A Method of Preparing Frozen Pieces of Bread Dough and of Preparing Bread Products

Europaisches Patentamt 19 European Patent Office

Office europeen des brevets © Publication number: 0 384 539 B1

12 EUROPEAN PATENT SPECIFICATION

@ Date of publication of patent specification © int. ci.5: A21D 6/00, A21D 8/06 16.06.93 Bulletin 93/24

(2j) Application number : 90200412.6

(22) Date of filing : 21.02.90

(54) A method of preparing frozen pieces of bread dough and of preparing bread products.

(30) Priority : 22.02.89 NL 8900436 (56) References cited : US-A- 4 372 982 US-A- 4 374 151 (43) Date of publication of application PROCEEDINGS OF THE 56TH ANNUAL MEET- 29.08.90 Bulletin 90/35 ING OF THE AMERICAN SOCIETY OF BAKERY ENGINEERS (ASBE) 1980, pages 38-43; B.E. BOYD: "Manufacture and processing of fro- @ Publication of the grant of the patent : zen dough" 16.06.93 Bulletin 93/24 (73) Proprietor : Ahold Retail Services AG Baarerstrasse 82 @ Designated Contracting States : AT BE CH DE DK ES FR GB GR IT LI LU NL SE CH-6300 Zug (CH)

Inventor Pieter (56) References cited : (72) : Sluimer, EP-A 114 450 c/o TNO, Lawickse Allee 15 EP-A 115 108 NL-6701 AN Wageningen (NL) EP-A 145 367 EP-A 194 189 EP-A 311 240 @) Representative : Smulders, Theodorus A.H.J., FR-A 344 229 Ir. et al FR-A 589 043 Vereenigde Octrooibureaux Nieuwe Parklaan 97 NL-2587 BN 's-Gravenhage (NL)

CO If)

00 CO Note : Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been LU filed until the opposition fee has been paid (Art. 99(1) European patent convention).

