WEBER, Jean, L. (14275 88th Place North, Maple Grove, Minnesota, 55369, US)
RAY, Madonna, Madaline (765 Hiawatha Ave, Vadnais Heights, Minnesota, 55127, US)
STAEGER, Michael, A. (16500 The Strand, Minnetonka, Minnesota, 55345, US)
WEBER, Jean, L. (14275 88th Place North, Maple Grove, Minnesota, 55369, US)
RAY, Madonna, Madaline (765 Hiawatha Ave, Vadnais Heights, Minnesota, 55127, US)
WHAT IS CLAIMED IS:
1. A dough composition comprising flour, liquid, yeast, and yeast cell wall material from the species Saccharomyces cerevisiae.
2. The dough composition of claim 1, wherein the yeast cell wall material is present in an effective amount to provide the dough composition with at least one improved property when compared to a dough composition that does not include the yeast cell wall material.
3. The dough composition of claim 2, wherein the improved property is selected from the group consisting of: (a) increased baked specific volume in a baked article made from the dough composition; (b) increased carbon dioxide gas generation during leavening of the dough composition at retarder conditions; (c) reduced yeast lag time; and (d) improved handling or processing characteristics.
4. The dough composition of claim 3, wherein the dough composition has a rate of carbon dioxide gas generation during leavening at retarder conditions that is at least about 4% greater than a dough composition that does not include the yeast cell wall material.
5. The dough composition of claim 3, wherein the dough composition can be proofed at retarder conditions and can be baked to form a baked article having a baked specific volume that is at least about 15% greater than the baked specific volume of a dough composition that does not include the yeast cell wall material.
6. The dough composition of claim 5, wherein the baked specific volume is about 4.5 cm 3 /gram or greater.
7. The dough composition of claim 1, wherein the yeast cell wall material comprises about 0.5% weight or less of the dough composition.
8. The dough composition of claim 1 , wherein the yeast cell wall material comprises- about 0.01% to about 0.8% weight of the dough composition.
9. The dough composition of claim 1 , wherein the yeast cell wall material comprises a plurality of segmented cell wall portions comprising cell wall membrane and a minor amount of cell cytoplasm.
10. The dough composition of claim 9, wherein the segmented cell wall portions have lengths ranging from about 2 to about 10 microns.
11. The dough composition of claim 1, wherein the yeast cell wall material is not an active leavening agent.
12. The dough composition of claim 1 , wherein the yeast comprises about 2% to about 10% weight of the dough composition, and the yeast cell wall material comprises about 0.05% to about 0.8% weight of the dough composition.
13. The dough composition of claim 1 , wherein the yeast and the yeast cell wall material are present in the dough composition in a weight ratio ranging from about 2: 1 to about 100: 1.
14. The dough composition of claim 1, wherein the yeast cell wall material is prepared by a process comprising the steps of:
(a) providing yeast of the species Saccharomyces cerevisiae; (b) lysing the yeast to form a composition comprising yeast cell wall material and yeast extract;
(c) separating at least a portion of the yeast cell wall material from the yeast extract; and
(d) drying the yeast cell wall material.
15. The dough composition of claim 1, wherein the yeast cell wall material comprises polysaccharides, proteins, and lipids.
16. The dough composition of claim 15, wherein the yeast cell wall material comprises about 30% to about 60% weight polysaccharides, about 15% to about 30% proteins, and about 5 to 20% weight lipids.
17. The dough composition of claim 1, wherein the dough composition is a developed dough composition.
18. The dough composition of claim 1 , wherein the dough composition further includes a chemical leavening agent.
19. The dough composition of claim 1 , wherein the dough composition further comprises ascorbic acid.
20. The dough composition of claim 19, wherein the dough composition comprises about 0.005% to about 0.0175% weight ascorbic acid.
21. The dough composition of claim 19, wherein the dough composition comprises about 0.05% to about 0.8% weight yeast cell wall material and about 0.005% to about 0.0175% weight ascorbic acid.
22. The dough composition of claim 1, wherein the dough composition is a retarder-to-oven composition that can be proofed in a retarder at retarder conditions.
23. The dough composition of claim 1 , wherein the dough composition is a retarder-to-oven composition that can be both thawed and proofed in a retarder at retarder conditions.
24. The dough composition of claim 1, wherein the dough composition is a thaw, proof, and bake composition.
25. The dough composition of claim 24, wherein the dough composition can be proofed at ambient conditions.
26. The dough composition of claim 24, wherein the dough composition can be proofed at proof box conditions.
27. The dough composition of claim 1, wherein the dough composition is a freezer-to-oven dough composition.
28. A baked article prepared from the dough composition of claim 1.
29. A method of improving the activity of yeast in a yeast-leavened. dough composition, the method comprising the steps of:
(a) providing a yeast cell wall material from the species Saccharomyces cerevisiae; and
(b) adding the yeast cell wall material as an ingredient in a yeast-leavened dough composition that comprises flour, liquid, and yeast.
30. A method of proofing a frozen retarder-to-oven dough composition, the method comprising the steps of:
(a) providing a frozen dough composition comprising flour, water, yeast, and yeast cell wall material from the species Saccharomyces cerevisiae;
(b) thawing the frozen dough composition; and
(c) proofing the dough composition at retarder conditions.
