INGREDIENT SYSTEM FOR BAKERY PRODUCTS

Abstract

The present invention is directed to an ingredient system for flatbread products which are essentially free from added mono-diglycerides, comprising an ingredient system containing a fat-coated vegetable fibre particle, a fat-coated organic acid and an enzyme preparation containing at least an amylase: flatbread products which contains the ingredient system and the use of the ingredient system in flatbread products.

Claims

1. An ingredient system for flat bread products, comprising the following composition: A. fat-coated vegetable fibre particles in an amount of 60-90% by weight of the composition; B. a fat-coated organic acid in an amount of 0-30% by weight of the composition; and C. an enzyme preparation containing at least an amylase in an amount of 1-5% by weight of the composition.

2. The ingredient system, according to claim 1, wherein the fat-coated vegetable fibre particles comprise from 10% to 30% by weight of vegetable fibres and from 70 to 90% by weight of fat.

3. The ingredient system, according to claim 1, wherein the fat-coated vegetable fibres comprise a fat with a melting point between 40 and 80 degrees Celsius, selected from fully hydrogenated rapeseed oil or high erucic fully hydrogenated rapeseed oil, fully hydrogenated soybean oil, fully hydrogenated cottonseed oil, fully hydrogenated sunflower oil, fully hydrogenated palm, non-hydrogenated palm and blends of any of the foregoing.

4. The ingredient system, according to claim 1, wherein in the fat-coated vegetable fibre particles, the fibre is selected from wheat fibre, citrus fibre, carob tree husk fibre, psyllium husk powder, sugar beet fibre, soy fibre, pea fibre, apple fibre, carrot fibre, oat fibre, potato fibre and bamboo fibre.

5. The ingredient system, according to claim 1, wherein the fat-coated organic acid comprises 60-75% by weight of citric acid, malic acid or fumaric acid.

6. The ingredient system, according to claim 1, wherein the fat-coated organic acid comprises 25-40% by weight of fat.

7. The ingredient system, according to claim 1, wherein the amylase is an exoamylase selected from maltotetragenic amylases and glucan 1,4-alpha-maltotetrahydrolases.

8. The ingredient system, according to claim 1, wherein the enzyme preparation further comprises an auxiliary enzyme selected from fungal protease, fungal cellulase, glucose oxidase, bacterial or fungal xylanase, 1,3 lipase and blends of any of the foregoing.

9. A flat bread, wherein the flat bread comprises containing the ingredient system as described in claim 1 in an amount between 1.5 to 6% by weight of flour.

10. The flat bread, according to claim 9, wherein the flat bread is essentially free from added mono-diglycerides.

11. The flat bread, according to claim 9, wherein the flat bread has low adhesion of maximum score 2.

12. The flat bread, according to claim 9, wherein the flat bread freshness is defined by a foldability minimum score 4.

13. The flat bread, according to claim 9, wherein the flat bread has an extensibility of minimum 17 mm.

14. The flat bread, according to claim 9, wherein: component A is present in an amount between 1.5 and 2.5% by weight of the flour, component B is present in an amount between 0.3 and 1.2% by weight of the flour, and component C is present in an amount between 50 to 2000 ppm by weight of flour.

15. The flat bread, according to claim 9, wherein: component A is present in an amount between 1.5 and 2.5% by weight of the flour, component C is present in an amount between 50 to 2000 ppm by weight of flour, and component B is absent in the flat bread application that does not need pH control.

16. The flat bread according to claim 9, wherein the flat bread comprises a product selected from tortilla, wraps, lavash, roti, chapati and piadina.

17. The ingredient system, according to claim 6, wherein the fat-coated organic acid comprises 25-40% by weight of a fat(s) selected from fully hydrogenated rapeseed, fully hydrogenated rapeseed oil or high erucic fully hydrogenated rapeseed oil, fully hydrogenated soybean oil, fully hydrogenated cottonseed oil, fully hydrogenated sunflower oi, fully hydrogenated palm or non-hydrogenated palm and blends of any of the foregoing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] FIG. 1. Photograph showing damage due to tortilla-to-tortilla adhesion during the shelf life.

[0042] FIG. 2. Explanation of foldability scores of tortilla during shelf-life, where the limit of acceptability is 4 (less than 25% of the tortilla breaks during folding/rolling).

[0043] FIGS. 3A and 3B. Instrument for the measurement of freshness parameters. Tortilla extension and break force measured by Texture Analyzer (Stable Micro Systems). The greater the extension measured, the more flexible and fresh appearing the tortilla.

[0044] FIG. 4. Drawing describing the drop test system devised to verify if dough balls were sticking to the nylon basket during normal and abuse proving conditions.

[0045] FIG. 5. Illustration of pH levels measured for tortilla prepared from ingredient system examples S.1, S.2 and S.11, compared to combinations of individual components.

[0046] FIG. 6. Illustration of benefits of ingredient system for reduced tortilla-to-tortilla adhesion over shelf-life for examples S.1 and S.2 compared to combinations of individual components. The critical threshold value is 2 (dotted line), where tortillas can be separated from the stack without damage.

[0047] FIG. 7. Illustration of the increased in tortilla-to-tortilla adhesion over shelf-life observed when the level of component, as Example A.1, is reduced by 17% compared to the level present in ingredient systems example S.1 and S.2.

[0048] FIG. 8. Illustration of tortilla stickiness, as measured by probe adhesion of the Texture analyzer for tortillas from Trial 1 and 2 (table 9), prepared with ingredient system examples S.1 and S.2 at day 44.

[0049] FIG. 9. Illustration of the change in foldability of tortilla during shelf life, for tortilla from Trial 1 and 2 (table 9), prepared with ingredient systems examples S.1 and S.2, compared to those prepared with combinations of individual ingredients.

[0050] FIG. 10. Illustration of change in extensibility during shelf life for tortilla from Trial 1 and 2 (table 9), prepared with ingredient systems, examples S.1 and S.2, compared to those prepared with combinations of individual ingredients.

[0051] FIG. 11. Illustration of change in tortilla-to-tortilla adhesion over shelf life for tortilla from Trials 3-6 (table 10), prepared with ingredient systems examples S.3, S.4, S.5 and S.6.