Jouve, 18, rue Saint-Denis, 75001 PARIS 1 EP 0 384 539 B1 2

Description tein-rich flour, however, is difficult to obtain and expensive. This invention relates to a method of preparing EP-A-0, 145,367 (General Foods Corporation) frozen pieces of bread dough, in which dough is discloses a method of preparing entirely proofed pas- kneaded, and subsequently entirely shaped and 5 try dough, enabling to freeze doughpieces formed proofed doughpieces are prepared and frozen, which therefrom and, after a given storage period, to place pieces of bread dough can be stored in a freezer for these directly from the freezer in an oven to be baked. some time and subsequently placed from the freezer Defrosting and final proofing are not necessary ac- without defrosting step in an oven and be baked off. cording to EP-A-1, 045,367 when flour having a pro- The invention also relates to a method of preparing 10 tein content lower than 16% is used, the dough is bread products from frozen pieces of bread dough. kneaded at a low intensity and the doughpieces are The preparation of bread in which yeast is used frozen slowly. However, such a pastry dough is un- as a proofing agent, comprises substantially the fol- suitable for preparing bread products, and so is the lowing steps. First, the dough is kneaded, after which method described. the so-called preproof ing and preshaping take place. 15 EP-A-0, 114,450 (General Foods Corporation) Subsequently, the so-called intermediate proofing describes a method of preparing entirely proofed, step and the definitive shaping take place. Finally, the frozen doughpieces from bread dough, which dough- final proofing or pan proofing takes place and then pieces can be baked off in an oven directly from the the entirely raised and shaped dough is baked. The freezer, without intermediate defrosting step. To ob- end product is a bread product. 20 tain an end product of good quality according to this The total process takes quite a long time, depend- known technique, it is necessary that gum, surfac- ing on the ingredients used, local tradition and the tants and ingredients that can form a protein film are like, which in certain cases may be as long as about added to the dough. six hours, The process cannot be interrupted in prin- EP-A-1 ,094, 189 (Grands Moulins de Pantin) de- ciple, since the action of the yeast, i.e. the proofing 25 scribes a method of preparing French bread, in which process, continues. frozen doughpieces are prepared that can be placed Owing to the long duration of this process and the directly from the freezer in an oven to be baked off. demand for fresh bread in the morning hours, bread The technique described, according to which the preparation mostly takes place during the night, which doughpieces should rise at low temperature (about is felt as a drawback. Besides, variations in demand 30 0°C) for a prolonged period (about 48 hours) and sub- cannot be coped with. Therefore, a possibility to inter- sequently be frozen at -50°C, requires much time and rupt the bread preparation process has been looked is difficult to realize in actual practice. Furthermore, for. The process can then take place, at least partly, no final proofing takes place according to this known at a more convenient point of time and, if desired, in method. a different place. 35 FR-A-2,344,229 (Bourdon) describes a method It is known to cool the dough after shaping and of preparing products from puff pastry dough, in prior to the final proofing, to e.g. -12°C. The proofing which a flour is used that is rich in gluten. The pieces process is then interrupted and can be resumed one formed from the puff pastry dough are caused to rise, or some days later. but the proofing process is discontinued abruptly It is further known to freeze a definitively shaped 40 half-way by freezing the doughpieces quickly. doughpiece prior to the final proofing. Such a frozen US-A-4,374,151 (Lindstrom) discloses a method doughpiece can be further processed until about 3 of preparing frozen pieces of bread dough, in which months later. To that effect, the doughpiece is first de- dough is kneaded, and subsequently entirely shaped frosted at 0°C, which may take from one to ten hours, and proofed doughpieces are prepared and frozen, depending on the weight. Thereafter the final proof- 45 which pieces of bread dough can be stored in a freezing takes place at normal temperature for 1 to Vh er for some time and subsequently placed from the hours and finally, the doughpiece is baked. Accord- freezer in a cold oven without separate prior defrost- ingly, this so-called bake-off process takes much ing step and baked off. In order to obtain a good loaf time, so that a similar drawback is encountered as in volume and oven spring a large quantity of water and the non-interrupted bread preparation process. 