FLAT BREAD TECHNOLOGY

FLAT BREAD TECHNOLOGY

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FLAT BREAD TECHNOLOGY J alai ~rooni Consultant, Harrisburg, Pennsylvania CHAPMAN & HALL I CD p International Thomson Publishing New York. Albany. Bonn. Boston. Cincinnati. Detroit. London. Madrid. Melbourne Mexico City. Pacific Grove. Paris. San Francisco. Singapore. Tokyo. Toronto. Wasbington

Cover Design: Andrea Meyer, emdash inc. Copyright 1996 Softcover reprint ofthe hardcover I st edition 1996 Chapman & Hall Printed in the United States of America For more information, contact: Chapman & Hall 115 Fifth Avenue New York, NY 10003 Thomas Nelson Australia 102 Dodds Street South Melbourne, 3205 Victoria, Australia Nelson Canada 1120 Birchmount Road Scarborough, Ontario Canada, MIK 5G4 International Thomson Editores Campos Eliseos 385, Piso 7 Col. Polanco 11560 Mexico D.E Mexico Chapman & Hall 2-6 Boundary Row London SEi 8HN England Chapman & Hall GmbH Postfach 100 263 0-69442 Weinheim Germany International Thomson Publishing Asia 221 Henderson Road #05-10 Henderson Building Singapore 0315 International Thomson Publishing-Japan Hirakawacho-cho Kyowa Building, 3F 1-2-1 Hirakawacho-cho Chiyoda-ku, 102 Tokyo Japan All rights reserved. No part of this work covered by the copyright hereon may be reproduced or used in any form or by any means-graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems-without the written permission of the publisher. I 23456789 10 XXX 01 00 99 97 96 Library of Congress Cataloging-in-Publication Data Qarooni,lalal Flat bread technology / lalal Qarooni p. cm. Includes bibliographical references and index. ISBN-13: 978-1-4612-8498-7 e-isbn-13: 978-1-4613-1175-1 001: 10.1007/978-1-4613-1175-1 I. Bread. 2.Cookery, International. I. Title. TX769.Q27 1996 641.8'15-dc20 British Library Cataloguing in Publication Data available 95-44918 CIP To order this or any other Chapman & Hall book, please contact International Thomson Publishing, 7625 Empire Drive, Florence, KY 41042. Phone: (606) 525-6600 or 1-800-842-3636. Fax: (606) 525-7778, e-mail: order@chaphall.com. For a complete listing of Chapman & Hall's titles, send your requests to Chapman & Hall, Dept. BC, 115 Fifth Avenue, New York, NY 10003.

This book is dedicated to the farmers, millers, and bakers of the world

Contents Dedication Preface v xiii CHAPTER 1 Cereal Grains in Flat Bread Production 1 Introduction 1 Wheat 2 Corn 5 Rye 7 Barley 10 Sorghum 11 Pearl Millet 12 Rice 13 References 16 CHAPTER 2 Cereal Milling and Flour Production for Flat Breads 19 Introduction and Historical Background 19 Wheat Milling and Flour Extraction 20

viii Flat Bread Technology Effect of Wheat Milling Variables on Flour and Flat Bread Quality 22 Corn Milling to Flour and Masa Production 28 Production of Masa (Corn Dough) 29 Production of Rye, Sorghum, Millet, Barley, and Rice Flour 30 Rye Milling 30 Barley Milling 32 Sorghum and Millet Milling 33 Rice Milling 33 References 34 CHAPTER 3 Properties and Functions of Sourdough and Noncereal Ingredients in Flat Bread Production 37 Introduction 37 Sourdough and Leavening Agents 37 Organisms Involved in Food Fermention 39 Bacteria 39 The Tribe Streptococceae 39 The Tribe Lactobacillacilleae 41 The Family Propionibacteriaceae 42 Yeast 42 Mold 42 The Functionality of Microorganisms in Sourdough Bread Production 43 Sourdough in Flat Bread Production 44 Technology of Sourdough Production 44 Shortening 49 Emulsifiers 51 Definition and Classification of Emulsifiers 52 Surface-Active Emulsifiers 53 Naturally Occurring Materials 57 Legumes 60 Potato flour 62 References 62

Contents ix CHAPTER 4 Flat Breads 67 Introduction 67 Classification and Processing of Flat Breads 68 Dough-Based, Single-Layered Flat Breads 72 Arepa and Corn Tortilla 72 Barbari Bread 75 BaUaw 78 Bazlama 78 Candy Bread 78 CiabaUa 80 Chapati 80 English Muffins 81 Focaccia (Boboli) 82 Gomme 83 Hillalla 83 Kalachi 83 Khobz EI-Daar 84 Korsan 84 Lao Bing 86 Lavash 86 Malouge 86 Matlowa 87 Matzo 87 Meat Bread 87 Moroccan Whole Wheat Bread 87 Paratha 88 Pizza and Pizza Crust 88 The Pressing (Stamping) Method 90 The Sheeting and Die-Cut Method 92 Purl 93 Rice Bread (Lakoy) 93 Rye Flat Bread 94 Saiki 97 Samoli 98 Sangak 98 Shamsy or Sunny Bread 99 Tanoor Bread 99

