PROCESS FOR THE PRODUCTION OF A READY TO EAT SHELF-STABLE PACKAGED FOCACCIA
20220039405 · 2022-02-10
Assignee
Inventors
Cpc classification
A21D13/04
HUMAN NECESSITIES
International classification
Abstract
A shelf-stable ready-to-eat packaged focaccia, is described having appearance and organoleptic qualities comparable to those of a fresh focaccia, which has a relative humidity comprised between 25 and 32%, preferably 27% and water activity (a.sub.w) comprised between 0.85 and 0.92, preferably 0.89, and blind holes on its surface having depth of at least 50% of the thickness of the focaccia. A process for the production of a ready-to-eat shelf-stable packaged focaccia is also described which comprises the steps of: a) preparing a dough for focaccia comprising, by weight based on the total weight of the dough, 40-60% flour, 20-35% water, 7-16% vegetable oils and/or fats and/or fractions thereof, of which 1-6% extra virgin olive oil, 0.5-4% yeast, 0.1-3% salt, 0-15% at least one organoleptically characterising ingredient; 0-0.1% at least one baking processing aid, 0-0.8% at least one emulsifier and 0-1.5% dietary fibres; b) extrusion of the dough thus prepared thus obtaining a plurality of sheets of extruded raw dough for focaccia, and subsequent lamination of the plurality of sheets of raw dough for focaccia thus obtaining a layer of laminated raw dough for focaccia; c) first leavening of the layer of laminated raw dough for focaccia thus obtained at a temperature comprised between 20 and 30° C.; d) shaping of the layer of leavened raw dough for focaccia thus obtained forming a plurality of blind holes on the surface of the dough and filling of the holes with a saline solution; e) second leavening of the raw dough thus obtained at a temperature comprised between 30 and 37° C.; f) oiling of the upper surface of the dough thus obtained with filling with the oil of said holes; g) baking of the raw dough thus obtained in an oven at a temperature comprised between 210 and 240° C.; and h) packaging of the focaccia thus obtained.
Claims
1-21. (canceled)
22. A process for the production of a ready-to-eat shelf-stable packaged focaccia having relative humidity comprised between 25 and 32%, and water activity (a.sub.w) comprised between 0.85 and 0.92, which process comprises the steps of: a) preparing a dough for focaccia comprising, by weight based on the total weight of the dough, 40-60% flour, 20-35% water, 7-16% vegetable oils and/or fats and/or fractions thereof, of which 1-6% is extra virgin olive oil, 0.5-4% yeast, 0.1-3% salt, 0-15% at least one organoleptically characterising ingredient; 0-0.1% at least one baking processing aid, 0-0.8% at least one emulsifier and 0-1.5% dietary fibres; b) extruding the dough thus prepared thus obtaining a plurality of sheets of extruded raw dough for focaccia, and subsequently laminating said plurality of sheets of raw dough for focaccia thus obtaining a layer of laminated raw dough for focaccia; c) first leavening said layer of laminated raw dough for focaccia thus obtained at a temperature between 20 and 30° C.; d) shaping the layer of raw leavened dough for focaccia thus obtained forming a plurality of blind holes on the surface of the dough and filling said holes with a saline solution; e) second leavening the raw dough thus obtained at a temperature comprised between 30 and 37° C.; f) oiling the upper surface of the dough thus obtained with filling with the oil of said holes; g) baking the raw dough thus obtained in an oven at a temperature comprised between 210 and 240° C.; and h) packaging the focaccia thus obtained.
23. The process according to claim 22, wherein said step a) comprises kneading the dough and comprises a first step wherein said flour, water, said optional at least one baking processing aid, said optional at least one emulsifier and/or said optional dietary fibres and said optional at least one organoleptically characterising ingredient are mixed; and a second step wherein said vegetable oils and/or fats and/or fractions thereof, yeast and salt are introduced into the dough thus formed.
24. The process according to claim 22, wherein said step b) of extruding and laminating is carried out with a passage of said dough in a “stress free” roller extruder thus obtaining a continuous layer of extruded raw dough, followed by the passage of said layer of extruded raw dough through a series of calibration rollers thus obtaining a sheet of extruded raw dough.
25. The process according to claim 24, wherein said step b) of extruding and laminating involves the superimposition of from 2 to 8 of said sheets of extruded raw dough, thus obtaining a layer of laminated raw dough for focaccia with total thickness of 4-7 mm.
