PROCESS FOR PRODUCTION OF A BAKED PRODUCT

FIELD OF INVENTION

The present invention relates to a process for the production of baked product from laminated dough. Particularly, the present invention provides a process for producing puff pastry from a laminated dough.

BACKGROUND OF THE INVENTION

There have been known various methods for producing baked product having a laminated structure represented by pies and pastries.

Examples of these methods include one which comprises wrapping a fat such as butter or margarine in a rolled dough to thereby form a dough/fat/dough structure and folding it in such a manner as to give a multilayered structure; and one which comprises dispersing a fat in the form of particles in a dough to thereby give a structure wherein the fat is wrapped in the dough and then folding it in such a manner as to give a multilayered structure. When baked in an oven, the laminated dough having the alternate structure of dough and fat layers gives a confectionery product having a laminated structure, since the fat layer appropriately suppresses the emission of water vapor (including carbon dioxide when baker's yeast is employed) and thus is puffed up.

With the recent high growth of economy, eating habits have been changed accompanied by fancy for high-grade and diversified foods. In the field of baking, oven-fresh bakeries, which supply various fresh baked products including not only conventional white bread, bean-jam buns, jam buns and cream buns but also a number of variety buns, pies, pastries and buns stuffed with prepared foods, enjoy great popularity. The selling points of these oven-fresh bakeries reside in the freshness and variety of the products of which the customers will not tire.

According to Bailey's Industrial Oil and Fat Products vol. 3 (1985), pp 109-1 10, puff pastry requires the use of a very specialized shortening. The fat is placed on top of the (pre-) dough and folded and rolled to form many alternating layers of dough and fat. The shortening has a tough waxy body over a wide temperature range. It must approximate the consistency of the dough to remain in a continuous unbroken layer as it stretches and becomes thinner. Puff pastry shortening almost always contains an aqueous phase. The fat keeps the layers of dough separate and flaky, and the moisture attributes the "puff" as it turns to steam during the baking process. Commonly 90% fat shortenings or 80% fat pastry margarines are used. For the preparation of other laminated doughs, similar types of lamination shortenings and margarines are used. It is difficult under these circumstances to prepare various laminated confectionery products such as pies and pastries the preparation of which requires much labor in, e.g., fat wrapping, rolling and folding. When a butter of an excellent flavor is to be used for producing these products, further, the characteristics of the butter (i.e., a large change in viscosity depending on temperature) cause the splitting of the fat layer and the adhesion of the dough layers to each other, which makes it impossible to form an excellent laminated dough. When laminated dough is temporarily stored in a frozen stage in order to save labor, the deterioration is furthermore accelerated.

In the case of a laminated dough containing baker's yeast, the activity of the yeast is lowered during the frozen storage, regardless of the use of butter. When such dough is baked in an oven, no laminated products showing good puffing properties can be obtained.

Therefore there exists a need for further processes for production of laminated dough having improved properties.

SUMMARY OF THE INVENTION

In a first aspect, the invention relates to a process for producing a laminated dough comprising steps of a) mixing flour, water, a glucose oxidase and xylanase to obtain a dough; b) laminating the dough; and c) obtaining the laminated dough.

In a second aspect, the invention relates to a process for producing a baked product from a laminated dough.

In a third aspect, the invention relates to a use of a glucose oxidase and a xylanase in the preparation of a laminated dough or a baked product from a laminated dough.

In a forth aspect, the invention relates to a laminated dough made by the process of the first aspect. DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a process for producing a laminated dough comprising steps of a) mixing flour, water, a glucose oxidase and xylanase to obtain a dough; b) laminating the dough to obtain the laminated dough. Further, the process may comprise adding a maltogenic amylase and/or beta amylase in step a).

Laminated dough is prepared by using flour. The flour component of the invention may be either processed or unprocessed flour, and may be either white or whole grain flour. Flour means a material obtained by comminuting or grinding a cereal grain or edible seed. Flour is a mixture of starch and protein, usually gluten-forming proteins, e.g. glutenin and gliadin mixtures. Artificial flours which are mixtures of starches and proteins may also be used herein. Typical flours include wheat flour, barley flour, rye flour, oat flour, rice flour and corn flour. Mixtures of starches and proteins may also be used. The flours may be bleached or unbleached, enriched, steamed or heat treated. Peanut and other nut flours may also be used. However, these flours are preferably used with other flours since they generally have distinctive flavors and would be better used as subtle flavorants. The flours may also contain fiber or non-digestible polysaccharides.

