Whole Grain Saltine Crackers: Formulation, Processing, and Quality Improvements

See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/269643106

Article in Cereal Foods World · July 2013 DOI: 10.1094/CFW-58-4-0180

CITATIONS READS 0 80

3 authors, including:

Gary Hou Wheat Marketing Center

40 PUBLICATIONS 487 CITATIONS

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Soft wheat functionality View project

Whole grain products View project

All content following this page was uploaded by Gary Hou on 20 December 2016.

The user has requested enhancement of the downloaded file. Whole Grain Saltine Crackers: Formulation, Processing, and Quality Improvements

(10), as well as provide prebiotic benefits facture. However, they lack the unique J. Li and lower the risk of gum disease, tooth flavor of saltine crackers imparted by the Jiangnan University, Wuxi, Jiangsu, loss, and asthma (5,16). The USDA Dietary sourdough starter and yeast fermentation. PRC, and Wheat Marketing Center, Guidelines for Americans, 2010 (18) rec- Although laboratory-scale methods for Inc., Portland, OR, U.S.A. ommends that at least 50% of all grains producing traditional saltine and chemi- consumed should be whole grains. In May cal crackers have been developed (7, G. G. Hou1 2013, the AACCI Board of Directors 12,14), there is no consensus method for approved the AACCI Whole Grains Work- producing whole grain crackers. In addi- Wheat Marketing Center, Inc. ing Group’s characterization of whole tion, the processing and quality character- Portland, OR, U.S.A. grain products. The characterization istics of these products can be negatively asserts that a whole grain food product affected by use of whole grain flour. The Z. Chen must contain 8 g or more of whole grain limited gluten strength and high water Jiangnan University per 30 g of product (www.aaccnet.org/ absorption of whole grain flour inhibit Wuxi, Jiangsu, PRC about/newsreleases/Pages/WholeGrain- the formation of a gluten network, which ProductCharacterization.aspx). results in reduced oven spring during n recent years, greater emphasis has Crackers, an important product line baking (8). Ibeen placed on the health benefits of within the large-scale baking industry, There has been little research performed whole grains. In 1999, AACC Interna- can be divided into three broad catego- on the quality characteristics of whole tional (AACCI) adopted the following ries: chemical, enzyme, and saltine (soda) grain saltine crackers. This article reports definition for whole grains (www.aaccnet. (11). Saltine cracker production typically on the effects of whole grain flour on the org/initiatives/definitions/Documents/ utilizes a sponge-and-dough (≈24 hr fer- quality attributes of saltine crackers and WholeGrains/wgflyer.pdf): “Whole grains mentation) preparation method. The pro- the use of functional ingredients to shall consist of the intact, ground, cracked longed sponge fermentation produces the improve the end-product quality of whole or flaked caryopsis, whose principal ana- unique flavor and crispy texture associ- grain crackers. tomical components—the starchy endo- ated with saltine crackers (13). In con- sperm, germ, and bran—are present in trast, chemical crackers typically require Whole Wheat Saltine Cracker the same relative proportions as they exist a leavening system that does not utilize Preparation in the intact caryopsis.” sourdough starter and yeast. In addition Whole wheat cracker flour samples The strong appeal of whole grains is to leavening agents, enzymes (protein- were composited from blends of soft driven by the nutritional benefits they ases) are incorporated into the formula- white whole wheat (SWWW; Ultragrain, offer versus refined flours. Studies have tion of enzyme crackers. Both chemical ConAgra Flour Mills Inc.), soft red winter shown that whole grains contain high and enzyme crackers are relatively simple wheat (SRW; Golden Shield, enriched and concentrations of nutrients and phyto- to handle and require less time to manu- unbleached, General Mills, Inc.), and hard chemicals and are rich in dietary fiber, resistant starches, oligosaccharides, vita- mins, trace minerals, and antioxidants, including phytate, phytoestrogens, and phenolic compounds, with known health benefits (9). Compared with other cereal grains, barley contains relatively high levels of -glucan (2), a soluble polysaccha- ride with health-promoting properties that include helping reduce the health risks associated with high cholesterol and high blood pressure (19,20). Epidemiological studies have demon- strated that whole grain intake can reduce the risk of certain cancers, cardiovascular disease, type 2 diabetes, obesity, and stroke