26. The process according to claim 24 wherein said step b) of extruding and laminating comprises a step of dosing of at least one organoleptically characterising ingredient in a quantity comprised between 5 and 15% between two extruded sheets of raw dough for focaccia.
27. The process according to claim 26, wherein said organoleptically characterising ingredient is tomato.
28. The process according to claim 22, wherein said step c) of first leavening is carried out for a time between 25 and 35 minutes, at a temperature between 20 and 30° C., and a relative humidity between 55 and 65%.
29. The process according to claim 22, wherein said step d) of shaping is carried out by poking said dough by means of a plurality of cylinders.
30. The process according to claim 22, wherein said saline solution comprises from 25% by weight of salt based on the volume of the solution to saturation.
31. The process according to claim 30 wherein said saline solution is saturated and comprises about 35% by weight of salt based on the volume of the solution.
32. The process according to claim 22, wherein said step e) of second leavening is carried out for a time between 80 and 130 minutes, at a temperature between 30 and 37° C., and a relative humidity between 80 and 95%.
33. The process according to claim 22, wherein in said step g) of baking, the oven is of the convection type and the baking is preferably carried out for a time between 13 and 19 minutes, at a temperature between 210 and 240° C.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0139]
[0140]
DETAILED DESCRIPTION
[0141] The present invention will be described further by referring to the exemplary embodiments given here below and with reference to
Example 1
[0142] Plain Focaccia
[0143] In a first kneading step, a dough for focaccia was prepared with the ingredients given in Table 1, in the quantities indicated, in a mixer with spiral hook at a speed of the stirrer of 35 rpm for 5 minutes in environment set to a temperature of 25° C. To this, in a second kneading step, at 75 rpm for 7 minutes, the ingredients listed in Table 2 were then added in the quantities indicated. At the end a dough with total weight of 2.5 kg was obtained.
TABLE-US-00001 TABLE 1 Formulation of the dough of the first kneading step % based on the Ingredients total Type 0 wheat flour 53.57 Ascorbic acid 0.05 Malted barley flour 0.38 Gluten 0.63 Fatty acid monoglycerides 0.40 Water 30.00 Guar fibre 0.91 Powder natural yeast 1.05 starter Flavourings 0.15 Alpha-amylase 0.02
TABLE-US-00002 TABLE 2 Ingredients added in the second kneading step Extra virgin olive oil 1.46 Palm fat 8.05 Natural yeast 1.83 Salt 1.50 Total: 100%
[0144] The raw dough for focaccia thus obtained was subjected to an extrusion step with a model V4 extruder produced by Rheon Japan with “stress free” rollers in order not to cause mechanical damage, thus obtaining a continuous layer of the thickness of approximately 35 mm and width of 400 m. This continuous layer was then made to pass through a series of calibration rollers with the SM2 multi-roller “stretcher” apparatus produced by Rheon Japan, thus obtaining a sheet of dough of approximately 8 mm in thickness and 800 mm in width.
[0145] Four of the sheets thus obtained were superimposed one with the other in order to increase the elasticity of the dough and were then subjected to a lamination step in order to obtain a final thickness of 5 mm.
[0146] The dough thus obtained was portioned and cut for placing in the baking tray. The baking tray was with an edge on the four sides and was 25 mm deep.
[0147] A first leavening was then carried out, inserting the baking tray inside a thermostat-controlled cell at 25° C. for 30 minutes and at controlled relative humidity of 60%.
[0148] Upon leaving the cell the dough had a thickness of 6 mm and was subjected to a shaping step by means of the penetration in the dough of dedicated cylinders which form a series of blind holes of a depth of 5.5 mm with a device built ad hoc.
[0149] These holes were then filled with the dosing of a saturated saline solution of 35% salt in water (by weight based on the volume of the solution) in the amount of 0.1 g in each hole.
[0150] The dough was then subjected to a second leavening, inserting the baking tray inside a thermostat-controlled cell at 32° C. for 100 minutes and at controlled relative humidity of 85%.
[0151] On exiting the cell the dough had a thickness of 22 m.
[0152] The focaccia was then covered with approximately 150 ml (which corresponds to 5.6% of the total dough weight) of extra virgin olive oil on the upper surface and inside the holes.
[0153] The focaccia was then baked in a convection oven at an average temperature of 215° C. for 14 minutes. When the cooked focaccia exited the oven, the thickness of the focaccia was approximately 25 mm and the depth of the shaping holes was about 24 mm.
[0154] Within two minutes from exiting the oven the focaccia was removed from the baking tray and placed on a baking rack for about 30 minutes to cool.