Laminated dough of the invention includes water. The total amount of water (e.g., the amount of water from all sources) should be effective to provide a desirable layer dough consistency suitable for laminated dough of the invention. Water gives extensibility to the layer dough, which facilitates the molecules moving and stretching. Desirable extensibility facilitates the laminated dough of the invention to be baked into a product having a desirable specific volume. A desirable specific volume of a baked product according to the invention is at least 3 ml/g, preferably about 4.5 ml/g to about 10 ml/g, and more preferably about 4.5 ml/g to about 8.5 ml/g.

Glucose oxidase

According to the invention glucose oxidase is used in the preparation of laminated dough. The glucose oxidase enzyme is an enzyme classified in EC 1.1.3.4. Glucose oxidase is an oxido- reductase that catalyses the oxidation of glucose to hydrogen peroxide and D-glucono-5-lactone. Glucose oxidase may be derived from Aspergillus sp. , preferably from Aspergillus oryzae or Aspergillus niger or from Bacillus sp., preferably from Bacillus licheniformis.

Commercially available glucose oxidases include G LUZYM E TM (available from Novozymes A/S) and GRINDAMYL TM (Danisco A/S), GLUCOSE OXIDASE HP S100 and GLUCOSE OXIDASE HP S120 (Genzyme) and GLUCOSE OXIDASE SPDP (Biomeda).

Glucose oxidase is added into the dough in an effective amount. The glucose oxidase may added to the dough in an amount of 0.1 to 500 GODU/kg of flour, 1 to 50 GODU/kg of flour, preferably 2 to 25 GODU/kg of flour

Xylanase

According to the invention a xylanase is used in the preparation of laminated dough, i.e. an enzyme having the activity classified as EC 3.2.1 .8 according to Enzyme Nomenclature.

The xylanase may be a G H 1 1 xylanase, e.g. , a polypeptide having the amino acid sequence as shown in positions 1-182 of SEQ ID NO: 2 in WO 2005/077191 ) or the xylanase disclosed in EP 0 463 706. The xylanase may be a GH 8 xylanase, e.g., a polypeptide having the amino acid sequence as shown in positions 28 to 433 of SEQ ID NO: 3 in WO 201 1/070101 or a polypeptide having the amino acid sequence shown as SEQ ID NO: 8 in WO 2004/023879. The xylanase may be of any origin including mammalian, plant or animal origin, e.g. of microbial origin. In particular the xylanase preparation may be derived from a filamentous fungus or a yeast. More particularly, the xylanase may be derived from a strain of the following genus or species: Aspergillus, A. niger, A. awamori, A. aculeatus, A. oryzae, A. tubigensis, Trichoderma, T. reesei, T. harzianum, Penicillium, P. camenbertii, Fusarium, F. oxysporum, Thermomyces, T. lanuginosus, Humicola, H. insolens, Bacillus, B. halodurans, B. pumilus.

Suitable commercially available xylanase preparations suitable for use in the present invention include PENTOPAN MONO BG and PENTOPAN 500 BG (available from Novozymes), GRINDAMYL POWERBAKE (available from Danisco), and BAKEZYME BXP 5000 and BAKEZYME BXP 5001 (available from DSM).

Xylanase is added into the dough in an effective amount. Xylanase may be added to the dough amount of 0.1 to 100 FXU/g of flour, 1 to 50 FXU/g of flour, preferably 2.5 -10 FXU/g of flour. Maltogenic Amylase

Maltogenic amylase may be used with glucose oxidase and xylanase in the preparation of laminated dough. The maltogenic alpha-amylase is an enzyme classified in EC 3.2.1.133. The enzymatic activity does not require a non-reducing end on the substrate and the primary enzymatic activity results in the degradation of amylopectin and amylose to maltose and longer maltodextrins. It is able to hydrolyze amylose and amylopectin to maltose in the alpha-configuration, and is also able to hydrolyze maltotriose as well as cyclodextrin.

