Performance of mechanically developed dough in pita bread production

The feasibility of adapting a mechanical dough development process, using a high speed mixer (Tweedy-35), to pita bread production was studied 'on line' at a commercial, traditional pita bakery.
A satisfactory pita bread was produced from a mechanically developed dough under the following conditions: work input 5.5 Whr/kg dough (mixing time 2 min), 3% yeast, 55% water absorption, dough temperature 30°C, no oxidizing agents and intermediate proofing (between mixing and dividing) of 10 min. The advantages of the mechanical over the conventional process were: increase in water absorption by 10%, which brought about a proportional gain in product yield per unit weight of flour; and reduction in holding floor time from 40–60 min to 12 min.
The baking performance of the pita bread under different controlled conditions gave insight into the mechanisms involved in the baking process, especially the relationship between dough mechanical properties and heat transfer during baking.     

Bread baking: Technological considerations based on process modelling and simulation

This paper presents a study of bread baking, mainly from a technological point of view, i.e. focused on transport phenomena and major quality changes occurring during the process. Such study was carried out by numerical simulation of a previously developed and validated mathematical model, which describes the simultaneous heat and mass transfer (with phase change in a moving boundary) taking place in bread during baking. Kinetic models for starch gelatinization and browning development were coupled to the transport model. Input variables to the model were oven temperature, heat transfer coefficient, and bread radius. A total of 105 operating conditions were simulated using the finite element method, and the end point of baking was established for three values of surface lightness. It is shown that an intense heating strategy can produce a browned but unbaked product, besides nutritional quality is negatively affected. Furthermore, minimization of baking time is restricted by internal resistance to heat transfer.     

Porous multiphase approach for baking process – Explicit formulation of evaporation rate

A multiphase model for simultaneous heat and mass transfer in porous medium was developed to simulate the baking process of a bread product. The model was based on Fourier’s law for conductive heat transfer and Darcy’s and Fick’s laws for mass transfer of liquid (water) and gas (water vapour and CO₂) phases. Explicit formulation was adopted for the evaporation rate allowing direct solution of the system of equations. The use of the non equilibrium approach, allowed the implementation of the model in commercial software. Numerical Finite Element Method (FEM) scheme was used to solve the equations. The model was compared with experimental results reported in literature. Results show a good agreement between experimental and numerical results. Sensitivity analysis of the effect of the evaporation rate constant and process operating conditions on the temperature and moisture content were conducted and showed that the baking process was affected mainly by the convective heat transfer and the product initial moisture characteristics.     

Overall and Local Bread Expansion,Mechanical Properties,and Molecular Structure During Bread Baking: Effect of Emulsifying Starches

In order to determine the relationship between molecular structure of wheat bread dough, its mechanical properties, total and local bread expansion during baking and final bread quality, different methods (rheological, nuclear magnetic resonance, magnetic resonance imaging and general bread characterisation) were employed. The study was extended on wheat dough with starch modified by octenyl succinic anhydride (OSA) in order to generalise the results. The interest of investigating multi-scale changes occurring in dough at different phases of baking process by considering overall results was demonstrated. It was found that OSA starch improved the baking performance during the first phase of baking. This feature was due to a higher absorption of water by OSA starch granules occurring at temperatures below that of starch gelatinization, as confirmed by NMR, and consecutive higher resistance to deformation for OSA dough in this temperature range (20–60 °C). This was explained by a delayed collapse of cell walls in the bottom of the OSA dough. In the second phase of baking (60–80 °C), the mechanism of shrinkage reduced the volume gained by OSA dough during the first phase of baking due to higher rigidity of OSA dough and its higher resistance to deformation. MRI monitoring of the inflation during baking made it possible to distinguish the qualities and defaults coming from the addition of OSA starch as well as to suggest the possible mechanisms at the origin of such dough behaviour.     

Computational fluid dynamics (CFD) modeling of an electrical heating oven for bread-baking process

Radiation is the most dominant heat transfer mode in an electrical heating oven. A 3D CFD model for an electric heating baking oven was developed. Three different radiation models namely, discrete transfer radiation model (DTRM), surface to surface (S2S) and discrete ordinates (DO) were employed for the simulation of the electrical baking oven. All models predicted almost similar results, which tallied well with the experimental measurements. During the full heating cycle, the oven set-point temperature was reached after 360 s. Lower temperature zones occurred near oven wall due to lower air flow. Based on preliminary evaluation of applicability, the DO radiation model was selected for bread baking simulation and validated with the experimental measurement of bread temperature. Bread simulation was carried out to study the profiles of temperature and starch gelatinization of crust and crumb of the product. This study indicated the baking process to be complete at 1500 s when the temperature of bread-center reached 100 °C.     

