BACKGROUND OF THE INVENTION

The present invention relates to bagels and bagel-making. More

particularly, the present invention relates to preparing frozen toroidal-shaped

dough pieces which, when thawed and baked, have organoleptic properties at

least as desirable as fresh bagels produced by conventional boil and bake or

steam and bake processes. The present invention relates as well to both the

frozen dough pieces and the baked bagels prepared in accordance with the

invention.

According to one legend, in 1683 in Vienna, Austria, a Jewish baker

wanting to thank the King of Poland for protecting his countrymen from Turkish

invaders, made special hard rolls in the shape of a riding stirrup ~ "bugels" in

German ~ to commemorate the King's interest in horseback riding. The

"bugels" eventually made their way from Poland and Austria to Russia, where

they were sold on strings and said to bring good luck and possess magical

powers. Over time, these toroidal or ring-shaped rolls came to be known as

"bagels". At the turn of the century, bagels were brought to America by Eastern

European Jewish immigrants. Since that time, bagels have become a staple food

throughout the United States.

Traditionally, bagels have been made from a toroidal shaped yeast dough

piece which is first placed in boiling water for 1-2 minutes, and then baked.

Some years ago, steaming for a period of about 20-60 seconds began to be used

in lieu of boiling. The boiling (or steaming) gelatinizes the surface of the dough

piece to produce, after baking, a roll with a dense and chewy crumb and a

relatively thick shiny crust. This gives bagels their unique mouthfeel and their

other distinctive organoleptic properties. The dense and chewy crumb and

relatively thick crust also makes bagels a bread product particularly suitable for

use in making sandwiches.

In order to obtain uniform and economic bagels, it is desirable to make

large quantities of frozen toroidal-shaped dough pieces at a central location for

storage either at the manufacturing site or at an off-site location. The frozen

dough pieces can then be shipped if necessary and thawed and baked as needed.

While methods for preparing frozen toroidal-shaped dough pieces for

making bagels have been suggested in the past, prior bagels obtained after

freezing, storage, thawing and baking have often not risen as much as desired

and have had unduly thin and soft crusts and an unduly soft crumb. These prior

frozen and baked bagels have also often been misshapen and have had unsightly

blisters and surface holes, making them also visually undesirable.

Finally, although it is desirable to produce novel bagels incorporating

whole and chopped secondary ingredients such as chocolate and carob chips,

dried fruit (raisins, blueberries, etc.), dried vegetables, nuts, cookie bits, cheeses

and candies, boil (or steam) and bake methods generally have limited the

development of such novel bagels. It is often difficult if not impossible to form

bagels from doughs containing such secondary ingredients since they interfere

with shaping and closing or sealing of the toroidal bagel shape. Furthermore,

certain sensitive secondary ingredients, if put in bagels produced by such

conventional boil (or steam) and bake processes, would bleed or dissolve into or

away from the doughs due to the temperature rise produced in the boiling or

steaming step.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an improved and highly

efficient process for preparing frozen toroidal dough pieces which, when thawed

and baked, will have mouthfeel and other organoleptic properties at least as

desirable as fresh bagels produced by conventional boil and bake or steam and

bake processes, without an intermediate freezing step.

Yet another object of the present invention is to provide an improved

process for preparing bagels which does not require a boiling or a steaming step

prior to final baking.

Still another object of the present invention to provide from frozen

toroidal dough pieces visually attractive bagels which are not misshapen or

blistered and which do not have unsightly surface holes.

It is a further object of the present invention to provide a method of

preparing bagels having a cake-like dense and moist crumb and particularly

thick and crispy alligatored outer crusts.

A still further object of the present invention is to provide novel bagels

incorporating whole or chopped secondary ingredients.

A yet further object of the present invention is to provide frozen toroidal

dough pieces from which finished baked bagels can be obtained which are

particularly well-adapted for use in making sandwiches.

Additional objects, advantages and novel features of the invention will be

set forth in the description and claims which follow, will become apparent to

those skilled in the art upon examination of the following, or may be learned by

practice of the invention. The objects and advantages of the invention may be

realized and attained by means of the instrumentalities and combinations

paπicularly pointed out in the appended claims.

