11/10/2019

1

Global Global Global Global opportunities and challengesopportunities and challengesopportunities and challengesopportunities and challenges

for bakersfor bakersfor bakersfor bakers

Stanley P. Cauvain

www.baketran.com

Global opportunities and challengesGlobal opportunities and challengesGlobal opportunities and challengesGlobal opportunities and challenges

1. Finding ways to make bakery products ‘healthier’

2. Improving process efficiency and reducing energy costs in bread production

3. Developing relevant scientific, technical and production skills

www.baketran.com

Nutritional areas Nutritional areas Nutritional areas Nutritional areas of interestof interestof interestof interest

www.baketran.com

SALT

FAT FIBRE

SUGAR

ENERGY DENSITY

(CALORIES)

TARGETS

RECIPE

www.baketran.com

The route to healthier bakery products The route to healthier bakery products The route to healthier bakery products The route to healthier bakery products

EXISTING PRODUCT

Too often the project brief is BRIEF!

� What are your targets?

� Reduction of 1 or more ingredients?

� Product energy reduction?

� Which replacement ingredients?

� What shelf-life?

� What product form?

� What equipment is available?

www.baketran.com

Developing healthier bakery productsDeveloping healthier bakery productsDeveloping healthier bakery productsDeveloping healthier bakery products

www.baketran.com

Impact of a recipe changeImpact of a recipe changeImpact of a recipe changeImpact of a recipe change

EXISTING PRODUCT

RECIPE

NEW (HEALTHIER) PRODUCT

RECIPE

11/10/2019

2

www.baketran.com

Texture (structure)Texture (structure)Texture (structure)Texture (structure)key to product acceptance by consumerskey to product acceptance by consumerskey to product acceptance by consumerskey to product acceptance by consumers

Eating bakery products is more about gaining sensory pleasure than sustaining life

• Appearance• Eating quality• Flavour

Texture more important in products with bland flavours.

Processing options matter!

World of bakery productsWorld of bakery productsWorld of bakery productsWorld of bakery products

www.baketran.com

www.baketran.com

ReducedReducedReducedReduced----fat doughnutsfat doughnutsfat doughnutsfat doughnuts

The reformulation conundrumThe reformulation conundrumThe reformulation conundrumThe reformulation conundrum

www.baketran.com

STANDARD -25% -50%

Increasing energy density

Change one

ingredient and

you change the

balance of all

the others.

Impact of sugar

reduction

www.baketran.com

Lowering fat and sugar in cakesLowering fat and sugar in cakesLowering fat and sugar in cakesLowering fat and sugar in cakes

Controlling the foam to sponge conversion

Air bubbles

incorporated

Foam to Sponge

conversion

MIXINGBAKING

SOLID FAT CRYSTAL

AIR BUBBLE

Getting more fibre into Getting more fibre into Getting more fibre into Getting more fibre into nonnonnonnon----bread productsbread productsbread productsbread products

www.baketran.com

More difficult for cakes

because of interference with

maintaining the foam.

A significant challenge with

pastries because of negative

structure impact and mouthfeel

(e.g. laminated products).

Process changes play a key role

in delivering more fibre into non-

bread products

11/10/2019

3

Fibre and seeds for healthier bread products Fibre and seeds for healthier bread products Fibre and seeds for healthier bread products Fibre and seeds for healthier bread products

• Wholemeal and fibre-rich flours.

• Reduce dough gas retention by interrupting gluten network.

• Potential negative impact on texture.

• Slow uptake of water affects dough rheology and makes processing more challenging.

www.baketran.com www.baketran.com

Latest publication from BakeTran

BAKING TECHNOLOGY and NUTRITIONTOWARDS a HEALTHIER WORLD

STANLEY P. CAUVAIN and ROSIE H. CLARK

1. Further evolution of carbon dioxide from yeast activity (until 55°C) and expansion of the gas bubbles in combination with steam and gas expansion.

2. Coalescence of gas bubbles as starch gelatinises (~60°C) and protein sets (~75°C). Gas pressures equalise and loaf stops expanding.

3. Once temperature approaches 100°C water can be driven off and the loaf loses weight.

www.baketran.com

Bread Bread Bread Bread A foam A foam A foam A foam to sponge conversion to sponge conversion to sponge conversion to sponge conversion –––– 3 stages3 stages3 stages3 stages

Important to

recognise that

the to foam to

sponge

conversion

happens

gradually from

the surface to

the centre.

Energy usage in bread baking

www.baketran.com

4 times as much

energy required to

make the foam to

sponge conversion

in the oven as was

required to

prepare the dough

for baking and to

cool the cool the

product

House of bread quality

www.baketran.com

FOUNDATIONS

WALLS

ROOF

FLOUR PROTEIN – HYDRATION AND DEVELOPMENT OF GLUTEN NETWORK

WORK INPUT IN MIXING

CONTROL OF DOUGH TEMPERATURE

AA

OXIDATION

OF THE

GLUTEN

OXYGEN

INGREDIENTS WHICH IMPROVE

GAS RETENTION (IMPROVERS)

GAS BUBBLE NUCLEI

CARBON DIOXIDE

PRODUCTION BY YEAST

TO INFLATE BUBBLES

Importance of dough temperature controlImportance of dough temperature controlImportance of dough temperature controlImportance of dough temperature control

Probably the most critical technical control point in breadmaking because it:

