1. Alternative Baking Processes
Chapter 7:
Alternative Baking Processes
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2. © 2009 Cengage Learning. All Rights Reserved.
Introduction
Alternative Methods of Baking
Alterations may be to fermentation, baking, cooling, storage and distribution.
Techniques include:
Par-baked
Frozen Dough
Pre-proofed Frozen
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3. Alternative Methods of Baking
Par-Baked
It has been used in the United States since the 1950’s
In the United States it is known as “brown and serve”
Par-bake of French type products only became popular in the 1990’s
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4. Alternative Methods of Baking: Par-Baked
Par-Bake Process
Par baked process falls between traditional baking and frozen dough
It has the same first steps of traditional baking
It also has the same storage and /or freezing of frozen dough
The only step which applies to this technique is the par baking
It has two baking process, two cooling process and storage at the par baked stage
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5. Alternative Methods of Baking: Par-Baked
Formulation
Traditional formulation can be used it may include any prefermented dough like sponge or poolish
Hydration is reduced to encourage a fuller volume of the par baked item.
Sugar levels must be low to avoid crust coloration during par baking
Shortening levels must also be low to avoid bread collapsing due to weaker structure.
Formulation may also include other materials like bran, whole wheat flour and rye flour etc.
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6. Alternative Methods of Baking: Par-Baked
Mixing and Fermentation
These steps are identical to the traditional method.
All methods to improve the dough strength and flavor may be included in the process include the use of preferments.
Mixing may also include the use of an autolyse to reduce mixing time and promote the preservation of the bread flavor, an increase in bread volume and an improvement of crumb structure.
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7. Alternative Methods of Baking: Par-Baked
Dividing and Pre-Shaping
The par baked product’s ability to maintain its structure is based on the weight and shape of the dough pieces
The shape and diameter of the product will determine if it can be successfully par baked
Product tend to collapse if the diameter is too big
Baguettes and batards are better suited than boules in the par bake process
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8. Alternative Methods of Baking: Par-Baked
Resting and Shaping
This step is carried out in the traditional way
The weight and dimension of the shaped dough is an important for maintaining part baked bread’s structure and rigidness
This is important as it is subjected to much handling after part baking
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9. Alternative Methods of Baking: Par-Baked
Proofing and Scoring
Proof time is generally shorter than traditional proofing
Over proofing will result in a weaker structure
Scoring should be deeper because of the stiffer and under proofed dough
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10. Alternative Methods of Baking: Par-Baked
First Bake
This is the only step unique to par baking
The objective of par baking is to obtain a sufficiently rigid semi-finished product
The goal is to form a superficial skin without browning
Crust formation leads to risks of flaking during the final bake, an increased water loss and acceleration of staling
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11. Alternative Methods of Baking: Par-Baked
Baking Techniques:
High temperature, short time
Favors the opening of the cuts and ovenspring
If the baking is too quick, it will brown before the structure is set
The same goes for doughs that are too large
Low temperature, long time
Creates a thicker rigid skin without browning
Cuts will be less open, volume smaller and the moisture loss greater
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12. Alternative Methods of Baking: Par-Baked
Cooling
Par baked bread should not be stacked when cooling
When air cooled, it loses about 4% of its weight per hour compared to 2.5% for a fully baked product
The temperature and humidity of the cooling room can be controlled to reduce this weight loss
Alternatively, it is possible to shorten the cooling time and freeze the product
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13. Alternative Methods of Baking: Par-Baked
After Cooling-Fresh Par-Baked Bread
Considered “fresh” par baked if product is not frozen after par baking
The cooling, storage and distribution are usually carried out on baking trays
Shelf life is limited to a maximum of 4 days but rarely exceed 2 days
Product subjected to drying, rapid staling at room temperature and risk of mold growth
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14. Alternative Methods of Baking: Par-Baked
After Cooling-Frozen Par-Baked Bread
Freezing stops the development of micro organisms and mold growth
Freezing also stops the process of staling
Staling rate it at its maximum between 20ºc and -10ºc
It is best to cover this large staling temperature span as quickly as possible
Unfortunately, par baked products freeze more slowly than raw dough
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15. Alternative Methods of Baking: Par-Baked
After Cooling-Distribution
The major disadvantage about par baking is the space requirements for freezing, storage and transport
Par baked baguette takes up approximately 4 times as much space as an equal number of frozen dough
There is no apparent moisture loss even after 7 weeks of freezer storage.