[0052] FIGS. 12A & 12B. Illustrations of the distribution of adhesion scores for tortilla from Trials 3-6 (table 10), prepared with ingredient system examples S.3, S.4, S.5 and S.6, at days 91 and 119 of shelf life.

[0053] FIG. 13. Illustration of change in foldability scores over shelf life for tortillas from Trials 3-6—(Table 10), prepared with ingredient systems examples S.3, S.4, S.5 and S.6.

[0054] FIG. 14. Illustration of change in tortilla extensibility over shelf life for tortillas from Trials 3-6—(table 10), prepared with ingredient system examples S.3, S.4, S.5 and S.6.

[0055] FIG. 15. Illustration of break force vs distance on day 119 of shelf life for tortillas from Trials 3-6—(table 10), prepared with ingredient systems examples S.3, S.4, S.5 and S.6.

[0056] FIG. 16. Illustration of change in tortilla-to-tortilla adhesion over shelf-life for tortillas from Trials 7-10 (table 11) prepared with ingredient system examples S.7, S.8, S.9 and S.10, which include two types of maltotetragenic amylases as examples of Component C.

[0057] FIG. 17. Illustration of change in foldability over shelf life for tortillas from Trials 7-10 (table 11) prepared with ingredient system examples S.7, S.8, S.9 and S.10, which include two types of maltotetragenic amylases as examples of Component C.

[0058] FIG. 18. Illustration of change in tortilla extensibility for tortillas from Trials 7-10 (Table 11) prepared with ingredient system examples S.7, S.8, S.9 and S.10, which include two type of maltotetragenic amylases as examples of Component C.

[0059] FIG. 19. Illustration of effect of ingredient system on change in tortilla-to-tortilla adhesion over shelf-life for ingredient system examples S.3, S4 and S.8.

[0060] FIG. 20. Illustration of effect of ingredient system on change in foldability of tortillas over shelf-life for ingredient system examples S.3, S4 and S.8.

[0061] FIG. 21. Illustration of effect of ingredient system on change in extensibility of tortillas over shelf-life for ingredient system examples S.3, S4 and S.8.

[0062] FIG. 22. Illustration of pH of tortilla from trials 11-12 (Table 12), prepared with ingredient system examples S.11 and S.12, which contain Components A and C only.

[0063] FIG. 23. Illustration of change in tortilla-to-tortilla adhesion over shelf life for tortilla from trials 11-12, prepared with ingredient system examples S.11 and S.12, which contain Components A and C only.

[0064] FIG. 24. Illustration of change in foldability over shelf life for tortilla from trials 11-12, prepared with ingredient system examples S.11 and S.12, which contain Components A and C only.

[0065] FIG. 25. Illustration of change in tortilla extensibility over shelf life for tortilla from trials 11-12, prepared with ingredient system examples S.11 and S.12, which contain Components A and C only.

[0066] FIGS. 26A and 26B. Illustrative photographs of the coated fat (triglyceride)-fibre particle changes when exposed to water over time and during heating. 26A. relates to coated fat-fibre particle in water, heated from 25° C. to 60° C. at 10° C./minute. 26B relates to Coated fat-fibre particle in water, 20° C. (below melting temperature of fat).

DETAILED DESCRIPTION OF INVENTION

[0067] The present invention relates to an ingredient system for flatbread products comprising the following composition: [0068] A. fat-coated vegetable fibre particles in an amount of 60-90% by weight of the composition; [0069] B. a fat-coated organic acid in an amount of 0-30% by weight of the composition; [0070] C. an enzyme preparation containing at least an amylase in an amount of 1-5% by weight of the composition.

[0071] The ingredient system of the present invention may also contain other materials in an amount up to 5% by weight of the composition, such as fillers and carriers, which are not functionally active ingredients in the system.

[0072] Component A. This component comprises fat-coated vegetable fibre particles prepared with a solid fat source, mostly consisting of triglycerides. Technologically suitable fat sources include fully hydrogenated rapeseed (canola) oil, fully hydrogenated high erucic rapeseed oil, fully hydrogenated soybean oil, fully hydrogenated cottonseed oil, fully hydrogenated sunflower oil, fully hydrogenated palm oil, non-hydrogenated palm oil or a blend thereof.

[0073] The fibre included in component A can be selected from wheat fibre, citrus fibre, carob tree husk fibre, psyllium husk powder, sugar beet fibre, soy fibre, pea fibre, apple fibre, carrot fibre, oat fibre, potato fibre and bamboo fibre. The fat-coated vegetable fibre particles may be prepared by intimately mixing the fibre with the molten fat and atomizing the slurry in a cold air-stream. Alternatively, the fat-coated vegetable particles may be prepared by spraying the molten fat onto the fibre particles under continuous mixing, followed by cooling.

[0074] The resulting composite particles have a particle size of 30-800 μm (FIG. 21, picture 1.A). Their morphology is subject to changes over time when placed in water and the structural changes are accentuated when the temperature increases. As the particle is placed in water, the hydrophilic fibre interior slowly hydrates, swells and starts fragmenting and dispersing the fat layer. The exposed fibre particles continue its hydration (FIGS. 26A and B) and is released in the dough system.

[0075] The fat-coated vegetable fibre particles comprise from 10% to 30% by weight of vegetable fibres and from 70 to 90% by weight of a fat with a melting point between 40 and 80 degrees Celsius.

[0076] The primary function of the vegetable fibre in component A is as a carrier of the fat, with the delivery mechanism shown in FIGS. 26A and 26B However, it can have a secondary effect which is to counter unwanted effects arising from the action of the amylase, Component C. The hydrolytic activity of Component C on the starch can result in unwanted side effects such as excessive softening of the dough in the early dough processing phases, and on the rounded dough balls, compromising their processability. This can be moderated by the delayed hydration of the vegetable fibre of Component A.

[0077] Component B. This component contains a fat-coated organic acid, such as citric, malic or fumaric acid. The coated material is conveniently chosen from a suitable fat source such as fully hydrogenated rapeseed oil or hydrogenated sunflower oil or other vegetable source. The acid is used for pH correction: neutralizing and lowering the final tortilla pH to values below 6.0.