Modeling of simultaneous heat and mass transfer during convective oven ring cake baking

The convective oven ring cake baking process was investigated experimentally and numerically as a simultaneous heat and mass transfer process. The mathematical model described previously by the authors for cup cake baking was modified to simulate ring cake baking. The heat and mass transfer mechanisms were defined by Fourier’s and Fick’s second laws, respectively. The implicit alternating direction finite difference technique was used for the numerical solution of the representative model. Prior to the utilization of the developed model in predicting the temperature and moisture profiles for ring cake baking, the results of the numerical model were compared with analytical results involving only heat or mass transfer with constant thermo-physical properties. Excellent agreement was observed. The numerical temperature and moisture contents predicted by the model were compared with the experimental profiles. They agreed generally reasonably well with the experimental temperature and moisture profiles.     

Rheological properties of sheeted wheat flour dough measured with large deformations

Abstract

Large deformation rheological properties of a bread dough sheet were compared with baking quality of dough from the same sheet. Both rheological test and baking test could differentiate between dough made from a strong and a weak flour. Apparent viscosity at large deformation appeared to be the best predictor of the minimum sheeting requirement to obtain high loaf volume. This is similar to Mechanical Dough Development (MDD) mixing of dough where the mixing curve (apparent viscosity) is used to determine mixing requirement. Baking tests showed that loaf quality (volume and crumb texture) for bread made with sheeting was different from bread made with MDD mixing, particularly when dough was developed beyond the minimum sheeting requirement. These differences indicate that dough development (or over‐development) by sheeting may occur through a different mechanism than by MDD mixing.     

Image analysis of structural changes in dough during baking

The bakery market is developing new technologies based on dough partial baking and the study of the changes that dough undergoes through the whole baking process could help in the selection of baking times. The aim of this work was to study the changes of dough structure and their relationship with dough temperature, mass loss and loaf height during baking by applying image analysis techniques. Results showed that during baking, bubble coalescence was presented, observing a maximum at the first stages of baking (<250 s). This phenomenon was associated with an increment in dough height without a significant change in dough centre temperature. Fractal dimension of texture of crumb, fractal dimension of contour of cells and crumb grain features were useful indicators of coalescence as well as to distinguish the baking time needed for crumb features remain invariable.     

Modelling the browning of bread during baking

In this work, we study the development of browning at bread surface during baking. Computer vision is applied to follow the progress of browning at surface, while the variations of temperature and water activity are obtained by numerical simulation of a mathematical model previously validated. The formation of the bread crust is a complex process where temperature and water content change continuously during baking, making browning a non-isothermal process occurring in a non-ideal system. Minimum requirements for initiation of colour formation are temperature greater than 120 °C and water activity less than 0.6. We apply a non-isothermal kinetics approach to model the browning development at bread surface during baking, where the variation of local temperature and water activity is taken into account. The methodology presented here is suitable for modelling and predicting browning during baking; model parameters can be estimated by using a non-ideal system closer to real processing conditions.     

Effects of wheat sourdough process on the quality of mixed oat-wheat bread

The aim of this work was to study the effects of sourdough fermentation of wheat flour with Lactobacillus plantarum, on the quality attributes of mixed oat-wheat bread (51 g whole grain oat flour and 49 g/100 g white wheat flour). Emphasis was laid both on β-glucan stability as well as bread structure and sensory quality. The variables of the sourdough process were: dough yield (DY), fermentation time, fermentation temperature, and amount of sourdough added to the bread dough. The sourdough process was shown to be a feasible method for mixed oat-wheat bread, and, when optimized, provided bread quality equal to straight dough baking. A small amount (10g/100 g dough) of slack sourdough fermented at high temperature for a long time resulted in the most optimal sourdough bread with the highest specific volume (3.5 cm³/g), the lowest firmness after 3 days storage (0.31 kg), and low sensory sourness with high intensity of the crumb flavour. Wheat sourdough parameters did not affect the content of oat β-glucan in the bread. Additionally, both straight dough and sourdough bread contained 1.4-1.6 g β-glucan/100 g fresh bread. The average molecular weight of β-glucan was 5.5 × 10⁵ in both types of bread, while that of oat flour was 10 × 10⁵. This indicates that a slight degradation of β-glucan occurred during proofing and baking, and it was not affected by variation in the acidity of the bread between pH 4.9-5.8.     