180 / JULY–AUGUST 2013, VOL. 58, NO. 4 red winter wheat (HRW; Harvest King course of the study. Water was added at was mixed and placed in the fermentation winter wheat, enriched and unbleached, the minimum level of cracker flour cabinet to proof for another 2 hr. After General Mills, Inc.) flours. Preliminary absorption, rather than the maximum the dough was proofed, 500 g of cracker trials determined that the optimum blend level, to develop a dough wet enough to dough was placed in a plastic container to level of HRW flour was 15% based on the sheet, yet dry enough to avoid the forma- shape into a rectangular dough block breaking strength of the end-products (at tion of an elastic dough. More water was (15 × 13.5 × 2.5 cm). The shaped dough HRW ≥ 20%, end-product texture was required in the preparation of sponge block was laminated into a thin sheet harder and less crispy). HRW flour was dough that contained higher levels of (SSO-615 Seewer reversible lamination added at the same level in each group, SWWW flour to achieve proper dough machine, Rondo Inc.). Dough lamination except for the 100% SWWW group (Table handling and processing characteristics. settings are provided in Table V. The final Ι). Whole wheat cracker flour blends were Any excess water must be removed height, width, and length of the dough analyzed for protein, moisture, ash, starch through baking, which results in a longer sheet were 1.5 mm, 22.5 cm, and 40.0 cm, damage, wet gluten, and gluten index baking time (15). Tota l titratable acidity respectively. The dough sheet was trans- according to AACCI Approved Methods (TTA) tests were used as indicators of the ferred to a specially designed cutter-docker (Table II) (1). fermentation process. The amount of (14), and the dough sheet was perforated The whole wheat saltine cracker formu- baking soda to be added was determined using a rolling pin. The dough sheet was lations used are detailed in Table III. Bak- based on the TTA of the sponge after sprinkled with salt and rested under a ing soda, mineral yeast food, vegetable 18 hr of fermentation and the pH of the covered couche for 1 min. The cracker shortening, and instant dry yeast were end-products (≈7.0–8.0). The amount of dough sheet was then transferred to a purchased from a local supermarket. All baking soda required based on sponge specially designed wire mesh belt (CB5 ingredients were scaled on a 500 g flour TTA is listed in Table IV. Baking Band, Ashworth) on a rectangu- weight basis. The original sourdough A laboratory-scale, whole grain saltine lar-shaped rack that was preheated in a starter was supplied by Oregon State Uni- cracker-making process is illustrated in a deck oven (PICCOLOI-3, Wachtel Com- versity and maintained by adding old schematic diagram (Fig. 1). The sponge pany) for 30 min. The top-level baking starter (50 g), HRW flour (100 g), and ingred ients were combined in a mixer temperature was 220°C, and the bottom- distilled water (50 g) daily during the (Hobart A-200 mixer and McDuffy mix- level baking temperature was 215°C. The ing bowl, National Manufacturing, Co.). baking time was ≈6–7 min. After the The sponge was fermented at 28°C and cracker dough was properly baked, the 85% RH in a fermentation cabinet for cracker sheet was removed from the oven, 18 hr. After 18 hr of fermentation, the and vegetable oil was sprayed on the sur- remaining flour, water, shortening, and face. After cooling, the cracker sheet was dry ingredients (Table III) were combined broken into individual pieces along the with the fermented sponge. The dough perforated lines and sealed in plastic bags at room temperature until analyzed.

End-product Evaluation The stack height, stack weight, specific volume, and breaking strength of the whole wheat saltine crackers were determined. The data shown in Table VI indi- cate that cracker characteristics were affected by the composition o f the whole wheat flour blend used. Stack weight, stack height, specific volume, and breaking strength of crackers decreased as the

Fig. 1. Schematic diagram of laboratory-scale, whole grain saltine cracker production. WWF: whole wheat flour.

