Process for the production of a shelf-stable filled sponge-type bakery product

Abstract

A process for the production of a shelf-stable bakery product comprising a) preparation of a first batter containing sugar, flour, oils and/or fats etc.; b) emulsification and dosing of the first batter on a baking surface; c) steaming the first batter to form a layer of semi-baked mixture; d) dosing of a filling inside the layer of semi-baked mixture of step c), placed in a baking mold and thus obtaining an open filled semi-finished product; e) preparation of a second batter containing sugar, flour, fats and/or oils etc.; f) emulsification and dosing of the second batter on the open and filled semi-finished product of step d), thus obtaining a covered and filled semi-finished product; g) steam baking the product obtained in step f) to form a baked and filled bakery product; h) cooling; and i) packaging.

Claims

1. A process for the production of packaged shelf-stable sponge-type bakery product having a casing of chemically leavened cake and filling inside said casing, which comprises the steps of: a) preparation of a first batter comprising sugar, flour, animal and/or vegetable fats and/or oils, at least one leavening agent, starch, egg products, optionally water and optionally at least one ingredient characterizing the taste and the appearance of the packaged shelf-stable bakery product; b) emulsification and dosing of said first batter on a baking surface, wherein said emulsification is carried out by passing the first batter in a turboemulsifier and with the incorporation of between 26% and 30% air by volume of the first batter; c) steam baking of said first batter dosed on the flat baking surface to form a layer of semi-baked mixture; d) placing the semi-baked mixture in a baking mould of semispherical shape which gives to said layer of semi-baked mixture a concave shape; e) dosing of a filling inside said layer of the semi-baked mixture obtained in step d), thus obtaining an open and filled semi-finished product; f) preparation of a second batter comprising sugar, flour, animal and/or vegetable fats and/or oils, at least one leavening agent, starch, egg products, optionally water and optionally at least one ingredient characterizing the taste and the appearance of the packaged shelf-stable bakery product; g) emulsification and dosing of said second batter obtained in step f) on said open and filled semi-finished product of step e), thus obtaining a covered and filled semi-finished product, wherein said emulsification is carried out by passing the second batter in a turboemulsifier and with the incorporation of between 35% and 40% air by volume of the second batter; h) steam baking of said covered semi-finished product obtain in step g) to form the bakery product that comprises the casing of the chemically leavened cake and filling inside the casing, wherein the cake casing has a humidity content of between 20% and 30%; i) cooling of said baked and filled bakery product; and j) packaging of said baked and filled bakery product.

2. The process according to claim 1 wherein in step a) of preparation of the first batter and in step e) of preparation of the second batter, said first and second batter comprise, by weight based on the total weight of each respective batter, 23-28% sugar, 10-15% flour, 8-13% animal and/or vegetable fats and/or oils, 0.3-0.8% of at least one leavening agent, 10-15% starch, 20-30% egg products, 0-5% water and 0-8% of said at least one ingredient characterizing the taste and the appearance of the finished bakery product.

3. The process according to claim 1, wherein the at least one ingredient characterizing the taste and the appearance of the finished bakery product in the first and second batter is selected from the group consisting of cocoa, chocolate, milk, coffee, nuts, cereal grain particles, malt, fruit and vegetable juices and purees, or mixtures thereof.

4. The process according to claim 3, wherein said at least one ingredient characterizing the taste and the appearance of the finished bakery product is present at 2-6% by weight based on the total weight of the first and second batter respectively.

5. The process according to claim 1, wherein the starch is selected from the group consisting of the group consisting of starch of wheat, rice, potato, corn, tapioca and mixtures thereof, wherein the starch is optionally deglutinated.

6. The process according to claim 1, wherein said flour in the first and second batter is selected the group consisting of from any cereal flour, wholemeal or refined, with or without gluten.

7. The process according to claim 1, wherein the weight ratio between the contents of starch and of flour in the first and second batter is between 0.5 and 3.

8. The process according to claim 1, wherein in steps b) and g) of emulsification and dosing of said respectively first and second batter, the emulsification is carried out by passing the batter in a turboemulsifier, with the incorporation of a percentage of air by volume based on the volume of the first batter is 28% in step b) and 38% in the second batter in step f).