[0078] Component B is an acid coated with fat layer, using materials such as described in patent GB 2417184. It can also be specifically formulated to contain the same fat phase as used in components A.1, A.2, A.3 and A.4 (table 1). It is included in the ingredient system to address issues of pH correction, tortilla structure and appearance, as in patent GB 2417184, but also as a supplementary source of the fat which has been found to control adhesion of the tortilla over shelf-life.

[0079] The fat coating of Component B serves two purposes: the primary purpose is segregation of the organic acid core, during dough mixing and preventing the direct reaction with sodium bicarbonate and controlling that the dissolution does not occur before the gluten network is adequately formed. A secondary purpose is to contribute to the total solid fat delivered to the flatbread recipe, together with component A.

[0080] Component B can have a fat proportion from 25% to 45% and the organic acid, such as citric or malic acid is 55% to 75% of the weight.

[0081] In a preferred embodiment of the invention, the fat-coated organic acid comprises 60-70% by weight citric acid or malic acid and 30-40% by weight of a fat such as such as fully hydrogenated rapeseed or high erucic fully hydrogenated rapeseed oil, fully hydrogenated soybean oil, fully hydrogenated cottonseed oil, fully hydrogenated sunflower oil, fully hydrogenated palm or non-hydrogenated palm or a blend thereof.

[0082] However, it is possible to remove component B from the ingredient system in specific flatbread products that utilize alternative methods of pH regulation, alternative preservation methods not depending on pH, alternative raising systems not requiring neutralization, or even because due to operational or commercial reasons, it might be preferable to add it separately to the tortilla recipe.

[0083] Component C. This component comprises a fresh-keeping amylase, in particular an exoamylase of the family of glucan 1,4-alpha-maltotetrahydrolases (E.C. 3.2.1.60), hereafter also referred to as maltotetragenic amylase. The maltotetragenic amylase has the main fresh-keeping effect in flatbread, mainly tortillas. Its action is related to starch hydrolysis, principally starting from non-reducing end (exo-), cleaving molecule of 4 glucose (maltotetraose), the enzyme action ends at the inactivation temperature around 85° C. Suitable malto-tetragenic amylases and methods of their preparation are disclosed in some patent documents part of the state of the art, such as WO 20097083592 (here referred as maltotetrahydrolase type 1) and in EP2432875 B1 (here referred as maltotetrahydrolase type 2).

[0084] The amylase of component C can be delivered as single enzyme or optionally, in mixture with other enzymes including activities selected from the group consisting of fungal or bacterial protease, fungal cellulase, fungal or bacterial xylanase, 1,3 lipase, glucose oxidase or a blend thereof. In terms of function, a fungal protease helps dough relaxation; xylanase or cellulase for dough relaxation and strengthening, 1,3 lipase producing fatty acids from triglycerides affects the starch swelling properties. Glucose oxidase reduces dough surface stickiness and helps dough processability. Any of these enzymes acts as process aids during preparation of the dough part. The auxiliary enzyme or enzymes are added to complement the action of the other components for instance, the protease helps in pressability when the tortilla producer wants to avoid using L cysteine or sulphite. Xylanases can improve dough relaxation and at the same time help and maintain the dough strength.

[0085] Although the functionalities of some of the individual components of the ingredient system are known to some tortilla producers (such as B and C), as for example the benefits on tortilla appearance achieved when using component B and the effect of component C on fresh-keeping, the surprising performance of the combination of these ingredients in the inventive system on all aspects of flatbread product quality have not been previously demonstrated. The performance of the ingredient system of the invention in managing foldability, fresh-keeping and adhesion is significantly greater than could be assumed from an understanding of the performance of the individual components. This is particularly the case given that the individual components can have contrasting effects on the desirable characteristics such that balancing these competing functionalities is a non-trivial task.

[0086] The present invention also covers a flatbread product containing the previously described ingredient system in an amount between 1.5 to 6% by weight of the flour

[0087] The produced flatbread product object of the invention has no added monoglycerides or mono-diglycerides of fatty acids, which produces benefits in combined desired technical features of the product, as demonstrated in the experimental section, such as: [0088] a low adhesion of maximum score 2, so that tortillas can be taken from the stack without damage; [0089] a desired freshness defined by a foldability minimum score 4, and; [0090] an extensibility of minimum 17 mm

[0091] These features provide the product with a good appearance due to the limited translucency, suitable for a long ambient shelf life, with good flexibility and minimal adhesion damage when separated from each other from the package.

[0092] Therefore, the flatbread product of the invention has superior in some aspects or at least equal in other aspects, technical qualities, as reference flatbread containing monoglycerides at the same time of the shelf life, produced under the same conditions.

[0093] Additionally, the inventive combination of the ingredient system, prevents that in the production of the flatbread product, the portioned and moulded dough balls sticks to the proofing baskets. It allows proper release to the press in the same way as flatbread dough prepared with the addition of emulsifiers.

[0094] In one embodiment of the invention, the flat bread comprises the described ingredient system, wherein: [0095] component A is present in an amount between 1.5 and 2.5% by weight of the flour, [0096] component B is present in an amount between 0.3 and 1.2% by weight of the flour, and [0097] component C is present in an amount between 50 to 2000 ppm by weight of flour.

[0098] In another embodiment of the invention, the flat bread comprises the described ingredient system, wherein: [0099] component A is present in an amount between 1.5 and 2.5% by weight of the flour, [0100] component C is present in an amount between 50 to 2000 ppm by weight of flour; [0101] wherein component B is absent in the flatbread application that does not need pH control.

[0102] In a preferred embodiment, component (A) of the ingredient system is present in an amount of at least 1.5%, preferably 1.8%, based on the weight of the flour. Component (B) is present in an amount of 0.35% and increase to a max level of 1.2% on flour basis, to achieve the convenient tortilla pH target (this level is based on a bicarbonate level of 0.5% fb), and wherein component (C) is present in an amount of at least 100 ppm based on the flour weight.

[0103] The present invention also covers the use of the claimed ingredient system in flatbread products, selected from the group of tortilla, wraps, lavash, roti, chapati and piadina, preferably tortilla.