An example of a maltogenic alpha-amylase is the amylase cloned from Bacillus stearothermophilus (amino acids 1 -686 of S EQ I D N O : 1 ) as descri bed i n E P 1 20 693 (NOVAMYL®). Other examples of maltogenic alpha-amylases are described in 2006/032281 and WO 1999/43794, and include, e.g., the maltogenic alpha-amylase of amino acids 1-686, but having substitutions F188L+ V336L+ T525A; the maltogenic alpha-amylase of amino acids 1-686, but having substitutions F188I+ Y422F+ I660V; the maltogenic alpha-amylase of amino acids 1-686, but having substitutions N1 15D+ F188L; the maltogenic alpha-amylase of amino acids 1-686, but having substitutions A30D+ K40R+ D261 G; the maltogenic alpha-amylase of amino acids 1-686, but having substitutions T142A+ N327S+ K425E+ K520R+ N595I; the maltogenic alpha-amylase of amino acids 1 -686, but having substitutions F188L+ D261 G+ T288P (OPTICAKE®); the maltogenic alpha-amylase of amino acids 1-686, but having substitutions K40R+ F188L+ D261 G+ A483T; and the maltogenic alpha-amylase of amino acids 1 -686, but having substitutions T288K. These and many other maltogenic alpha-amylases are described in , e. g. , WO 2006/032281 and WO 1999/43794. Commercial maltogenic alpha-amylases available include NOVAMYL® and OPTICAKE® 50BG (both available from Novozymes A/S).

In one aspect, maltogenic alpha-amylase is added into the dough in an effective amount. In one aspect, the amount of maltogenic amylase added to the dough is about 1 to 10000 MANU/kg, preferably 10 to 1000 MANU/kg of flour and more preferably 100-500 MANU/kg of flour.

Beta -amylase

Beta-amylase may be used with glucose oxidase, and xylanase in the preparation of laminated dough. A beta-amylase (E.C 3.2.1.2) is the name traditionally given to exo-acting maltogenic amylases, which catalyze the hydrolysis of 1 ,4-alpha-glucosidic linkages in amylose, amylopectin and related glucose polymers. Maltose units are successively removed from the non- reducing chain ends in a step-wise manner until the molecule is degraded or, in the case of amylopectin, until a branch point is reached. The maltose released has the beta anomeric configuration, hence the name beta-amylase.

Beta-amylases have been isolated from various plants such as wheat, barley, and microorganisms, such as Bacillus sp. (Fogarty and Kelly, 1979, Progress in Industrial Microbiology 15: 112-115).

Commercially available plant beta-amylases contemplated for use in the methods of the invention include; OPTI MALT BBA (Genencor I nternational I nc.) and NOVOZYM™ WBA

(Novozymes A/S).

Beta-amylase is added into the dough in an effective amount. Beta-amylase added to the dough in anamount of 0.1-100 degree DP units/kg of flour, or preferably 1-10 degree DP units/kg of flour. Additional enzyme

One or more additional enzymes may be used in the production of laminated dough.

Optionally, additional enzyme(s) may be added during the process for producing laminated dough. The additional enzyme may be an alpha-amylase, a cyclodextrin glucanotransferase or a branching enzyme, or the additional enzyme may be a peptidase, in particular, an exopeptidase, a transglutaminase, a lipase, a phospholipase, a galactolipase, a cellulase, a hemicellulase, a protease, a protein disulfide isomerase, and an oxidoreductase, e.g., a peroxidase, a pyranose oxidase, hexose oxidase, a lipoxygenase, an L-amino acid oxidase or a carbohydrate oxidase, an acyltransferase, protein disulfide isomerases, a laccase and/or pectin lyase. The additional enzyme may be of any origin, including mammalian plant, and microbial (bacterial, yeast or fungal) origin and may be obtained by techniques conventionally used in the art.