31. The method of claim 30, wherein both the thawing step and the proofing step are conducted at retarder conditions.
32. A method of making a baked article, the method comprising the steps of: (a) providing a frozen dough composition comprising flour, water, yeast, and yeast cell wall material from the species the species Saccharomyces cerevisia; (b) thawing the frozen dough composition; 7 012943
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(c) proofing the dough composition at retarder conditions; and
(d) baking the proofed dough composition to form a baked article.
33. The method of claim 32, wherein both the thawing step and the proofing step are conducted at retarder conditions.
34. The method of claim 32, wherein the baked article has a baked specific volume of about 4.5 cm 3 /gram or greater. |
YEAST-LEAVENED DOUGH COMPOSITIONS COMPRISING YEAST CELL WALL MATERIAL
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Serial Number 60/810,367, filed June 2, 2006, the disclosure of which is incorporated herein by reference.
BACKGROUND Yeast is a known dough ingredient that can produce a metabolic gas such as carbon dioxide to leaven and proof a dough composition prior to cooking. During the proofing step, the action of the yeast causes the dough to rise to the desired precooked density. One drawback of leavening a dough composition with yeast is that a separate and time-consuming proofing step is typically required before cooking. This step increases the total time required to prepare a cooked dough product. On a commercial scale, proofing machines are sometimes used that hold the dough composition at a desired temperature for proofing. This equipment increases the cost of preparing a proofed, yeast- leavened cooked dough product.
Dough composition may be frozen for later processing or to preserve dough compositions for longer periods. Frozen yeast-leavened dough compositions are typically thawed prior to cooking at a temperature that is above freezing but below room temperature, for example, in an apparatus known as a retarder. Such processing adds time and cost to the process of preparing the cooked dough product. After thawing, the yeast-leavened dough is typically proofed outside of the retarder, either by placing the dough in a proof box or by exposing the dough composition to ambient conditions (i.e., "floor time"). The amount of time for proofing can be substantial, for example, about 0.5 to 4 hours.
In order to improve efficiency and reduce cost, there is an ongoing need to identify improved dough compositions. For example, dough compositions that can be thawed and proofed at retarder conditions so that a separate proofing step is not required are very desirable.
SUMMARY
The invention relates to yeast-leaveried dough compositions that comprise cell wall material from the yeast species Saccharomyces cerevisiae. Although not wishing to be bound by theory, it is believed that the yeast cell wall material acts as a yeast food or as a chemoprotectant to increase the generation of carbon dioxide gas (Cθ 2 ( g )) during leavening of the dough composition. The yeast cell wall material is a dried preparation of comprising the insoluble fraction of whole yeast cells, namely the cell wall membrane with minor fractions of the cell cytoplasm. The yeast cell wall material is a byproduct of the yeast extract process that produces yeast extract for other applications. The yeast cell wall material itself is not an active leavening agent as compared to metabolically active whole yeast. Rather, it is believed to function cooperatively with the yeast in order to increase the generation of carbon dioxide gas by the yeast during leavening.
The invention is generally applicable to any type of yeast-leavened dough composition. For example, the dough compositions may be conventionally proofed dough compositions, retarder-to-oven dough composition (i.e., RTO), or freezer-to- oven (i.e., FTO) dough compositions. Examples of dough compositions of the invention include those used to produce food products such as yeast-leavened rolls (e.g., cinnamon rolls), yeast-leavened breads (buns, rolls, bread sticks, etc.), yeast- leavened donuts, and other such similar dough products.
In one aspect, the invention provides yeast-leavened dough compositions that comprise flour, water, yeast, and yeast cell wall material from the species Saccharomyces cerevisiae. In many embodiments, the yeast cell wall material is added in an effective amount in order to improve at least one property of the dough composition or baked article formed from the dough composition. For example, in some embodiments, the dough composition of the invention exhibits one or more improved properties, such as (1) increased baked specific volume (BSV) in baked articles made from the dough composition; (2) increased carbon dioxide gas (Cθ 2(g) ) generation during leavening; (3) reduced yeast lag time; and/or (4) improved dough handling or dough processing characteristics.
In some embodiments, the dough composition has a rate of carbon dioxide gas (CO 2 ( g )) generation during leavening at retarder conditions that is at least about
4% greater than a dough composition that does not include the yeast cell wall material. In some embodiments, the rate of carbon dioxide generation during leavening at retarder conditions is at least about 25% greater than a dough composition that does not include the yeast cell wall material. In yet other embodiments, the rate of carbon dioxide generation during leavening at retarder conditions is at least about 50% greater than a dough composition that does not include the yeast cell wall material. In other embodiments, the rate of carbon dioxide generation during leavening at retarder conditions is at least about 75% greater than a dough composition that does not include the yeast cell wall material. In yet other embodiments, the rate of carbon dioxide generation during leavening at retarder conditions is at least about 100% greater than a dough composition that does not include the yeast cell wall material. The rate of carbon dioxide gas generation can be measured, for example, using a Risograph device as described herein.
