DOUGH CONDITIONER FOR BAKED PRODUCTS AND THE LIKE, WHICH REPLACES THE FAT CONTENT THEREOF AND PROCESS FOR MANUFACTURING THE SAME
20230270123 · 2023-08-31
Inventors
Cpc classification
A21D10/002
HUMAN NECESSITIES
International classification
Abstract
A conditioner of doughs for baked and other bakery products, which fully or partially replaces the fat in such products is provided. Furthermore, a process of producing such a conditioner is provided. The conditioner makes it possible to strengthen the doughs, making them more tolerant to all the stresses to which they are subjected during their passage through the machines, during transport, transfers, until their arrival at the baking process or final application. By improving the behavior of the dough, gas retention is favored, making it possible to obtain products of greater volume, with a finer and more even crumb, while increasing shelf life and preventing starch retrogradation. Its appearance is similar to that of a fat (semi-solid) with the color and aroma of a lipid.
Claims
1-17. (canceled)
18. A dough conditioner, comprising emulsifiers between 0.0 and 10% by weight, humectants between 3.0 and 25% by weight, solids between 3.0 and 25% by weight, antioxidants between 0.1 and 0.2% by weight, stabilizers between 0.1 and 5% by weight, and crosslinkers between 0.0-0.5% by weight.
19. The conditioner for dough of claim 18, wherein the emulsifiers are selected from the group of mono and diglycerides of fatty acid, glyceryl stearate, sodium lactate stearate, DATEM, and CITREM.
20. The dough conditioner of claim 18, wherein the humectants are selected from the group of glycerin, sorbitol, corn syrup, or inverted sugar.
21. The dough conditioner of claim 18, wherein the antioxidants are selected from the group of citric acid, Alpha Tocopherol and Rosemary essential oil, or sodium ascorbate.
22. The dough conditioner of claim 18, wherein the solids are selected from the group of corn starch (native) and/or Waxy corn starch (native), native Cassava (Tapioca) starch and wheat flour.
23. The dough conditioner of claim 18, wherein the stabilizers are gelatin and/or sodium alginate.
24. The dough conditioner of claim 18, wherein the crosslinking agents are selected from the group of calcium sulfate and/or calcium lactate.
25. The dough conditioner according to claim 18, further comprising mono- and di-glycerides of fatty acids between 0.1 and 10% by weight, glycerin between 3.0 and 25% by weight, corn starch between 3.0 and 25% by weight, citric acid between 0.1 and 0.2% by weight, gelatin between 0.1 and 5% by weight, and calcium sulfate between 0.0-0.5% by weight.
26. The dough conditioner according to claim 18, wherein the dough conditioner is a product of plant origin, semi-solid, white or cream in color, and with aroma and lipid flavor.
27. A process for preparing a dough conditioner comprising: a. a stage of loading the raw materials to the mixer in a pneumatic way; b. a heating stage; c. a mixing stage; d. a vacuum generation stage; e. a stage of shutting down of the mixer motor; and f. a stage of unloading the product.
28. The process for preparing a dough conditioner according to claim 27, further comprising including a previous stage of filtering the liquid raw material and sieving the solid raw material.
29. The procedure for preparing a dough conditioner according to claim 27, wherein the loading of raw materials from step a) is carried out pneumatically.
30. The process for preparing a dough conditioner according to claim 27, wherein the heating step b) lasts between 40 and 180 minutes.
31. The process for preparing a dough conditioner according to claim 27, wherein the vacuum generation stage reaches a vacuum pressure between 40 and 70 kilo-Pascals below atmospheric pressure.
32. The procedure for preparing a dough conditioner according to claim 27, further including a final stage of packaging the product.
33. The process for preparing a dough conditioner according to claim 27, wherein the mixing step c) comprises three mixing sub-steps; a mixing substage i) that is carried out with an anchor-type mixer at a speed between 20 and 35 rpm, for a period of time between 40 and 180 minutes; a mixing substage ii) that is carried out with a blade-type mixer at a speed between 20 and 45 rpm, for a period of time between 40 and 180 minutes; a mixing substage iii) that is carried out with a turbine at a speed between 1500 and 3000 rpm, for a period of time between 40 and 150 minutes.
