AU2015202939A1

AU2015202939A1 - Method for producing a bread product

Info

Publication number: AU2015202939A1
Application number: AU2015202939A
Authority: AU
Inventors: Bill Brinkley; Jorge Gironda; Chloe Tarby
Original assignee: ALLIED MILLS Pty Ltd
Current assignee: ALLIED MILLS Pty Ltd
Priority date: 2010-10-01
Filing date: 2015-05-29
Publication date: 2015-06-18
Also published as: AU2011226977A1

Abstract

Method for producing a bread product Abstract The present invention relates to a novel method for producing a bread product. More specifically, the present invention relates to a method for producing a partially baked 5 artisan bread product.

Description

C:\NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 Method for producing a bread product Technical Field The present invention relates to a novel method for producing a bread product. More specifically, the present invention relates to a method for producing a partially baked 5 artisan bread product. Background of the Invention Artisan breads are typically made by skilled bakers in small bakeries and are highly labour intensive. Artisan breads have fewer additives, less uniformity and greater eating qualities than mass-produced bread products. Artisan breads are characterised by a 10 crunchy, biscuit-like crust, an open, resilient and moist interior, and an uneven airy crumb profile. Much research and development effort has focused on producing partially baked (or par baked) artisan-style breads that can be finished by the end user in a suitable oven prior to serving. However, once finished, such par baked products often lack one or more of the desired characteristics of artisan bread noted above. 15 The present inventors have developed an improved method for producing a par baked artisan bread, which, when finished by the end user, delivers a high quality no compromise product possessing all of the desired characteristics noted above. Summary of the Invention In one aspect, the present invention provides a method of producing a bread product 20 comprising: a) preparing a mixture comprising the following components: high ash flour, water and a starter culture; b) fermenting the mixture obtained following step a) so as to provide a ferment; c) preparing a mixture comprising: flour, salt, water and the ferment; 25 d) fermenting the mixture obtained following step c) such that a fermented dough is obtained; e) sheeting and dividing the dough; f) forming the dough; g) proofing the dough; 30 h) partially baking the dough to provide the bread product; and i) cooling the bread product.

C:\NRPortbl\DCC\NXL\3217436 L.DOC-29/05/2015 -2 The starter culture may comprise a mixture of Lactobacillus brevis, Lactobacillus casei and aromatic yeast. The high ash flour may have an ash content of at least 1.0%. 5 The high ash flour may have an ash content of between about 1.0% and 2.2%. The high ash flour may have a particle size of less than about 212 jam, or less than about 180 jam. The high ash flour may have a moisture content of less than 15%. The high ash flour may have a protein content (N x 5.7) between about 13% and 10 19%. The high ash flour may be wheat flour. In step a), the mixture may further comprise plain flour. The plain flour and high ash flour may be present in the mixture in a ratio between about 1:1 and 1:9 15 In step a), water may be present in an amount between about 40% and 60% by weight of the total weight of the mixture. In step b), the mixture may be fermented for at least 18 hours. In step b), the mixture may be fermented at a temperature between about 20 'C and 40 0 C. 20 In step c), the mixture may further comprise one or more of: gluten, an improver and bakers yeast. Step c) may comprise adding the water to a mixture comprising flour, salt, and ferment, in two stages. In step c), the total amount of water present in the mixture may be between about 25 40% and 60% by weight of the total weight of the mixture. In step d), the mixture may be fermented for a period of time between about 1 hour and 5 hours. In step d), the mixture may be fermented at a temperature between about 20 0 C and 40 0 C. 30 In step e), sheeting and dividing the dough may be performed under conditions which maintain, or substantially maintain the network of gas cells created within the dough by fermentation in step d). In step f), forming the dough may involve application of pressure to the dough in an C:\NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 -3 2 amount that is less than about 0.1 kg/cm Step f) may comprise application of pressure to opposite ends of the dough in an 2 amount that is less than about 0.1 kg/cm , so as to impart a desired shape to each end, wherein the network of gas cells created within the dough by fermentation in step d) is 5 maintained or substantially maintained in the dough located between the opposite ends. The desired shape may be a rounded shape, such that the dough resembles the shape of a football. Step g) may comprise subjecting the dough to a temperature between about 25 'C and 40 'C for a period of time between about 30 minutes and 60 minutes. 10 Step h) may comprise baking the dough at a temperature between about 180 'C and 240 0 C. Step h) may comprise baking the dough for a period of time between about 5 minutes and 1 hour. Step h) may comprise baking the dough in an environment comprising steam, is followed by baking in an environment which is substantially free of steam, followed by baking in an environment comprising steam. Step i) may comprise cooling the temperature of the bread product at a rate of between about 0.1 0 C and about 10 0 C per minute. Step i) may result in the bread product losing no more than about 10% moisture, or 20 no more than about 5% moisture. The method may further comprise freezing the bread product after cooling. In another aspect, the present invention provides a bread product when obtained by the method of the invention. Definitions 25 In the context of the present specification, the terms "a" and "an" are used herein to refer to one or to more than one (i.e. to at least one) of the grammatical object of the article. By way of example, "an element" means one element or more than one element. In the context of the present specification, the term "comprising" means "including principally but not necessarily solely". Furthermore, variations of the word "comprising", 30 such as "comprise" and "comprises", have correspondingly varied meanings.