In some embodiments, the dough composition can be proofed at retarder conditions. Typically, retarder conditions are not conducive to proofing of conventional yeast-leavened dough compositions. That is, after thawing in a retarder, conventional yeast-leavened dough compositions do not become proofed, but remain unproofed until being removed from the retarder and placed in a proofing environment (e.g., room temperature or slightly higher for an extended period of time). By contrast, embodiments of the dough composition of the invention can be thawed and proofed at retarder conditions, and can be baked without a separate proofing step to form a baked article having a baked specific volume that is at least 10% greater than the baked specific volume of a dough composition that does not include the yeast cell wall material. For example, the baked specific volume may be about 4 cm 3 /gram to about 8.5 cm 3 /gram. In other embodiments, dough products have a baked specific volume of about 5 cmVgram to about 8.5 cmVgram. And in still other embodiments, dough products have a baked specific volume of about 5 cm 3 /gram to about 7.5 cm 3 /gram. Baked specific volume can be measured, for example, using a calibrated bread volume measurer such as a BVM-L500 (from Tex VoI Industries).
In some embodiments, the yeast cell wall material comprises about 0.5% weight or less of the dough composition. For example, in some embodiments, the
yeast cell wall material may be present in an amount ranging from about 0.01% to about 0.8% weight of the dough composition. In some embodiments, the yeast and yeast cell wall material are present in a weight ratio of yeast to yeast cell wall material ranging from about 2:1 to about 100:1. In some embodiments, the yeast cell wall material is prepared by a process including the steps of: (a) providing yeast of the species Saccharomyces cerevisiae; (b) Iysing the yeast to form a composition comprising yeast cell wall material and yeast extract; (c) separating at least a portion of the yeast cell wall material from the yeast extract; and (d) drying the yeast cell wall material. The resulting yeast cell wall material comprises a plurality of discrete segmented cell wall portions comprising cell wall membrane with minor amounts of cell cytoplasm that make up the largely aqueous insoluble fraction of whole yeast cells. The individual portions of cell wall typically have a length ranging from about 2 to about 10 microns.
The yeast cell wall material comprises polysaccharides, proteins, lipids, and minerals. For example, in some embodiments, the yeast cell wall material comprises about 30% to about 60% weight polysaccharides, about 15% to about 30% proteins, and about 5% to 20% weight lipids. Yeast cell wall material may also contain vitamins such as B vitamins, folic acid, pantothenic acid, and biotin. It may also contain minerals such as potassium, phosphorus, magnesium, calcium, iron and zinc. In some embodiments, the dough composition further includes ascorbic acid.
Although not wishing to be bound by theory, it is believed that the combination of yeast cell wall material and ascorbic acid in a yeast-leavened dough composition provide a synergistic effect leading to improved properties as described herein. In some embodiments, the dough composition comprises about 0.002% to about 0.1075% weight ascorbic acid. In some embodiments, the dough composition comprises about 0.05% to about 0.4% weight yeast cell wall material and about 0.0065% to about 0.012% weight ascorbic acid.
In another aspect, the invention provides a method of improving the activity of yeast in a yeast-leavened dough composition, the method comprising the steps of: (a) providing a yeast cell wall material from the species Saccharomyces cerevisiae; and
(b) adding the yeast cell wall material as an ingredient in a yeast- leavened dough composition that comprises flour, liquid, and yeast. In another aspect, the invention provides a method of proofing a frozen retarder-to-oven dough composition, the method comprising the steps of: (a) providing a frozen dough composition comprising flour, water, yeast, and yeast cell wall material from the species Saccharomyces cerevisiae;
(b) thawing the frozen dough composition; and
(c) proofing the dough composition at retarder conditions.
In yet another aspect, the invention provides a method of making a baked article, the method comprising the steps of:
(a) providing a frozen dough composition comprising flour, water, yeast, and yeast cell wall material from the species the species Saccharomyces cerevisia;
(b) thawing the frozen dough composition; (c) proofing the dough composition at retarder conditions; and
(d) baking the proofed dough composition to form a baked article. Allowing the dough composition to proof in a retarder can eliminate an otherwise needed proofing step that may take place in a proof box or in the open at ambient temperature (i.e., "floor time") between the retarder and oven. Thus, exemplary embodiments of a method of the invention can be to proof a dough composition at retarder conditions (e.g., in a retarder) and bake the dough composition directly or soon after removal of the proofed dough composition from the retarder, for example within 30 minutes.
Advantages that can be associated with embodiments of the invention include that the dough compositions can be thawed and proofed at retarder conditions and then cooked without the delay normally associated with a separate proofing step outside of the retarder. Further, there is no requirement to transfer the dough composition out of the retarder (e.g., to a proof box or to the floor) for resting or proofing. These advantages can result in improved efficiency compared to preparation of other normally-yeast-leavened dough compositions that are removed from a retarder after being thawed, and then proofed outside of the retarder, before baking.
Dough compositions and methods of the invention may also eliminate the substantial cost of equipment (e.g., a proof box, if used) and can reduce waste that can occur by use of a conventional proofing step that takes place in a proof box. Even though a proofing step can be a relatively easy and simple step, it is possible to over-proof certain dough compositions, especially if a proof box is used. Waste from such over-proofed dough can be reduced by the use of dough compositions and methods of the invention.
The term "proofed" is used herein refers to a dough composition that has been processed by a step intended to cause a volumetric rise in the dough. For example, a "proofed" dough composition has been subject to a specific holding stage for causing the volume of the dough to increase by about 50 percent or more (e.g., 50 percent to 300 percent). The terms "proof and "proofing" as used herein relate to a process intended to provide a proofed dough composition.