[0104] In a preferred embodiment, the invention covers the use of a fat coated vegetable fibre particles as described above as component A, together with an amylase as component C, functionally replacing emulsifiers (monoglyceride or mono-diglyceride) in a bakery product, preferably a flatbread or tortilla, in which the fat coated vegetable fibre particles comprise 10-30% by weight of vegetable fibres and 70-90% by weight of a fat such as a hydrogenated vegetable oil.

[0105] In the execution of the invention solid fat may be spray-coated onto vegetable fibre particles to produce a composite material that, used in combination with a specific class of fresh-keeping amylases, provides a long-life tortilla without the inclusion of food additives such as distilled monoglycerides of fatty acids, mono-diglycerides of fatty acids (E471) and of hydrocolloids, which are commonly used in tortilla formulations. The novel ingredient system is also beneficial to the production of tortilla in which vegetable oils such as sunflower oil or rapeseed oil are used instead of plastic fat used in bakery (shortenings) or palm extracted fats.

[0106] The method of producing the present ingredient system, comprises the steps of: preparing the fat-coated vegetable fibre particles by (i) selecting a fat source that has a melting point between 40° C. and 80° C., (ii) melting the fat, (iii) mixing the melted fat with the selected vegetable fibres, and (iv) atomizing the melted fat-vegetable fibre suspension into a cold air-stream to prepare discrete fat-coated vegetable fibre particles.

[0107] Alternatively, the discrete fat-coated fibre particles can be made by (i) selecting a fat source that has a melting point between 40° C. and 80° C., (ii) melting the fat, (iii) atomizing the melted fat onto the selected vegetable fibre under high shear mixing and in a jacketed vessel, and (iv) cooling the fat-coated fibre particles under continuous shear to below the melting point of the fat, to give discrete fat-coated vegetable fibre particles.

[0108] Alternatively, the discrete fat-coated fibre particles can be made by (i) selecting a fat source that has a melting point between 40° C. and 80° C., (ii) melting the fat, (iii) spraying the melted fat onto the selected vegetable fibre in a fluidized bed coater until the requisite amount of fat has been added and (iv) cooling the fat-coated fibre particles to below the melting point of the fat, to give discrete fat-coated vegetable fibre particles.

[0109] The fat-coated organic acid is made by hot-melt coating in a fluid bed. The acid particles are filled into the bed and fluidized on a stream of hot air. The molten fat is atomized onto the fluidized acid particles, into such a way as to form a continuous and uniform coating. The final product is a fat-coated particle with a discrete core of organic acid.

[0110] Once thus prepared, the fat-coated vegetable fibre particles and the fat-coated organic acid particles can be mixed together in a suitable mixer, with the enzyme-containing powder, to form the final ingredient system.

[0111] The benefits obtained with the ingredient system are also described in the experimental section below.

EXPERIMENTAL SECTION

[0112] Materials

[0113] In preferred embodiments of the invention:

[0114] Component A was produced from sugar beet fibre, coated with fully hydrogenated rapeseed oil or high erucic rapeseed oil or a mixture of both. The composition of the particle is at least 8%, preferably between 10-15% sugar beet fibre, and the remaining part is fully hydrogenated rapeseed oil.

[0115] Component B was produced by fluid bed hot-melt coating of citric acid or malic acid with an appropriate fat source. The composition is at least 25% fat and preferably 30% to 45% fat and the remainder being citric or malic acid. The fat coating is preferably the same as described in Examples A.1, A.2, A.3 or A.4 in order to contribute to the control of adhesion among tortilla. Suitable products can be selected from the Protex range supplied by DuPont Nutrition Biosciences ApS (Tårnvej 25, DK-7400 Grindsted, Denmark) but also coated acid from other suppliers can be suitable. The component C is an amylase from the family of maltotetragenic amylases, glucan 1,4-alpha-maltotetrahydrolases (E.C. 3.2.1.60) of the type as described in WO2009083592 later referred as type 1 and the more thermostable variant as described in patent EP2432875 B1 later referred as type 2.

[0116] Unlike components A and B, component C should be included in the system formulation as a direct blend, with a carrier, as a single enzyme or in a complex with other auxiliary enzymes. A test preparation of maltotetragenic amylase containing 50 amylase units (maltotetrahydrolase type 1) or 100 units per gram of preparation with maltotetrahydrolase type 2) where the activity is measured using a standard assay for amylase activity, such as the Ceralpha assay (Megazyme, Ireland) was obtained from DuPont Nutrition Biosciences ApS (Tårnvej 25, DK-7400 Grindsted, Denmark).

[0117] The enzyme preparations alone or in complex with auxiliary enzyme activities, can be obtained from DuPont Nutrition Biosciences ApS (Tårnvej 25, DK-7400 Grindsted, Denmark). Alternative preparations of the amylase can be utilized for the purposes of the invention.

[0118] The component C can be further used to deliver an auxiliary enzyme, as a single activity such as fungal protease, glucose oxidase, fungal cellulase, bacterial xylanase or 1,3 lipase, or in a complex of the above.

Examples

[0119] Four examples of fat-coated fiber were prepared as shown in Table 1. In each case, the fat phase was melted and heated to above 85° C. The fiber was added to the hot fat and mixed thoroughly to form a uniform and homogeneous mixture. The fiber-fat slurry was pumped into a Niro NP6,3 spray tower and atomized by rotating disk into a cold air-stream. Process parameters are given in Table 2.

TABLE-US-00001 TABLE 1 Compositions of 4 examples of fat coated vegetable fibre: component A Example A.1 A.2 A.3 A.4 Fat Phase Fully hydrogenated Fully hydrogenated Fully hydrogenated Fully hydrogenated rapeseed oil high erucic high erucic high erucic 1740 g rapeseed oil rapeseed oil rapeseed oil 1820 g 380 g 4500 g Fully hydrogenated Fully hydrogenated rapeseed oil rapeseed oil 1400 g 4500 g Fiber Sugarbeet fiber Sugarbeet fiber Sugarbeet fiber Sugarbeet fiber 260 g 180 g 220 g 1000 g

TABLE-US-00002 TABLE 2 Process parameters for preparation of fat coated vegetable fibre: component A Parameter Setting Air Flow (kghr.sup.−1) 500-900 Inlet air (° C.) −10-10  Outlet air (° C.)  5-20 Atomizing wheel (rpm) 10000-15000 Feed Temp (° C.)  85-105

Examples of Component B

[0120] Three examples of fat-coated organic acid are shown in Table 3. In each case, the fat phase was melted and heated to above 85° C. before being sprayed onto the organic acid in a fluid bed (Aeromatic MP1). Spraying was carried out under conditions selected to ensure a uniform, smooth coating that comprised a multiplicity of layers. Process parameters are given in Table 4.

