industrial production of artisan breads · industrial production of artisan breads ibie october...
TRANSCRIPT
Industrial Production of Artisan Breads
IBIE October 11th 2016
Frank Devos (VP R&D) - David Deblauwe (Regional Product Mgr Bakery Flavors)
Agenda
• What are artisan breads ?
• Upscaling to industry
• Tasting session
Through the Eyes of the Consumer
Artisan Breads for the Professional
process• Lean simple recipe • gentle process • Time !
Visual
• Crust with shred• Dusting Flour
• Open crumb• Off-white color
• Irregular shape• Variety
Position• Story• Point of Sales• Packaging
Texture• Crust hard or soft• Crumb slight rubbery
Flavor• Crust notes• Fermentation notes• Mild to sour
Fundamentals of Artisan Baking
26/09/2016, Page 5
From Artisan to Industry ?
Hurdles & solutions
26/09/2016, Page 6
Hurdles to Overcome
26/09/2016, Page 7
(sponge) Ingredients-mixing
Bulk proof
Divide & Make up Final proof Bake Cool &
pack
26/09/2016, Page 8
1h 3
0’
Bre
ad &
Bun
High Speed Bread & Bun Line Artisan
preferment Ingredients-mixing
Bulk proof
Divide & Make up Final proof Bake Cool &
pack
26/09/2016, Page 9
++++ ++
clean label ++++ +++ ++no stress !
1h 3
0’
24h +
4h
Bre
ad &
Bun
Art
isan
High Speed Bread & Bun Line Artisan
Why use Preferments?
26/09/2016, Page 10
TASTE
Bio-chemicalLeavening
Acidification
RheologicalExtensibility
Machinability
NutritionEg GI lowering
Starch digestibility
Finished BreadHolistic health
Diversity / tradition
Families of Preferments
26/09/2016, Page 11
Mixture of flour, water and commercial baker’s yeast
(Saccharomyces cerevisiae)
Mixture of flour, water and Lactic Acid Bacteria (LAB) &
wild yeasts
Fermented for 2-12 hours Fermented for >12 hours
Sponge - flour brew –poolish - biga
Sourdough – starter – sour – levain – masa madre…
Make Your Own Sourdough?
26/09/2016, Page 12
DaxnerBertrand
ready-to-usesourdough
26/09/2016, Page 13
mixing
proofing
moulding
baking
long fermentation
sourdough process
Shelf life stableConsistency
Flavor differentiation
Or Buy as Ingredient?
preferment Ingredients-mixing
Bulk proof
Divide & Make up Final proof Bake Cool &
pack
26/09/2016, Page 14
++++ ++
clean label ++++ +++ ++no stress !
1h 3
0’
24h +
4h
Bre
ad &
Bun
Art
isan
High Speed Bread & Bun Line Artisan
Ingredients
26/09/2016, Page 15
Trends
Ingredients
26/09/2016, Page 16
Basic Ingredients
YEAST SALT
High hydration : 65%
PREFERMENT
or
26/09/2016, Page 17
Functional Ingredients
Ingredients
ToleranceFreshness & Moistness
Mold Control
Clean label or organic dough conditioners
Freshness enzymesCorrect packaging
Fermented wheatClean room
Pasteurisation
Mixing
• Critical : dough development with maximum water
• Mixer design to incorporate more water
– Hydra (Sancassiano)
– Rapidojet
– ...
• Process
– Autolysis : 20-60 min
– Bassinage
26/09/2016, Page 18
preferment Ingredients-mixing
Bulk proof
Divide & Make up Final proof Bake Cool &
pack
26/09/2016, Page 19
++++ ++
clean label ++++ +++ ++no stress !
1h 3
0’
24h +
4h
Bre
ad &
Bun
Art
isan
High Speed Bread & Bun Line Artisan
Bulk Fermentation
26/09/2016, Page 20
• Minimum 45 minutes (mostly 1-2h’)
• Temperature control
• Why important?
– Open crumb
– Rubbery – cohesive texture
– Flavor
Dividing & Make-up
26/09/2016, Page 21
Solution : Stress-free Lamination Lines
26/09/2016, Page 22
Rheon
26/09/2016, Page 23
Koenig Menes
Rondo
Driem Kaak
Dough Extrusion
Multi Roller
Cutting
Final Make-up
preferment Ingredients-mixing
Bulk proof
Divide & Make up Final proof Bake Cool &
pack
26/09/2016, Page 24
++++ ++
clean label ++++ +++ ++no stress !
1h 3
0’
24h +
4h
Bre
ad &
Bun
Art
isan
High Speed Bread & Bun Line Artisan
Baking
• Type
– Crust: Thick or soft / thin
– Parbaked: White or fully colored
• Create ideal heat transfer
– Bottom heat
26/09/2016, Page 25
Mecatherm
Selling & Road to Market – Many Options
• Fresh, Frozen or Packed Ambient
• Parbaked or Thaw & Serve
• Packaging• Paper (+window) prefered by consumers
Can artisan bread & industrial production go
hand in hand?
26/09/2016, Page 27
Let’s Taste !