[0155] Having reached the temperature of 30° C. the product was cut by ultrasounds and portioned into portions of 33 grams measuring 71×97 mm and the portions were packaged in a casing type packaging made with metallised film having air and light barrier properties after spraying ethyl alcohol at 1.4% on a wet basis.
Example 2
[0156] Olive Flavoured Focaccia with Olives
[0157] This focaccia was prepared by following the same process of Example 1 with the difference that in the first kneading step a dough was prepared based on the ingredients listed in Table 3. To this dough, the ingredients listed in Table 4 were added in the second kneading step.
TABLE-US-00003 TABLE 3 Formulation of the dough of the first kneading step % based on the Ingredients total Type 0 wheat flour 51.54 Ascorbic acid 0.05 Malted barley flour 0.36 Gluten 0.61 Fatty acid monoglycerides 0.63 Water 24.70 Guar fibre 0.35 Powder natural yeast 1.01 starter Flavouring 0.21 Alpha-amylase 0.02
TABLE-US-00004 TABLE 4 Ingredients added in the second kneading step Extra virgin olive oil 1.41 Palm fat 4.23 Natural yeast 1.76 Salt 1.73 Sliced frozen black olives 11.39 Total: 100%
[0158] Upon the focaccia exiting the oven the thickness was approximately 25 mm and the depth of the shaping holes was approximately 24 mm.
[0159] At the end of baking and cooling on a baking rack, the product was cut by ultrasounds and portioned into portions of 35 grams measuring 71×97 mm and the portions were packaged in a casing type packaging made with metallised film having air and light barrier properties after spraying with ethyl alcohol at 1.4% on a wet basis.
Example 3
[0160] Tomato Flavoured Focaccia
[0161] This focaccia was prepared by following the same process of Example 1 with the difference that in the first kneading step a dough was prepared based on the ingredients listed in Table 5. To this dough, in the second kneading step, the ingredients listed in Table 6 were added, and with the difference that in the step of overlaying of the 4 sheets of dough a quantity of 8% by weight (with respect to the dough) of fragmented and IQF osmotically dehydrated cherry tomato was dosed between two sheets (see Table 7).
TABLE-US-00005 TABLE 5 Formulation of the dough of the kneading step % based on the Ingredients total Type 0 wheat flour 48.1 Ascorbic acid 0.06 Malted barley flour 0.69 Gluten 0.57 Fatty acid monoglycerides 0.46 Water 27.9 Guar fibre 0.83 Powder natural yeast 0.95 starter Pizza flavouring 0.05 Alpha-amylase 0.02
TABLE-US-00006 TABLE 6 Ingredients added in the second kneading step Extra virgin olive oil 1.33 Palm fat 7.35 Natural yeast 2.05 Salt 1.64
TABLE-US-00007 TABLE 7 Ingredients added in the lamination step Fragmented and IQF osmotically 8% dehydrated cherry tomatoes. Total: 100%
[0162] When the focaccia exited the oven the thickness was approximately 25 mm and the depth of the shaping holes was approximately 24 mm.
[0163] At the end of baking and cooling on a baking rack the product was cut by ultrasounds and portioned into portions of 35 grams measuring 71×97 mm and the portions were packaged in a bag type packaging made with metallised film having air and light barrier properties after spraying with ethyl alcohol at 1.4% on a wet basis.
[0164]
[0165] The three focaccias of the three examples were compared for some physical-chemical parameters immediately after packaging and after 120 days of storage at ambient temperature. In particular, the following were measured: relative humidity, water activity, pH, saturated and total fats content, salt content, resistance to compression in terms of hardness and recovery from deformation in terms of elasticity, colour, characterisation of the internal cells (size and shape by image analysis) and microbiological characteristics.
[0166] The pH was measured with a digital pH-meter at 20±2° C. with the potentiometric method. In order to measure the pH of the finished focaccia, the latter was ground finely, then homogenised and suspended at 10% in water, while stirring (UNI EN 1132 (February 1997)).
[0167] To measure hardness and elasticity an SMS texture analyser dynamometer (Stable Micro Systems) was used, fitted with a circular probe which lowers itself onto the sample, applying a load on the latter. The hardness and the elasticity are measured in the section comprised between the start of compression and 25% of the height of the sample following two actions of compression with a load of 25 kg in which the disk probe is 35 mm in diameter (1000 m.sup.2). The speed of compression is 1 mm/s. An associated software acquires the data and produces a load/displacement graph.