C.NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 -4 In the context of this specification, the term "about" is understood to refer to a range of numbers that a person of skill in the art would consider equivalent to the recited value in the context of achieving the same function or result. Detailed Description of the Invention 5 The present invention relates to a method of producing a bread product. By use of the method of the invention it is possible to prepare a high quality, no compromise, par baked artisan bread which can be conveniently baked for a short period of time by the end user prior to consumption. When desired to be served, the end user simply removes the product from the freezer and bakes it in the oven. Once baking is complete, the bread io product retains freshness for about 24 hours. The finished bread product is characterised by a crunchy, biscuit-like crust, an open, resilient and moist interior, and an uneven airy crumb profile. The method of the invention may be employed on a large commercial scale if desired and can be used to mass produce artisan bread which possesses all of the characteristics of artisan bread produced by a baker. 15 The method of the invention comprises the following steps: a) preparing a mixture comprising the following components: high ash flour, water and a starter culture; b) fermenting the mixture obtained following step a) so as to provide a ferment; c) preparing a mixture comprising: flour, salt, water and the ferment; 20 d) fermenting the mixture obtained following step c) such that a fermented dough is obtained; e) sheeting and dividing the dough; f) forming the dough; g) proofing the dough; 25 h) partially baking the dough to provide the bread product; and i) cooling the bread product. The high ash flour may have an ash content of at least 1.0%. In embodiments of the invention the high ash flour has an ash content between about 1.0% and 3.0%, or between 30 about 1.0% and 2.5%, or between about 1.0% and 2.2%, or between about 1.4% and 1.6%. The high ash flour may have a protein content (N x 5.7) between about 13% and 19%. The high ash flour may have a particle size of less than about 212 jam, or less than about 200 jam, or less than about 190 jam or less than about 180 jam.