34. Use of the dough conditioner according to claim 18 in the preparation of products for human or animal consumption by ingestion.
35. The use of the dough conditioner according to claim 34 in the preparation of baked goods, tortillas, soda cookies, cookie fillings and desserts.
Description
BRIEF DESCRIPTION
[0024] Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denote like members, wherein:
[0025]
[0026]
[0027]
[0028]
DETAILED DESCRIPTION
[0029] Embodiments of the present invention relate to a conditioner for baked goods dough, which totally or partially replaces the fat in the products. Likewise, embodiments of the present invention relate to the manufacturing process of the conditioner.
[0030] Below is a series of definitions that allow a better understanding of the scope of protection of embodiments of the present invention. [0031] Machinability: Resistance and/or ease of use of a dough in industrial machines (punching, molding, crushing) without damaging its physicochemical properties. [0032] Pumpable: That can be transported through pipelines. [0033] Elasticity: Texture relative to the speed and degree of recovery after the application of a force. [0034] Stickiness: Adhesion, especially presented in products of low and medium viscosity. [0035] Extensibility: It is the ability of a product, in this case bakery, to be laminated, or to obtain a product in sheets (for example, without flexibility). [0036] Flexibility: Cohesiveness in terms of the deformation property of a product (especially a laminated product), before breaking. [0037] Gelatinization: Refers to the process in which starch and water are mixed and heated to the point where the starch absorbs the water. [0038] Gelation: Formation of a gel from a polymer system. [0039] Low Fat Spreads: Emulsion of fats, water and other compounds that mimic fatty products, with a lower amount of fat, generally to spread over other food. [0040] Shortening-type fat: Fat used to soften a baked dough, avoiding hardness over time generated by proteins and carbohydrates. [0041] Dough fatigue: Loss of extensibility of the dough due to excessive mechanical work. [0042] Aeration: Characteristic of a dough to retain air, carbon dioxide or other gases. [0043] Plasticity: Ability of a solid to resist deformation stress of minimum value, but to behave fluidly, like a liquid at deformation stress above the minimum value.
[0044] Embodiments of the present invention, in addition to being a partial or total substitute for fat with a reduced caloric content, generates improvements as a conditioner in the processing of dough (machinability) in the vast majority of cases without adaptations of the processes, by the food producers.
[0045] Some of these improvements are the correct plasticity of the finished products that use the conditioner disclosed in embodiments of the present invention, this property is even more evident in the applications of baked products or using heat, since it can be pumpable and is reconstituted to its original plasticity. In these cases, when applying the dough conditioner, a low “elasticity” and “stickiness” is obtained, especially in products with wheat and corn (such as arepas or corn tortillas, among others), allowing no extra work on the dough to be required, and additionally, allowing an easy “extensibility”, which facilitates the work with continuous doughs for the die-cutting or partitioning process.
[0046] On the other hand, the products using the conditioner disclosed in embodiments of the present invention show a significant improvement in “flexibility” allowing their manipulation, (such as folding in the case of tortillas) and making the products less brittle, (such as the case of the arepa, a corn-based product), during its storage and cold chain.
[0047] It should be noted that one of the main differences of embodiments of the present invention compared to the state of the conventional art consists in the fact that it does not use maltodextrin or modified starches as raw material, usually soluble in the aqueous phase, as solids (body agents), which help to mimic fats, on the contrary, it uses native starches (based on corn or cassava) being incorporated into the process with a high level of shearing, obtaining an optimal distribution, together with temperature control and pressure control (vacuum), which guarantees adequate hydration and a slight gelatinization of the starch.
[0048] In this way, gelatinization is completed in the application product during the baking, roasting and/or cooking process, among others. Then there is a dual effect, with the subsequent application of heat in the preparation of the finished products. Thus, adequate plasticity is achieved, but without the stickiness of excess hydrocolloids and/or modified starches. The final plasticity is achieved in the processing of the final product, in most cases with the final gelling of the duly hydrated native starches.
