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Asb 2019 Diosna presentation
- 1. 1 ASB October Conference Wednesday, 30th October 2019, Brisbane
- 2. 2 How to make your bread naturally delicious! Understanding pre-dough technology Ralf Bohne, DIOSNA Dierks & Söhne
- 3. 3 Examples Rye sourdough Wheat sourdough Yeast pre-dough Levain Solid sponge Poolish Liquid spongeHot soaker Cold soaker Wetting grains Brewed soaker cooked dough Bread fermentation Scalding dough Biga Pâte fermentée Pasta madre Autolyse
- 4. 4 Examples Pre-dough with bacteria (lactobacillus) Rye sour-dough Wheat sour-dough Bread fermentation Levain Pasta madre Pre-dough with thermic process Brewed soaker Hot soaker Cooked dough Cold soaker Wetting grains Scalding dough Pre-dough with yeast Yeast pre-dough Liquid sponge Solid sponge Biga Pâte fermentée Poolish Autolyse
- 5. 5 What are pre-doughs? Pre-dough is all dough made from cereal products (also in combination with other raw products, such as seeds), which are made before the main dough and are kept under thermic and/or microbiological special conditions for a specific length of time in order to keep functional attributes. Microbiological pre-doughs are made with selective use of microorganism to form aroma components and affect the behaviour of doughs and baking goods. Thermic pre-doughs are made without any microorganism In order to optimize the water content in baked products with heating process.
- 6. 6 waterabsorption stressstability drysurfaceofthedough doughrelaxationbehavior freezing>storagestability aW-value volume softnessofthecrumb Taste Aroma elasticityofthecrumb reductionoffat reductionofegg crust freshness freezing>storagestability storagestability wheat pre-dough (based on yeast) wheat pre-dough (mild fermentation) wheat pre-dough (strong fermentation) AromaStück® Kochstück Application matrix of different pre-dough technologies for the targeted control of wheat dough and product properties. dough properties product properties Application matrix for wheat pre-doughs Die Backkultur What can achieved with pre-doughs?
- 7. 7 Examples Pre-dough with bacteria (lactobacillus) Rye sour-dough Wheat sour-dough Bread fermentation Levain Pasta madre Pre-dough with thermic process Brewed soaker Hot soaker Cooked dough Cold soaker Wetting grains Scalding dough Pre-dough with yeast Yeast pre-dough Liquid sponge Solid sponge Biga Pâte fermentée Poolish Autolyse
- 8. 8 8 0~ 2000 BC ~ 1700 ~ 1920 Start of yeast cultivation Start of sour-dough cultures cultivation Spontaneous fermentation 1800 1900 History of yeast cultures Historically: Spontaneous fermentation (natural yeast/leavening/sourdough) Example: Masa Madre Spontaneous Fermentation Consumer Taste ✓ Digestibility ✓ Health ✓ Bread Consistency ✓ Bread Storage ✓
- 9. 9 9 End of 18th century: Use of brewer‘s yeast for baking Mid of 19th century: Start of industrial production of baker‘s yeast (Saccharomyces cerevisiae)Yeast cells 0~ 2000 b.C. ~ 1700 ~ 1920 Start of yeast cultivation Start of sour-dough cultures cultivation Spontaneous fermentation 1800 1900 Baker‘s Yeast History of yeast cultures
- 10. 10 0~ 2000 b.C. ~ 1700 ~ 1920 Start of yeast cultivation Start of sour-dough cultures cultivation Spontaneous fermentation 1800 1900 History of yeast cultures Yeast Fermentation Consumer Artisan Baker Industrial Baker Taste ✓ ✓ ✓ Digestibility ✓ Health Activation of natural enzymes ✓ partly ✓ partly Bread consistency ✓ Bread storage Improved water binding ✓ longer freshness ✓ cost rele- vance ✓ cost rele- vance Soft structure ✓ Product size/volume ✓ ✓ ✓ Useful for fast production processes (√) ✓ effici-ency
- 11. 11 Process of liquid/solid sponge dough (poolish etc.) Environmentalparameters water Yeast cultures fermentation micro flora of the flour flour Fermented dough with dominance of yeasts from the defined mother dough Pre-dough/poolish Volume + Taste growth + multi- plication Mother dough
- 12. 12 Example Pre-dough with bacteria (lactobacillus) Rye sour-dough Wheat sour-dough Bread fermentation Levain Pasta madre Pre-dough with thermic process Brewed soaker Hot soaker Cooked dough Cold soaker Wetting grains Scalding dough Pre-dough with yeast Yeast pre-dough Liquid sponge Solid sponge Biga Pâte fermentée Poolish Autolyse
- 13. 13 13 0~ 2000 b.C. ~ 1700 ~ 1920 Start of yeast cultivation Start of sordough culture cultivationSpontaneous fermentation 1800 1900 History of sour dough cultures ~ 1920 Start of sourdough culture production Starter Cultures Lactobacillus (Microscope, enlarged)
- 14. 14 Process of sour dough (levain) Environmentalparameters water defined starter cultures Defined from Lactic and acid bacteria of milk, yogurt and flour, developed and researched to starter cultures fermentation micro flora of the flour growth + multi- plication flour Fermented dough with dominance of the lactobacillus and natural yeast from the defined mother sour dough Sour-dough/levain Mother dough Volume + Aroma + Dough specified character + useful properties + better Digestion + Longer Shelf life + pH- level