C.NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 -5 High ash flour suitable for use in the present invention may be obtained from an appropriate miller, for example Allied Mills, Picton, NSW. The inventors have found that high ash flour possesses favourable bran, alleurone and ash content, which is believed to stimulate enzyme activity and increase bacterial metabolism during fermentation. 5 The starter culture may comprise a mixture of Lactobacillus brevis, Lactobacillus casei and aromatic yeast, for example a mixture of Lactobacillus brevis (He), Lactobacillus casei (Ho) and Saccharomyces Cerevisae. Other starter cultures that may be used in the method of the invention include, but are not limited to, the following mixtures: Pediococcus acidilactici and aromatic yeast; Lactobacillus plantarum and aromatic yeast; 10 Pediococcus pentosaceus and aromatic yeast; Lactobacillus brevis, Lactobacillus plantarum and aromatic yeast; Lactobacillus brevis and yeast. Starter cultures comprising the above noted bacteria/yeast blends that are suitable for use in the method of the invention may be purchased from Lallemand Inc, under the trade name LALVAIN du jour@ Lal through La6. 15 In step a), the mixture may further comprise plain flour. The plain flour is preferably wheat flour, although other types of flour may be used if desired. The plain flour and high ash flour may be present in the mixture in a ratio between about 1:1 and 1:9. In one embodiment, the plain flour and high ash flour may be present in the mixture at a ratio of about 1:1. The high ash flour may be present in an amount 20 between about 20% and 50% by weight of the total weight of the mixture. Water may be present in an amount between about 40% and 60% by weight of the total weight of the mixture, or in about 50% by weight of the total weight of the mixture. The starter culture may be present in an amount between about 0.005% and 0.1% by weight of the total weight of the mixture, or in an amount between about 0.0 1% and 0.1% by weight of the 25 total weight of the mixture, or in about 0.05% by weight of the total weight of the mixture. The high ash flour, water and starter culture (and where present, plain flour) may be mixed in a mixer, for example, for between about 1 and 30 minutes, or between about 1 and 20 minutes, or between about 1 and 10 minutes, or between about 2 and 3 minutes. Preferably, the mixing is performed slowly. 30 In step b), the mixture obtained in step a) is fermented. Fermentation may be performed for at least 18 hours, or for a period of time between about 18 hours and 24 hours. Fermentation may be performed at a temperature between about 20 'C and 40 'C, or at a temperature between about 25 'C and 35 'C, or at a temperature between about 20 C:\NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 -6 'C and 30 'C, or at about 26 'C. In one embodiment, the mixture is fermented for about 18 hours at a temperature between about 26 'C and 30 'C. Following step b), the ferment may be cooled to below 10 'C, or about 4 'C so as to optimise consistency, storage and production flexibility. 5 Step c) involves the preparation of a dough comprising the following components: flour, salt, water and the ferment obtained following step b). The mixture in step c) may further comprise an improver, which may be a natural improver that enhances loaf volume, softness and shelf life. Suitable improvers that may be used are well known to those skilled in the art, and include those sold under the trade names Essential@ PBR-FD and io Essential@ SOFT by Lallemand Inc. The mixture in step c) may further comprise baker's yeast and/or gluten. Step c) may involve adding flour in an amount between about 35% and 55% by weight of the total weight of the mixture, or in an amount between about 40% and 55% by weight of the total weight of the mixture, or in an amount between about 40% and 50% by is weight of the total weight of the mixture, or in an amount of about 45% by weight of the total weight of the mixture. Step c) may involve adding salt in an amount between about 1% and 2% by weight of the total weight of the mixture. Step c) may involve adding water in an amount between about 20% and 50% by 20 weight of the total weight of the mixture, or in an amount between about 25% and 45% by weight of the total weight of the mixture, or in an amount between about 30% and 40% by weight of the total weight of the mixture, or in an amount of about 34% by weight of the total weight of the mixture. Step c) may involve adding the ferment from step b) in an amount between about 25 15% and 35% by weight of the total weight of the mixture, or in an amount between about 15% and 30% by weight of the total weight of the mixture, or in an amount between about 15% and about 25% by weight of the total weight of the mixture, or in an amount between about 15% and 20% by weight of the total weight of the mixture, or in an amount of about 18% by weight of the total weight of the mixture. 