50 a melting-point depressant, which may be ethanol, is EP-A-0,115,108 (General Foods Corporation) added to the dough, as well as a large amount of su- discloses a method of freezing fully shaped and gar. The need for a cold oven makes this method un- proofed doughpiece. The frozen doughpiece, accord- suitable for commercial purposes. ing to the known method, can be placed directly from It appears from the above cited literature that it the freezer in an oven to be baked off. To obtain a 55 has been tried in the past in various manners to de- good quality of the end product, however, it is neces- velop methods for both bread products and other sary according to this known technique, to use flour dough products, according to which a frozen dough- having a protein content of 16% or higher. Such a pro- piece can be prepared that has a long storage and 2 3 EP 0 384 539 B1 4 shelf life in frozen condition and which can be baked dough structure and also has an adverse effect on off directly from the freezer without intermediate de- the yeast cells. frosting step. According to the present invention, the bread A drawback of the known methods is that in ac- product preparation is interrupted, not after shaping, tual practice these are difficult to realize and/or time- 5 but after the final proofing step by freezing the after- consuming and/or expensive, while also the quality of proofed doughpieces, as illustrated in Fig. 3 at 10. It the end product is not always optimal. has been established experimentally that doughpiec- The present invention specifically relates to the es thus frozen can be baked off directly in a preheat- preparation of frozen pieces of bread dough, and pro- ed or non-preheated oven and that nevertheless a vides an improved effective method of preparing froz- 10 good product can be obtained. Consequently, prior en pieces of bread dough, and bread products respec- (slow) defrosting is not necessary and the final proof- tively. According to the invention, a method of preparing has already been accomplished before the freezing frozen pieces of bread dough as described above ing step. A defrosting cell can be dispensed with as is characterized in that alcohol is added during knead- well. As a result, bake-off can take place at any de- ing with an intensity chosen insuchamannerthatthe ls sired moment and hence can be effected in the su- temperature of the raw materials is increased by 1 0°C permarket, but also in the consumer's home without or more. any problems. The present invention will now be described, by According to a further elaboration of the present way of example, with reference to the accompanying invention, at least for certain types of bread products, drawings, in which: 20 the quality of the end product is further enhanced by Fig. 1 is a flow sheet illustrating a known bread imparting to the dough an excess of baking value, preparation process without interrupted proof- which as used herein means the capacity of a flour ing; or meal to produce good-quality dough in terms of the Fig. 2 is a flow sheet illustrating a known bread way in which the meal reacts to the baking process. preparation process with interrupted proofing; 25 A first possibility therefor is the use of a much and better flour quality than conventional. The flour may Fig. 3 is a flow sheet illustrating a method accord- be of rusk quality (strong flour) and, if desired, may ing to the present invention. have been fortified with wheat gluten flour. Fig. 1 is a flow sheet showing a normal bread Furthermore, preferably a high kneading intensi- preparation process without interruption. At 1 the 30 ty is used which is in the order of 160% or more of the dough, made from the desired ingredients and con- normal kneading intensity. The temperature rise of taining yeast, is kneaded. At 2 pre-proofing takes the raw materials is then 10°C or more. place, at 3 preshaping, at 4 intermediate proofing and According to experiments, a good end result is at 5 shaping. During shaping, the doughpieces are enhanced by adding alcohol during the dough prepa- brought into the final shape, with or without the use 35 ration, as indicated with an arrow 12 in Fig. 3. Alcohol of pans. At 6 the final proofing or pan proofing takes of a purity of 98% can be added during the kneading place and at 7 the bread product is baked. step, e.g. in a quantity in the order of 1 to 5%, prefer- According to the method illustrated in Fig. 2, the ably 2% of the weight of the flour used for the prep- process is interrupted after shaping (step 5), because aration of the dough. the doughpieces formed are cooled to a temperature 40 Another measure preferably taken is extreme de- substantially below 0°C, e.g. by freezing. The freezing gassing during the shaping phase. As a result, a finer step is shown diagrammatically in Fig. 2 with a block distribution of carbon dioxide gas in the dough is ob- 8 and the defrosting step with a block 9. tained. A process in which, prior to the final proofing Degassing may be effected e.g. by rolling out the step, the doughpieces are frozen for them to be 45 dough tothin slices, e.g. thinnerthan normal by afac- baked later, mostly in a different place, is called