According to the present invention, the foregoing and other objects are

attained by:

preparing a bagel dough;

forming the bagel dough into one or more toroidal-shaped dough pieces;

proofing the toroidal-shaped dough pieces;

bathing the toroidal-shaped dough pieces in an aqueous acidic solution

warmed to a temperature below the boiling point of the aqueous acidic solution;

and

freezing the acid-treated, toroidal-shaped dough pieces.

It is highly preferred but not required that the dough pieces be refrigerated after

proofing to firm up the dough, making the dough pieces easier to manage.

In accordance with another aspect of the present invention, bagels are

prepared by thawing the acid-treated, toroidal-shaped dough pieces produced as

described above and then baking these thawed dough pieces, to produce a bagel

at least as desirable as fresh bagels produced by conventional boil and bake

processes.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

The first step in practicing the method of the present invention is the

preparation of a bagel dough. While any conventional bagel dough may be used

in the practice of this invention, it is preferred that the bagel dough include the

following ingredients, in the indicated levels, in percentages by weight:

Ingredient Broad Range Preferred Level flour 50-70 61 water 25-35 29 yeast 1.2-0.4 0.6 non-diastatic malt syrup 2.0-5.0 3.1 (liquid) non-diastatic malt syrup 1.2-0.4 0.6 (powder)

Ingredient Broad Range Preferred Level sugar 0.8-1.8 1.3 molasses 0.5-2.0 1.1 salt 0.7-2.0 1.4 powdered egg whites 0.8-1.8 1.3 dough conditioner 1.2-0.4 0.6

If secondary ingredients having significant amounts of moisture are used,

less water should be added to the bagel dough mix. If the secondary ingredients

tending to inhibit yeast activity are used, additional yeast will be included in the

mixture. If hard secondary ingredients like nuts or dried fruits are used, the

mixing time will be increased to better incorporate those ingredients into the

dough. Finally, additional ingredients such as sugar may be added to

complement certain secondary ingredients, such as blueberries or chocolate

chips.

While flours other than unbleached enriched flours may be used to make

the bagel dough, unbleached enriched flours are preferred. Bleached flours are

less desirable because they produce a white crumb. The preferred enriched flour

may contain, for example, unbleached flour, malted barley flour, reduced iron,

niacin, thiamine mononitrate and riboflavin. It is preferred that the flour have a

protein level (in percentage by weight) of about 11.0 to 14.2% and more

preferred that the protein level be about 13.8 to 14.2%.

The dough conditioner in the above preferred bagel dough functions as an

oxidizer during baking. For example, dough conditioners comprising mixtures

of L-cysteine, ascorbic acid and fungal and cereal enzymes which are available

commercially from many sources, including, for example, Elf Atochem of

Minneapolis, Minnesota, Puratos of Cherryhill, New Jersey, Archer Daniels

Midland Co. of Decatur, Illinois, and Caravan Products of Totowa, New Jersey

may be used. One such dough conditioner is described in United States Patent

No. 3,934,040.

The ingredients will be mixed in a manner recognized by those skilled in

the art to make a conventional dough for bagel-making. For example, the above

ingredients, when used in the most preferred ranges, will be mixed from about

8.5 to 11 minutes to produce a dough having a temperature after mixing of

approximately 80-90°F.

The bagel dough, as described above, is divided and formed into toroidal-

shaped dough pieces. It is preferred that the dough pieces be formed

immediately after completion of the mixing process. Also, although the toroidal

shapes may be made by hand, in commercial scale operations it is contemplated

that the shapes will be made using conventional high speed automatic bagel-

forming machines.

Once formed, the toroidal-shaped dough pieces should be proofed.

Proofing may be carried out from about 20 to 60 minutes at about 90 to 105°F

under conditions of about 75 to 90% relative humidity. It is preferred that the

proofing be carried out for from about 30 to 40 minutes at about 95 to 100°F

and at about 80 to 85% relative humidity. It is most preferred that the proofing

be carried out for about 30 to 35 minutes at about 100°F in a conventional

proofing cabinet maintained at about 85% relative humidity.

After proofing, it is highly preferred but not required that the dough

pieces be refrigerated to firm up the dough, making the dough pieces easier to

manage. Refrigeration may be accomplished, for example, by quick-chilling to

about 38-40°F for about 30 minutes to one hour.