TABLE-US-00003 TABLE 3 Compositions of 3 examples of fat coated acids: component B Example B.1 B.2 B.3 Fat Phase Fully Fully Fully hydrogenated hydrogenated hydrogenated rapeseed oil high erucic high erucic 30% rapeseed oil rapeseed oil 30% 15% Fully hydrogenated rapeseed oil 15% Organic Citric acid Citric acid Malic acid Acid 70% 70% 70%

TABLE-US-00004 TABLE 4 Process parameters for preparation of fat coated acids: component B Parameter Setting Amount Organic Acid (kg) 2.8 Amount Fat Coating (kg) 1.2-1.8 Product Temperature (° C.) 43-53 Inlet Air Temperature (° C.) 45-55 Air Flow Rate (m.sup.3hr.sup.−1) 50-90 Atomizing Air Pressure)  90-110 Atomising Air Temperature (° C.)  90-110 Feed Temperature (° C.)  90-110 Spray Rate (kghr.sup.−1) 0.75-1.25

Examples of the Complete Ingredient System Preparation

[0121] The ingredient system was prepared by mixing a fat-coated vegetable fibre, component A (examples A.1, A.2, A.3, and A.4), and optionally a coated acid component B (examples B.1, B.2 and B.3) together with the enzyme preparation, component C (such as maltotetrahydrolase alone or in a complex with auxiliary enzymes such protease or xylanase), a filler, such as calcium carbonate in a powder mixer suitable to obtain a homogeneous powder preparation.

TABLE-US-00005 TABLE 5 Formulation of ingredient system Ingredient system composition example S.1 and S.2 Exam- Exam- System Component ple S.1 ple S.2 Component A, fat-coated fiber EXAMPLE A.1 70-75 75-80 Component B, coated acid EXAMPLE B.1 15-20 10-15 70% payload Component C, amylase Maltotetrahydrolase 1-5 1-3 (type 1) 50 unit/g Filler and anticaking Calcium Carbonate 5-0 0-7 Total 100 100 Dose on flour basis 2.5-3.5 2.35-2.85

TABLE-US-00006 TABLE 6 Ingredient system composition example S.3, S.4, S.4 and S.6 EXAMPLE EXAMPLE EXAMPLE EXAMPLE System Component S.3 S.4 S.5 S.6 Component A, fat- Example A.1 75-80 — — — coated fiber Example A.3 — 70-75 70-75 Example A.4 — 70-75 Component B, Example B.1 13-18 20-25 13-28 20-25 coated acid 70% Component C, Maltotetrahydrolase 2-5 1-6 2-5 1-6 enzyme complex (type 1) 50 unit/g with amylase Filler and anticaking Calcium Carbonate 3-5 0-1 3-5 0-1 Total 100 100 100 100 Dose on flour basis 2.2-3.5 2.2-3.0 2.5-32 2.0-2.8

TABLE-US-00007 TABLE 7 Ingredient system composition example S.7, S.9 (maltotetrahydrolase type 1) and S.8 and S10 maltotetrahydrolase type 2) EXAM- EXAM- EXAM- EXAM- PLE PLE PLE PLE System Component S.7 S.8 S.9 S.10 Component EXAMPLE A.1 70-80 70-80 — — A, fat-coated fiber EXAMPLE A.4 — — 70-80 70-80 Component EXAMPLE B.1 15-20 15-20 15-20 15-20 B, coated acid 70% Component Maltotetrahydrolase 4-6 — 4-6 — C, enzyme type 1 50 unit/g complex with amylase Maltotetrahydrolase — 2-3 — 2-3 type 2 100 unit/g Filler and Calcium 0-1 0-1 0-1 anticaking carbonate Total 100 100 100 100 Dose (% on flour basis) 2.5-3.0 2.5-3.0 2.5-3.0 2.5-3.0

TABLE-US-00008 TABLE 8 Ingredient system composition example S.11 and S.12, prepared without Component B EXAM- EXAM- PLE PLE System Component S.11 S.12 Component A, fat-coated fiber EXAMPLE A.3 85-93 90-95 Component C, enzyme complex Malto- 1-7 1-8 amylase and auxiliary enzyme tetrahydrolase (glucose oxidase or protease) type 1 50 unit/g Filler and anticaking Calcium 10-1  1-8 carbonate Total 100 100 Dose (% on flour basis) 2% 1.5-1.6%

[0122] Test of the Ingredient System in Tortilla

[0123] Tortillas were produced using the ingredient system blend made of components A, B and C as described in examples S.1 to S.10. For all trials, the reference tortilla were baked using POWERFlex 1100®, a commercial product available from DuPont Nutrition Biosciences ApS (Tårnvej 25, DK-7400 Grindsted, Denmark) and which contains distilled monoglyceride coated onto vegetable fibre particles, adopting a technology described in customer education publication Technical Memorandum TM 1025 e2 that can be obtained from DuPont Nutrition Biosciences ApS (Tårnvej 25, DK-7400 Grindsted, Denmark and to a certain extent also in WO2019115388A1, and citric coated with fully hydrogenated rapeseed oil and amylase. The amount of acid contained allows for neutral or slight acid pH with the given amount of bicarbonate utilized (0.5% flour basis). Examples of other suitable systems that can be used as a reference are POWERFlex®, 2301, POWERFlex® 2201, POWERFlex® 3205 which utilize hydrocolloid as well as monoglyceride and enzyme.

[0124] The reference and the test recipe can also contain additional coated acid, such as Protex 2300 NP, as indicated in tables 8 and 9, utilized to adjust the tortilla pH to a desired target pH. Protex 2300 NP is a commercial product, available from DuPont Nutrition Biosciences ApS (Tårnvej 25, DK-7400 Grindsted, Denmark).