Modelling of coupled heat and mass transfer during a contact baking process

A mathematical model of coupled heat and mass transfer of a contact baking process is developed. In the current model formulation, a local evaporation of water is described with a reaction-diffusion approach, where a simultaneous diffusion and evaporation of water takes place. The resulting coupled model equations (unsteady state heat transfer, liquid water and water vapour) were solved using the Finite Element Method (COMSOL Multi-physics® version 3.5). During the baking process, local temperatures and overall moisture loss were measured continuously. The model - predicting temperature, liquid water content in the product and water in the vapour phase - was calibrated and partially validated using data obtained during baking of a representative food model (a pancake batter) under controlled conditions on a specially designed experimental rig. The unknown parameters in the model equations were estimated using the standard least squares method by comparing the measured with the predicted temperature profile. Good agreement was achieved between model predictions and the experimental values.     

Adhesion of Bread Dough to Solid Surfaces Under Controlled Heating: Balance Between the Rheological and Interfacial Properties of Dough

The adhesion of wheat dough affects many aspects of industrial baking, from kneading raw dough to the final baking process. In this work, an original method was developed to study the effect of temperature on the adhesive properties of bread dough in contact with a solid surface during heating. Using this approach, it will be possible to understand the factors that affect adhesion between dough and a baking surface, which will aid in developing methods to prevent dough from sticking. Overall, the dough's adhesion to a hydrophobic surface globally decreased with an increase in temperature from 35 to 97 °C, with the exception of the temperature range between 55 and 70 °C, in which the energy of adhesion increased slightly. Under these circumstances, the evolution of adhesion was primarily shaped by the rheological properties of the dough. However, when we used a solid surface with different surface energy, the results changed significantly, which suggests that the mechanisms of adhesion during heating are governed by a balance between the interfacial and bulk properties of the heated dough. The overall decrease in the adhesion of the dough to the hydrophobic glass surface may be explained by a decrease in dough hydrophobicity due to structural and chemical changes in the dough.     

Effect of butter content and baking condition on characteristics of the gluten‐free dough and bread

This study aimed to investigate effect of butter content (0–30 g/100 g flour) and baking conditions hot air baking (HA), microwave baking (MW) and hot air‐microwave baking (HA‐MW) on quality of the rice flour dough and bread. The increased butter (up to 15 g butter/100 g flour) enhanced elastic modulus (G′) and viscous modulus (G″) of dough and specific volume of bread. Additionally, the increased butter improved crust colour and reduced hardness of the bread. The HA‐MW and MW conditions were useful for the gluten‐free bread by reducing baking time and predicted glycemic index (GI), regardless of butter content. However, enthalpy of retrogradation and crystallinity in the HA‐MW and MW bread stored at 4 °C for 7 days were increased and higher than those of the HA bread, indicating a faster staling. The predicted GI of both MW and HA‐MW bread remained at a medium level during storage.     

A moving boundary problem in a food material undergoing volume change – Simulation of bread baking

This paper presents a mathematical model for describing processes involving simultaneous heat and mass transfer with phase transition in foods undergoing volume change, i.e. shrinkage and/or expansion. We focused on processes where the phase transition occurs in a moving front, such as thawing, freezing, drying, frying and baking. The model is based on a moving boundary problem formulation with equivalent thermophysical properties. The transport problem is solved by using the finite element method and the Arbitrary Lagrangian–Eulerian method is used to describe the motion of the boundary. The formulation is assessed by simulating the bread baking process and comparing numerical results with experimental data. Simulated temperature and water content profiles are in good agreement with experimental data obtained from bread baking tests. The model well describes the stated general problem and it is expected to be useful for other food processes involving similar phenomena.     

Bread baking and its color kinetics modeled by the spatial reaction engineering approach (S-REA)

Baking is a relatively complex process involving simultaneous heat and mass transfer coupled with reactions and structural changes. An accurate and physically-meaningful model of baking is useful to assist process design and product quality improvement. The reaction engineering approach (REA), which has been proven to accurately model the drying rate of porous foods, is implemented here to describe the local evaporation/condensation rate during bread baking for the first time. The REA is coupled with a set of equations of conservation of heat and mass transfer to yield the spatial reaction engineering approach (S-REA). The results of modeling match well with the experimental data. The S-REA can also model the browning kinetics during bread baking accurately. The S-REA is readily implemented for process design by implementing it in computational fluid dynamics (CFD)-environment. The S-REA can also be used for optimization to determine baking trajectories to achieve the desired product properties.     