The term "unproofed" is used herein to refer to a dough composition that has not been processed to include any step intended to cause proofing of the dough. For example, the dough may not have been subject to a specific holding stage for causing the volume of the dough to increase by 50% or more.
"Retarder conditions" means temperatures below room temperature (e.g., below 65°F) at which thawing and proofing can occur. Typical retarder conditions range from about 38° F to about 47 0 F.
"Ambient conditions" means a temperature in the range from 65°F to 85°F, more typically about 65°F to 80°F, and most typically about 75°F.
BRIEF DESCRIPTION OF THE FIGURES FIG. 1 shows the results of a Risograph Study of Example 1 with the elapsed time of the study displayed on the X-axis and the amount of Cθ 2 ( g > generated displayed on the Y-axis.
FIG. 2 is a magnified image of typical yeast cells. FIG. 3 is a magnified image of yeast cell wall material.
DETAILED DESCRIPTION
The embodiments of the invention described herein 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 that others skilled in the art can appreciate and understand the principles and practices of the invention.
In one aspect, the invention provides yeast-leavened dough compositions that comprise a yeast cell wall material from the species Saccharomyces cerevisiae. The dough compositions comprise flour, a liquid composition of water, yeast, a yeast cell wall material from the species Saccharomyces cerevisiae, and may further comprise one or more optional ingredients such as chemical leavening agents, salt, oil, shortening, sweeteners, dairy products, egg products, processing aids, emulsifiers, particulates, dough conditioners, flavorants, gums, etc. The flour component can be any suitable flour or combination of flours, including glutenous flour, nonglutenous flour, and combinations thereof. The flour or flours can be whole grain flour, wheat flour, flour with the bran and/or germ removed, or combinations thereof. Amounts of flour to be used in dough compositions are well known and can depend on the type of dough. For example, developed dough compositions of the invention typically comprise about 45% to about 60% weight flour based on the total weight of the dough composition.
Examples of liquid components include water, milk, eggs, and oil, or any combination of these. Amounts of such liquid components are well known. The amount of liquid component included in any particular dough composition can depend on a variety of factors including the desired moisture content of the dough composition. In many embodiments, the liquid component is water. Water may be present in dough compositions of the invention to provide the dough composition with the desired thickness and/or texture. The precise amount of water depends on factors known to those skilled in the art including, for example, the type and amount of flour used, the desired final product, and the amount and type of other ingredients. The amount of liquid from all sources, for example, water, eggs, milk, etc. should not be so high that the dough composition becomes soft and cannot maintain its
desired closed-cell structure including bubbles of carbon dioxide and water vapor. Also, the amount of liquid should not be so low that the dough composition is dry and has no ability to expand. Water may be added during processing in the form of ice, to control the dough temperature in process. Yeast can contribute to proofing of a dough composition of the invention by generating a gas (e.g., carbon dioxide) due to metabolic activity of the yeast. As used in the invention, yeast can contribute to proofing a dough composition at retarder conditions. Yeast included in the inventive dough composition may be any type of suitable yeast that can leaven and contribute to proofing a dough composition at retarder conditions. Useful yeasts that can contribute to proofing a dough composition at retarder conditions include,. for example, fresh crumbled yeast (also called cake yeast or compressed yeast), yeast cream, instant dry yeast, dry active yeast, protected active dry yeast, frozen yeast, and combinations of these. Yeast ingredients such as these can differ in the amount of moisture contained in a yeast ingredient, which can in turn influence how much of a particular yeast ingredient should be combined with other ingredients to provide a dough composition according to the invention. This selection will be readily understood by those skilled in the dough and baking arts. For example, fresh crumbled yeast (cake yeast and compressed yeast ingredients) has a higher moisture content than dry active yeast ingredient.
The moisture content of a yeast ingredient can affect the total amount of a yeast ingredient included in a dough composition. Fresh crumbled yeast, cake yeast, and compressed yeast have a moisture content of about 70% by weight of the yeast ingredient. Yeast cream typically has a higher moisture content, and dry active yeast typically has a lower moisture content, e.g., of about 8% by weight of the yeast ingredient. Thus, due to the difference in moisture content, a lower total amount of an overall dry active yeast ingredient (including less water) would likely be needed in place of a higher moisture content yeast ingredient such as fresh crumbled yeast, cake yeast, or compressed yeast. To be clear, the total amount of the yeast portion of the yeast ingredient that is added should be similar, but the amount of moisture included by adding each ingredient will differ, causing different total amounts of the ingredients to be used.
Exemplary amounts of fresh crumbled yeast that can contribute to proofing a dough composition at retarder conditions include amounts in the range from about 2% to about 10% weight of the dough composition. In some embodiments, the amount of fresh crumbled yeast may range from about 3% to about 7% weight, or from about 4% to about 6% weight. Other yeast ingredients that have similar moisture content to fresh crumbled yeast can be used in this same range. Yeast ingredients that have different (higher or lower) percent moisture can be used in higher or lower amounts (respectively), but still in amounts that will provide the same or similar amount of the yeast component of the yeast ingredient. Dough compositions of the invention comprise yeast cell wall material from the species Saccharomyces cerevisiae. Although not wishing to be bound by theory it is believed that the yeast cell wall material acts as a yeast food and/or as a chemoprotectant. for the active yeast that is present in the dough composition. A chemoprotectant is a material that increases the viability of the yeast by protecting it from harmful chemicals (e.g., low molecular weight fatty acids) and increasing the tolerance of yeast to ethanol. The yeast cell wall material is also rich with survivor factors such as sterols.