30 The flour used in step c) may have a protein content (N x 5.7) between about 10% and 20%, or between about 10% and 15%, or between about 11% and 14%, or between about 11.6% and 13%, or about 12.5%. The flour used in step c) may have a H1 value (45 mins) between about 250 and 600BU, or between about 400 and 600 BU. The flour used C:\NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 -7 in step c) may have a moisture content of up to 15%. The flour used in step c) may have a Minolta (L-b) value between about 80 and 85. The flour used in step c) may have a water absorption value between about 62% and 68%, or about 65%. The flour in step c) may have an El value (45 mins) between about 18 and 24 cm, or about 21 cm. In step c), the 5 flour may be a baker's flour. Step c) may be performed by admixing the flour, salt, water and ferment (and where desired, one or more of: an improver, gluten and bakers yeast) and mixing until a fully developed dough is obtained. Alternatively, the flour, salt, water and ferment (and where desired, one or more of: an improver, gluten and bakers yeast) may be mixed, during io which time water is added gradually. As a further alternative, the water may be added gradually in two distinct stages. Mixing may be carried out in a spiral mixer for example, for a period of about 6 to 20 minutes, or about 6 to 13 minutes. In step c), the total amount of water present in the mixture may be between about 40% and 75%, or between about 40% and 60%, by weight of the total weight of the is mixture. In step d), the mixture obtained in step c) is fermented. Fermentation may be performed for a period of time between about 1 and 5 hours, or between about 2 and 4 hours, or about 2 hours. Fermentation may be performed at a temperature between about 20 'C and 40 'C, or at a temperature between about 20 'C and 35 'C, or at a temperature 20 between about 22 4C and 30 4C, or at a temperature between about 22 4C and 26 4C, or at a temperature of about 26 'C. In a preferred embodiment, the mixture is fermented for about 2 hours at a temperature between about 22 'C and 26 'C, or at about 26 'C. Fermentation under the preferred conditions optimises the distinctive open texture and crumb characteristics of the final bread product by creating a network of irregularly shaped gas 25 cells within the dough. Following fermentation in step d), the dough may increase in size by more than 60%, 70%, 80%, or by more than 90%, or by about 100%. Following step d), the dough may not be knocked back. Following step d), the fermented dough is sheeted and divided into discrete portions 30 in step e). When handling the dough in step e) minimal pressure is preferably applied so as to avoid stressing the dough. Because the final bread texture should be coarse and open, the sheeting and dividing process should be gentle and as stress-free as possible. In one embodiment, sheeting and dividing the dough may be performed under conditions which C:\NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 maintain, or substantially maintain the network of gas cells created within the dough by fermentation in step d). In one embodiment, sheeting and dividing the dough may be performed under conditions which maintain, or substantially maintain the dough structure obtained following fermentation in step d). 5 Step f) comprises forming the dough into a desired form. Typically, the desired form will be that of a football (i.e. a rugby or Australian rules football), although alternative shapes are contemplated. When forming the dough in step f) minimal pressure is also applied so as to minimise stress on the dough. Preferably, when forming the dough 2 2 the pressure applied thereto is less than about 0.1 kg/cm 2 , or less than about 0.08 kg/cm2 2 2 io or less than about 0.04 kg/cm , or less than about 0.02 kg/cm2. Preferably, when forming the dough the pressure applied thereto is between about 0.001 kg/cm 2 and about 0.1 2 ~22 kg/cm 2 , or between about 0.001 kg/cm and about 0.04 kg/cm 2 , or between about 0.005 22 22 kg/cm 2 and about 0.02 kg/cm , or between about 0.005 kg/cm and about 0.04 kg/cm 2 , or 22 between about 0.0001 kg/cm and about 0.04 kg/cm 2 . In one embodiment, step f) may 15 comprise application of pressure to opposite ends of the dough in an amount that is less 222 than about 0.1 kg/cm , or less than about 0.08 kg/cm 2 , or less than about 0.04 kg/cm 2 , or less than about 0.02 kg/cm 2 , so as to impart a desired shape to each end of the dough (for example a rounded end shape). In one embodiment, step f) may comprise application of pressure to opposite ends of the dough in an amount between about 0.001 kg/cm 2 and 20 about 0.1 kg/cm 2 , or between about 0.001 kg/cm 2 and about 0.04 