Method of producing bakery products, such as batch breads, and baked products thus obtained

Abstract

A method of producing bakery products, more particularly sandwich loaves or the like. The method consists essentially in preparing a dough, optionally, in fermenting said dough, in placing the dough in a mold, in performing at least one step of baking the dough present in the mold by means of microwaves, optionally, in performing another step of baking by other baking means, in detaching the resulting baked product from the walls of the mold, optionally, in cooling the baked product and/or the mold, and in demolding the baked product. The method is an effective, high-performance method of producing breadmaking products, notably crustless batch breads, by microwave baking, which is reliable, simple, inexpensive and give satisfaction in terms of industrial production and organoleptic quality.

Claims

1. A method of producing a crustless bakery product, said method consisting essentially of: preparing a dough, optionally fermenting said dough, placing the dough in a mold having walls and edges, and which includes means for evacuating steam produced during and after baking, wherein said means for evacuating steam comprises perforations distributed all over the walls of the mold, said perforations having a diameter of between 1 and 5 mm and representing between 0.1 and 10% of the wall surface, performing at least one step of baking the dough present in the mold by microwaving, optionally performing another step of baking by other baking means, thereby producing a crustless bakery product, detaching the resulting crustless bakery product from the walls of the mold by applying a pressurized gas jet to the faces of the mold and which enters into the mold through said perforations, optionally cooling the crustless bakery product and/or the mold, and demolding the crustless bakery product without damaging the integrity of the crustless bakery product, wherein said mold is made from a non-fibrous bulk structure of a heat-resistant plastic polymer.

2. The method of claim 1, wherein perforations are also made in all or a portion of the edges of the mold, at a rate of one perforation every 4 cm+/0.5 cm.

3. The method of claim 1, wherein perforations are also made in all or a portion of the edges of the mold, at a rate of one perforation every 1.5 cm+/0.5 cm.

4. The method of claim 1, wherein the crustless bakery product and/or the mold is cooled by means of a cooling gas jet and/or alternatively by means of a ventilation system which diffuses a stream of air.

5. The method of claim 1, wherein the at least one step of baking by microwaving consists essentially of using a total power of between 70 Wh/kg and 110 Wh/kg.

6. The method of claim 1, wherein the at least one step of baking by microwaving consists essentially of: carrying out a first phase of baking the dough present in the mold by microwaving with a nominal power P1, comprising an emission power Pe1, expressed in watts/min/gram of dough, is between 10.sup.3 and 10.sup.1; or an emission power Pe1, expressed in watt-hours/kilogram of dough, is between 10 Wh/kg and 40 Wh/kg; and subsequently carrying out a second phase of baking by microwaving with a nominal power P2, comprising an emission power Pe2, expressed in watts/min/gram of dough, is between 10.sup.3 and 10.sup.1; or an emission power Pe2, expressed in watt-hours/kilogram of dough, is between 30 Wh/kg and 100 Wh/kg; and wherein P1<=P2.

7. The method of claim 6, wherein the at least one step of baking further consists essentially of a third phase of baking by microwaving with a nominal power P3, comprising an emission power Pe3, expressed in watts/min/gram of dough, is between 10.sup.3 and 10.sup.1; or an emission power Pe3, expressed in watt-hours/kilogram of dough, is between 15 Wh/kg and 75 Wh/kg; and wherein P1<=P2.

8. The method of claim 6, further consisting essentially of heating by conventional heating means other than microwaves, consisting essentially of placing the heat-resistant plastic polymer mold containing the dough in a heated chamber having a temperature which is below the melting point of the heat-resistant plastic polymer from which the mold is made, and wherein said temperature is between 100 C. and 300 C.

9. The method of claim 1, wherein the at least one step of baking is in a baking chamber, and during the at least one step of baking, humidity is modified by adding steam and/or by evacuating all or a portion of the steam present in the baking chamber by chimneys.

10. The method of claim 1, wherein the crustless bakery product obtained at the end of the method has a texture and a flexibility such that slices cut from said crustless bakery product can be rolled up on themselves.

11. The method of claim 1, wherein the composition of the dough is the following in parts by weight: TABLE-US-00006 flour 100 water 50-60 sugar 1-15 yeast 2-5 fat 1-15 additives 0-5.

12. The method of claim 1, further consisting essentially of a fermentation of the dough prior to baking, said fermentation is activated by exposure of the dough to a microwave source with an emission power Pef, wherein an increased temperature induced at the core of the dough is less than or equal to the temperature of inactivation of the yeast, wherein the temperature induced at the core of the dough for this microwave activation being between 30 C. and 50C, and wherein the hygrometry being between 60 and 99% Equilibrium Relative Humidity (ERH).