The yeast cell wall material is added to the dough composition in order to provide the dough composition with one or more improved properties as described herein. In many embodiments, the dough composition comprises about 0.5% weight or less of the yeast cell wall material, for example, about 0.4% weight or less, about 0.3% weight or less, about 0.2% weight or less, about 0.15% weight or less, or about 0.1% weight or less. In some embodiments, the dough composition comprises about 0.01% to about 0.20% weight of the non-viable yeast cell wall material, for example, from about 0.05% to about 0.15% weight, or from about 0.05% to 0.125% weight.
Yeast cell wall material is produced as a co-product during the production of yeast extract. For example, to manufacture cell wall material, yeast is first lysed and the insoluble cell wall material is separated from the soluble yeast extract, for example, by centrifugation. The separated cell wall material is then dried, for example, by spray drying or roller drying. The resulting cell wall material takes the form of discrete segmented cell wall portions comprising cell wall membrane with minor amounts of cell cytoplasm that make up the largely aqueous insoluble fraction
of whole yeast cells. Typically, the portions have a length ranging from about 2 to about 10 microns. FlG. 2 shows typical active yeast cells. FIG. 3 shows typical yeast cell wall material. Yeast cell wall material typically comprises polysaccharides, proteins, lipids, and chitin. For example, the yeast cell wall material may comprise about 30% to about 60% weight polysaccharides, about 15% to about 40% proteins, about 5 to 20% weight lipids, and a small amount of chitin. A portion of the protein is linked to the mannan-oligosaccharides (MOS) and is referred to as mannoprotein complex. In many embodiments, the yeast cell wall material comprises about 15% to about 30 % weight beta-glucan and about 15% to about 30% MOS. Yeast cell wall material also may contain vitamins such as B vitamins, folic acid, pantothenic acid, and biotin. It also may contain minerals such as potassium, phosphorus, magnesium, calcium, iron and zinc.
Yeast cell wall material is also known as "yeast hulls" or "yeast ghosts." Suitable yeast cell wall material is commercially available under the trade designation "NUTREX 370" (from Sensient Flavors, Milwaukee WI). Dough compositions of the invention may optionally include fat ingredients such as oils and shortenings. Examples of suitable oils include soybean oil, corn oil, canola oil, sunflower oil, and other vegetable oils. Examples of suitable shortenings include animal fats and hydrogenated vegetable oils. An amount of fat used can depend in large part on the particular type of dough composition being prepared (e.g., a bread, a bagel, or a donut, roll, or other pastry). Fat can typically be used in amounts less than about 6% weight, often less than about 4% weight of the total weight of a dough composition. In some embodiments, the dough composition includes one or more types of fat that are added to the dough composition at the time the dough is prepared and are substantially interspersed and distributed throughout the dough composition. In other embodiments, the dough composition is provided in the form of a dough laminate product, for example, a danish or croissant. In these embodiments, there are typically two fat components in the dough composition, a "mixed-in" fat component and a "rolled-in" fat component. The mixed-in fat component is typically added into the dough composition at the time the dough is prepared and is substantially interspersed and distributed throughout the dough composition. The amount of fat in the dough product due to the mixed-in fat
component will depend upon the type of dough composition being prepared, but will typically range from about 1% to about 5% weight of the dough composition. The rolled-in fat component is added to the dough composition by laminating the dough and roll-in fat component in alternating layers. The amount of fat added by virtue of the roll-in component typically ranges from about 5% to about 30% weight of the dough composition.
The dough compositions may optionally include one or more sweeteners, natural or artificial, liquid or dry. If a liquid sweetener is used, the amount of other liquid components can be adjusted accordingly. Examples of suitable dry sweeteners include lactose, sucrose, fructose, dextrose, maltose, corresponding sugar alcohols, and mixtures thereof. Examples of suitable liquid sweeteners include high fructose corn syrup, malt, and hydrolyzed corn syrup. Often, dough compositions include between about 0.5 and about 8 weight percent sweetener, e.g., from about 1 weight percent to about 3 weight percent sweetener. Sweeteners may be obtained commercially from United Sugars Corp.; Imperial Sugar Co.; Michigan Sugar Co.; Western Sugar; Sweeteners Plus, Inc.; C&H Sugar Co.; and Cargill, Inc.
The dough compositions may optionally include additional flavorings, for example, salt, such as sodium chloride and/or potassium chloride; whey; malt; yeast extract; inactivated yeast; spices; vanilla; natural and artificial flavors; etc.; as is known in the dough product arts. The additional flavoring can typically be included in an amount in the range from about 0.1 weight percent to about 10 weight percent of the dough composition, e.g., from about 0.2 to about 5 weight percent of the dough composition.