- 15. 15 Fermentation What happens during fermentation? Formation of fermentation products from Starch Lactic acid Acetic acid Alcohol Carbon dioxide (CO2) Additional fermentation products (important for flavour) Homofermentativ Lactic acid Heterofermentativ Acetic acid, CO2 Ethanol / Lactic acid CO2, Ethanol Lactobacillus Yeast
- 16. 16 What is the pH-value ? The pH-value is the indicator of the strength of an acid. It is measured by a pH-meter. A low pH is equal to a strong acid. The normal ranges are: Sourdough is between pH 3.30 und 4.8 (depends on the production process) baked Bread loafs are between pH 4.0 and 6.5 (depends on the product) sour basicneutral 7
- 17. 17 What is acidity degree? The acidity degree describes the amount of acid. A high content of titratable acid (TTA) shows a high proportion of acid The normal ranges are: Sourdoughs are between 7.0 and 34.0 (depends on the production process) Wheat bread loafs under 6 Wheat-mix bread 6 – 8 Rye-mix bread 7 – 10 Rye bread 8 – 12 Rye wholemeal bread 8 - 14
- 18. 18 Why is the amount of acidity degree important? Yeast pre-dough Breadfermentation Rye 3-step method Rye sour dough with salt Rye sour dough with salt 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Wheat sourdough - mild „Bologna“ Wheat sourdough - strong „San Francisco“ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Acidity degree influence aroma, pH-value influence the dough function
- 19. 19 How to do it? Preparation wheat fermentation Wheat flour 100 parts Water 120 parts Starter 1 part Fermentation time 16 hours
- 20. 20 Example Pre-dough with bacteria (lactobacillus) Rye sour-dough Wheat sour-dough Bread fermentation Levain Pasta madre Pre-dough with thermic process Brewed soaker Hot soaker Cooked dough Cold soaker Wetting grains Scalding dough Pre-dough with yeast Yeast pre-dough Liquid sponge Solid sponge Biga Pâte fermentée Poolish Autolyse
- 21. 21 Difference between Aroma and Hot Soaker technology Aroma technology Hot soaker technology Process Thermic and enzymatic Thermic Objectives Formation of maltose and aromatic compounds Gelatinization of the starch and a high water absorption Result in the bread loaf - Aromatic and rounded taste - Neutralization or extreme sour extremes in bread taste - Cost reduction - Longer freshness - Softer dough structure - Cost reduction
- 22. 22 Temperature of Aroma and Hot soaker process 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C KochStück AromaStück Hot Soaking Doughs ▪ Cooking Temperature 85 °C for 1-2 hours ▪ For more Freshness and Shelf life Aroma Technology ▪ Cooking Temperature 65 °C for 3 hours ▪ For more flavour, taste and colour
- 23. 23 Hot soaker / scalding process Flour and/or grain products plus water will be heated with a high flour-water-ratio (100:300), mean TA 400 from wheat up to TA 700 from oats) ▪ Gelatinization of the starch and thereby a real water binding in the soaker and in the dough. ▪ After cooling the soaker is stable, sliceable and permanently soaked. ▪ more water in the dough – more water in bread ▪ Longer freshness
- 24. 24 Aroma cooking technology Flour and/or grain products + water and enzymatic starter will be heated with a high flour-water-ratio (100:200) ▪ Gelatinization and a selective enzymatic reaction of the starch and the protein to a formation of maltose and aroma components ▪ Maltose and aroma components result in a rounded taste or even sweetness and a distinctly flavourful profile ▪ Neutralizing too much acid and sour extremes ▪ Possible reduction of additional malt products
- 25. 25 Aroma cooking technology Preparation Aroma pre-dough Flour 100 parts Water 200 parts Starter 2 parts Fermentation time 3 hours
- 27. 27 Quote from a Bakery Instruction Booklet Once the dough is good, the bread will be okay. What should be followed when preparing good doughs?
- 28. 28 What should be followed when preparing doughs? Different types of doughs require different kneading methods and processes ▪ kneading technology ▪ type and design of the kneading tool ▪ speed of kneading tool and bowl ▪ kneading time / efficiency of the system ▪ temperature of raw materials ▪ Wheat flour doughs ▪ Rye flour doughs ▪ Mixes of wheat/rye flour doughs ▪ Doughs with different additives ▪ Doughs for different Types of Products
- 29. 29 Development of the gluten structure flour and water (blending) Blending and mixing (dissolving + soaking) ready mixd dough (optimum) Over kneaded dough INTENSIVE and optimal blending and kneading is NECESSARY
- 30. 30 Sensoric characteristics of a ready kneaded wheat dough ▪ surface of dough is remarkable brighter ▪ dough comes easily off from the bowl wall ▪ dough has a smooth surface ▪ dough appears to be dry
- 31. 31 ▪ Aromatic smell and taste ▪ Improved freshness ▪ Better water binding ▪ Improved frozen storage stability ▪ Reduce or even leave out several baking additives ▪ Clean Label ▪ Shelter against mould (dependent to product) ▪ Re-use of not saleable bread ▪ Re-use of scrap dough ▪ Benefits for health and digestion ▪ Low FODMAP Benefits for baked goods with pre-dough
- 32. 32 Thank you for attention!