After proofing (and optional preferred chilling), the toroidal-shaped dough

pieces are treated with a heated aqueous acidic solution. Typically, the aqueous

acidic solution should be maintained at a temperature of about 140 to 190°F,

more preferably at about 160 to 185°F, and most preferably at about 170-180°F.

The pH of this solution should be from about pH 3.0 to 6.0, more preferably

from about pH 3.5 to 5.0, and most preferably at about pH 4.0 to 4.5.

The acidic aqueous solution should be heated to a temperature below its

boiling point. This warm, acidic surface treatment is believed to gelatinize the

surface of the dough pieces without adversely affecting the yeast viability inside

the dough piece. This is in contrast to conventional boiling or steaming of bagel

dough in which the surface starch is gelatinized by the boiling water or steam

restricting later expansion of the dough piece and killing the yeast. Thus, when

the present dough pieces are baked, the heat penetrates faster than in boiled or

steamed dough pieces, aerating the dough and making it more porous. Faster

heat penetration also gives a crisper crust and makes the crumb more open and

the bagel less dense.

Any food-grade acid which does not break down at the temperature

chosen may be used, including, for example, acetic, lactic, or fumaric acid.

Vinegar (aqueous acetic acid) is the preferred acid.

The toroidal-shaped dough pieces will be bathed in the aqueous acidic

solution for from about 15 to 40 seconds, more preferably from about 20 to 35

seconds, and most preferably for about 25-30 seconds or until they float to the

surface.

The toroidal-shaped dough pieces are then removed from the aqueous

acidic solution and sprayed with clear water. The water should be cool,

preferably in the range of about 35 to 50°F and more preferably in the range of

about 38-42°F. After this spraying step, the toroidal shapes may be dusted with

ground cornmeal (preferably medium fine ground) and flipped over so that they

rest on the dusted side. This facilitates handling of the shapes which will be

sticky on the uncoated surfaces.

The toroidal-shaped dough pieces are then transported to a first freezer.

The first freezer should be maintained at a temperature of at least about -15°F,

and preferably at least about -20°F. A blast freezer is particularly preferred

because it cools the bagel shapes with minimum damage to the yeast cells in the

dough which must be available to generate gas in the later thawing and baking

steps. Also, a blast freezer accomplishes cooling in a minimal amount of time,

which is highly desirable from a practical manufacturing standpoint.

It is preferred that the moisture on the surface of the bagel shapes be

maintained during the freezing step. That is, the moisture remaining on the

surface of the dough pieces after the water wash preferably will not be removed.

Thus, when a blast freezer is used as the "first freezer", a pre-freezer may be

employed to insure that the surface moisture is frozen in place before the dough

pieces enter the blast freezer. Retention of this surface moisture further

improves the crispness of the crust in the final baked bagel.

The toroidal-shaped dough pieces should remain in the first freezer until

they are cooled to at least about 10°F at the core. It has been found that this

will take about 35-40 minutes. After this, they may be packaged and stored in a

second freezer at about 0°F for up to 60 days, but preferably no longer than 45

days.

When it is desired to produce bagels from the frozen toroidal-shaped

dough pieces, the frozen dough pieces should be thawed under controlled

conditions. In one preferred embodiment, they will be thawed by refrigerating

for from about 8-16 hours at about 38-42°F and about 65% relative humidity

and then heated for about 15 minutes at about 90°F and about 75% relative

humidity to achieve a core temperature of about 65-70°F. Of course, different

times and temperatures may be used, although in all cases at least about 6 hours

of thawing under such controlled conditions will be required. This insures that

fermentation by the yeast and oxidation of gluten in the dough piece begins

before initiation of the baking step to aid regular expansion of the dough pieces

in the baking step.

Once the desired core temperature is reached, the toroidal-shaped dough

pieces are ready for baking. This may be done by any conventional method. It

is preferred that the dough pieces be baked at about 425-525°F and preferably at

about 450-500°F for about 10-14 minutes, with about eight seconds of steam

addition at the outset. Steam addition over about 5-15 seconds may be used

with about 6-12 seconds being preferred. Baking time depends on the size of

the dough pieces, the presence or absence of whole or chopped ingredients, the

amount or number of bagels being baked, the altitude, and sugar levels in the

dough pieces.

