Process for the production of patterned, three dimensional dough systems

Abstract: Dough systems that form three dimensional patterns on heating in an oven are obtained if the dough comprises at least two different areas with different dough compositions that have different expansion capabilities during fermentation and/or heating.

Description: The invention relates to a process for making three-dimensional baked bakery dough products according to the preamble of claim 1. Although doughs with many different compositions are known for many years, dough systems wherein different dough compositions are present are rare in the prior art. If disclosed, such as in US 5.145,699 one of the doughs is used for a particular purpose, such as in this reference as a control means for regulating the moisture content of the dough layer and not to obtain optical effects e.g. in the form of patterns. On the other hand quite a number of different baked bakery products are known wherein a pattern is aimed for. In these products the patterns are achieved by hand shaping of different dough layers of always the same dough system. This thus means a time consuming methodology for preparing the dough products. WO 9211767 discloses a method for producing direct baked dough and food products obtained by baking such a dough. Two separate doughs are prepared and placed on top of each other. US 3917856A discloses a refrigerated corn bread dough which is divided into biscuits like dough pieces and packed in refrigerated dough containers. These layers are obtained by extruding and subsequently these layers are bonded together. Pastry product made from materials having differing consistencies are described in EP 0 522 891. We studied whether we could find ways, which would result in a dough-product, either after fermentation and/or after baking, that displayed a predetermined three dimensional pattern, and with which above problems could be avoided. This aim is realized with the characterizing features of claim 1. According to the process of the invention dough systems are provided that will form three dimensional patterns when heated in an oven, wherein the dough comprises at least two independent areas with a different dough composition. Preferably the different dough compositions contain at least 20 wt% of flour and have different expansion capabilities, either during fermentation and/or during heating. Very conveniently the different dough compositions are present in a way that creates a preselected three dimensional pattern upon baking of the dough system. Although many factors influence the expansion capability of a dough we found that a very easy way to achieve a different expansion capability in different doughs is by using different levels of leavener(s) in the different dough compositions. In this instance the leavener in the different dough compositions can be the same leavener or can be different. Alternatively at least one of the dough compositions can be free of leavener, whereas the other dough composition(s) contain at least one leavener. Useful leaveners are selected from the group consisting of chemical leaveners, in particular sodium hydrogen carbonate, but other well-known chemical leaveners can be applied as well, and yeasts. The level wherein the leaveners are applied can range from 0.2-15 wt% for a chemical leavener and from 0.5-20 wt% for a yeast. So very good results were obtained with a dough system wherein one dough layer contained 1 wt% of yeast and the other dough layer contained 10 wt% of the same yeast. It is of course also possible to combine a dough layer wherein a yeast is present with a dough layer wherein a chemical leavener is present, as long as the expension capability of the two dough layers are different. Expansion capability is defined here as the ability of a dough to expand in volume during a fermentation for 30 min at 32 oC and 80% rel. hum. (in case a yeast is applied) and is measured after freezing at -32°C for 30 minutes or as the increase in volume of a dough upon heating at 140 oC in case a chemical leavener is used. Very attractive patterns are obtained if the expansion capabilities of the different dough compositions differ at least 10%. In particular very nice patterns are achieved if the dough with the highest expansion capability is at least partly, preferably completely embedded in the dough composition with the lowest expansion capability. In this way the driving force of the dough with the highest expansion capability is used to create patterns in the dough with the lowest expansion capability. Another way to achieve the different expansion capabilities in the different dough compositions is to use different types of yeasts with different activities in the different dough compositions. Alternatively a difference in expansion capability can also be the result of the presence of different bread improver ingredients or of different levels of the same bread improver ingredients in the different dough compositions. Examples of these bread improver ingredients are: emulsifiers, such as DATA-esters, lecithins and HYMONO's, enzymes, such as amylases, xylanases, oxydases etc, anti-oxidants, such as ascorbic acid etc. An efficient way to obtain the desired results is to use the leavener(s) and/or yeast(s) in levels that result upon heating at 140 oC in a difference in ovenspring for the different doughs of at least 10 vol%, ovenspring being defined here as the increase in volume of a dough upon heating in an oven per gram of dough. According to another embodiment of our invention we can also apply different leaveners in the different doughs that create different ovensprings at different temperatures upon baking of the doughs, this will e. g. be the case if different chemical leaveners are used in the different doughs, or if a yeast is applied in one dough and a chemical leavener is applied in another dough. Our new finding is not limited to the use of bread type doughs with a certain rheology, according to our invention it is also possible to use a batter as one of the dough compositions. Examples of such batters are cake batters or pan cake batters. These batters can contain a chemical leavener although they also can be free of any leavener. The dough system according to the invention can be used at ambient temperatures, however it is also possible, depending on the exact dough composition to cool the dough to so called chilled temperatures (about 0-10 oC), or even to freeze the dough systems to temperatures below 0 oC. In these instances the dough composition can require the presence of specific components, e.g. as disclosed in our WO 95/17099. Above dough systems can be applied as completely unproofed doughs, although we prefer the doughs to be at least partly proofed or even fully proofed. Part of our invention are also the baked products having a three dimensional pattern that can be obtained after baking of preshaped dough systems with the composition according to our invention. Although the novel dough compositions can be made by conventional techniques, a very convenient way to make them is by a process wherein (i) a dough (D-1) is made having an expansion capability of E-1 (ii) at least one other dough (D-2) is made having an expansion capability of E-2, which is different from E-1 (iii) D-1 is rolled out to a flat piece of dough (iv) D-2 is (are) formed to one or more strand(s) of dough (v) one or more strands of dough D-2 are rolled in the dough D-1 to form a cylinder of dough comprising doughs D-1 and D-2 (vi) the cylinder of (v) is cut into slices, optionally after cooling of the dough cylinder, whereby each slice comprises areas of the different doughs D-1 and D-2 (vii) the slices resulting from (vi) are proofed during 10-60 min at 28-36 oC (viii) the proofed slices of (vii) are baked at 180-250 oC for 10-60 min. EXAMPLES By using the process as described above a dough D-1 and a dough D-2 were prepared. D-1 contained 3 wt% of baker's yeast and D-2 contained 13 wt% of the same baker's yeast. The yeast applied was Koningsgist from Gist-Brocades. Therefore the expansion capability of the two dough compositions differed considerably(>200 %). According to step (iv) of our process 3 strands of D-2 were made,each having a diameter of about 2 cm. D-1 was rolled out to a rectangle of 25x40 cm. The 3 strands of D-2 were rolled in separately into the rolled out D-1. This resulted in a cylinder of dough D-1 wherein three areas of D-2 were embedded. This cylinder was cooled to 10 oC and the cylinder was cut into slices sothat each slice consisted of an area of D-1 wherein three areas of D-2 were incorporated. Each slice was subjected to proofing at 32 oC during 50 min.The proofed slices were baked in an oven at 240 oC during 8 min. The products obtained displayed a three dimensional pattern because of the different ovensprings that occurred during the bake off.