13. The method of claim 1, wherein said perforations are distributed homogeneously over all of the walls of the mold.

Description

EXAMPLES

Examples 1 to 7

Static Mode

(1) The dough used in the examples which follow has the following composition:

(2) TABLE-US-00002 flour 100 water 56 yeast 3.5 sugar 11 salt 2 vegetable fat 4 soft improver additives (emulsifier, 1 hydrocolloids) technological additives (oxidizing agent, 0.5 alpha-amylase, reducing agent) microbiological storage additives 0.5

(3) The preparation of this dough comprises the following steps: kneading in a spiral kneading machine for 4 min at slow speed plus 10 min at fast speed, shaping in the shape of a quenelle 30 cm long and placing in a mold, fermentation in a climatized oven (hygrometry 85% and temperature 35 C.).

(4) The material used for the microwave baking is a SAMSUNG M192 DN microwave oven for implementation in the batch mode (static mode).

(5) For the optional steps of baking by conventional means, a BONGARD electric deck oven is used in the following examples.

(6) The mold used is a DuPont THERMX PCT mold that is parallelepipedal in shape and has the dimensions: top length of 300 mm, bottom length of 285 mm; height of 85 mm; bottom width of 10 cm, top width of 11 cm.

(7) According to the invention, the mold is pierced with 55 holes of 3 mm per face. The edges of the mold have also been pierced with 3 mm perforations every 2 cm.

(8) The amount of dough per mold is 660 g.

(9) Table 1 below gives the baking protocols for Examples 1 to 5 and 7 and for counterexample 6, and also the results obtained.

(10) TABLE-US-00003 TABLE 1 Examples BAKING PROTOCOL RESULTS 1 MW: D1 = 2; P = 450, Surface hardening i.e. Pe1 = 0.02 Medium development watts/min/gram of Toasted zones dough, i.e. 20 Wh/kg (browning) on the of dough inside MW: D2 = 130; P = 850, Correct exterior i.e. Pe2 = 0.05 appearance watts/min/gram of dough, i.e. 50 Wh/kg of dough Po: deck oven: 3 at 220 C. with evacuation of the humidity by opening the damper provided on the oven 2 MW: D1 = 230; P = 450, Surface hardening i.e. Pe1 = 0.03 Medium development watts/min/gram of No toasted zones dough, i.e. 30 Wh/kg (browning) on the of dough inside MW: D2 = 1; P = 850, Correct exterior i.e. Pe2 = 0.02 appearance watts/min/gram of dough, i.e. 20 Wh/kg of dough Po: ventilated patisserie oven: 5 at 180 C. with evacuation of the humidity by opening the damper provided on the oven 3 Po: ventilated Surface hardening patisserie oven: 4 Good development at 150 C. with Toasted zones saturation of the (browning) on the oven chamber with the inside humidity produced by Correct exterior the dough appearance MW: D1 = 130; P = 450, i.e. Pe1 = 0.02 watts/min/gram of dough, i.e. 20 Wh/kg of dough MW: D2 = 2; P = 850, i.e. Pe2 = 0.04 watts/min/gram of dough, i.e. 40 Wh/kg of dough 4 MW: D1 = 5; P = 450, Very slight surface i.e. Pe1 = 0.06 hardening watts/min/gram of Good development dough, i.e. 60 Wh/kg Very correct of dough exterior appearance MW: D2 = 1; P = 1000, i.e. Pe2 = 0.02 watts/min/gram of dough, i.e. 20 Wh/kg of dough 5 MW: D1 = 2; P = 300, No surface hardening i.e. Pe1 = 0.02 Good development watts/min/gram of Very correct dough, i.e. 20 Wh/kg exterior appearance of dough MW: D2 = 2; P = 850, i.e. Pe2 = 0.04 watts/min/gram of dough, i.e. 40 Wh/kg of dough MW: D3 = 130; P = 450, i.e. Pe3 = 0.02 watts/min/gram of dough, i.e. 20 Wh/kg of dough Counterexample MW: D1 = 130; P = 850, No surface hardening 6 i.e. Pe1 = 0.03 Correct strength watts/min/gram of Medium development dough, i.e. 30 Wh/kg Medium exterior of dough appearance MW: D2 = 345; P = 450, Soft part too firm. i.e. Pe2 = 0.04 Firmness of the soft watts/min/gram of part: 1.77 dough, i.e. 40 Wh/kg of dough MW: D3 = 2; P = 450, i.e. Pe3 = 0.03 watts/min/gram of dough, i.e. 30 Wh/kg of dough 7 MW: D1 = 2; P = 300, No surface hardening i.e. Pe1 = 0.02 Very good watts/min/gram of development. Very dough, i.e. 20 Wh/kg good strength of dough Correct exterior MW: D2 = 345; P = 450, appearance. Very i.e. Pe2 = 0.04 correct result for watts/min/gram of the soft part: dough, i.e. 40 Wh/kg moist. Firmness of of dough the soft part: 0.96 MW: D3 = 130; P = 850, i.e. Pe3 = 0.03 watts/min/gram of dough, i.e. 30 Wh/kg of dough Legend: MW means microwaves, P (in watts) corresponds to the set power of the MW oven and Po represents an optional phase of conventional oven baking, which is carried out before or after the MW baking in the example under consideration. D1, D2 and D3 in minutes seconds . The term development denotes the increase in volume of the dough piece. The term strength denotes the deformation of the walls of the batch bread after baking. The values of firmness of the soft part are given in Newtons and are obtained by measuring using a Lloyds texturometer.