The following examples are presented in order to illustrate the present

invention, but nothing therein should be taken as limiting the scope thereof:

EXAMPLES

Example 1

Frozen bagel dough shapes were prepared in accordance with the

invention as follows: First, a bagel dough was prepared by combining the

following ingredients in a Hobart mixer with a stainless steel mixing bowl and

dough hook on second speed.

Ingredient Percentage By Weight

unbleached enriched flour 61

water 29

yeast 0.6

non-diastatic malt syrup (liquid) 3.1

non-diastatic malt syrup (powder) 0.6

sugar 1.3

molasses 1.1

salt 1.4

powdered egg whites 1.3

dough conditioner 0.6

In preparing the dough, the water was placed in the mixing bowl followed by

the other ingredients which were stirred until uniformly mixed. The ingredients

were mixed for a total of about 10 minutes to produce a dough having a

temperature after mixing of approximately 85°F. The bagel dough was divided

into toroidal-shaped dough pieces immediately after completion of the mixing

process using a conventional high speed automatic bagel-forming machine. The

enriched flour included unbleached flour, malted barley flour, reduced iron,

niacin, thiamine mononitrate, and riboflavin, and a protein level, in percentage

by weight, of about 14.0%. The dough conditioner comprised a mixture of L-

cysteine, ascorbic acid, and fungal and cereal enzymes.

Once formed, the toroidal-shaped dough pieces were proofed for about

30-35 minutes at about 100°F in a conventional proofing cabinet maintained at

about 85% relative humidity. The proofed, toroidal-shaped dough pieces were

then quick-chilled to about 38-40°F for about 45 minutes.

Next, an aqueous solution of acetic acid was prepared in a vat with

sufficient acetic acid (200 grain vinegar) to achieve a pH of about 4.0 to 4.5.

The vat of acidic aqueous solution was heated to about 170-180°F whereupon

the toroidal-shaped dough pieces were bathed in the vat for about 25-30

seconds. It was found that the dough pieces initially sank to the bottom of the

vat but, after being in the bath for about 25-30 seconds, they floated to the

surface.

The acid-treated dough pieces were then removed from the acidic bath

and sprayed with clear water at a temperature of about 40°F. The toroidal

shapes were then placed on a flat tray, dusted with medium fine ground

cornmeal, and flipped over so that they rested on the dusted side.

The tray containing the bagel shapes was then transported to a first

freezer maintained at a temperature of about -20°F. The dough pieces remained

in the first freezer until they cooled to at leujt about 10°F at the core, which

took about 35-40 minutes. The resulting frozen dough pieces were packaged

and stored at about 0°F.

Example 2

After storage for several days, the frozen dough pieces of Example 1 were

thawed for about 10 hours in a refrigerated room at about 40°F and 65%

relative humidity and then heated for about 15 minutes at about 90°F and about

75% relative humidity, thereby achieving a core temperature of about 65-70°F.

The thawed dough pieces were then baked at about 500°F for about 12 minutes,

with about 10 seconds of steam injection at the beginning of the baking cycle.

The resulting baked bagels were visually attractive and not misshapen or

blistered, and were free of surface holes. The bagels had a cake-like, dense and

moist crumb and a particularly thick and crispy alligatored outer crust. Some of

the bagels were cut and found to have a short bite, making them well-suited for

use in preparing sandwiches.

Example 3

The procedure described in Example 1 were used in making novel bagels

incorporating blueberries. The dough was prepared from the ingredients used in

Example 1 except for the addition of dehydrated blueberries and sufficient sugar

to produce a sweet product. Once formed, proofed and frozen bagels were

thawed and baked as described in Example 2. The resulting baked product was

tasty and had well-defined and juicy blueberries which had neither bled nor

dissolved into or away from the bagel crumb.

While the present invention is described above in connection with the

preferred or illustrative embodiments, those embodiments are not intended to be

exhaustive or limiting of the invention. Rather, the invention is intended to

cover any alternatives, modifications or equivalents that may be included within

its sphere and scope, as defined by the appended claims.