[0168] The software then calculates the resistance to compression (N) on the basis of the force exerted for the compression at 25% of displacement. The resistance (N) to compression (or hardness) is a measure of the structural hardness of the sample and is defined as the maximum peak force during the first cycle of compression.
[0169] The elasticity is, instead, a measurement of how much the sample recovers from the deformation both in terms of speed and derived forces. The latter parameter is calculated by the software as the ratio between the area 2 and the area 1, where the area 1 is calculated between the start of the first peak up to the maximum point and the area 2 from the maximum point up to the end of the peak.
[0170] This ratio is comprised between 0 and 1, in which a value closer to 1 indicates a more elastic sample.
[0171] The colour was measured with a photographic visual method and expressed in terms of temperature of colour (° K) which describes an empirical scale of light spectrum emitted by a certain illuminant, performed in defined light conditions. The values can vary from 2500-3500° K (red-yellow) and 7-8000° K (blue).
[0172] The characterisation of the dimensions and shape of the cells was performed by means of image analysis: an image analysis was performed at 256 levels of grey (Image Pro Plus software, Media Cybernetics, USA) on images of different slices of samples of the focaccia of the invention, following freezing, acquired at high resolution with optical scanner and appropriately processed (black/white conversion, increase in contrast, correction of the dynamic range and construction of a mask on the cells) to obtain the following measurements on the cells: area, average diameter, maximum diameter, minimum diameter, perimeter, roundness and fractal dimension. All these parameters were evaluated as a whole by means of the PCA multivariate statistical analysis (principal components analysis) with appropriate software (SIMCA, Umetrics, Sweden).
[0173] Tables 8-10 sum up the results of the measurements made:
TABLE-US-00008 TABLE 8 Physical-chemical measurements of the focaccia of Example 1 immediately after packaging and after 120 days of storage. Immediately After 120 days Parameter after packaging of storage Humidity (%) 27.0% 27.0% Water activity 0.89 0.89 (a.sub.W) pH 5.1 5.1 Total fats 16.6% 16.6% content, of 5% 5% which saturated fats Salt content 2.0% 2.0% Resistance to SMS hardness: 4.5 N SMS hardness: 5.5 N compression Recovery from SMS elasticity: 0.23 SMS elasticity: 0.26 deformation Characterisation 9% cells: <10 pixels 9% cells: <10 pixels of cells 69% cells: 10 < pixels 69% cells: 10 < pixels < 100 < 100 20% cells: 20% cells: 100 < pixels 100 < pixels < 1000 < 1000 2% cells: > 1000 2% cells: > 1000 pixels pixels Colour Digital photography Stable with respect to with comparison the digital photo taken method immediately after packaging Microbiological Free from salmonella Free from salmonella characteristics Total aerobic Total aerobic mesophilic bacterial mesophilic bacterial load max. 500 ufc/g load max. 500 ufc/g Total enterobacteria Total enterobacteria max. 10 ufc/g max. 10 ufc/g Yeasts and moulds Yeasts and moulds max. 10 ufc/g max. 10 ufc/g Coagulase-positive Coagulase-positive staphylococci max. 5 staphylococci max. 5 ufc/g ufc/g
TABLE-US-00009 TABLE 9 Physical-chemical measurements of the focaccia of Example 2 immediately after packaging and after 120 days of storage. Immediately After 120 days Parameter after packaging of storage Humidity (%) 28% 28% Water activity 0.90 0.90 (a.sub.W) pH 5.4 5.4 Total fats content, 15.7% 15.7% of which saturated 5% 5% fats Salt content 2.4% 2.4% Resistance to SMS hardness: 6 N SMS hardness: 6.9 N compression Recovery from SMS elasticity: 0.25 SMS elasticity: 0.29 deformation Characterisation 8% cells: <10 pixels 8% cells: <10 pixels of cells 66% cells: 10 < pixels 66% cells: 10 < pixels < 100 < 100 25% cells: 25% cells: 100 < pixels 100 < pixels < 1000 < 1000 1% cells: > 1000 1% cells: > 1000 pixels pixels Colour Digital photography Stable with respect to with comparison the digital photo taken method immediately after packaging Microbiological Free from salmonella Free from salmonella characteristics Total aerobic Total aerobic mesophilic bacterial mesophilic bacterial load max. 500 ufc/g load max. 500 ufc/g Total enterobacteria Total enterobacteria max. 10 ufc/g max. 10 ufc/g Yeasts and moulds Yeasts and moulds max. 10 ufc/g max. 10 ufc/g Coagulase-positive Coagulase-positive staphylococci max. 5 staphylococci max. 5 ufc/g ufc/g