The dough compositions may optionally include one or more chemical leavening agents. Chemical leavening agents typically comprise acidulants and bases. Representative examples of acidulants include SALP, SAPP 3 and GDL. Representative examples of bases include sodium bicarbonate, potassium bicarbonate, and ammonium bicarbonate. If present, a chemical leavening is typically present in a minor amount relative to the total weight of the leavening agent (yeast and chemical leavening agent).
The dough compositions may optionally include a dough conditioner blend, for example, a mixture of DATEM; ammonium sulfate; calcium sulfate;
azodicarbonamide; potassium iodate; and L-cystein in a wheat flour carrier. The dough conditioner functions to oxidize or reduce the dough in order to deliver optimal gas holding capacity. Typically, the dough conditioner blend is present in an amount less than about 1 percent by weight of the dough composition, more typically less than about 0.5 percent by weight of the dough composition.
The dough compositions may optionally include a dough conditioner enzyme blend, for example, a blend of alpha amylase and glucose oxidase in a wheat flour, dextrin, and salt carrier. The dough conditioner enzyme blend functions to soften and oxidize the dough composition in order to deliver optimal eating characteristics and increase shelf life. Typically, the dough conditioner enzyme blend is present in an amount less than about 0.03% weight of the dough composition, more typically less than about 0.01% weight of the dough composition. Suitable dough conditioners are commercially available from Novozymes, Inc.
The dough compositions may optionally include particulates such as raisins, currants, fruit pieces, nuts, seeds, vegetable pieces, and the like, in suitable amounts.
The dough compositions may optionally include other additives, colorings, and processing aids such as emulsifiers including lecithin, mono- and diglycerides, polyglycerol esters, and the like, e.g., diacetylated tartaric esters of monoglyceride (DATEM), calcium stearoyl lactylate (CSL), sodium stearoyl lactylate (SSL). Yeast-leavened dough compositions of the invention may be developed or undeveloped dough compositions. Developed doughs are generally understood to include doughs that have a developed gluten matrix structure; a stiff, elastic rheology; and that are capable of forming a matrix of relatively elastic bubbles or cells that hold a leavening gas while the dough expands, leavens, or rises, prior to or during cooking (e.g., baking). Features that are sometimes associated with a developed dough, in addition to a stiff, elastic rheology, include a liquid component content, e.g., water content, that is relatively high; a high protein content; a relatively low fat content; and processing steps that include time to allow the dough ingredients (e.g., protein) to interact and "develop" or strengthen the dough. Developed doughs in general can be yeast-leavened and are normally relatively less dense prior to and after cooking (i.e., on average have a relatively higher specific volume) compared to undeveloped doughs. Examples of specific types of doughs
that can be considered to be developed doughs include doughs for pizza crust, breads (loaves, French bread loaves, Kaiser rolls, hoagie rolls, dinner rolls, baguettes, focaccia, flat breads, bread sticks), raised donuts and sweet rolls, cinnamon rolls, croissants, Danishes, pretzels, etc. In contrast to developed doughs, doughs generally referred to as undeveloped (or "non-developed") doughs have an undeveloped (or less developed) matrix structure resulting in a non-elastic (or less elastic) rheology and, therefore, have relatively lower raw and baked specific volumes due to reduced gas retention by the dough. Examples of undeveloped types of doughs include cookies, cakes, cake donuts, muffins, and other batter-type doughs such as brownies, biscuits, etc.
Yeast-leavened dough compositions of the invention can be prepared according to methods and steps that are presently known (e.g., the sponge method and straight-dough method), or developed in the future. Exemplary steps include steps of mixing or blending ingredients, folding, lapping with and without fat or oil, forming, shaping, cutting, rolling, filling, etc., which are steps well known in the dough and baking arts for making developed doughs (i.e., steps that can provide a developed gluten matrix structure and a stiff, elastic rheology which are characteristic of a developed dough).
Dough compositions of the invention can be packaged in an unfrozen or frozen state and may be unproofed, partially proofed, or pre-proofed. In some embodiments, the dough compositions of the invention are frozen in an unproofed state. Dough compositions of the invention can be packaged in any conventional package. A package may be a standard flexible package of a flexible film (e.g., plastic) that contains one or more portions (e.g., loaves, rolls, etc.) either loosely or supported by a rigid structure such as cardboard or plastic. The package may be included in a larger package such as a cardboard box for sale and distribution.
Thawing a frozen, dough composition of the invention can be performed using methods known in the art. Exemplary methods include subjecting the frozen dough composition to retarder conditions, ambient conditions, proof-box conditions, and even in a cold oven. In many embodiments, thawing is performed at retarder conditions. Retarder conditions are well known in the art and generally include temperatures above freezing (32°F) and below the lower end of ambient
temperatures (65 °F). Typical retarder temperatures include those in the range from about 38°F to about 47°F. Retarder conditions can be provided by equipment such as retarders, which are well known in the dough processing arts. Preferably, a frozen dough composition of the invention is positioned in a rack of the type typically used in thawing procedures and covered so that the dough does not dry out during thawing. At retarder conditions, large dough pieces (e.g., large loaves such as French loaves having a weight of about 500 grams) typically have a thaw time ranging from about 6 to about 10 hours. By contrast, at retarder conditions small • dough pieces (e.g., having a weight of about 50 to 100 grams) typically have a thaw time ranging from about 4 to about 5 hours.