x Flat Bread Technology Tamees 101 Terabelsi 101 Tortillas (Wheat Flour) 10 1 Tortilla de Harina 106 Yufka 106 Batter-Based Flat Breads (Leavened) 106 Blintzes 107 Crepes 107 Crumpets or Pikelets 108 Dosai 109 Injera 109 Kisra 112 Pancakes and Waffles 112 Quesadella 112 Rogag 115 References 115 CHAPTER 5 Double-Layered Flat Breads 121 Arabic (Pita) Bread 121 Dough Mixing 123 Bulk Fermentation 126 Intermediate Proofing 127 Dough Sheeting 128 Final Proofing 130 Baking 132 Cooling and Packaging 136 Baladi Bread 137 References 139 CHAPTER 6 Quality of Flat Breads 141 Quality Requirement of Flat Breads 141 Quality Assessment of Flat Breads 142 Flour Quality Requirement for Flat Breads 146

Contents xi Comparison of Flat Bread Quality Prepared in a Laboratory and Commercial Bakery 150 Shelf Life of Flat Bread 151 References 156 Appendices Appendix I Formulation and Processing Steps of Selected Flat Breads 159 Appendix II Conversion of Common Units to International System of Units (SI) 175 Appendix IlIA Suppliers of Leavening Agents in the United States and Canada 177 Appendix IIIB Suppliers of Dough Strengtheners and Crumb Softeners in the United States and Canada 179 Appendix IIIC Suppliers of Gums. Thickeners. and Stabilizers in the United States and Canada 181 Appendix IIID Suppliers of Oxidixing Agents in the United States and Canada 183 Appendix IIIE Suppliers of Reducing Agents in the United States and Canada 185 Appendix IIIF Suppliers of Enzymes in the United States and Canada 187 Appendix IIIG Suppliers of Mold Inhibitors in the United States and Canada 189 Appendix IIIH Suppliers of Acidulants in the United States and Canada 191 Appendix IV Suppliers of Makeup Equipment and Ovens for Pita (Arabic). Pizza and Tortilla Production Lines in the United States and Canada 193 Appendix V Suppliers' Addresses. Phone and Fax Numbers 195

Preface Flat breads are the most popular breads throughout the world. It is estimated that the number of people consuming various types of traditional flat bread reaches over 1.B billion. This includes the population of Central America, where tortillas prepared from com and wheat are consumed daily; the countries of southern Europe, where pizza, focaccia, ciabatta, and pita are popular products; the Scandinavian countries, where many types of traditional and crisp flat breads made from rye, barley, wheat and other cereal grains are popular; the countries of north Africa, where khobz el-daar, baladi, kisra, shamsi, injera, and many other flat breads are popular; the countries of the Middle East, Turkey, Iran, and the southern states ofthe former Soviet Union (Georgia, Azerbaijan, Armenia, Turkmenistan, Uzbekistan, Tajikstan), where many types of flat breads from a wide range of cereal grain, mainly wheat, have a long tradition of being the daily breads; the countries of Afghanistan, Pakistan, India, Bangladesh, and parts of China, where chapati, tandoor, naan, dosai, etc. provide the essential nutrients for the masses. The consumption of flat breads is not limited to these countries. The popularity of pizza, pita and recently tortillas in the United States, Canada, Europe, Australia, and other countries is a clear indication of the future market value of these, and all other natural, high-fiber, healthy flat breads.

xiv Flat Bread Technology Although flat breads are popular worldwide, a very limited number of resources are available that discuss the function of their ingredients, processing steps, quality assessment, and shelf life of the final products. The purpose of this book is to provide an in-depth knowledge and know-how of flat breads to a wide range of readers, from breeders of cereal grain to technical personnel of milling and baking industries, ingredients suppliers, as well as students of food and cereal technologies. Chapter 1 provides the historic background of various grains, and their structure and chemical compositions. The effect of the milling process to flour, and the production of mas a is discussed in chapter 2. Chapter 3 provides a thorough background discussion of the different microorganisms involved and the method of sourdough production, as well as the different types of synthetic and naturally occurring emulsifiers and other flat bread ingredients. The technology of flat bread production is discussed in chapters 4 and 5. The former chapter is assigned to discuss the classification of flat breads and the technology of single-layered breads prepared from a dough and a batter of raw materials. Chapter 5 discusses the processing of double-layered flat bread, mainly pita (ArabiC) and sourdough-based baladi bread. Chapter 6 describes the quality criteria for the most popular breads and their cereal and flour requirements for optimum quality production, as well as their shelf life stability. I would like to express my appreciation to the individuals who gave me permission to reprint some ofthe figures and tables. My special thanks to my wife, MaIjaneh Talebi, for her encouragement and support, and long hours she spent developing the computer-generated figures. Further, my sincere thanks to Dr. Eleanor Riemer of Chapman & Hall for her contribution in the publication of this book. Jalal Qarooni