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16. Alternative Methods of Baking: Par-Baked
Defrosting is quicker than for frozen dough
A constant storage temperature is crucial to prevent partial defrosting which can result in drying, condensation, surface flaking and staling
There is no weight loss during defrosting
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17. Alternative Methods of Baking: Par-Baked
Second or Final Bake
Final bake can be carried out in any oven
Steam on defrosted or frozen par baked products will result in less moisture loss
Not defrosting saves time, reduces moisture loss and limits staling before baking
Final baking forms the crust, gives it color by drying, carmalization and Maillard reaction and freshens the crumb
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18. Alternative Methods of Baking: Par-Baked
Cooling
Cooling loss is identical to traditional baking: 2.5% in 1 hour
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19. Alternative Methods of Baking: Par-Baked
Par-Baked Bread Conclusion
Compromise between frozen dough and traditional process
Most versatile of alternative methods
Use of preferments, different flours
Ability to serve fresh bread all day
Requires technical knowledge and significant investment in equipment
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20. Alternative Methods of Baking
Frozen Dough Process
The baking process is stopped after shaping.
The products are stored at -18ºc
Efficient for larger production with distribution and baking possible to several bake-off points
Specific processes must be followed to ensure integrity of final baked breads
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21. Alternative Methods of Baking: Frozen Dough Process
Two main problems:
Gas production
Keeping the yeast active and maintaining its gassing power
Gas retention
Maintaining the physical properties of the dough and its ability to retain gas
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22. Alternative Methods of Baking: Frozen Dough Process
Flour
Low Protein Bread Flour
Higher protein quality vs protein quantity
Higher dough hydration encourages ice crystal formation
Dough needs to be able to withstand machinability as well as thawing process.
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23. Alternative Methods of Baking: Frozen Dough Process
Water
Temperature should be close to 0 ºc (+1 / +2 ºc)
Percent should be low enough to achieve a stiffer dough
To reduce ice crystallization phenomena
To reduce tendency to sag during thawing
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24. Alternative Methods of Baking: Frozen Dough Process
Yeast
Maintaining the stability of yeast and its fermentation power depends on :
Its physiological state before deep freezing
Whether or not fermentation has started before freezing
Freezing method used: time, temperature, and final core temperature.
Thawing method used: fast or slow
Storage conditions: temperature and length of time
Formation of ice crystals during freezing can damage yeast cells. This depends on the crystal size which depends on the rate of freezing
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25. Alternative Methods of Baking: Frozen Dough Process
Yeast dosage
Fermentation power decreases during product storage time
Higher dosage necessary to compensate for loss of fermentation power
Normally 1.5 to 2 times normal yeast level
Too high dosage may have adverse effects on physical reaction and gas retention of the dough
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26. Alternative Methods of Baking: Frozen Dough Process
Salt
Slightly more salt is used to strengthen the gluten and add flavor
Not more than 2.5 %
Also beneficial in delaying the start of the fermentation
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27. Alternative Methods of Baking: Frozen Dough Process
Sugar
If any is used, quantity should be reduced to compensate for reduced fermentation
Some sugar may benefit the frozen dough process by inhibiting the formation of ice crystals
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28. Alternative Methods of Baking: Frozen Dough Process
Dough Conditioners
Reduces effect of lack of gluten conditioning during bulk fermentation
Assists dough in maintaining shape during thawing
Improve gas retention during proofing
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29. Alternative Methods of Baking: Frozen Dough Process
Dough Conditioners
Reduces effect of lack of gluten conditioning during bulk fermentation
Assists dough maintain shape during thawing
Improve gas retention
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30. Alternative Methods of Baking: Frozen Dough Process
Dough Conditioner Usage
Fungal amylase
Too much may cause extensibility and sagging during thawing
Oxidizing agents
Ascorbic acid or others
Emulsifiers:
DATEM
SSL
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31. Alternative Methods of Baking: Frozen Dough Process
Mixing
Mix to obtain cold dough to limit start of fermentation
Give maximum development for gas retention
Produce firmer dough to limit sagging during thawing
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32. Alternative Methods of Baking: Frozen Dough Process
Fermentation
Time between end of mixing and placing the shaped dough in blast freezer must be as short as possible
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33. Alternative Methods of Baking: Frozen Dough Process
Dividing
Must be carried out as soon as mixing is done.