Quality prediction of bakery products in the initial phase of process design

The development of food production processes is facilitated by tools which explore the interaction between process design, operation conditions and product characteristics. In this work an approach how to set-up a simulation model is presented for the phenomena and transformations which occur during baking and which fix the product quality. The simulation model has three consecutive parts: mass and heat transport in the product, transformations concerning starch state transition and color, and the formation of quality attributes (color, softness, crispness and staling). The model for mass and heat transfer is based on laws of conservation and expressed in partial differential equations for spatial products. The starch state transition and color formation are a mixture of qualitative and quantitative information, while the product quality model is mainly based on qualitative information. The model is applied to three bakery products: bread, biscuit and a cake-type. The results show that the model estimates the product quality and its transformations as a function of dough composition, baking and storage condition. The results fit well to observed changes of properties and product quality during baking.Industrial relevanceFood industries require tools to evaluate processing options in the feasibility phase of process design. Therefore, simulation of process models is important for this purpose. However, knowledge of different aspects is subject to area of expertise (for example heat and mass transfer versus product quality formation) and often these areas are hardly connected. This work presents a systematic modeling approach for the dominant processes during baking and their interconnection. The main functions of the model are to explore the consequences of choices in design, to rank design options and to find in what direction properties will change when operational conditions change. Moreover, the model can be used for sensitivity analysis to explore on what items further information must be gathered.     

香菇面包的制作工艺研究

以面粉和香菇茵柄粉为原料,通过对面团配比、发酵、醒发以及烘烤等工艺参数的研究,研制出一种新型的营养面包。结果表明,香菇面包的生产工艺条件为：高筋面粉：香菇菌柄粉：糖：酵母为100：2．0：18：1．2,发酵温度为30℃,发酵时间为100min,醒发温度为32℃,醒发时间为130min,烘烤温度为上火190℃,底火200℃,烘烤时间为12min。对香菇面包进行品质评价,产品具有香菇特有的香气,膳食纤维丰富,营养价值高于普通面包。     

Impact of the Baking Duration on Bread Staling Kinetics

This paper presents a study on the impact of the duration of the baking plateau on staling kinetics in the case of bread crumb made of sourdough; it follows Le-Bail et al. Journal of Cereal Science 50:235–240, (2009)a previous study proposed by Le-Bail et al. Journal of Cereal Science 50:235–240, (2009) on the impact of heating rate during baking on staling parameters. Degassed bread dough was baked in a miniaturized baking system with baking plateau of 0, 4, and 8 min at 98 °C corresponding to a total baking time of 10, 14 and 18 min respectively (simulating from underbaked to fully baked bread). Results showed that longer baking time resulted in the higher Young’s modulus of the baked dough at the end of staling was. It was observed as in Le-Bail et al. Journal of Cereal Science 50:235–240, (2009) that the crystallization of amylopectin occurred a few days before the hardening of the baked crumb during staling. The amount of freezable water decreased during staling (over 10 days period), which was in agreement with the increase in amylopectin crystallites during staling which trap water. The amount of soluble amylose increased with increasing duration of the baking plateau at 98 °C, indicating that for prolonged baking, an increasing amount of amylose is leached outside of the starch granules. This was proposed as an explanation for the higher Young’s modulus of the crumb at the end of staling.     

DEVELOPMENT OF DYNAMIC MODULUS AND CELL OPENING OF DOUGH DURING BAKING

The dynamic shear modulus (elastic and viscous modulus) development of dough during baking was studied. Flooded parallel plate geometry was used to monitor the rheological changes of commercially available canned doughs (bread dough, bun dough and biscuit dough). The normal force exerted on the upper plate by the expanding dough was measured to study the cell‐opening event. The dough‐baking process was simulated in a rheometer oven. The morphology of baked dough was studied using a scanning electron microscope to elucidate the effect of ingredients and process parameters on the properties of the final baked product. Three stages of modulus development were observed during the baking process: bubble growth and packing, rapid expansion/starch gelatinization and final curing. The cell opening coincided with the sudden rise in modulus caused by starch gelatinization. The rate at which starch gelatinization takes place controls the temperature of the cell opening. The type and concentration of various ingredients have a greater effect on the modulus and on the cell opening than the heating rates. Frequency dependence was observed during baking, but the effect on modulus development diminished at higher frequencies.     

Computational fluid dynamics modeling of bread baking process

A computational fluid dynamic (CFD) model was developed to study the temperature and browning profile of bread. This study differs from previous work of CFD modeling reported in literature in that phase change during evaporation as well as evaporation-condensation mechanism during baking process was incorporated in this model. Simulation results were validated with experimental measurements of bread temperature at three different positions. In this study crumb temperature does not cross 100 °C due to incorporation of evaporation-condensation mechanism in this model. Baking process completes within 25 min of processing time once the temperature of crumb becomes stable at 98 °C. Formation of crust and browning of bread surface were studied using earlier reported kinetic model and it predicted more browning at bread edges than the surfaces. However, predicted browning index was well within the range (< 52).