1. © 2009 Cengage Learning. All Rights Reserved. Chapter 3: The Baking Process and Dough Mixing

2. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Introduction This chapter includes: An overview for the baking process Detailed explanation of mixing process

3. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process Traditional Method - Basic steps never changed over centuries - Preferment - Mixing - First fermentation - Dividing - Pre-shaping - Resting time - Shaping - Final Proof - Oven Loading - Scoring - Unloading the Oven

4. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process The proper transformation of basic ingredients into bread Succession of 12 steps Handling of each step greatly affects on the quality of final product

5. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Preferment - Before mixing of the final dough - Improvement of the final product - A portion of dough is allowed to ferment - Different preferments provide different characteristics

6. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Mixing - All the ingredients are combined to form a dough - Effects on the quality of final product

7. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method First Fermentation - A dough is allowed to ferment as a large mass - Increase dough strength (mass effect) - Develop flavor

8. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Dividing – desired weight For Manual Dividing: –Caution must be paid not to damage the dough –Try to cut a dough in one piece For Mechanical Dividing: –Choice of equipment is critical

9. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Pre-Shaping –By hand or by machine –Loose ball for boules and batards, cylinders for baguettes –Adjustment on the dough strength –Important to assess the dough characteristics –Form smooth skin on outside to promote proper and better shaping

10. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Resting Time (or Intermediate Proof) –The dough is relaxed between pre-shaping and shaping –Continue producing gas –The dough pieces should always be protected from drying out

11. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Shaping - Forming into the final shape By Hand: - The characteristics of the dough must be carefully examined - Adjustment by the strength of the dough By Machine: - Choose equipment with minimum pressure and stress on the dough

12. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Final Proof –Gas accumulates and creates internal pressure –The balance of gluten strength and gas pressure creates volume and crumb structure –The dough should be protected from drying out –Use of rack cover, linen and proofs box

13. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Oven Loading By hand: –Use of an oven peel or loader –Minimize damage during transferring the dough By Machine (for a larger production): –Automatic loading system –Even spacing for an even heat distribution

14. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Scoring –an incision on the skin of the dough –Direct impact one volume and final appearance of the bread

15. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Unloading the Oven –With an oven peel or a loader –Avoid damaging the crust of the bread

16. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Baking Process: Traditional Method Cooling –The bread goes through a series of transformation after baking and during cooling –The quality of the bread can be severely compromised

17. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. The Dough Mixing Process Mixing – the first mandatory step to producing bread Dough consistency and gluten development are determined during mixing

18. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Four Critical Steps of Dough Mixing Scaling –Precise scaling of ingredients is very important

19. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Four Critical Steps of Dough Mixing Water Temperature –Controls the final dough temperature, which is directly related to the rate of fermentation –Desirable Dough Temperature for most dough: 74°-77°F –Factors: Temperatures of the room, flour, preferment and the friction from mixer –Friction of mixer varies by the type of mixer, the shape of the hook, quantity of the dough etc

20. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Four Critical Steps of Dough Mixing Water Temperature Calculation to determine water temperature Room°F + Flour°F + Preferment°F+ Friction°F=X DDT(75°F) x 4 = 300°F Water °F = (300 – X) °F

21. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Four Critical Steps of Dough Mixing Ensuring Clean Equipment –Make sure the mixer bowl and hook are clean –Old dough scrap will not dissolve in the next dough

22. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Four Critical Steps of Dough Mixing Adding Ingredients to the Mixing Bowl –Add the flour first, then water –Flour based on 100% For mixer without reverse option: –Add the half of the water first, then flour, and then the rest of the water until the desired consistency is achieved

23. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Ingredient Incorporation: Autolyse Special Considerations for Autolyse –When using instant dry yeast, add it one minute before the autolyse is over to properly hydrate the yeast cell –Liquid preferments must be incorporated before autolyse –Stiff preferments must be incorporated after autolyse

24. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Ingredient Incorporation During mixing on 1 st speed; The ingredients are incorporated as well as the preferments A baker must pay a close attention to see if additional water is necessary

25. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Ingredient Incorporation Autolyse –Resting the flour and water for a minimum of 15-20 minutes –Salt, yeast and preferment are added after an autolyse –Better hydration of the flour = better gluten structure –Protease degrades some gluten bonds = better extensibility and machine ability

26. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development After all ingredients are incorporated, the dough is continuingly mixed to achieve a desired degree of dough development Can be done in first or second speed

27. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development Dough Temperature –Confirm the dough temperature right after mixing –The first fermentation time varies depending on the dough temperature –Do not continue mixing when the dough temperature is too cold – over development of the dough –Over-mixed dough creates excess extensibility and lack of elasticity

28. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development Physical Changes During the Formation of Dough –Hydrates the flour components, primarily starch and protein –Starch: native starch and damaged starch –Protein: Glutenin (provides elasticity) and Gliadin (provides extensibility) –Glutenin and Gliadin form chains of proteins, called Gluten

29. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development Physical Changes During the Formation of Dough As the dough hook continues mixing, it organizes the cell structure by stretching and folding –The longer the mixing, the finer the crumb –Rheological change – less extensibility, more elasticity

30. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Physical Changes During the Formation of Dough Protein Hydration and Mixing Time in First Speed –Protein hydrates at slower rate than starch –For a larger batch of dough, 5 to 6 minutes of mixing on 1st speed is necessary

31. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development Chemical Changes During the Formation of the Dough –When water is introduced into the mix, Fermentation Activity and Enzyme Activity start –The wetter the dough, the faster the fermentation rate becomes – adjust yeast amount depending on the hydration

32. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Chemical Changes During the Formation of the Dough Oxidation of the Dough –Caused by oxygen naturally incorporated into dough during mixing –Positive affects: Strengthen gluten bonds –Creates micro cells – gas produced by yeast accumulates in the cells –“Alveoles” or the cell structure of the crumb

33. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Chemical Changes During the Formation of the Dough Oxidation of the dough –Negative affects: Damage on Carotenoid pigments = whiter crumb, blander flavor –Salt slows down chemical reaction in dough

34. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development Incorporation of Secondary Ingredients into a Dough System –Examples of primary ingredients

35. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Incorporation of Secondary Ingredients into a Dough System Incorporation of Fat –2 to 4% of solid fat can be incorporated with the flour at the beginning of the mixing –5 to 15% of solid fat can be added when the dough is halfway trough development –more than 15% of fat should be incorporated when the gluten is almost fully developed –The fat lubricate the gluten and prevent from bonding easily

36. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Incorporation of Secondary Ingredients into a Dough System Incorporation of Fat –Liquid fats can be incorporated at the beginning of the mixing –Larger quantity can be incorporated after the gluten is fully developed

37. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Incorporation of Secondary Ingredients into a Dough System Incorporation of Sugar –Up to 12% of sugar can be incorporated the beginning of the mixing. –Higher % of sugar is incorporated in several steps –Hydroscopic characteristic

38. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Incorporation of Secondary Ingredients into a Dough System Incorporation of Eggs –Should be incorporated at the beginning of the mixing –Major part of hydration –At least 10% of water in addition to the egg is necessary to hydrate flour properly

39. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Incorporation of Secondary Ingredients into a Dough System Incorporation of Dry Ingredients –Malt and milk powder can be incorporated at the beginning of the mixing

40. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development: Incorporation of Secondary Ingredients into a Dough System Incorporation of Solid Ingredients like Nuts, Dry Fruits, Chocolate Chips and More –Nuts, seeds and fruits must be incorporated at the end of the mixing –Incorporate on 1 st speed –Gentle incorporation will reduce damage to the gluten structure

41. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Dough Development Mixing Process Conclusion –Following each step of mixing with precision and close attention results in a consistent production

42. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Mixing Techniques Three main mixing techniques –Short mix –Intensive mix –Improved mix Quality of bread depending on different gluten development

43. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Mixing Techniques Short Mix –Popular technique before mechanical mixers became available –Hand mixed dough: Not sufficient gluten development –Long fermentation with folds

44. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Mixing Techniques Intensive Mix –Mechanical mixers with two speeds enabled intensive development of gluten –Shorter fermentation time –Tight crumb with large volume –Oxidation of the dough leads to lack of flavor

45. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Mixing Techniques Improved Mix –Shorter mixing time than intensive mix –Gluten is not fully developed –Limits the oxidation of the dough –Enable to produce higher quality of bread with a larger quantity

46. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Short Mix Description Similar to hand-mixed dough Under-developed gluten requires a long fermentation time and two to four folds Low percentage of yeast Gassy and soft dough

47. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Short Mix Description Short Mix Effects of Bread Characteristics –Very creamy crumb color due to no oxidation during mixing –Long fermentation time enhances flavor and shelf life of the final product

48. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Intensive Mix Description The ingredients are mixed on first speed to an incorporation It is then mixed on second speed to a full development of gluten Great machine ability Stiff and fluffy dough Short first fermentation time

49. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Intensive Mix Description Intensive Mix Effects on Bread Characteristics –Oxidation of the dough creates a very white crumb color –Tight cell structure –Large volume on the final product –Lack of shelf life and flavor

50. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Improved Mix Description Compromise between the short mix and the intensive mix Ingredients are incorporated in first speed and then mixed to half development of gluten in second speed Medium-soft consistency of dough Sufficient dough for hand-shaping or a semi- mechanized process

51. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Improved Mix Description Improved Mix Effects on Bread Characteristics –Creamy color and open crumb –Flavorful product with a good shelf life –Volume is between that of short mix and intensive mix

52. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Improved Mix Description: Improved Mix Effects on Bread Characteristics Visual Comparison of the Three main Mixing Techniques

53. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Improved Mix Description: Improved Mix Effects on Bread Characteristics Double Hydration –Growing popularity of “super” hydrated dough created this technique –Water incorporation in two phases –Enough water is incorporated to create a medium- soft consistency of dough –When the dough reaches 2/3 of its full development, the rest of water is added in stages –Very soft dough with sufficient strength for machine ability

54. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time Based on the revolution of the dough hook Short mix – 600 revolutions in first speed Improved mix – 1000 revolutions in second speed Intensive mix – 1600 revolutions in second speed

55. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time Mixing time of the dough = Total Revolutions Required / RPM (RPM=Revolutions per Minute) RPM varies with the brand of mixer

56. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time Factors Affecting Mix Time –Type and design of mixer –Batch size –Characteristics of the flour –Dough hydration –Incorporation of additional ingredients

57. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time: Factors Affecting Mix Time Type and Design of Mixer –Motor speed –Shape of the hook –Mixer design –Different type of mixer requires different mixing time

58. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time: Factors Affecting Mix Time Batch Size –Smaller batches mix faster than larger batches

59. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time: Factors Affecting Mix Time Flour Characteristics –Stronger flour may require longer mixing time –Flour with lower quality and quantity of protein (example: Rye flour) requires more gentle mixing; longer mixing in first speed and shorter in second speed

60. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time: Factors Affecting Mix Time Dough Hydration –Stiffer dough (lower hydration) requires longer mixing time

61. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time: Factors Affecting Mix Time Incorporation of Extra Ingredients –Seeds, fruits and nuts must be added after gluten development has been completed –Incorporation should be done in first speed

62. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time Comparison of the Main Mixing Techniques

63. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. How to Calculate Mixing Time Comparison of Mixing Processes and Effects on the Final Products

64. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Developing Your Own Process Balance of mixing and fermentation Understand that mixing and fermentation works together – if the mixing is changed, so as the fermentation time

65. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Developing Your Own Process Which Method to Use? Factors: –Desired characteristics of the final product –Schedule / Time limitation –Equipment issues (batch size, type of mixer, etc.) –Understand outcomes of each mixing method and fermentation time

66. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Developing Your Own Process Mixing and Training –The bake who is in charge of mixing should see the final products of his mixing shift –In a large product, standardizing the mixing procedure is important to maintain a good consistency

67. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. What Can Go Wrong and How to Fix It Scaling –Incorrect scaling of water or flour: should be noticeable within the first few minutes –Salt and yeast: may not be noticed until the first fermentation or the baking process is completed –Always double check the measurements before mixing

68. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. What Can Go Wrong and How to Fix It Ingredient Incorporation –Salt or yeast can be dissolved in a small quantity of water and added to the dough when forgotten, only when the dough has just finished mixing

69. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. What Can Go Wrong and How to Fix It Dough Development –Under- or Over- mixing of dough can affect on the first fermentation time

70. CHAPTER 3 © 2009 Cengage Learning. All Rights Reserved. Conclusion of Mixing and Mixing Techniques When mixing is done carefully, the following steps will be easy Be accurate and careful when scaling, incorporating ingredients and during mixing A good understanding of mixing and fermentation helps to troubleshoot