[0125] In the trials the total fat level in the recipes is held constant at 8% on flour basis by allowing for contributions from Component A, the fat-coated vegetable fiber and Component B, the fat-coated acid and adjusting the amount of rapeseed oil added.

[0126] The recipes for the tortilla trials are given in Table 8, 9 and 10.

TABLE-US-00009 TABLE 9 recipe tortilla with ingredient system examples S.1 to S.2 Reference Trial 1 Trial 2 Flour 100 100 100 Water 42 42 42 Rapeseed Oil 8 6 6 Glycerol 5 5 5 Salt 1.5 1.5 1.5 Sugar 1.0 1.0 1.0 Sodium bicarbonate 0.5 0.5 0.5 Calcium propionate 0.3 0.3 0.3 Potassium sorbate 0.3 0.3 0.3 Protex 2300 NP 0.55 0.55 0.55 ingredient system with emulsifier 1.30 Ingredient system Example S.1 2.5 Ingredient system Example S.2 2.35

TABLE-US-00010 TABLE 10 recipe tortilla with ingredient system examples S.4 to S.6 Trial Trial Trial Trial Ref 3 4 5 6 Flour 100 100 100 100 100 Water 42 42 42 42 42 Rapeseed Oil 8 6 6 6 6 Glycerol 5 5 5 5 5 Salt 1.5 1.5 1.5 1.5 1.5 Sugar 1.0 1.0 1.0 1.0 1.0 Sodium bicarbonate 0.5 0.5 0.5 0.5 0.5 Calcium propionate 0.3 0.3 0.3 0.3 0.3 Potassium sorbate 0.3 0.3 0.3 0.3 0.3 Protex 2300 NP 0.4 0.4 0.4 0.4 0.4 ingredient system with emulsifier 1.30 Ingredient system Example S.3 3.3 Ingredient system Example S.4 2.5 Ingredient system Example S.5 3 Ingredient system Example S.6 2.5

TABLE-US-00011 TABLE 11 recipe tortilla with ingredient system examples S.7 to S.10 Trial Trial Trial Trial Ref 7 8 9 10 Flour 100 100 100 100 100 Water 42 42 42 42 42 Rapeseed Oil 8 6 6 6 6 Glycerol 5 5 5 5 5 Salt 1.5 1.5 1.5 1.5 1.5 Sugar 1.0 1.0 1.0 1.0 1.0 Sodium bicarbonate 0.5 0.5 0.5 0.5 0.5 Calcium propionate 0.3 0.3 0.3 0.3 0.3 Potassium sorbate 0.3 0.3 0.3 0.3 0.3 ingredient system with emulsifier 1.30 Ingredient system Example S.7 2.9 Ingredient system Example S.8 2.9 Ingredient system Example S.9 2.9 Ingredient system Example S.10 2.9

TABLE-US-00012 TABLE 12 recipe tortilla with ingredient system examples S.11 to S.12 - example without Component B, coated acid Ref Trial 11 Trial 12 Flour 100 100 100 Water 42 42 42 Rapeseed Oil 8 6 6 Glycerol 5 5 5 Salt 1.5 1.5 1.5 Sugar 1.0 1.0 1.0 Sodium bicarbonate 0.5 0.5 Baking powder (E500, E450) 1.2 SAPP (E450 0.65 Calcium propionate 0.3 0.3 0.3 Potassium sorbate 0.3 0.3 0.3 ingredient system with emulsifier 1.7 and acid Ingredient system Example S.11 2.0 protease Ingredient system Example S.12 2.0 GOX

[0127] Methods

[0128] Method to Manufacture Tortillas in a Pilot Plant

[0129] The tortilla trials were carried out in a pilot plant using a Kemper spiral batch mixer to mix the dough, a Koenig moulder to prepare the dough balls and a Lawrence Micro Combo 3 tortilla press and oven. The finished tortilla were packaged using a Multivac modified atmosphere packaging unit.

[0130] Process to make a tortilla [0131] 1. Mix all dry ingredients in the bowl 1 minute slow-add water [0132] 2. Mix 1 minutes slow-5 minutes fast (gear 2). Mixing time can depending on flour type and recipe and adjusted by the baker upon dough development assessment [0133] 3. Dough temperature target 30-32° C. [0134] 4. Scale using Koenig moulder, using guidelines below: [0135] 20 cm (8″): 48 g [0136] 25 cm (10″): 78 g [0137] 5. Rest in cabinet for 10 minutes at 30° C./55 RH [0138] 6. Run the dough through the press and oven at settings reported in Table 13 [0139] 7. Cool tortillas on sieved trays for 10 minutes at ambient temperature, use gloves when handling the tortillas [0140] 8. Pack the tortillas with 8 pieces in each package using program 08: 90,0 vacuum, 25,0 gas (70% Nitrogen; 20% CO2) and 2,0 seal [0141] 9. Clean the tortilla machine after use. [0142] 10. Store at ambient temperature.

TABLE-US-00013 TABLE 13 Process parameters for the baking process Settings for Settings for Parameter Small Tortilla Large Tortilla Weight dough g/diameter cm 48/20 78/25 Press pressure 700 1000 Press time, s 1.6 1.8 Press temperature upper, ° C. 200 200 Press temperature lower, ° C. 180 180 Baking temp set point, ° C. 230 230 Baking time, s 21 sec 30 sec Cycle rate set point 13 16 Teflon belt delay time 0.3 0.3 Teflon belt speed adjust 100 100

[0143] Method for Dough Processability Assessment

[0144] One of the issues associated with the simplification and elimination of additives from tortilla recipe is a decrease in processing quality. Dough balls positioned in the proving baskets undergo a rest period of typically of 5-10 min before pressing, and in cases of stoppages, adhere to the baskets and cannot be released onto the press chute. This issue might occur for example if there is an unplanned maintenance stop on the line. A drop test was developed to test this specific aspect of the ingredient system performance and this was executed in parallel with the baking trials reported above.

[0145] Specific trays, hosting nylon net baskets, were purpose constructed. The dough balls were placed in the proving baskets after being scaled and rounded, and proved at a set humidity and temperature for a variable resting time, according to the decided test conditions. The baskets were then turned upside down allowing the dough balls to drop by gravity onto a table. The operator recorded the time needed to release the dough balls. FIG. 4 illustrates the test device.