The dough

The dough is prepared by mixing flour, water, a glucose oxidase and xylanase. Further, a maltogenic amylase and/or beta amylase may be added while mixing. The dough may then be rested. The dough formed is sheeted, e.g., by using a sheeter, and laminated using fat. Fat which are solid at room temperature are suitable in the process of production of laminated dough. The solid fats preferably include triglycerides having C ₁₂ to C ₂₂ hydrocarbon chains with three fatty acid moieties. These materials may be derived from plants or animals or may be edible synthetic fats or oils. For example, animal fats such as lard, tallow, oleo oil, oleo stock, oleo stearin. Also, liquid oils, e.g., unsaturated vegetable oils, may be converted into plastic fats by partial hydrogenation of the unsaturated double bonds of the fatty acid constituents of the oil followed by conventional chilling and crystallization techniques or by proper mixture with sufficient triglycerides which are solid at room temperature to form a rigid interlocking crystalline structure which interferes with the free- flowing properties of the liquid oil. The sheet of dough is layered one above the other and folded. This type of folding or laminating is common in the pastry industry and is used for making dough for puff pastry and similar pastry formulations. This folded dough is then rolled to a desired thickness. The dough is then folded again and rerolled to the same thickness. This folding and rolling is continued until the dough has at least 3 layers.

Laminated dough includes any dough having alternating shortening layers and water-flour layers. The laminated dough of the invention is shelf stable without storage in a package with a modified atmosphere such as, for example, without storage in carbon dioxide, nitrogen, or limited headspace. "Shelf stable" refers to laminated dough that is capable of withstanding at least one freeze/thaw cycle, wherein a freeze/thaw cycle comprises a temperature fluctuation of the dough between about 32 degree C and about 50 degree C. The shelf stable dough is suitable for storage at freezing temperatures without the dough breaking down, for example, microbial growth, water accumulation, failure of the leavening agent, and the like, and becoming unsuitable for consumption.

Conventionally, the laminated dough is a leavened dough or dough to be subjected to leavening. The dough may be leavened in various ways, such as by adding chemical leavening agents, e.g., sodium bicarbonate or by adding a leaven (fermenting dough). Thus, the dough may be leavened by adding a suitable yeast culture, such as a culture of Saccharomyces cerevisiae (baker's yeast), e.g. a commercially available strain of S. cerevisiae. The laminated dough of the invention may not require proofing before being frozen or baked to produce a desirable baked product. Proofing describes the process of letting a dough product increase in size to at least about two times the original dough size by reaction of yeast before baking.

The laminated dough may be unfermented, unleavened, partially fermented, full fermented, frozen and/or retarded.

The dough may also comprise other conventional dough ingredients, e.g.: proteins, such as milk or milk powder, gluten, and soy; eggs (either whole eggs, egg yolks or egg whites); shortening agent such as granulated fat or oil; an oxidant such as ascorbic acid, potassium bromate, potassium iodate, azodicarbonamide (ADA) or ammonium persulfate; a reducing agent such as L- cysteine; a sugar; a salt such as sodium chloride, calcium acetate, sodium sulfate or calcium sulfate. The dough may further comprise an emulsifier such as mono- or diglycerides, diacetyl tartaric acid esters of mono- or diglycerides, sugar esters of fatty acids, polyglycerol esters of fatty acids, lactic acid esters of monoglycerides, acetic acid esters of monoglycerides, polyoxyethylene stearates, phospholipids, lecithin and lysolecithin.

In one aspect, the invention relates to a process of producing a baked product from a laminated dough comprising steps of (a) obtaining a laminated dough and (b) baking the laminated dough to obtain the baked product.

The laminated dough may be obtained at process temperature of about 10 degree C to 40 degree C.

In one aspect, the baked product prepared from laminated dough is either of a soft or a crisp character, either of a white, light or dark type.

Preferably the baked product has an increase in volume compared to the baked product produced without the addition of enzymes.

According to the invention the dough is prepared by mixing dough ingredients, including enzymes, to obtain the dough; it is understood that each enzyme is added in an effective amount. The term "added in an effective amount" implies that the enzyme is added to the dough in an amount sufficient to achieve an increased volume of the baked product.

The "increased volume of the baked product" is measured as the specific volume of a given product (volume/weight). Specific volume (SV) in the unit of ml/g is defined as the volume (ml) of a given baked product per unit weight (g). The specific volume may be determined by the traditional rape seed displacement method or by using laser based scanner In one aspect, the flour used for the production of laminated dough or baked product has one or more properties selected from gluten content, sedimentation value, falling number, gluten strength and stability, water absorption. In one aspect, the gluten content of the flour is in the range 8 to 16 weight percent.