(11) During baking, the steam produced was able to escape via the perforations made in the mold and did not accumulate in the very small space between the walls of the mold and the dough.

(12) After baking and immediately after removal from the oven, a jet of compressed air at a pressure of 4 bar is applied, for a brief period of a few seconds, to all the faces of the molds containing the baked products obtained. The compressed air that is introduced into the perforations made in the mold makes it possible to detach the baked product from the walls of the mold.

(13) Next, the step of cooling the bread in the mold consists in applying, to all the faces of the mold, a jet of air at a pressure of 1 bar, in such a way as to wash over the faces of the mold so as to evacuate the steam escaping from the perforations. The baked product is thus cooled more rapidly in the mold and no formation of starch paste is observed between the walls of the mold and the baked product. The baked product, which has a core temperature of less than 70 C., is then very easily demolded. Since it is already cooled, it can also be handled without risk of burning.

(14) By way of comparison, the same tests were carried out, but without using a perforated mold. In all cases, the baked products are very difficult to demold, since the products adhere to the walls of the mold.

Example 8

Dynamic Mode

(15) The dough used in the examples which follow has the following composition:

(16) TABLE-US-00004 flour 100 water 56 yeast 5 sugar 11 salt 2 vegetable fat 3 soft improver additives (emulsifier, 1 hydrocolloids) technological additives (oxidizing agent, 0.5 alpha-amylase, reducing agent) microbiological storage additives 0.5

(17) The preparation of this dough comprises the following steps: kneading in a spiral kneading machine for 4 min at slow speed plus 10 min at fast speed, shaping in the shape of a quenelle 30 cm long and placing in a mold, fermentation in a climatized oven (hygrometry 85% and temperature 35 C.).

(18) The material used for the microwave baking: a tunnel equipped with 10 microwave generators distributed in 3 baking zones Zone 1: two 0.8 Kw generators Zone 2: two 0.8 Kw generators+two 1.2 Kw generators Zone 3: four 1.2 Kw generators.

(19) The mold used is a DuPont THERMX PCT mold with a parallelepipedal shape and having the dimensions: length 235 mm; height 117 mm; width 125 mm.

(20) According to the invention, the mold is pierced with approximately 450 holes of 2 mm. The edges of the mold were also pierced with 2 mm perforations every 1.5 cm.

(21) The amount of dough per mold is 570 g.

(22) The detaching step is carried out in a stainless steel casing pressurized with compressed air (pressure of 4 bar), which enables the introduction of air via all the holes pierced in the mold.

(23) The bread is cooled in its mold on an assembly composed of a frame containing a France Air fan, 1400 rpm, power 1500 W, enabling 4 breads to be cooled simultaneously.

(24) This oven is a tunnel oven which operates with a line comprising various successive zones corresponding to nominal powers P1, P2 and P3 and emitted powers Pe1, Pe2 and Pe3.

(25) Table 2 below gives the baking protocols and also the results obtained for the present example 8.

(26) TABLE-US-00005 TABLE 2 Example BAKING PROTOCOL RESULTS 8 Total power 80 Wh/kg Correct exterior P1: 1.6 Kw D1: 30 Pe1: appearance, no 12 Wh/kg crust, no hard zone. P2: 4.2 Kw D2: 33 Pe2: Firmness value 32 Wh/kg measured with a P3: 4.8 Kw D3: 33 Pe3: texturometer at 35 Wh/kg D + 7: 0.80 N. Detaching in a casing brought Product tasted by a to 4 bar for approximately 1 jury of experts, second. having the Cooling in the mold for characteristics of a 10 min. soft bread. Slow cooling at ambient Identical to a bread temperature for 120 min. baked by Loss of water during the conventional baking various phases of the method. Baking approximately: 2.5% Cooling in the mold: 4% Slow cooling: 2% Final water content of the bread 36.5%

(27) The method according to the invention is simple and economical to implement in an industrial environment and makes it possible to obtain bakery products, in particular crustless batch breads or the like, baked by means of microwaves, which demold easily, which have an attractive appearance, and which have organoleptic qualities comparable to conventionally baked bakery products.