CEREAL FOODS WORLD / 181 addition level of SWWW flour increased. extra water during the preparation of grain crackers. For example, endoxy- Higher amounts of whole wheat flour whole wheat cracker dough. Any excess lanases can be used to decrease the water- tended to yield an uneven internal texture water added to the formulation must then holding capacity of wheat bran (water- with less puffiness. Crackers with higher be removed during baking, which increases unextractable arabinoxylans) and redis- levels of SWWW flour were also more the baking time and energy consumption tribute water in the dough system (4). fragile (less breaking force). As expected, of cracker production. Another difficulty They can also be used to increase the the color of the end-products became encountered in the production of whole extensibility of dough and softness of browner and darker with increasing wheat crackers is the limited gluten bread and other leavened products and to amounts of whole wheat flour in the strength caused by the shearing and dilu- improve dough handling and machinabil- blend (Fig. 2). tion of wheat bran. The resulting weak ity (15). Gum arabic is a natural gum exu- gluten network reduces the gas retention date with a highly branched, compact End-product Quality Improvement capacity of the wheat dough and the oven arabinogalactan structure that produces a A cracker is a low-moisture product. spring of the baked product (8). low-viscosity solution and a central pro- The high water-absorbing capacity of Several functional ingredients can be tein fraction that provides good emulsifi- whole wheat flour requires the addition of used to improve the quality of whole cation properties. It is a multifunctional ingredient with properties that enable its use as a texturizing agent, film former, emulsifier, and stabilizer (17). Gum arabic offers many benefits for bakery products in terms of processing, texture, and shelf life due to its moisture regulation and film-forming properties. Vital wheat gluten traditionally has been used to improve dough strength and film formation, mix- ing and fermentation tolerances, gas retention and product volume, structure in whole grain products, and flavor, as well as to reduce breakage in snack products (6). Using the low-field nuclear magnetic resonance technique, we found that the addition of endoxylanases, gum arabic, or vital wheat gluten increases water mobility from the arabinoxylan matrix to gluten, which aids in the formation of the gluten network and improves the oven spring of whole wheat saltine crackers (Li et al., unpublished data). In this study, different addition levels of endoxylanases (0.01, 0.02, 0.03, and 0.04%), gum arabic (0.5, 1, 2, and 3%), or vital wheat gluten (1.0, 2.0, 3.0, and 4.0%) (flour weight basis) were blended into SWWW flour to prepare 100% whole wheat saltine crackers according to the methods described previously. The control flour was 100% SWWW flour with no added ingredients. The quality attributes of 100% whole wheat saltine crackers with these additions were determined. The stack height and specific volume of end-products increased with increasing levels of endoxylanases, while stack weight and breaking strength decreased (Table VII). As increasing amounts of endoxylanases were added, cracker dough became much softer (decrease in resis- tance to extension) and more extensible (increase in extensibility), which improved cracker oven spring during baking. The stack height and specific volume of end- Fig. 2. Whole wheat saltine crackers made from blends of five levels of soft white whole wheat products also increased with increasing (SWWW) flour. levels of gum arabic, while breaking

182 / JULY–AUGUST 2013, VOL. 58, NO. 4 strength decreased. The stack weight of the end-products had no significant cor- relation with the level of gum arabic added (Table VII). Whole wheat cracker dough was softened by the addition of gum arabic, which was expected to improve the oven spring and crispy texture of the end-products. As levels of vital wheat gluten increased, stack weight, stack height, specific volume, and breaking strength of end-products increased (Table VII). The original SWWW flour had limited gluten strength, resulting in breakage of the cracker dough sheet during lamination. Gluten strength and the gluten network were enhanced by added vital wheat gluten, resulting in the development of a gluten network in the whole wheat cracker dough that was strong enough to retain gas, improve oven spring, and entrap more bubbles. How- ever, excessive addition of vital wheat gluten would greatly increase the toughness of the cracker dough and restrict the puffiness of end-products.