In another aspect, the sedimentation value of the flour is in the range 18 to 30 weight percent.

In another aspect, water absorption of the flour is in the range 50 to 70 weight percent. In one aspect, the flour used for the production of laminated dough or baked product has increased strength. The increased strength is defined as the property of the flour that has generally more elastic properties and/or requires more work input to mould and shape.

In one aspect, the flour used for the production of laminated dough or baked product has increased elasticity. The increased elasticity is defined as the property of the flour which has a higher tendency to regain its original shape after being subjected to a certain physical strain.

In one aspect, the flour used for the production of laminated dough or baked product has increased stability. The increased stability is defined as the property of the flour that is less susceptible to mechanical abuse thus better maintaining its shape and volume.

In one aspect, the baked product is selected from puff pastries/khari, Danish pastries, phyllo (filo) pastries, quick or blitz pastries and/or croissants.

In a preferably embodiment the baked product may be a puff pastry, e.g., a khari.

The invention is further illustrated in the following example, which is not intended to be in any way limiting to the scope of the invention as claimed. EXAMPLES

Materials and Methods

Glucose-oxidase activity: 1 Glucose-oxidase Unit (GODU) is the amount of enzyme, which oxidizes 1 μηηοΙ of beta-D-Glucose per minute. Glucose-oxidase (beta -D-glucose: oxygen-1-oxido- reductase, EC 1 .1 .3.4.) oxidises beta -D-glucose in the presence of oxygen to delta-glucono- lactone and hydrogen-peroxide. The generated hydrogen-peroxide oxidises ABTS-R (2, 2-Azino-di- (3-ethylbenzthiazoline)-6-sulfonate) in the presence of peroxidase (POD). This generates a green- blue colour, which is measured photometrically at 405 nm.

Beta - D - glucose + 0 ₂ 00^ 30 -^ 5,6 ^> Delta-glucono-lactone + H ₂ 0 ₂

H ₂ 0 ₂ + ABTS _red ^ _5ir ^2 H ₂ 0 + ABTS _0X Reaction conditions

Substrate Glucose 90 mM (16.2 g/L)

ABTS 1.25 mM (688 mg/L)

Glucose-oxidase 0.0061-0.0336 GODU/mL

Peroxidase (POD) 2930 U/L

Buffer Acetate, 100 mM

PH 5.60 ± 0.05

Temperature 30 °C ± 1

Reaction time 36 sec. (8 x 4.5 sec.)

Wavelength 405 nm

Xylanolvtic activity: The xylanolytic activity can be expressed in FXU-units, determined with remazol- xylan (4-O-methyl-D-glucurono-D-xylan dyed with Remazol Brilliant Blue R, Fluka) as substrate at standard reaction conditions, i.e. at 50.0°C, pH 6.0, and 30 minutes reaction time. The background of non-degraded dyed substrate is precipitated by ethanol. The remaining blue colour in the supernatant (as determined spectrophotometrically at 585 nm) is proportional to the xylanase activity.

Maltogenic alpha-amylase activity: The activity of a maltogenic alpha-amylase may be determined using an activity assay such as the MANU method. One MANU (Maltogenic Amylase Novo Unit) is defined as the amount of enzyme required to release one micro-mole of maltose per minute at a concentration of 10 mg of maltotriose substrate per ml in 0.1 M citrate buffer at pH 5.0, 37°C for 30 minutes.

Specific volume: Specific volume (SV) in the unit of ml/g is defined as the volume (ml) of a given baked product per unit weight (g). The baked product was cooled out of the baking tray for 30 minutes and was weighed after cooling for 1 hour. The specific volume was measured using laser based scanner.