9. The process according to claim 1, wherein said flat baking surface is a grid covered with a sheet of baking paper.

10. The process according to claim 1, wherein step c) of steam baking is carried out in a steam oven with a homogeneous atmosphere of saturated steam at ambient pressure, at a temperature between 90 and 100 C. and for a time between 3 and 7 minutes.

11. The process according to claim 10, wherein at the end of step c) of steam baking, said layer of semi-baked mixture has a humidity between 20% and 30%.

12. The process according to claim 1, wherein said filling is hydrated and is selected from the group the group consisting of a cocoa flavoured cream, jam, honey, fruit puree and combinations thereof.

13. The process according to claim 1, wherein in step e) of dosing of the filling the quantity of filling that is dosed on said layer of semi-baked mixture is such as to constitute at least 40% by weight based on the weight of the finished baked bakery product.

14. The process according to claim 13, wherein said quantity of filling that is dosed on said layer of semi-baked mixture is from 60 to 70% by weight based on the weight of the finished baked bakery product.

15. The process according to claim 1, wherein step h) of baking of said covered semi-finished product is carried out in a steam oven with a homogeneous atmosphere of saturated steam at ambient pressure, at a temperature between 90 and 100 C. and for a time between 8 and 16 minutes.

16. The process according to claim 13, wherein at the end of step h) of baking, the cake casing has a humidity content of about 28%.

17. The process according to claim 1, wherein said first batter of step a), said second batter of step f) and said filling of step e) are gluten free.

18. The process according to claim 1, wherein no artificial preservatives are added.

19. The process according to claim 1, wherein step h) of cooling is followed by a step of surface decoration of said baked bakery product, carried out with dosing of an anhydrous filling.

20. The process according to claim 1, wherein in step j) of packaging, said bakery product is packaged in a metallized barrier film.

21. The process according to claim 6, wherein said cereal flour is selected from the group comprising durum wheat, soft wheat, turanicum wheat (triticum turgidum ssp. Turanicum), rye, corn, rice, spelt, barley, sorghum, millet, oats, triticale, buckwheat, quinoa, or mixtures thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a flow diagram that summarises the process of the invention.

(2) FIG. 2 is a photograph of a product obtained according to the process of the invention.

DETAILED DESCRIPTION

(3) The present invention will be described further by referring to the exemplary embodiments given here below by way of a non-limiting illustration.

Example 1

(4) A first liquid mixture (first batter) was prepared having the composition described in Table 1.

(5) TABLE-US-00001 TABLE 1 Composition of the first batter Quantity expressed in percentage by weight based on the weight of Ingredients the mixture Cocoa powder 5.6 Caster sugar 25.8 Concentrated butter 4 Fractionated palm fat 4.6 Monoglycerides in paste 5.1 De-shelled whole eggs 13.8 Liquid egg yolk 11 Water 2.2 Wheat starch 13.9 Sodium bicarbonate 0.20 Ammonium carbonate 0.10 Acid sodium pyrophosphate 0.30 Soft wheat flour 11.7 Spray egg white 1 Flavouring 0.50 Salt 0.20

(6) The batter was prepared, at room temperature, in a planetary mixer fitted with a wire whisk.

(7) In a first step 1, cocoa and sugar were mixed, dry, at 20 rpm for one minute, to avoid the formation of lumps in the later steps. Then, in a step 2, butter, palm fat and mono- and diglycerides of fatty acids were added, with mixing at 20 rpm for one minute followed by mixing at 50 rpm for 3 minutes. In a step 3, the eggs, the egg yolk and water were added, mixing at 20 rpm for one minute and then at 30 rpm for 2 minutes. Finally, in a step 4, the powders (i.e. the remaining ingredients of Table 1) were added with mixing at 40 rpm for 2 minutes and then at 20 rpm for 2 minutes.

(8) The humidity content of the mixture thus formed was 27%.

(9) The mixture thus obtained was transferred to a turboemulsifier where it was subjected to a treatment with the following parameters (Table 2) to homogenize the mixture.

(10) TABLE-US-00002 TABLE 2 Parameters of homogenisation of the first batter Rotor turns 150 rpm % Air 28 Counter-pressure 2 bars Specific weight at entry 0.95-1.05 g/ml Specific weight at exit 0.68-0.72 g/ml Mixture flow rate upon exit 0 cm/min (Bostwick 30) Mixture temperature 26-30 C. upon exit

(11) The mixture thus processed was then made to proceed to the dosing system which comprises a rotary stencil machine.