[0049] On the other hand, by applying vacuum in the manufacturing process, most of the air in the product is eliminated, significantly increasing its useful life, also allowing an “expansion” or “growth” to be evident in the final product, which translates in the optimization of the raw material.
[0050] It is important to add that, to achieve adequate plasticity, the use of hydrogenated fats is NOT required (Undesirable in the vast majority of products). And in some cases, the presence of fats is dispensed with, obtaining plasticity with colloids in some cases with calcium salts as an appropriate cross-linking agent, and with duly processed native starches. In this sense, it is not possible to classify embodiments of the present invention within the products usually known as “Low Fat Spreads”.
[0051] Specifically, embodiments of the present invention are characterized by presenting a conditioner for doughs, characterized by comprising emulsifiers between 0.0 and 10% by weight, humectants between 3.0 and 25% by weight, solids between 3.0 and 25% by weight, antioxidants between 0.1 and 0.2% by weight, stabilizers between 0.1 and 5% by weight, and crosslinkers between 0.0-0.5% by weight, where the percentage surplus is completed with water to obtain 100%.
[0052] Wherein the emulsifiers are selected from the group consisting of mono and diglycerides of fatty acid, glyceryl stearate, sodium lactate stearate (SSL), DATEM, CITREM. Wherein the humectants are selected from the group of glycerin, sorbitol, corn syrup or inverted sugar. Wherein the antioxidants are selected from the group of citric acid, Alpha Tocopherol and Rosemary essential oil, or sodium ascorbate. Wherein the solids are selected from the group of corn starch (native) and/or Waxy corn starch (native), Native Cassava (Tapioca) starch and wheat flour. Wherein the stabilizers can be gelatin and/or sodium alginate. Wherein the crosslinkers are selected from the group of calcium sulfate and/or calcium lactate.
Example 1
[0053] Dough conditioner characterized by comprising mono- and di-glycerides of fatty acids between 2.5 and 3.0% by weight, glycerin between 23 and 24% by weight, corn starch between 24.5 and 25% by weight, citric acid between 0.15 and 0.2% by weight, gelatin between 3.8 and 4% by weight, and calcium sulfate between 0.1-0.15% by weight, water between 44-46% to complete 100%.
[0054] The dough conditioner of embodiments of the present invention is a semi-solid, white or cream in color product of vegetable origin, and with aroma and lipid flavor.
[0055] On the other hand, embodiments of the present invention present a process for preparing the previously disclosed dough conditioner, characterized by comprising the following stages: [0056] a) A stage of loading the liquid and solid raw materials to the mixer in a pneumatic manner; [0057] b) A stage of heating to a temperature between 50 and 60° C.; [0058] c) A mixing stage; [0059] d) A stage of generating vacuum between 40 and 70 kilo-Pascals below atmospheric pressure; [0060] e) A stage of shutting down the mixer motor; [0061] f) A stage of unloading the product.
[0062] Wherein the process for preparing the conditioner includes a previous stage of filtering the liquid raw material and sieving the solid raw material.
[0063] The steps described in items a), b), c), and d) can be carried out sequentially or simultaneously.
[0064] Where the loading of raw materials is pneumatically.
[0065] Wherein the mixing stage c) comprises three mixing substages; a Mixing Substage i) being carried out with an anchor-type mixer at a speed between 20 and 35 rpm, for a period of time between 40 and 180 minutes; a mixing substage ii) being carried out with a blade-type mixer at a speed between 20 and 45 rpm, for a period of time between 40 and 180 minutes; a mixing substage iii) being carried out with a turbine at a speed between 1500 and 3000 rpm, for a period of time between 40 and 150 minutes.
[0066] In an embodiment, the heating stage lasts between 40 and 180 minutes.
[0067] In an embodiment, the vacuum generation stage lasts up to 150 min (2 h30), and reaches a vacuum pressure of 70 kilo-Pascals below atmospheric pressure.
