9/29/16. Controlled Test Baking and Fundamentals of Bread Dough Systems. Kathy Brower, AIB InternaConal. The GoToWebinar Attendee View

Transcription

1 Controlled Test Baking and Fundamentals of Bread Dough Systems Kathy Brower, AIB InternaConal The GoToWebinar Attendee View How to Participate Today Open and close your Panel View, Select, and Test your audio Submit text quescons Raise your hand Q&A addressed at the end of today s session 1

2 Controlled Test Baking and Fundamentals of Bread Dough Systems Kathy Brower, AIB InternaConal Controlled Test Baking & Fundamentals of Bread Dough Systems Kathy Brower Manager, Pilot Plant Welcome to the Bake Lab! Adventure awaits Explore the scene Collect informacon Discover something new 2

3 It s your baking story Develop the objeccves Choose the proper applicacons Outline the process Gather the details Tell it how it is Controlled Baking Laboratory Guidelines: Op8mize Make every sample count! You may only have one chance to tell the story of an ingredient or process. Controlled Baking Laboratory Guidelines: Organize D D R R Define all systems with a^encon to Detail for the bake to be Reliable and Repeatable. 3

4 Where to start AnalyCcal Lab Cake Cookies Biscuits TorCllas Test Baking Lab: Yeast Leavened or Chemically Leavened Bread Rolls Buns Sweet Dough Controlled Baking Laboratory Guidelines: Organiza8on Everything in it s place. Design for funcconality plays a key role in Cme management which is criccal for consistent test baking. Scaling, Mixing, FermentaCon 4

5 Keep it balanced Accuracy for < 1 gram: use analyccal balance Scaling Ingredients Label Containers Use containers with lids Scaling Ingredients Flour first Minor ingredients on top of flour in separate piles Use weigh boat to add minors 5

6 Scaling, Mixing, FermentaCon Mixing stacon: Small Scale vs. Large Scale 6

7 McDuffee vs. Standard Bowl Mixing stacon: preparacon = Cme savings! Water porcons pre- weighed and labeled Labeled dough container conveniently located at base of mixer Thermometer ready to take dough off temp. Controlled Baking Laboratory Guidelines If schedule is King, mixer operator is Queen! Once the schedule is set, mixer operator is the task manager controlling the flow of the bake. 7

8 EvaluaCng the dough off mix FermenCng Sponges 4 hours Temperature 84 F Sponge nearing the end of FermentaCon 8

9 Dough DiagnosCcs FermentaCon properces (sponge characterisccs) Mixing characterisccs Dough handling properces Proofing tolerance Controlled Baking Laboratory Guidelines: Orchestrate CalibraIon is key! Each instrument as well as technologist must be adept to the task. Dividing & Rounding Dough White Pan Bread: Scaling weight = 524 g of dough each 9

10 Uniformity counts! Dough passing through head roll Acme Sheeter / Straight Grain Moulder Senngs for White Pan Bread: Head Roll 2.8 mm Sheeter Roll 1.7 mm Pressure Roll 4.0 mm 10

11 Hygrometer in Proof Cabinet RelaCve Humidity 81.5 % rh Temperature 110 F Bread Proofing Proof to Height of 90 mm total (20 mm from top of pan) Typical proof Cme: ~ 60 minutes Proof Height Meter 11

12 Controlled Baking Laboratory Guidelines: Opportunity Find the OR in ERROR! Is an unexpected result a set- back, OR a chance to understand things differently??? Oven Spring Reed oven with 4 revolving shelves White Pan Bread 420 F 20 minute bake Baked loaves 12

13 Out of the oven Record Cme out De- pan immediately Start from low shelf to high Cool for one hour prior to packaging Volume Avg. weight of two loaves (g) Avg. volume of two loaves (cc) Volume / Weight = Sp.Vol. External Product EvaluaCon 13

14 Internal Product EvaluaCon Sponge & Dough Formulas Sponge: Example Formula for Pure Wheat Variety TesIng Bakers % Grams Bread Flour 70 var. (%m.b.) Compressed Yeast 2 14 Yeast Food, No Oxidant Fungyl alpha amylase 0.4g/100g flour 2.8 Water Dough: Bread Flour 30 var. (%m.b.) Granulated Sugar 7 49 Shortening, AP 3 21 Salt 2 14 Calcium Propionate Water var. Example Formula for Control Flour OpImizaIon Sponge: Bakers % Grams Bread Flour Compressed Yeast 2 14 Yeast Food, No Oxidant SSL (sodium stearoyl lactylate) Water Dough: Bread Flour Granulated Sugar 7 49 Shortening, AP 3 21 Salt 2 14 Calcium Propionate Water var. Straight & No- Time Dough Formulas Example Formula for Straight Dough Bakers % Grams Bread Flour Granulated Sugar 7 49 Salt 2 14 SSL (sodium stearoyl lactylate) Yeast Food, No Oxidant Calcium Propionate Shortening, AP 3 21 Compressed Yeast 2 14 Ascorbic Acid 60 ppm Water var. Example Formula for No- Time Dough Bakers % Grams Bread Flour Granulated Sugar 7 49 Salt 2 14 SSL (sodium stearoyl lactylate) Yeast Food, No Oxidant Calcium Propionate Compressed Yeast Shortening, AP 3 21 Ascorbic Acid 60 ppm Water var. 14