(12) The dispenser deposited a round disk of mixture having weight of 7.5 g on a sheet of baking paper with weight of 80 g/m.sup.2 and this enters a first steam baking oven. The oven has a homogeneous atmosphere of saturated steam at ambient pressure and the temperature inside the chamber is 98 C. The baking process had a duration of about 5 minutes.

(13) The baked disk thus obtained was detached from the baking paper and inserted in a metal mould with imprint of semispherical shape. The mould was Teflon-coated in order to obtain a good extraction of the product without the use of release agents.

(14) 19 g of a hydrated cream having the composition of Table 3 was then dosed inside the mould containing the disk of baked mixture, having previously been brought to the temperature of 30 C. by means of a scraped surface heat exchanger. The flow rate of the cream was 8 cm/30 measured by the Bostwick method.

(15) TABLE-US-00003 TABLE 3 Composition of the cream Quantity expressed in percentage by weight based on the weight of Ingredients the mixture Glucose syrup 21.8 Water 22.8 Refined palm fat 7.1 (melted at 60 C.) Mono- and diglycerides 0.5 of fatty acids Dark chocolate 15.5 Corn starch 4 Caster sugar 7.4 20/22 cocoa powder 4.1 Skimmed milk powder 10 Dextrose 6.8

(16) A second mixture was prepared as per the first batter described above, with the difference that the parameters of homogenisation are as per Table 4.

(17) TABLE-US-00004 TABLE 4 Parameters of homogenisation of the second batter Rotor turns 200 rpm % Air 38 Counter-pressure 1.8 bars Specific weight at entry 0.95-1.05 g/ml Specific weight at exit 0.62-0.66 g/ml Mixture flow rate upon exit 0 cm/min (Bostwick 30) Mixture temperature 31-33 C. upon exit

(18) Finally 8.5 g of the second batter was dosed by means of a rotary nozzle on the semi-finished product thus obtained, to cover the surface of the product and thus close the semi-finished product obtained, forming a flat surface.

(19) The baking moulds were then placed in the steam oven and baked for a time of 12 minutes with average temperature of 98 C.

(20) The baked product was removed from the mould immediately after the exit from the oven with suction pad system and left to cool in an air-conditioned environment at 20 C. for approximately 15 minutes.

(21) At the end of the cooling phase the surface decoration of the product was carried out with a milk-based anhydrous cream by means of a jet printer.

(22) The bakery product which is obtained has the following overall composition (Table 5).

(23) TABLE-US-00005 TABLE 5 Overall composition of the finished product Dosings grams % Baked mixture 15.5 44.3 Filling cream 19 54.3 Anhydrous 0.5 1.43 decoration cream Total 35 100

(24) The product was then packaged in a filtered and controlled air chamber in metallized barrier film. The shelf life of the thus packaged product at ambient temperature is 6 months.

(25) The product obtained had a humidity of 28% and a water activity value of 0.87 homogeneously distributed. The product had a regular appearance and a uniform colour. The product was also found to be uniformly soft and free of crusts, with a cream filling in the centre. The casing of cake was found to be in one piece, no point of joining between the two mixtures being essentially visible.

(26) The finished product of the invention had a diameter of the flat base of 70 mm and a height of 26 mm.

(27) The product also had the following nutritional profile (Table 6).

(28) TABLE-US-00006 TABLE 6 Nutritional profile of the product of Example 1 per 100 g Energy/kcal 347 Proteins (g) 6 Fats (g) 14 of which saturated (g) 6.8 Carbohydrates (g) 48.2 of which sugars (g) 31 Fibres (g) 2.3 Salt (g) 0.45

(29) Referring to FIG. 2, a product 1 is shown according to the invention which can be obtained according to the process as just described, wherein reference numeral 2 corresponds to the casing resulting from the joining of the first batter (upper) with the second batter (base), reference numeral 3 corresponds to the filling enclosed inside the casing, in this case a cocoa-flavoured cream, and reference numeral 4 corresponds to the anhydrous decoration.