After thawing, the dough is typically proofed. Proofing can occur at a wide variety of conditions such as retarder conditions, ambient conditions ("floor proof), proof-box conditions, and even in a cold oven. Retarder conditions and proof-box conditions are typically provided with equipment well known in the dough processing arts such as retarders and proof-boxes, respectively. In some embodiments, the dough compositions of the invention are proofed at retarder conditions. At retarder conditions, large dough pieces (e.g., large loaves such as French loaves having a weight of about 500 grams) may be proofed in a time period ranging from about 10 to about 24 hours. At retarder conditions, small dough pieces (e.g., having a weight of about 50 to about 100 grams) may be proofed in a time period ranging from about 4 to about 12 hours. In exemplary embodiments, the dough compositions are both thawed and proofed at retarder conditions.
In some embodiments, the dough compositions of the invention are proofed at ambient temperature. Preferably, a dough composition of the invention is positioned in a rack of the type typically used in proofing procedures and covered so that the dough does not dry out during proofing. Depending on factors such as dough mass and/or dough configuration a dough composition of the invention can proof at an ambient temperature in a time period from 30 minutes to about 6 hours, preferably from about 1 to about 4 hours. In some embodiments, an advantage of a dough composition of the invention is that it can be proofed at retarder conditions or at ambient temperature in a lesser time period as compared to conventional frozen dough having a standard level of
yeast and an enzyme that facilitates the production of hydrogen peroxide in the dough composition.
In some embodiments, an advantage of a dough composition of the invention is that it does not need to be proofed at proof-box conditions (e.g., in a proof-box), but can be proofed at retarder conditions or ambient conditions while providing a proofed dough composition having substantially similar, even superior, characteristics (e.g., raw specific volume).
Although a dough of the invention could be proofed at proof-box conditions, by eliminating the requirement of proof-box conditions, cost savings can be realized by, e.g., not having to provide equipment (e.g., a proof-box) for a conditioned atmosphere. Proof-box conditions are well known in the art and include a temperature greater than 85°F or 90°F and a relative humidity in the range of 80- 95%. Also, although a dough composition of the invention could be proofed at retarder conditions (e.g., in a retarder), proofing at ambient conditions can be more cost effective by, e.g., not having to provide equipment (e.g., a retarder) for such a conditioned atmosphere.
Another advantage of eliminating the requirement that a dough be proofed at proof-box conditions is that monitoring and controlling the proofing atmosphere (i.e., proofing conditions) at, e.g., ambient conditions is much less demanding than proofing at proof-box conditions. This can be a significant benefit to certain commercial proofing operations where relatively unskilled bakery workers are sometimes responsible for proofing a frozen, unproofed dough composition. In general, many prior art doughs that are proofed at proof-box conditions are relatively much more sensitive to changes in the proofing atmosphere (e.g., changes in one or more of relative humidity and temperature) and typically require skilled training and experience to provide a proofed dough composition of suitable quality. Advantageously, a dough composition of the invention being proofed at ambient conditions is much less sensitive to changes in the proofing atmosphere and, therefore, can be proofed by a relatively less skilled worker. After proofing, a proofed dough composition of the invention can be directly cooked, without any additional floor time, or can sit in its proofed condition at a given set of proofing conditions (retarder conditions, ambient conditions, or proof-
box conditions, but preferably ambient conditions) for a period of time as needed or desired (e.g., for scheduling) prior to cooking. This may be necessary or desirable, for example, if a dough composition is thawed and proofed overnight at retarder conditions and cooked in the morning. Dough compositions of the invention are typically cooked following proofing. Methods of cooking are well known in the dough and baking arts, and typically can include baking or frying for a yeast-leavened, developed dough composition. More specifically, a dough composition of the invention may be cooked by conventional means, such as being baked in an oven (e.g., conventional, convection, impingement, microwave) or fried to provide a suitable baked specific volume. Baking a dough composition of the invention in an oven can occur with or without steam injection. Baking in an oven with steam injection is well known in the dough baking arts and typically includes injecting steam into an oven at the beginning of the bake cycle. Baking with steam injection can help a dough product maintain shape and structure, and provide certain appearance and texture characteristics. In certain embodiments, baking can occur at a temperature in a range from 310 0 F to 385 °F and in a time period from 12 to 35 minutes.
A baked dough composition of the invention can have a baked specific volume in the range from about 3.5 cm 3 /gram or greater, depending on the type of dough product ultimately made. In certain embodiments, dough products have a baked specific volume of about 4 cm 3 /gram to about 8.5 cm 3 /gram. In still other embodiments, dough products have a baked specific volume of about 5 cm 3 /gram to about 8.5 cnnVgram. And in still other embodiments, dough products have a baked specific volume of about 5 cmVgram to about 7.5 cm 3 /gram. A baked dough product made with a dough composition of the invention can be one or more of a wide variety of developed dough products that have been yeast leavened, for example, doughs for pizza crust, breads (loaves, French bread loaves, Kaiser rolls, hoagie rolls, dinner rolls, baguettes, focaccia, flat breads, bread sticks), raised donuts and sweet rolls, cinnamon rolls, croissants, Danishes, pretzels, etc. Preferably, a cooked dough product made with a dough composition of the invention is selected from the group consisting of a hoagie roll, a French bread loaf, and a Kaiser roll.