a torof two. Alternatively, during the kneading step, gas bake-off process. An additional advantage of the inclusions could be avoided by kneading in a partial bake-off process is that the bread can be baked in the vacuum. shop itself, which is attractive for the consumer. How- By using an adapted yeast strain, a good end re- ever, a drawback is the long duration of the bake-off 50 suit can be promoted. Suitable yeast strains are those process, including defrosting, so that accurate plan- used in the bake-off process for use in deep-freeze ning is required and bread cannot be baked in the dough. Moreover, a high yeast percentage is prefer- shop without more ado at any point of time of the day. ably used, e.g. in the order of 6-10% of the flour In that case too, no allowance can be made, in fact, weight, instead of the normally employed percentage for short-term variations in the demand for bread 55 of about 2%. In that case, preferably a relatively low products. Moreover, the known bake-off process nec- dough temperature is used, e.g., in the range of 16- essitates a defrosting cell in which a temperature of 24°C, but preferably between 18 and 22°C. 0°C prevails. Quicker defrosting results in an inferior For certain products, such as a big loaf, the 3 5 EP 0 384 539 B1 6 dough can be frozen in a pan wherein the product can 2. A method as claimed in claim 1 , characterized in be directly baked later. that alcohol having a purity of 98% is added in a Freezing is effected at a relatively high tempera- quantity in the order of 1 to 5% of the weight of ture. In general, foodstuffs should be frozen as quick- the quantity of flour used for the preparation of ly as possible, To that end, mostly the freezing tem- 5 the dough. perature is -80°C. Dough does not allow this, inas- much as it would destroy the yeast cells present at or 3. A method as claimed in claim 2, characterized in near the exterior of the doughpieces. Therefore, in that alcohol is added in a quantity in the order of the process according to the present invention, the 2% of the weight of the quantity of flour. dough is frozen at the relatively high temperature of 10 e.g. about -30 to -40°C. It is observed in this connec- 4. A method as claimed in anyone of the preceding tion that it has been established experimentally that claims, characterized in that as the doughpieces at a still higher freezing temperature, of e.g. about -12 are being shaped, the dough is degassed ex- to -18°C, the keeping qualities of the frozen product tremely. are increased. 15 When one or more lengths of wet string are 5. A method as claimed in claim 4, characterized in placed over the frozen doughpieces, and the dough- that degassing of the dough is promoted by roll- pieces are subsequently baked off in an oven, this ing out the dough to relatively thin slices. has a favourable effect on the course of the baking process, while at the same time the bread obtains an 20 6. A method as claimed in any one of the preceding attractive appearance. At the location of the strings, claims, characterized in that gas inclusion in the crust formation during the baking process is retarded. dough is prevented by kneading in a partial-va- As a result, steam developed in the bread during the cuum space. baking process can escape at the location of the strings. 25 7. A method as claimed in any one of the preceding It is observed that in view of the above, various claims, characterized in that a yeast percentage modifications will readily occur to those skilled in the in the order of 6 to 10% calculated on the flour art. For instance, the above described additional weight is used. steps for improving the quality of the product can be used each separately or in combination with any or all 30 8. A method as claimed in any one of the preceding of the other features described. It is also possible claims, characterized in that freezing is per- sometimes to employ certain steps to a lesser degree formed while the dough is in a baking tin. than indicated, without this resulting in an end product of insufficient quality. Besides, compensation of 9. A method as claimed in anyone of the preceding one step by another is possible. It is for instance con- 35 claims, characterized in that flour of high quality, ceivable to use a yeast percentage of 5-7% with or of the rusk flour type, is used. without a higher kneading intensity than indicated. Also, a lower yeast percentage than indicated can be 10. A method as claimed in anyone of the preceding compensated by using for instance a special yeast claims, characterized in that flour fortified with strain. 40 wheat gluten flour is used. Similarly, a kneading intensity slightly lower than e.g. 160% of the conventional kneading intensity 11. Amethod of preparing bread products, character- might be compensated by a higher yeast percentage. ized in that frozen pieces of bread dough prepared according to any one of the preceding 45 claims are placed in an oven without prior defrost- Claims ing and baked off.