Preparation of laminated dough: The laminated dough was prepared from the following basic recipe: Table 1 : Ingredients for the Preparation of the Dough

Ingredient Amount (grams) %

Flour, refined wheat 500 100 Water 275 55

Shortening Agent 20 4

Salt 12.5 2.5

Puff Pastry Margarine 250 50

The ingredients as shown in Table 1 were mixed to form the dough. The ingredients are widely available commercially. The dough was allowed to rest 30 to 40 minutes prior to first sheeting and lamination After first lamination with 50% of the total puff pastry margarine, the dough is rested an additional 30 to 40 minutes. The lamination was repeated for the second time with the remaining 50% of fat (puff pastry margarine). Further the dough was rested for another 30 to 40 minutes. Final lamination of the dough was done and the dough was cut into small strips. The dough strips were folded and kept in baking trays and then baked in a conventional oven at 210 °C for 15 to 20 minutes.

Example 1 Effect of glucose oxidase and xylanase on laminated dough and baked product

Four samples of dough were prepared using the above procedure with various concentrations of enzymes. The four different samples of dough were evaluated for various properties such as stickiness, softness, extensibility and elasticity according to the scoring chart in Table 2 compared to a control without the addition of enzymes. The results are shown in Table 3.

Table 2: Chart for Scoring-Dough/Puff Pastry Property

Table 3: Dough Properties with the Addition of Enzyme

1 2 3 4 5

(Control)

Glucose oxidase 25 50 75 100 0

(GODU/kg of flour)

Xylanase 50 50 50 50 0

(FXU/g of flour)

Stickiness

5 5 5 5 5 Softness

5 5 5 5 5

Extensibility

5 5 5 5 5

Elasticity

Dough temperature 28.5-29.4 29-28.9 28.7-29.3 28.8-29.1 28.9

(Degree Celsius)

The dough was maintained at temperatures as indicated in table 3 and then baked to puff pastry. The puff pastry was evaluated for vanous properties such as crust colour, crispiness, appearance and specific volume in comparison to the control without the addition of enzymes. The results are shown in Table 4.

Table 4: Puff pastry properties with the addition of enzyme

It is observed (as shown in Table 3) that there were no changes in dough properties with the addition of glucose oxidase and xylanase. It is observed (as shown in Table 4) that there was an increase in specific volume of puff pastry with increase in dosage of glucose oxidase in combination with xylanase when compared to the control.

Example 2

Effect of enzymes (glucose oxidase, xylanase and maltogenic amylase) on laminated dough and baked product

Four samples of dough were prepared using the above procedure with various concentrations of enzymes. The four different samples of dough were evaluated for various properties such as stickiness, softness, extensibility and elasticity according to the scoring chart in Table 2 compared to a control without the addition of enzymes. The results are shown in Table 5.

Table 5: Dough properties with the addition of enzyme

The dough was maintained at temperatures as indicated in table 5 and then baked to puff pastry. The puff pastry was evaluated for various properties such as crust colour, crispiness, appearance and specific volume in comparison to the control without the addition of enzymes. The results are shown in Table 6.

Table 6: Puff pastry properties with the addition of enzyme

It is observed (as shown in Table 5) that there were no changes in dough properties with the addition of glucose oxidase, xylanase and maltogenic amylase. It is observed (as shown in Table 6) that there was an increase in specific volume of puff pastry with combination of glucose oxidase, xylanase and maltogenic amylase when compared to the control.

Example 3

Effect of beta-amylase on laminated dough and baked product

Five samples of dough were prepared using the above procedure with various concentrations of enzymes. The five different samples of dough were evaluated for various properties such as stickiness, softness, extensibility and elasticity according to the scoring chart in Table 2 compared to a control without the addition of enzymes. The results are shown in Table 7.

Table 7: Dough properties with the addition of beta amylase

The dough was maintained at temperatures as indicated in table 7 and then baked to puff pastry. The puff pastry was evaluated for various properties such as crust colour, crispiness, appearance and specific volume in comparison to the control without the addition of enzymes. The results are shown in Table 8.

Table 8: Puff pastry properties with the addition of beta amylase

Crispiness 5 5 5 5 5

Appearance 5 5 5 5 5

Specific volume (ml/g) 5.36 5.63 5.07 4.57 4.55

Specific volume % of 118 124 111 101 100

control

It is observed (as shown in Table 7) that there were no changes in dough properties with the addition of beta amylase. It is observed (as shown in Table 8) that there was an increase in specific volume of puff pastry (10-70 degree DP units/kg of flour) compared to control.