Whole Barley-Fortified Saltine Cracker Preparation and Quality Improvement Whole barley flour (10.5% protein, 11.0% moisture, and 1.25% ash) was purchased from Giusto’s Specialty Foods Company. The high fiber content (both soluble and insoluble fiber) of whole barley flour is associated with a high water- absorption capacity. Gum arabic, guar gum, and xanthan gum are hydrocolloids that are widely used in the baking industry to modify gluten and its hydration properties (3). Gum arabic (Pre-Hydrated Gum Arabic FT), pre-hydrated guar gum, and xanthan gum (Ticaxan Xanthan 200EC) were provided by TIC gums, Inc. Two addition levels (1.0 and 2.0%) of each gum (wt/wt, cracker flour weight basis) and four levels (0, 25, 50, and 75%) of whole barley flour were blended. Whole barley-fortified cracker flour blends are presented in Table VIII. The control flour was a whole barley-fortified blend with- out added gums. The formulas and proce- dures used to produce whole barley-fortified saltine crackers were developed according to the methods described for the preparation of whole wheat saltine crackers, except that different gum addition levels were used and slightly more water (1–2%) was added. The stack weight, stack height, specific volume, and breaking strength of whole barley-fortified saltine crackers were mea- sured according to the evaluation methods described previously (Table IX). Stack

CEREAL FOODS WORLD / 183 weight and breaking strength of end- tion due to the high water-absorption specific volume of whole barley-fortified products increased and stack height and capacity and limited gluten strength of saltine crackers. specific volume generally decreased the whole grain flour used. Both the pro- as increasing amounts of whole barley cessing characteristics and end-product Acknowledgments flour were added. With increasing levels quality attributes, especially oven spring, We thank TIC Gums, Inc. for supplying the of added gum arabic, stack weight, stack were negatively influenced by the use of gum samples, Novozymes Company for pro- height, and specific volume of end-prod- whole grain flour. However, the addition viding the endoxylanases, and MGP Ingredi- ucts increased, while breaking strength of functional ingredients can be used to ents, Inc. for providing the vital wheat gluten. generally decreased. Guar and xanthan improve the quality characteristics of gums had a similar effect on the quality whole wheat saltine crackers. References of whole barley-fortified saltine crackers. Results showed that the stack height 1. AACC International. Method 08-01, Stack height and specific volume of and specific volume of whole wheat sal- Ash—Basic Method; Method 38-12, Wet barley-fortified saltine cracker decreased tine crackers were increased by the use of Gluten and Gluten Index; Method 44-15, and breaking strength increased with endoxylanases, gum arabic, and vital wheat Moisture; Method 46-30, Protein; Method 76-33, Starch Damage. Approved Methods increasing levels of added guar and xan- gluten. Because water tends to migrate of Analysis, 11th ed. Published online at than gums. However, xanthan gum exhib- from high water-absorbing components http://methods.aaccnet.org. AACC Inter- ited greater effects on the stack weight (such as arabinoxylans or -glucan) to national, St. Paul, MN. and breaking strength of whole barley- gluten in the presence of endoxylanases, 2. Bamforth, C. W. Barley -glucans: Their fortified saltine crackers than did gum gum arabic, and vital wheat gluten, great- role in malting and brewing. Brew. Dig. arabic or guar gum, which suggests that er gluten network formation is achieved 57:22, 1982. xanthan gum was more effective in modi- in whole grain dough when these ingredi- 3. Bárcenas, M. E., De la O-Keller, J., and fying the internal structure of the end- ents are added, and the oven spring of Rosell, C. M. Influence of different hydro- products. whole grain saltine crackers is improved. colloids on major wheat dough compo- For the whole barley-fortified saltine nents (gluten and starch). J. Food Eng. 94:241, 2009. Conclusions crackers, three types of gums (gum arabic, 4. Courtin, C. M., and Delcour, J. A. Arabi- Although the whole grain saltine crack- guar gum, and xanthan gum) were com- noxylans and endoxylanases in wheat flour ers tested in this study possessed a unique pared for their impact on end-product bread-making. J. Cereal Sci. 35:225, 2002. flavor, crispy texture, and significant quality. Results showed that gum arabic 5. Grootaert, C., Delcour, J. A., Courtin, C. nutritional and health benefits, some dif- was more effective than guar or xanthan M., Broekaert, W. F., Verstraete, W., and ficulties were experienced during produc- gum for improving the stack height and Van de Wiele, T. Microbial metabolism

An ad appeared here in the print version of the journal.