15 Dough Method Comparison Mix Time FermentaIon Mix Time Sponge Stage 1: 1 st Rise Stage 2: & Sponge Ingredients Sponge pre- ferment Dough Ing. 30 Mix Mix sec low Dough 1 min. low, 1 min. high 4 hours Add sponge, 30 sec. low High speed uncl fully developed Straight Mix all ingredients Dough Ferment Dough 1 min. low, high speed 1 hour uncl fully developed No- Time Mix all ingredients No Ferment Dough 1 min. low, high speed uncl fully developed Dough Method Comparison Sponge Floor Time Dividing Intermediate Proof / Rest & 20 minutes 524 g (18.5 oz) 10 minutes Dough in ferment cabinet room temp Straight Dough None 524 g (18.5 oz) 10 minutes room temp No- Time Dough None 524 g (18.5 oz) 10 minutes room temp Control Test Design: Sodium ReducCon Ingredient (%f.b.) Control (- ) Control - 25% NaCl - NaCl + KCl Flour Sugar Water Oil Yeast Salt (NaCl) KCl

16 sponge w= sponge sponge sponge spng dough w= time water sponge off back back char sponge abs water dough mix off divide mold Item grams temp mixer time temp (0-6) comments % grams temp time mixer time time Controlled Baking Laboratory Guidelines Be prepared! Prepare document sheets and schedules plus any pre- scaling in advance to reduce the likelihood of errors. Game plan + team work = WIN Assign duces for consistency Increase accuracy Become more efficient Special thanks to Renee Boeckman for many of the fantastic photos found in these slides and to Carmen Scott for not erasing my numbers. J DocumentaCon: ProducCon Schedule Date: Bakers Flour(s)

17 System: Project #: Bread Type: Date Mixed: Baker: Date Scored: Experimental Variable: QUALITIES sl = slightly Dough: v = very Sponge off mixer (2) A. bold B. flat, collapsed Sponge out of ferm. (5) C. sticky D. dry E. tough Dough out of mixer (10) A. sticky B. slack C. elastic D. bucky Dough at make-up (10) E. dry Dough Score (27) External: Symmetry (5) A. shrunk sides B.flat C. sm end D. uneven Crust Character (3) A. tough B. brittle C. thick D. blistered Crust Color (5) A. light B. dark C. dull D. uneven Break and Shred (5) A.w ildb.shelledc.bulged D.double E.insuf f icient External Score (18) F. uneven Internal: Grain (20) A.openB. coarsec.thick cells D.holes E. non-unif Texture (10) A.rough B.core C. crumbly D. dry Crumb Body (10) A. w eak B. firm Crumb Color (5) A. dull B. gray C. streaked D. yellow Taste/Aroma (5) A. sour B. sw eetc.bitter D. foreign E. af tertaste Mouthfeel (5) A. dry B. gummy C. coarse Internal Score (55) Total Score (100) Comments Absorption: % Mixing Time: minutes Proof height: mm Proof Time: minutes Specific Volume: cc/g Volume: cc System: Project #: Bread Type: Date Mixed: Baker: Date Scored: Experimental Variable: QUALITIES sl = slightly Dough: v = very Sponge (2) A. bold B. flat, collapsed Sponge out of ferm. (5) C. sticky D. dry E. tough Dough out of mixer (10) A. sticky B. slack C. elastic D. bucky Dough at make-up (10) E. dry Dough Score (27) External: Symmetry (5) A. shrunk sides B.flat C. sm end D. uneven Crust Character (3) A. tough B. brittle DocumentaCon: Dough EvaluaCon DOUGH SCORE SHEET - SPONGE & DOUGH Date: Bakers: Project: Dough out of mixer Dough at makeup Bucket Flour Rating Rating Number Number (out of 10) Comment (out of 10) Comment 1 CNT DocumentaCon: Bread EvaluaCon THANK YOU! Drink a coffee, Add- a- Cat! C alibrated A lert T echnologist 17

18 More offerings from AIB: CerIfied Bread Specialist Industrial A career competency program for baking professionals FoundaIons: All About Baking October Manha^an, KS Learn more at: Check out our blog: foodfirst.aibonline.org Q&A Session Reminder for subminng a quescon: Please make sure your a^endee panel is open Enter your quescon in the quescon box and click send. Thank You For A^ending Follow up and survey More QuesCons? American Society of Baking Amanda Gonzalez, Membership Manager , ext 3 agonzalez@asbe.org 18