kg/cm 2 , or between about 2 2 2 0.005 kg/cm and about 0.02 kg/cm2, or between about 0.005 kg/cm and about 0.04 2 ~22 kg/cm 2 , or between about 0.0001 kg/cm and about 0.04 kg/cm 2 so as to impart a desired shape to each end of the dough (for example a rounded end shape). The application of such an amount of pressure at each end of the dough results in the 25 network of gas cells created within the dough by fermentation in step d) being maintained or substantially maintained in the dough located between each end, thereby optimising the distinctive open texture and crumb characteristics of the final bread product. In step g) the dough is subjected to proofing conditions. Proofing may be achieved utilising conditions well known to those skilled in the art, for example by subjecting the 30 dough to a temperature between about 25 'C and 40 'C. In one embodiment, proofing is achieved by subjecting the dough to a temperature between about 25 'C and 40 'C for a period of time between about 30 minutes and 1 hour, or alternatively by subjecting the dough to a temperature between about 25 'C and 30 'C for a period of time between about C.NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 -9 30 minutes and 1 hour. Proofing may be performed under conditions which provide a proofed volume of from about 1.0 to 2.0, or about 1.5, times the preproofed dough volume. Proofing may be performed in an atmosphere having high humidity. Proofing may be performed in an atmosphere having between about 50% and 100% humidity, or between 5 about 60% and 90% humidity, or between about 70% and 90% humidity, or about 80% humidity. Following proofing, the dough is then partially baked. Baking may be performed by placing the proofed dough on a hot surface (for example stone) in an oven which is preferably preheated to a temperature between about 180 'C and 240 'C, or between about 10 200 'C and 240 'C. Baking may initially take place in an environment comprising steam (for example an environment comprising saturated steam). Prior to completion of baking the environment comprising steam may be replaced by a dry heat environment, i.e., an environment that is free or substantially free of steam. When the baking environment comprising steam is replaced by a dry heat environment, the oven temperature may also be is reduced. In an alternative embodiment, following baking in an environment comprising steam and baking in a dry heat environment, the latter stages of baking may be performed in an environment comprising steam. Completing the baking process in the presence of steam may prevent the crust from cracking and assist in minimising moisture loss during the 20 cooling and freezing steps. The oven may be an oven having zones adapted for each stage of baking, or alternatively the oven may be an oven which is adapted for the introduction of steam. Baking in the presence of steam creates the foundation for the biscuit-like crust and maximises loaf volume by expanding the gas cells within the dough. Baking in the 25 presence of dry heat primarily serves to partially bake the dough and continue the formation of a biscuit-like crust. Those skilled in the art will recognise that the total baking time will be dependent on the size and shape of the dough, and by the final amount of baking required by the end user. Typically however, the degree of baking will be between about 60% and 90% of full bake, or in another embodiment up to about 80% of 30 full bake. Baking may be performed for a period of time between about 5 minutes and 40 minutes. In step i), the par baked bread product is cooled. The rate of cooling may be between about 0.1 'C and about 10 'C per minute, or between about 1 'C and about 10 'C C.NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 - 10 per minute, or between about 1 'C and about 5 'C per minute, or about 2 'C per minute. Cooling may take place in an enclosed space or room wherein air is extracted therefrom and wherein water (in the form of a spray for example) is introduced so as to ensure that the bread product retains moisture. 5 Step i) may result in the bread product losing no more than about 10% moisture, or no more than about 5% moisture. The cooling step may result in a uniform distribution of moisture between the crust and interior of the bread product. Freezing the bread product may be performed by techniques well known to those skilled in the art, for example blast freezing or flash freezing. 10 The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgement or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general is knowledge in the field of endeavour to which this specification relates. It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention without departing from the spirit or scope of the invention as broadly described. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive. 20