[0068] Wherein the process for preparing the conditioner also includes a final stage of packaging the product.
Example 2
[0069] In an embodiment, the previously disclosed process for preparing the dough conditioner is characterized by comprising the following steps: [0070] a) A stage of loading the liquid and solid raw materials to the mixer in a pneumatic manner; [0071] b) A stage of heating to a temperature between 50 and 60° C.; [0072] c) A mixing stage; [0073] d) A stage of generating vacuum between 40 and 60 kilo-Pascals below atmospheric pressure; [0074] e) A stage of shutting down the mixer motor; [0075] f) A stage of unloading the product.
[0076] Wherein the process for preparing the conditioner includes a previous stage of filtering the liquid raw material and sieving the solid raw material.
[0077] Wherein the stages described in items a), b), c), and d) are carried out simultaneously.
[0078] Where the loading of raw materials is performed pneumatically.
[0079] Wherein the mixing stage c) comprises three mixing substages; a Mixing Substage i) being carried out with an anchor-type mixer at a speed between 25 and 27 rpm, for a period of time between 40 and 180 minutes; a mixing substage ii) being carried out with a blade-type mixer at a speed between 30 and 40 rpm, for a period of time between 40 and 180 minutes; a mixing substage iii) being carried out with a turbine at a speed between 2600 and 2800 rpm, for a period of time between 40 and 150 minutes.
[0080] In an embodiment, the heating stage lasts between 40 and 150 minutes.
[0081] In an embodiment, the vacuum generation step lasts up to 150 min, and reaches a vacuum pressure of 60 kilo-Pascals below atmospheric pressure.
[0082] Wherein the process for preparing the conditioner also includes a final stage of packaging the product.
[0083] In this way, it is evident that the main advantages obtained by this product are: [0084] Substitute fat, achieving a reduction in saturated fats in the applied products. [0085] Improve the useful life of finished products, allowing a reduction in the use of chemical preservatives. [0086] Provide greater plasticity and flexibility (elasticity) to the application product. [0087] Improve the stability in the structure of foods (baked products, fatty fillings, creams in baking, biscuits, tortillas, pastries, cakes). [0088] Provide softness. [0089] Greater product aeration. [0090] Obtaining whiter or lighter and more flexible crumbs or mixtures, with finer and more uniform alveolates. [0091] Improve the cutting or portioning of the products. [0092] Volume contribution in some specific products (bakery among others). [0093] Improve the nutritional table by reducing saturated fats. [0094] Improvements in skins in the products (color). [0095] In corn and wheat products, it helps with lubrication, avoiding breakage or rupture when subjected to frying or freezing. [0096] Texture Improver. [0097] Prevents retrogradation of starch. [0098] Does not contain triglycerides. [0099] Reduces mass fatigue.
[0100] In general, it improves the physical properties of cooked products. For all of them, an increase in the volume of the product is always observed, which is sustained by: An improvement in air capture during kneading; A reinforcement of the gluten mesh that allows better retention of fermentation gases; A delay in gelling, prolonging the time in which the paste remains deformable and favoring its expansion.
[0101] For its part, the advantages of the manufacturing or preparation process are: [0102] Prevention and/or control of gelatinization of the product, reaching the desired plasticity and/or leaving the possibility of gelation in the final food shaping process, emulating a shortening type fat. [0103] Air extraction, which achieves a more compact shape of the product, ensuring greater plasticity and greater stability, also allowing aeration of the products during shake. [0104] Optimal homogenization and dispersion conditions are achieved, required to increase the stability of the product, allowing the simulation of a fat with an “adequate amount of total solids”, at temperatures of 60° C., difficult to achieve by Low Fat Spreads.
[0105] The main applications for embodiments of the present invention, without limiting, are: [0106] Bakery. [0107] Tortillas. [0108] Soda Type Cracker Biscuits. [0109] Fillings in cookies and desserts.
[0110] Although the present invention has been disclosed in the form of embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
[0111] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. The mention of a “unit” or a “module” does not preclude the use of more than one unit or module.