TABLE-US-00010 TABLE 10 Physical-chemical measurements of the focaccia of Example 3 immediately after packaging and after 120 days of storage. Immediately After 120 days Parameter after packaging of storage Humidity (%) 28% 28% Water activity 0.88 0.88 (a.sub.W) pH 5.3 5.3 Total fats content, 15% 15% of which saturated 4.2% 4.2% fats Salt content 2.2% 2.2% Resistance to SMS hardness: 5.1 N SMS hardness: 5.8 N compression Recovery from SMS elasticity: 0.25 SMS elasticity: 0.28 deformation Characterisation 9.5% cells: <10 pixels 9.5% cells: < 10 pixels of cells 70.5% cells: 10 < 70.5% cells: 10 < pixels < 100 pixels < 100 19% cells: 19% cells: 100 < pixels 100 < pixels < 1000 < 1000 1% cells: > 1000 pixels 1% cells: > 1000 pixels Colour Digital photography Stable with respect to with comparison the digital photo taken method immediately after packaging Microbiological Free from salmonella Free from salmonella characteristics Total aerobic Total aerobic mesophilic bacterial mesophilic bacterial load max. 500 ufc/g load max. 500 ufc/g Total enterobacteria Total enterobacteria max. 10 ufc/g max. 10 ufc/g Yeasts and moulds Yeasts and moulds max. 10 ufc/g max. 10 ufc/g Coagulase-positive Coagulase-positive staphylococci max. 5 staphylococci max. 5 ufc/g ufc/g
[0174] The focaccia of Example 1 has the following nutritional properties per 100 g: Energy 350 Kcal ca; proteins 8.1 g ca, carbohydrates 41 g ca, fats 16.6 g ca, fibres 3.8 g ca, salt 2.05 g ca.
[0175] The focaccia of Example 2 has the following nutritional properties per 100 g: energy 339 Kcalca; proteins 7.7 gca, carbohydrates 39.6 g ca, fats 15.7 gca, fibres 4.2 g ca, salt 2.4 gca.
[0176] The focaccia of Example 3 has the following nutritional properties per 100 g: energy 343 Kcal ca; proteins 7.7 g ca, carbohydrates 42.3 g ca, fats 15 g ca, fibres 4 g ca, salt 2.2 g ca.
[0177] The focaccia of the present invention therefore has organoleptic and appearance characteristics comparable to those of a fresh focaccia and exhibits evident shaping holes with depth of at least 50% of the thickness of the focaccia itself which have traces of salt and of oil.
[0178] Moreover the focaccia appears browned on the upper surface, with lighter zones (ivory colour) at the centre of the holes formed during the shaping step.
[0179] Upon tasting, the focaccia of the present invention is light and pleasantly oily, typical of fresh focaccias. The perception of saltiness alternates with that of less saltiness, typical of fresh focaccia. This sensation of dishomogeneous saltiness is guaranteed by the fact that in the focaccia of the present invention the saline solution is found at the shaping holes and not distributed homogenously and continuously on the entire upper surface. A sensation of light bitterness is also noted, given by the extra virgin olive oil. Upon chewing the focaccia is soft but not chewy.
[0180] As for the smell, the fragrance is discreetly intense, lightly persistent, without sweetish sensations, and is aromatic thanks to the olive oil. It also has aromas of bread or bread crust.
[0181] The focaccia of the present invention has a shelf life at ambient temperature of up to 120 days.
[0182] The focaccia of the present invention has the advantage of being ready to eat in that it has organoleptic and appearance characteristics comparable to those of a fresh focaccia without the need to heat it.
[0183] It therefore constitutes an excellent and practical snack to keep in a bag or in the office, and with the possibility of being eaten even when an equipped kitchen, and in particular an oven, is not available. Of course, the focaccia can also be eaten hot, but there is no need for this type of preparation.
[0184] By contrast, shelf-stable focaccias of the prior art are not suitable for being eaten directly from the packet, but require a preparation step, usually heating or cooking.
[0185] With the method of the present invention, a substantially homogenous upper surface of the focaccia and an homogenous thickness of the focaccia over the entire baking tray are obtained, such that in the case of portioning of the focaccia in a rectangular or square shape there are no trimmings (i.e. no waste) in that the entire content of a baking tray is cut and packaged. The process of the present invention therefore also has an advantage from the economic point of view in that no waste is produced.