043 parts ' by weight of water at 40°C, as well as 0.015-0.018 parts by weight of fat, preferably lard, at the end of ingredient blending. Adding 0.361-0.277 pails by weight of rye flour, grade 720, to the resulting mixture, depending on acidity/pH of the sour dough leaven, as well as 0.090-0.092 parts by weight of wheat flour, grade 750,.and 0.035-0.037 parts by weight of water. Then all is subjected to slow-speed blending for 8-10 minutes and the resulting dough is left at rest for 4-6 minutes and at 24-26°C the mature dough is divided to portions and put into metal moulds (tins) and the moulds, filled with dough, are put for about 65 minutes into warm oven at the temperature of 44-46°C and humidity of 78-82 % for the dough to rise. Then it is baked in a, preferably ceramic, baking furnace at 210-270° C for 25-45 minutes. Once baked, moulds with bread are removed from the furnace and the bread is put onto a spongy mat, then it is moved to sterile room or compartment where the bread is wrapped into polypropylene foil and sealed on the foil sides. Then bread is put into hermetic furnace at 104-106 0 C and pasteurized thermally with temperature within the bread going down to 92 0 C. Once thermally stabilized, the bread is packed into another double layer foil, preferably polyamide-polyethylene grade and sides are sealed with subsequent check for packing tightness.
Favourably the packing tightness check is performed in an apparatus equipped with tight water chamber, in which the bread is placed and vacuum is created to enable detection of even small air bubbles.
The method of refreshing rye bread of extended shelf life of this invention wherein the bread, packed tightly in double, preferably polyethylene and polyamide- poly-ethylene foil, is placed in the chamber of the apparatus at 90-100°C and left in it until warmed all through, then the bread is cooled in free air, removed from packing foil and left to acclimatize for approx. 20 minutes, then it is subject to slicing. Favourably the process of bread warming is conducted in an open kettle with water at the temperature of 90° C for 30 minutes. Also, preferably the process of bread warming is conducted in a perforated container in a chamber of convection-steam oven preheated to a temperature of approx. 100°C and humidity of 100% for approx. 30 minutes. It is also favourable when the process of bread warming is conducted in microwave oven at temperature of approx. 100 0 C for about 3 minutes.
95 The subject of the invention is explained in detail in the examples of its embodiments, which do not limit its scope.
Wholemeal rye bread of extended shelf life contains in its formula: a sour dough leaven containing lactic bacteria, rye flour, salt and water, as well as rye flour of grade 720, wheat flour of grade 750, yeast, malt extract, potato flakes, salt, animal fat, impro-
100 ving agent and water, whereas the detailed qualitative and quantitative composition of that bread is presented in the examples I- VII shown in the table 1, while the detailed qualitative and quantitative composition of the sour dough leaven, which is one of the basic ingredients qf this bread is presented in the examples VIII-XI shown in the table 2.
105 In turn^ihe method of making rye bread of extended shelf life based on its formulations as mentioned in the examples of its embodiments I-XI consists in being realized in three mutually independent stages consisting in making sour dough leaven with required acidity/pH, making, the wholemeal bread based on that sour dough leaven and refreshing this bread within the 18-month storage period, whereas this method is
110 explained closer in the subsequent examples of its embodiment.
Table 1
Table 2
Sour dough leaven making stage Example XII
Eighteen litres of water, warmed to 40 0 C 5 and 9 kg of rye flour, grade 2000, 0.38 kg of kitchen salt and 0.020 kg of lactic bacteria were added to the first leaven maker
115 vessel and, upon blending them, the mixture was left in a closed vessel for 24 hours, then the starter thus obtained was poured over to another vessel of the leaven maker, then 250 litres of. water at 45 0 C, 140 kg of rye flour, grade 2000, and 140 kg of rye flour, grade 720, were added, then everything was blended together and left resting for 24 hours. After that time the mixture of approx. 540 litres in volume was transferred to
120 the next vessel and put into air conditioned room at temperature not exceeding 16°C for another 24 hours. The sour dough leaven thus obtained was subjected to acidity test. Its pH was 25.
Example XIII
The process of sour dough leaven was conducted in identical manner as in the 125 -example XII except that- the- other vessel of the leaven'maker was ' filled with 28 Q ' litres '" , of water at 45"C, 75 kg of rye flour of grade 2000, 75 kg of rye flour of grade 720, and 150 kg of crumbled wholemeal bread. The sour dough leaven thus obtained had pH of 31.