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34. Alternative Methods of Baking: Frozen Dough Process
Resting Time and Shaping
Resting time of 7 to 10 minutes is necessary for dough to relax
This makes it easier to stretch during shaping
Slight reshaping necessary after preshape due to lack of dough extensibility
Use of reducing agent in formulation will greatly assist in dough relaxation
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35. Alternative Methods of Baking: Frozen Dough Process
Blast Freezing
Done immediately after shaping to limit start of fermentation
Blast freezer should be between -30 to -35ºc
Lower blast freezer temperature causes irreversible damage (ice crystal formation)
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36. Alternative Methods of Baking: Frozen Dough Process
Packaging
Packaging material for frozen dough must be:
Waterproof
Air tight
Flexible and resistance to low temperature (polyethylene)
Sealable
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37. Alternative Methods of Baking: Frozen Dough Process
Storage
Temperature:
-20ºc (+/- 2 ºc)
Time:
Local distribution from 2 to 6 weeks
Export market from 3 to 6 months
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38. Alternative Methods of Baking: Frozen Dough Process
Transportation
Cold chain must not be broken
Products must be kept at -18 / -20ºc
Products must be handled with care because they are fragile and break easily
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39. Alternative Methods of Baking: Frozen Dough Process
Thawing
High level of surface condensation rules out thawing on cloth for ready to proof products
Sticking means that thawing must take place in fluted trays
Baking on oven hearth is practically impossible unless proofed on special silicon baking mats
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40. Alternative Methods of Baking: Frozen Dough Process
Thawing: 3 options
Proof box
Room temperature
Retarder/Proofer
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41. Alternative Methods of Baking: Frozen Dough Process
Convection or deck oven
Fluted trays must be non - stick
Due to excess of fermentable sugars, oven temperature can be lowered and baking time increased
Must be carried out be trained staff capable of making judgment on proper thawing process, final proofing time and correct scoring of the dough
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42. Alternative Methods of Baking: Frozen Dough Process
Other Options
Frozen dough blocks.
Shaped loaves may be proofed on linen
Viennoiserie
Structure of enriched doughs is protected from fats, eggs and sugars
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43. Alternative Methods of Baking: Frozen Dough Process
Conclusion of the Frozen Dough Process
Provides flexibility on production schedule and convenience for end user
Ingredient, equipment and handling considerations must be taken into consideration
Some products can be frozen better than others
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44. Alternative Methods of Baking
Pre-Proof Frozen Dough Process
Freshly baked items available in 20 minutes
No need for end user to have specialty equipment or to be trained in evaluating proof
Most pre-proof frozen products are Viennoiserie
Products are proofed to 75% before freezing
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45. Alternative Methods of Baking: Pre-Proof Frozen Dough Process
Ingredients
Selection will determine gas retention
Flour should have a good quality protein
Vital wheat gluten may be added to the dough
Dough conditioner typically includes enzymes, oxidizers and emulsifiers to improve dough viscosity and gas retention
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46. Alternative Methods of Baking: Pre-Proof Frozen Dough Process
Dough should be mixed to optimum gluten development
Dough should not be too cold, nor too warm
After shaping, products are partially proofed, frozen in a blast freezer, packaged, stored and delivered
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47. Alternative Methods of Baking: Pre-Proof Frozen Dough Process
End user places frozen product on pan accordingly and bakes
Baking time should longer
Temperature should be lower
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48. Alternative Methods of Baking: Pre-Proof Frozen Dough Process
Conclusion of Pre-Proof Frozen Dough Process
This process offers convenience to the end user with minimal investment
Quality may be lower than traditional methods or par-bake processes
Most common application is Viennoiserie
Products should be eaten as fresh as possible
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49. Alternative Methods of Baking
Conclusion
Par-bake, frozen dough and pre-proof frozen processes afford the baker and end user many options
Attention to product formulation and process will ensure quality results
The investment in specialty equipment varies by process but for volume production they ensure consistent results
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