Claims: Process for making three-dimensional baked dough products, wherein (i) a dough (D-1) is made having an expansion capability of B-1 (ii) at least one other dough (D-2) is made having an expansion capability of E-2, which is different from E-1 (iii) D-1 is rolled out to a flat piece of dough (iv) D-2 is (are) formed to one of more strand(s) of dough (v) one or more strands of dough D-2 are rolled in the dough D-1 to form a cylinder of dough comprising doughs D-1 and D-2, characterised in that (vi) the cylinder of (v) is cut into slices, optionally after cooling of the dough cylinder, whereby each slice comprises areas of the different doughs D-1 and D-2 (vii) the slices resulting from (vi) are proofed during 10-60 min at 28-36°C (viii) the proofed slices of (vii) are baked at 180-250° C for 10-60 min. Process according to claim 1, wherein the different doughs (D-1 and D-2) contain at least 20 wt.% flour. Process according to claim 2, wherein the different expansion capabilities of D1-D2 are the result of the presence of different levels of leavener(s) in the different dough compositions. Process according to claim 3, wherein at least one of the dough compositions is free of leavener. Process according to claims 3-4, wherein the leavener(s) is (are) from the group, consisting of chemical leaveners and yeast. Process according to claims 2-5, wherein at least two dough compositions are present from which the expansion capability differs at least 10 vol. %. Process according to claim 2, wherein the different expansion capabilities are the result of the presence of different yeasts with different activity in the different dough compositions. Process according to claim 2, wherein the different expansion capabilities are the result of the presence of different bread improvers ingredients or the same bread improver ingredients, however in different levels in the different dough compositions. Process according to claims 2-7, wherein the leavener(s) and/or yeast(s) is (are) used in levels that result upon heating at 140 ° C in a difference in ovenspring for the different doughs of at least 10 vol.%. Process according to claim 2 wherein different leaveners are present in the different doughs that create different ovensprings at different temperatures upon baking of the doughs. Process according to claim 2, wherein at least one of the dough compositions is a batter, optionally free of leavener. Process according to claims 2-11, wherein the dough system is partly or completely proofed. Process according to claims 2-12, wherein the dough systems are chilled or frozen.

Inventors: VAN DER ZON PETRUS WILHELMUS M, VAN DER ZON, PETRUS WILHELMUS M.
Applicants: CSM NEDERLAND BV, CSM NEDERLAND B.V.
Application year: 1996
Main classification: A21D13
IPC codes: A21D13