• Affects flavour development in fermentation

• Impacts intrinsic chemical activities which contribute to dough development

• Affects dough rheology for processing

• Controls yeast activity in the prover

• Impacts enzyme activity from mixing to inactivation in the oven

www.baketran.com

11/10/2019

4

Understanding the relationship between dough Understanding the relationship between dough Understanding the relationship between dough Understanding the relationship between dough

mixing and processingmixing and processingmixing and processingmixing and processing

www.baketran.com

Getting the ‘right’ rheology is critical to good dough processing Rheology

determined in

the mixer

Around 90Around 90Around 90Around 90% of final bread quality is % of final bread quality is % of final bread quality is % of final bread quality is built built built built into commercial nointo commercial nointo commercial nointo commercial no----time doughs by the time doughs by the time doughs by the time doughs by the

time that they leave the mixertime that they leave the mixertime that they leave the mixertime that they leave the mixer

www.baketran.com

No processing

Understanding dynamic rheologyUnderstanding dynamic rheologyUnderstanding dynamic rheologyUnderstanding dynamic rheology

www.baketran.com

0

2000

4000

6000

8000

10000

12000

0 100 200 300 400 500 600

Mixing time (secs)

Av

era

ge

to

rqe (

FU

)

63

100

150

200

Comparison of full recipe and flour-water curves

(200 rpm)

0

2000

4000

6000

8000

10000

12000

0 100 200 300 400 500 600

Mixing time (secs)

Avera

ge t

orq

ue (

FU

)

Full recipe

Flour-water

DDDDough development ough development ough development ough development ---- dynamic rheologydynamic rheologydynamic rheologydynamic rheology

in a commercial contextin a commercial contextin a commercial contextin a commercial context

www.baketran.com

0.00

0.50

1.00

1.50

2.00

2.50

3.00

0 50 100 150 200 250

Mixing time (sec)

PL

C r

ead

ing

Energy curve from commercial mixer

Dough rheology during mixing and bread Dough rheology during mixing and bread Dough rheology during mixing and bread Dough rheology during mixing and bread cell structurecell structurecell structurecell structure

R² = 0.7245

8000

9000

10000

11000

12000

13000

14000

15000

16000

500 600 700 800 900 1000 1100 1200

Nu

mb

er

of

cell

s

doughLab torque

R² = 0.644

0.34

0.35

0.36

0.37

0.38

0.39

0.4

0.41

500 600 700 800 900 1000 1100 1200

Av

era

ge

ce

ll w

all

th

ick

ne

ss (

mm

)

doughLab torque

www.baketran.com

Assessing dough rheology using the Warburtons Stickiness Test rig

www.baketran.com

Dough

consistency

Stickiness

11/10/2019

5

www.baketran.com

Changes in

dough

rheology

during

processing

After mixing

After resting

After final moulding

Dough processing and stickinessDough processing and stickinessDough processing and stickinessDough processing and stickiness

www.baketran.com

0.600

0.800

1.000

1.200

1.400

1.600

1.800

2.000

Ex-mixer Ex-first mould Ex-rest Ex-second mould

Ad

he

sio

n p

ea

k (

kg

)

Effect of mixing speed and dough processing on dough stickiness

100

150

200

Potential innovations for plant bakersPotential innovations for plant bakersPotential innovations for plant bakersPotential innovations for plant bakers

• Reducing energy costs.

• Less complicated and more controlled processing.

• Gathering and using more relevant data.

• Identifying better process control options.

www.baketran.com

Modelling the Modelling the Modelling the Modelling the breadmakingbreadmakingbreadmakingbreadmaking processprocessprocessprocess

• Bread quality is the sum total of the ingredient, recipe and process inputs.

• We collect Quality Control data (of a sort) when things are going ‘right’.

• But we collect a lot more data when things are going ‘wrong’.

• If you don’t have a model, how do you know what to adjust?

www.baketran.com

Modelling individual stagesModelling individual stagesModelling individual stagesModelling individual stages

• Mixing – where most of the bread quality is determined.

• Interrogate mixing data.

• Dynamic rheology at the end of mixing conveys information for processing.

www.baketran.com

Evaluating flour batchesEvaluating flour batchesEvaluating flour batchesEvaluating flour batches

www.baketran.com

Dendrogram of TEST__No_

Distance

TE

ST

__

No

_

0 300 600 900 1200 1500 1800

3361

3399

3402

3365

3388

3392

3410

3397

3404

3362

3367

3370

3386

3379

3394

3377

Control

3390

3372

3385

3407

3382

3375

Data combines:

• Mixing rheology• Process rheology

• External bread quality

• Crumb structure• Crumb colour

11/10/2019

6

Making better use ‘inMaking better use ‘inMaking better use ‘inMaking better use ‘in----househousehousehouse’ ’ ’ ’ technicaltechnicaltechnicaltechnical

and process informationand process informationand process informationand process information

• Collect data when things are going ‘right’ to provide points of reference when things go ‘wrong’

• Treat manufacturing contributions to product physical and sensory characteristics as the equivalent of HACCP procedures

• Develop product and process models – a springboard for innovation

www.baketran.com

Systemising company Systemising company Systemising company Systemising company technical knowledgetechnical knowledgetechnical knowledgetechnical knowledge

• Accessing an under-used resource

• Differs from ‘training’ because it is company specific

• Combines ‘hard’ and ‘soft’ data

• Develops unique company knowledge base in structured form

• Leads to benefits such as;• Faster resolution of problems

• More rapid delivery of innovation

• Improves knowledge retention in companies

www.baketran.com

Future opportunities and challenges for bakersFuture opportunities and challenges for bakersFuture opportunities and challenges for bakersFuture opportunities and challenges for bakers

• Major opportunities to develop new and healthier bakery products

• Significant opportunities to improve process efficiency

• The integration of good process data and human technical skills to support future developments in the baking industry has yet to be sufficiently realised

www.baketran.com

Final thoughtFinal thoughtFinal thoughtFinal thought

“Thinking outside the box is easy - working outside the box is hard but that is where true innovations come from”

Stan Cauvain

www.baketran.com