[0146] In the challenge test, the proof time was extended from 10 min to 30 min and the relative humidity and temperature adjusted to be between 55% to 65% and 35-36° C. respectively.

[0147] Method for Tortilla Evaluation

[0148] Adhesion Assessment

[0149] One of the technical features of wheat tortilla is their propensity to adhere to each other after storage when the user or consumer is taking a single tortilla from the pack. FIG. 1 shows an example where stickiness becomes problematic, and results in a damaged tortilla.

[0150] The method adopted to evaluate adhesion during the shelf life is performed by one assessor that opens a pack of tortilla stored in test conditions, same top weight on the packet, detaches one tortilla at the time recording a score. The scoring utilized is described below: [0151] Score 1: No adhesion detected, the tortillas detach freely without sound [0152] Score 2: Some sounds (zippering) can be heard when pulling the tortilla apart, but there is no damage [0153] Score 3: The skin of some steam pockets or some puffings is peeling away when pulling tortillas apart [0154] Score 4: The tortilla is damaged when pulled apart

[0155] Foldability Assessment

[0156] One major aspect of tortilla performance is the foldability—the ability of the tortilla to be folded without breaking. This feature is evaluated over the shelf-life. The foldability can be assessed by a technician consistently bending the tortilla in the centre line and using a score system like the one represented in FIG. 2. This method was used to score the flexibility performance of the same batch of tortilla over 180 days (FIG. 2).

[0157] Determination of Tortilla Extensibility

[0158] An instrumental measurement strictly relating to the flexibility of tortilla is obtained with a texture analyzer mounted with a rig that allows to clamp a tortilla. A spherical probe slowly stretching it to the break point at which point it punches though (TA and rig from Stable Micro System®). During testing the distance and force are measured. The parameters collected are the extensibility (mm), force at rupture (in Netwton or g and the work of rupture point force) (Nmm). The extensibility, or distance to the break point, is a measurable parameter that describes the loss of flexibility and foldability of tortilla over shelf life. (FIG. 6).

[0159] All publications mentioned in the above specification are herein incorporated by reference. Various modifications and variations of the described methods and composition of the present invention will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. Although the present invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in chemistry applied in food industry or related fields are intended to be within the scope of the following claims.

[0160] Results

TABLE-US-00014 TABLE 14 synopsis the components contained in the trials reported in Chart 1, 2, and 4. Component C Component Reference amylase and C amylase system with single Component and distilled Example Example components C amylase auxiliary Component Description monoglyceride S.1 Trial 1 S.2 Trial 2 fibre and fat only enzyme A and C emulsifier yes no no no no no no mono- glyceride acid yes, two Yes, two Yes, two Yes, one Yes, one Yes, one no sources sources sources sources source source fibre yes Yes, from Yes, from Yes, added as no no Yes, from component component a single component A in A in ingredient A in integrated integrated integrated form form form Fat (TG) Yes, one Yes, two Yes, two Yes, one Yes, one Yes, one no from source sources sources sources source source coating Fat from NO Yes, Yes, NO, fat added NO NO Yes, ingredient Component Component as single Component system A and B. A and B. ingredient A enzyme maltotetragenic maltotetragenic maltotetragenic maltotetragenic maltotetragenic maltotetragenic maltotetragenic amylase with amylase with amylase amylase amylase amyalse with amylase auxiliary auxiliary auxiliary enzyme enzymes enzyme

[0161] The tortilla characterized in FIGS. 6-10 were produced with a standard tortilla recipe (table 8). An acceptable ambient tortilla meets a few quality parameters, such as the water activity, pH and moisture. In FIG. 5 it is shown that the pH has level of pH was 5.3 to 4 for longer life tortilla and a pH just below 7 for system without component B. pH control is achieved due to the presence of either component B in the ingredient system and/or Protex 2300 NP added as a single ingredient.

[0162] Disregarding the trial with high pH which was not on target for this trial, FIGS. 6 and 7 report the adhesion score of tortilla during the shelf life. Adhesion scores of 2 or below are preferable, while scores above 3 correspond to beginning of physical damage of tortilla during its use and are therefore not acceptable. The integrity of the product is pre-conditional to other aspects of quality such as freshness and foldability. The dotted line at score 2, correlating to an audible zippering sound, indicates the threshold above which the product start to become unacceptable. The study extends to 90 days. The ingredient systems example S.1 and S.2 allowed the production of tortilla that detach without damage or only minimal blister damage. From FIG. 6 it is evident that once the emulsifier (E471) has been eliminated, the use of constituent ingredients of component A, or of components B or C alone do not prevent the occurrence of damaged tortilla.

[0163] The organic acid is required for all trials in order to produce tortillas with a lower pH (<6), that remain microbiologically stable over shelf life. The acid is added in coated form as this ensures tortilla that are not translucent. As a result, a certain amount of fat is delivered via the coated acid in all trials. However, it is evident from FIGS. 6 and 7 that addition of Protex 2300 NP alone, at the same level, is insufficient to control adhesion damage. However, for ingredient system examples S.1. and S.2, which are formulated with a level of component B sufficient to produce a neutral and mildly acidic, so not an alkaline tortilla, components A and B work synergistically to control the adhesion among tortilla.

[0164] In support of that, FIG. 7 illustrates a variation of level of component A in the ingredient system. All ingredient components have been kept at the same level necessary to satisfy the condition of pH and quality, with exception of the level of the integrated fibre (component A) which was decreased (−17% value) compared to the level used in ingredient system examples S.1 and S.2. In conjunction with such reduction, the adhesion score of tortilla increased to value above the critical threshold of 2.

[0165] The adhesion of the tortilla can be also evaluated instrumentally. A Texture Analyser mounted with a cylindrical probe an operating in Texture Profile Analysis mode was used to measure the adhesion work. Lower negative values correspond to a stickier tortilla surface in this measurement. It is evident from FIG. 8 that addition of the enzymatic component alone results in higher adhesion values once the emulsifier is removed from the tortilla recipe, and that this inconvenient effect of the amylase of component C is optimally balanced in the ingredient system S.1 and S.2.