184 / JULY–AUGUST 2013, VOL. 58, NO. 4 and prebiotic potency of arabinoxylan fermentation. Cereal Chem. 57:185, 1980. oligosaccharides in the human intestine. 14. Pizzinatto, A., and Hoseney, R. C. A labo- Trends Food Sci. Technol. 18:64, 2007. ratory method for saltine crackers. Cereal 6. Kalin, F. Wheat gluten applications in food Chem. 57:249, 1980. products. J. Am. Oil Chem. Soc. 56:477, 15. Rogers, D. E., and Hoseney, R. C. Test to 1979. determine the optimum water absorption 7. Kweon, M., Slade, L., and Levine, H. Devel- for saltine cracker doughs. Cereal Chem. opment of a benchtop baking method for 64:370, 1987. chemically leavened crackers. II. Validation 16. Slavin, J. Whole grains and human health. of the method. Cereal Chem. 88:25, 2011. Nutr. Res. Rev. 17:1, 2004. 8. Li, J., Kang, J., Wang, L., Li, Z., Wang, R., 17. Thevenet, F. Acacia gum (gum arabic). Chen, Z. X., and Hou, G. G. Effect of water Page 11 in: Food Stabilisers, Thickeners migration between arabinoxylans and and Gelling Agents. A. Imeson, ed. Wiley- gluten on baking quality of whole wheat Blackwell, West Sussex, U.K., 2010. bread detected by magnetic resonance 18. U.S. Department of Agriculture and U.S. imaging (MRI). J. Agric. Food Chem. Department of Health and Human Ser- 60:6507, 2012. vices. Dietary Guidelines for Americans, 9. Liu, R. H. Whole grain phytochemicals 2010, 7th ed. Published online at www. and health. J. Cereal Sci. 46:207, 2007. cnpp.usda.gov/dgas2010-policydocument. 10. Marquart, L., Slavin, J. L., and Fulcher, R. htm. U.S. Government Printing Office, G., eds. Whole-Grain Foods in Health and Washington, DC, 2010. Disease. AACC International, St. Paul, 19. Wang, L., Behr, S. R., Newman, R. K., and MN, 2002. Newman, C. W. Comparative cholesterol- 11. Moore, T., and Strouts, B. Basic cracker lowering effects of barley -glucan and technology. Ι. Ingredients and formula- barley oil in golden Syrian hamsters. Nutr. tion. AIB Int. Tech. Bull. 4:1, 2008. Res. 17:77, 1997. 12. Moore, T., and Strouts, B. Basic cracker 20. Wood, P. J., and Beer, M. U. Functional oat technology. II. Processing. AIB Int. Tech. products. Page 1 in: Functional Foods— Bull. 6:1, 2008. Biochemical and Processing Aspects. G. 13. Pizzinatto, A., and Hoseney, R. C. Rheo- Mazza, ed. Technomic Publishing Com- logical changes in cracker sponge during pany, Lancaster, PA, 1998.

Juan Li is a Ph.D. candidate at the National Engineering Labora- tory for Cereal Fermentation Technology, Jiangnan University, Wuxi, China. Her major is in food science, with research in the area of cereal chemistry and engineering. Her Ph.D. research program focuses on the development of whole grain products and quality improvement. In 2012, Juan completed a research project on the development of whole grain saltine crackers as a visiting scholar at the Wheat Market- ing Center, Portland, OR. Juan is a member of AACC International and can be reached at [email protected].

Gary G. Hou is the technical director and wheat foods specialist at the Wheat Marketing Center, Portland, OR. He has been very active in conducting numerous research projects on wheat-based foods and ingredient functionality. One of Gary’s current research areas is the development of whole grain products, including Asian noodles, breads, crackers, pastas, and steamed breads. He also conducts a number of technical training courses on Asian noodles, artisan breads, biscuits and crackers, frozen dough technology, flat breads and flour tortillas, whole grain products, etc. Gary is a professional member of AACC International and the Institute of Food Technolo- gists. He can be reached at [email protected].

Zhengxing Chen is a professor, Ph.D. student supervisor, and executive deputy director of the National Engineering Laboratory for Cereal Fermentation Technology, Jiangnan University, Wuxi, Chi- na. In recent years, Zhengxing and his group have engaged in research on deep processing of grains, development of cereal products, and comprehensive utilization of grains, cereal chemistry, and functional ingredients. Zhengxing can be reached at [email protected].

CEREAL FOODS WORLD / 185

View publication stats