TABLE A provides exemplary ingredients and ranges for such ingredients for dough compositions of the invention. An exemplary procedure for preparing a dough composition of Table A includes the steps of: (1) combining all ingredients and then mixing on low speed (e.g. at about 36 rpm) for about 1 minute, (2) mixing on high speed (e.g., at about 72 rpm) for 7 to 12 minutes. The resulting dough composition typically has a final temperature in the range of about 65°F to 75°F and the dough rheology has a Brabender Farinograph value in the range of about 800 to 1 100 Brabender units.
TABLE A: Exemplary Dough Compositions
The invention will now be further described with reference to the following non-limiting examples.
EXAMPLES EXAMPLE l:
Dough compositions having the compositions shown in TABLES 1-5 were prepared and tested as described in the Example 1.
TABLE 1
Example 1-1 (0.1 %Nutrex 370)
TABLE 2
Comparative Example A (Base Formula)
TABLE 3
Comparative Example B (0.15% Calcium Sulfate)
TABLE 4
Comparative Example C (0.04% Ammonium Sulfate)
TABLE 5
Comparative Example D (0.04% NH 4 Cl; 0.04% CaSO 4 )
General Procedure for Making Dough Compositions
The above formulations were prepared in 2000 gram batches using the following procedure. First, the dry minor ingredients were preblended with the flour. Next, the dry ingredients were added to a Hobart brand mixer. After addition of the dry ingredients, the water and other liquid ingredients were added to the mixer. The resulting composition was then mixed on low speed for 60 seconds, followed by mixing on high speed for 585 seconds to form the dough composition. The dough composition was then transferred to a Rondo brand sheeter where it was sheeted to a thickness of 12- 15 millimeters. The resulting sheeted dough was cut into pieces having a target weight of 50 ± 2 grams using a hand cutter. The cut dough pieces were then transferred to a sheet pan lined with parchment paper. The dough pieces were then frozen in a blast freezer at -20° F to -30° F for 1 hour ± 15
minutes. The resulting frozen dough pieces were placed in plastic bags and stored in a freezer at -10° F prior to testing.
Risograph Test Procedure
A Risograph was used to determine the amount of CO 2 ( g ) that was generated by sample dough compositions. First, the dough samples were placed in separate sample cups that were each sealed with a lid and O-ring. Latex tubing was used to connect the sealed cups to the Risograph. The Risograph was placed in a retarder at 40° F. The CO 2 ( g ) produced by each dough sample traveled through the latex tubing and into the Risograph where the volume of CO2 ( g ) generated by the samples was measured. An empty sealed cup was connected to the Risograph to serve as a control. The results of the Risograph study are reported in TABLE 6 and in FlG.- 1.
TABLE 6
FIG. 1 displays the results of the Risograph study with the elapsed time of the study displayed on the X-axis and the amount
EXAMPLE 2:
Dough compositions having the formulations shown in TABLES 7-9 were prepared and tested as described in this Example 2.
TABLE 7
Example 2-1 (Nutrex 370, 100 ppm LAA)
TABLE 8
Comparative Example E (Base Formula)
TABLE 9
Comparative Example F (1: 1 NH 4 Cl-CaSO 4 )
Procedure for Mixing Dough Compositions
The above formulations were prepared in 22,500 gram batches using the following procedure. First, the dry minor ingredients were preblended with the flour. Next, the dry ingredients were added to a horizontal bar mixer. After addition of the dry ingredients, the water and other liquid ingredients were added to the mixer. The resulting composition was then mixed on low speed (36 rpm) for 60 seconds, followed by mixing on high speed (72 rpm) for about 585 seconds (i.e., target time is 1 minute past peak development based on the mixer power curve) to form a dough composition. The dough composition was extruded using a two-roll extruder to provide a dough sheet having a thickness of about 50 mm. The sheeted dough was transferred to a dough sheeter where it was 2-folded, 3-folded, and then reduced to a final thickness of about 15 mm. The resulting sheeted dough was cut into 1.5 inch wide strips. The dough strips were then cut to a dough pieces having a length of 10 ± 0.5 inches having a target weight of 230 ± 15 grams. The cut dough pieces were then transferred to a sheet pan lined with parchment paper. The dough pieces were then frozen in a blast freezer at -20° F to -30° F for 1 hour ± 15 minutes. The resulting frozen dough pieces were placed in plastic bags and stored in a freezer at -10° F prior to testing. The frozen dough pieces were removed from the freezer and were placed in a retarder at about 39° F to 40° F and 50% to 70% relative humidity for 36 hours. Sample dough pieces were removed at 16 hours, 24 hours, and 36 hours in the retarder. After removing the dough pieces, they were baked at 350° F (20 seconds of oven steam) for 18-22 minutes to form baked articles. The baked articles were then tested to determine their baked specific volume (BSV) using a calibrated Bread
Volume Measurer (BVM-L500 from Tex VoI Industries). The results are reported in TABLE 10.
TABLE 10
Other embodiments of this invention will be apparent to those skilled in the art upon consideration of this specification or from practice of the invention disclosed herein. Various omissions, modifications, and changes to the principles and embodiments described herein may be made by one skilled in the art without departing from the true scope and spirit of the invention which is indicated by the following representative claims.