Example XIV
130 The process of sour dough leaven was conducted in identical manner as in the example XII with formulation as specified in example X. The sour dough leaven thus obtained had pH of 35.
Example XV
The process of sour dough leaven was conducted in identical manner as in the example 135 XII with formulation as specified in example XI. The sour dough leaven thus obtained had pH of 20.
Wholemeal bread making stage
Example XVI
Seventy litres of sour dough leaven with pH = 26.5 and 15 litres of water were
140 poured into a kneading trough and blended while adding 3 kg of yeast and kitchen salt diluted in water, as well as 4.5 kg of potato flakes previously soaked in 32 litres of water at 40°C, 4 kg of 75.65% of malt extract diluted in 12 litres of water at 50°C and, at the end of ingredient blending, 4 kg of liquefied lard was also added. Then 75 kg of rye flour of 720 grade and 15 kg of wheat flour of 750 grade, as well as 10 litres of water were 45 added to the resulting mixture. Then all was subjected to slow-speed blending for 9 minutes with differing r.p.m. and, once thoroughly mixed, the resulting dough was left at rest for 5 minutes. At 25 °C the mature dough was then divided into portions of mass 8% bigger than that of a ready bread loaf which are put into pre-greased metal moulds (tins). Then the moulds, filled with dough, were put for about 65 minutes into warm oven at the 50 temperature of 45°C and humidity -of 80 % for the dough to rise. Then the dough was baked in ceramic baking furnace at 250°C for 30 minutes. After that time moulds with bread were removed from furnace and put onto a spongy mat, then moved in baskets to sterile room or compartment where still warm bread was wrapped into polypropylene foil
and sealed with the use of the 'flow-pack' machine equipped with sealing jaws of suitable
155 width. So packed bread is then put onto sheet metal pads about 3 -cm apart of each other and onto trolleys, with which it went into a hermetic furnace at 105°C and was pasteurized thermally until the temperature inside the bread reached 92°C. Once thermally stabilized, the bread was packed into another double-layer polyamide- polyethylene foil using the same 'flow-pack' machine and subsequently subjected to
160 check for packing tightness in a tester with water chamber and suitable vacuum enabling detection of small air bubbles, and thus even microscopic faults of bread packing sealing.
Random samples for laboratory testing were taken from the batch of bread with positive tightness test results. The test consisted of sensory and physicochemical assessments. Trfe former consisted of visual assessment, as well as check of bread weight,
165 taste and favour and the latter comprised the check of bread crumb moisture and pH, which were 46-53% and 6-8, respectively. Subsequently, five hours after bread removing from the oven and its complete cooling down and after the laboratory checks, the bread was packed into transportation cartons, 12 loaves per water-resistant carton of corrugated board, and stored in warehouses in stack not higher than 8 tiers.
170 Bread refreshing stage
Example XVII
After nine and eighteen months of bread storage in the manner described above, it was subjected to refreshing with the use of a water method, as well as methods using a convection-and-steam oven and that using a microwave oven.
175 ' The water method of bread refreshing consisted in placing the foil-wrapped bread in an open kettle with water at the temperature of 90 "C for 30 minutes, removing it from water and leaving it in open air , to cool down. Then it is removed from double foil packing, left in seasoning for 20 minutes and then sliced.
Convection- steam furnace method of bread refreshing consisted in placing the
180 foil- wrapped bread in a perforated container, and placing the container in the oven preheated to the temperature of 100°C. It remained at that temperature and oven chamber humidity of 100% for 30 minutes. After removing from oven chamber and cooling down the bread was removed from its double-foil packing, left in seasoning for a short time and then sliced.
185 In turn, the microwave oven method of bread refreshing consisted in placing the foil-wrapped bread in a microwave oven chamber and keeping it there at the temperature of 100°C for 3 minutes. After removing from microwave-oven chamber and cooling down the bread was removed from its double-foil packing, left in seasoning for a short time and then sliced.
190 It was found that as a result of employing all three methods of bread refreshing, after storing it for both 9 and 18 months, the bread manufactured by method of this invention met all requirements in both sensory and physicochemical respects. The bread had moisture content of 46-53 % and pH = 6-8, and kept the adequate flavour and taste.
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