[0166] FIG. 9 reports changes in foldability scores over the shelf life. The foldability scores of the ingredient system examples S.1 and S.2 are comparable to or marginally lower than those of the reference system with the emulsifier, distilled monoglyceride E 471.

[0167] FIG. 10 reports the instrumental description of freshness and pliability of tortilla, measured as extensibility. There is a general decline of extensibility in during the first 90 days of shelf life. Ingredient system examples S.1 and S.2 perform marginally poorer the reference with emulsifier in terms of freshness. Appearance (translucency) and parameters such as pH, water activity and moisture are at the same level. Considering all the results FIGS. 6-10 to 4 it appears the components A, B and C deliver a level of complementarity allowing the elimination of the distilled monoglyceride in ambient tortilla.

[0168] Additional formulations of the ingredient system of the invention are described in examples S.3, S.4, S.5 and S.6. Component A, as described in examples A.1 to A.4 (table 1), component B, as described in examples B.1 to B.3 (table 3) and component C (maltotetrahydrolase) in complex in auxiliary enzyme, are combined in different proportions, described in Table 4, to achieve a successful balance. The examples are tested in trials 3 to 6 using the recipe described in table 9. The performance of these solutions is described in FIGS. 11-15, which present the key aspects desired for the packaged tortilla through their shelf life and moment of use.

[0169] A basic requirement of the tortilla is given by parameters such as moisture, water activity and pH. The tortilla pH values satisfied the target pH of 5.2 to 5.4, which is known to be necessary for long-life tortilla in MAP. This was delivered partly via component B of the proposed ingredient system and partly by Protex 2300 NP, the dosage of which can be varied according to preferences and more stringent criteria of pH. FIGS. 11, 12A and 12B show the superior performance in controlling adhesion and adhesion-related damage over life for all ingredient system examples, as compared to the reference containing emulsifier. FIGS. 12A and 12B show in greater detail the distribution (% of tortilla) in each adhesion score bin from a total of two packets (16 tortilla pieces) assessed after 91 and 119 days (3 and 4 months) storage. The percentage of total tortilla with adhesion score 1 and 2 is equal to or higher than the reference tortilla containing distilled monoglyceride.

[0170] FIG. 13 illustrates that the foldability for the tortilla prepared with ingredient system examples S.3, S.4, S.5 and S.6 was superior to the reference with emulsifier over 6 months of shelf life.

[0171] FIG. 14 reports the extensibility of tortilla prepared with ingredient system examples S.3, S.4, S.5 and S.6 as superior to the reference with distilled monoglyceride during shelf life. While the values of extensibility tend to decrease during shelf life, the examples S.3 to S.6 maintained the superior performance of 16-18 mm after the first 6 months of ambient shelf life. FIG. 15 reports the value of force vs extensibility to break point; results for the ingredient system examples at 119 days (4 months) of shelf life are clearly superior to those for the reference.

[0172] FIGS. 16, 17 and 18 present data from a comparison of two variants of maltotetrahydrolase, as the core constituent of component C in the ingredient system, as described in Table 7. Ingredient system examples S.7 and S.9. are with maltotetrahydrolase type 1 and examples S.8 and S.10 are with maltotetrahydrolase type 2. Thus ingredient systems S.7 and S.8 are comparable, but contain different amylases, as are systems S.9 and S.10. This trial was conducted to cover a short shelf-life tortilla (45 days), therefore component B delivers all the acid necessary to reach a higher tortilla pH (6.4-6.6) and no additional coated acid is required (recipe in Table 10).

[0173] FIG. 16 illustrates that adhesion damage control through the shelf life is equal or superior to the control with emulsifier and similar for both amylases, when other components of the ingredient system are held constant. FIG. 17 describes a superior foldability and FIG. 18 describes a superior extensibility. This supports an interchangeability of the two amylases in the system in terms of basic functionality criteria, leaving the choice to other sensorial aspects.

[0174] Additional trials were carried out to investigate the processability in terms of dough handling. Ingredient systems examples S.3 and S.4 and S 0.8 were tested according to the drop test described in FIG. 4 and in the method for dough processability assessment section, and the evaluation complemented by tortilla evaluation methods and reported in FIGS. 19, 20 and 21F. In all cases the pH of the finished tortilla was 5.6-5.7. The appearance and translucency was acceptable. FIGS. 19-21 show that the evolution of adhesion, foldability and flexibility over 3-4 months of shelf-life is superior to that of the reference.

[0175] The results of dough processability testing for ingredient system examples S.3, S.4 and S.8 are summarized in table 15 below which shows the time required to release a dough ball of 100 g, kept for 30 min in a prover cabinet (abuse time condition). The benefit of low dough stickiness which is typically associated with the use of E number additive such as emulsifiers (reference with E 471) and hydrocolloids (xanthan, CMC, guar gum). Here a comparable performance is achieved with the ingredient system comprising components A, B and C that do not utilise mono-diglyceride (E 471).

TABLE-US-00015 TABLE 15 Example Example Example Reference S.3, S.8, S.4, system with dosage dosage dosage Trial emulsifier 2.9% fb 2.8% fb 2.5% fb Drop test time, Less than 1 s Less than 1 s Less than 1 s Less than 1 s (30 min rest)

[0176] Trials 11 and 12 illustrate the performance of a simplified ingredient system containing only Components A and C, described as S.11 and S.12 (Table 8). The tortillas are produced without the addition of organic acid, or component B. In these trials the pH neutralization of the sodium bicarbonate is achieved with alternative methods and pH reduction of the tortilla is not deemed important due to the shelf-life requirements. FIG. 22 shows the tortilla achieve a pH around 7. FIGS. 23, 24 and 25 document the adhesion, foldability and extensibility for tortilla from Trials 11 and 12 over the 60-day shelf-life. In each case, the performance of the tortilla prepared with ingredient system examples S.11 and S.12 matches or exceeds that of the reference tortilla, prepared with emulsifier.

[0177] All publications mentioned in the above specification are herein incorporated by reference. Various modifications and variations of the described methods and composition of the present invention will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. Although the present invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in chemistry applied in food industry or related fields are intended to be within the scope of the following claims.