Claims

1. A method of producing a bread product comprising: a) preparing a mixture comprising the following components: high ash flour, water and a starter culture; 5 b) fermenting the mixture obtained following step a) so as to provide a ferment; c) preparing a mixture comprising: flour, salt, water and the ferment; d) fermenting the mixture obtained following step c) such that a fermented dough is obtained; e) sheeting and dividing the dough; 10 f) forming the dough; g) proofing the dough; h) partially baking the dough to provide the bread product; and i) cooling the bread product. 15

2. The method of claim 1, wherein the starter culture comprises a mixture of Lactobacillus brevis, Lactobacillus casei and aromatic yeast.

3. The method of claim 1 or claim 2, wherein the high ash flour has an ash content of at least 1.0%.

4. The method of claim 3, wherein the high ash flour has an ash content of 20 between about 1.0% and 2.2%.

5. The method of any one of claims 1 to 4, wherein the high ash flour has a particle size of less than about 212 rm.

6. The method of any one of claims 1 to 5, wherein the high ash flour has a moisture content of less than 15%. 25

7. The method of any one of claims 1 to 6, wherein the high ash flour has a protein content (N x 5.7) between about 13% and 19%.

8. The method of any one of claims 1 to 7, wherein the high ash flour is wheat flour.

9. The method of claim 8, wherein in step a), the mixture further comprises plain 30 flour.

10. The method of claim 9, wherein the plain flour and high ash flour are present in the mixture in a ratio between about 1:1 and 1:9.

11. The method of any one of claims 1 to 10, wherein in step a), water is present C:\NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 - 12 in an amount between about 40% and 60% by weight of the total weight of the mixture.

12. The method of any one of claims 1 to 11, wherein in step b), the mixture is fermented for at least 18 hours.

13. The method of any one of claims 1 to 12, wherein in step b), the mixture is 5 fermented at a temperature between about 20 'C and 40 'C.

14. The method of any one of claims 1 to 13, wherein in step c), the mixture further comprises one or more of: gluten, an improver and bakers yeast.

15. The method of any one of claims 1 to 14, wherein in step c) water is added to a mixture comprising flour, salt, and ferment, in two stages. 10

16. The method of any one of claims 1 to 15, wherein in step c), the total amount of water present in the mixture is between about 40% and 60% by weight of the total weight of the mixture.

17. The method of any one of claims 1 to 16, wherein in step d), the mixture is fermented for a period of time between about 1 hour and 5 hours. 15

18. The method of any one of claims 1 to 17, wherein in step d), the mixture is fermented at a temperature between about 20 'C and 40 'C.

19. The method of any one of claims 1 to 18, wherein in step e), sheeting and dividing the dough is performed under conditions which maintain, or substantially maintain the network of gas cells created within the dough by fermentation in step d).

20 20. The method of any one of claims 1 to 19, wherein in step f), forming the dough involves application of pressure to the dough in an amount that is less than about 0.1 kg/cm 2 .

21. The method of any one of claims 1 to 19, wherein step f) comprises application of pressure to opposite ends of the dough in an amount that is less than about 2 25 0.1 kg/cm , so as to impart a desired shape to each end, wherein the network of gas cells created within the dough by fermentation in step d) is maintained or substantially maintained in the dough located between the opposite ends.

22. The method of claim 21, wherein the desired shape is a rounded shape, such that the dough resembles the shape of a football. 30

23. The method of any one of claims 1 to 22, wherein step g) comprises subjecting the dough to a temperature between about 25 'C and 40 'C for a period of time between about 30 minutes and 60 minutes.

24. The method of any one of claims 1 to 23, wherein step h) comprises baking C:\NRPortbl\DCC\NXL\3217436_ .DOC-29/05/2015 - 13 the dough at a temperature between about 180 'C and 240 'C.

25. The method of any one of claims 1 to 24, wherein step h) comprises baking the dough for a period of time between about 5 minutes and 1 hour.

26. The method of any one of claims 1 to 25, wherein step h) comprises baking 5 the dough in an environment comprising steam, followed by baking in an environment which is substantially free of steam, followed by baking in an environment comprising steam.

27. The method of any one of claims 1 to 26, wherein step i) comprises cooling the temperature of the bread product at a rate of between about 0.1 'C and about 10 'C per io minute.

28. The method of any one of claims 1 to 27, wherein step i) results in the bread product losing no more than about 10% moisture.

29. The method of any one of claims 1 to 28, further comprising freezing the bread product after cooling. 15

30. A bread product when obtained by the method of any one of claims 1 to 29.