1. A method of preparing frozen pieces of bread 12. Amethod as claimed in claim 1 1 , characterized in dough, in which dough is kneaded, and subse- that a length of wet string is placed over the froz- quently entirely shaped and proofed doughpieces 50 en doughpiece in one or more places before the are prepared and frozen, which pieces of bread frozen dough piece is placed in the oven. dough can be stored in a freezer for some time and subsequently placed from the freezer without defrosting step in an oven and be baked off, char- Patentanspruche acterized in that alcohol is added during kneading 55 with an intensity chosen in such a manner that 1. Verfahren zur Herstellung tiefgekuhlter Stucke the temperature of the raw materials is increased Brotteig, bei dem der Teig geknetet wird und da- by 1 0°C or more. nach vollstandig geformte und aufgegangene 4 EP 0 384 539 B1

Teigstucke hergestellt und tiefgekuhlt werden, 11. Verfahren zur Herstellung von Brotprodukten, da- wobei der Brotteig einige Zeit in einem Tiefkuhl- durch gekennzeichnet, dali tiefgekuhlte Stucke schrank gelagert werden kann und danach aus von Brotteig, die nach irgendeinem dervorherge- dem Tiefkuhlschrank ohne Auftauschritt in einen henden Anspruche hergestellt sind, in einen Ofen Ofen gelegt und abgebacken wird, dadurch ge- 5 ohne vorhergehendes Auf tauen gelegt und abge- kennzeichnet, dali Alkohol wahrend des Knetens backen werden. mit einer so gewahlten Intensitat, dali die Tempe- ratur des Rohmaterials urn 10 °C oder mehr ge- 12. Verfahren nach Anspruch 11, dadurch gekenn- steigert wird, zugefugt wird. zeichnet, dali eine Bahn feuchter Bander uber 10 das tiefgekuhlte Teigstuck an einer oder mehre- 2. Verfahren nach Anspruch 1, dadurch gekenn- ren Stellen gelegt ist, bevor das tiefgefrorene zeichnet, dali Alkohol miteiner Reinheitvon 98% Teigstuck in den Ofen gelegt wird. in einer Menge zugefugt ist, die in der Grolienord- nung von 1 bis 5 Gew.-% der Menge des Mehls liegt, das fur die Herstellung desTeigs verwendet 15 Revendications wird. 1 . Procede pour preparer des morceaux congeles 3. Verfahren nach Anspruch 2, dadurch gekenn- de pate a pain, dans lequel on petrit la pate et on zeichnet, dali Alkohol in einer Menge in der Gro- prepare et congele ensuite des morceaux de pate lienordnung von 2 Gew.-% der Menge des Mehls 20 ou patons entierement mis en forme et eprouves, zugefugt ist. ces morceaux de pate a pain pouvant etre stockes dans un congelateur pendant un certain 4. Verfahren nach irgendeinem der vorhergehen- temps et places ensuite hors du congelateur sans den Anspruche, dadurch gekennzeichnet, dali etape de decongelation dans un four et etre cuits, bei der Formung der Teigstucke der Teig stark 25 caracterise en ce que Ton ajoute de I'alcool pen- entgast wird. dant le petrissage dans une mesure choisie de maniere telle que la temperature des matieres 5. Verfahren nach Anspruch 4, dadurch gekenn- brutes augmente de 10°C ou plus. zeichnet, dali das Entgasen des Teigs durch Aus- rollen des Teigs in verhaltnismaliig dunne Schei- 30 2. Procede selon la revendication 1, caracterise en ben gefordert wird. ce que Ton ajoute de I'alcool ayant une purete de 98 % en une quantite de I'ordre de 1 a 5 % en 6. Verfahren nach irgendeinem der vorhergehen- poids de la quantite de farine utilisee pour la pre- den Anspruche, dadurch gekennzeichnet, dali paration de la pate. Gaseinschlusse in dem Teig durch Kneten in ei- 35 nem Teilvakuumraum vermieden werden. 3. Procede selon la revendication 2, caracterise en ce que Ton ajoute de I'alcool en une quantite de 7. Verfahren nach irgendeinem der vorhergehen- I'ordre de 2 % en poids de la quantite de farine. den Anspruche, dadurch gekennzeichnet, dali ein Hefeprozentsatz in der Grolienordnung von 6 40 4. Procede selon I'une quelconque des revendica- bis 10%, berechnet nach dem Mehlgewicht, ver- tions precedentes, caracterise en ce que pendant wendet wird. que Ton met en forme les morceaux de pate, la pate est degazee dans une mesure considerable. 8. Verfahren nach irgendeinem der vorhergehen- den Anspruche, dadurch gekennzeichnet, dali 45 5. Procede selon la revendication 4, caracterise en das Tiefkuhlen durchgefuhrt wird, wahrend der ce que Ton favorise le degazage de la pate en eta- Teig sich in einer Backform bef indet. lant celle-ci au rouleau de maniere a obtenir des tranches relativement minces. 9. Verfahren nach irgendeinem der vorhergehen- den Anspruche, dadurch gekennzeichnet, dali so 6. Procede selon I'une quelconque des revendica- Mehl von hoher Qualitat, vom Typ Semmelmehl, tions precedentes, caracterise en ce que Ton em- verwendet wird. peche I'inclusion de gaz dans la pate par petrissage dans un espace sous vide partiel. 10. Verfahren nach irgendeinem der vorhergehen- den Anspruche, dadurch gekennzeichnet, dali 55 7. Procede selon I'une quelconque des revendica- Mehl, das mit Weizen-Gluten verstarkt ist, ver- tions precedentes, caracterise en ce que Ton uti- wendet wird. lise un pourcentage de levure de I'ordre de 6 a 10 % calcule sur le poids de la farine. 5 9 EP 0 384 539 B1 10

8. Procede selon I'une quelconque des revendications precedentes, caracterise en ce que Ton ef- fectue la congelation pendant que la pate se trou- ve dans un bol de cuisson. 5 9. Procede selon I'une quelconque des revendications precedentes, caracterise en ce que Ton uti- lise une farine de haute qualite du type farine pour biscottes. 10 10. Procede selon I'une quelconque des revendications precedentes, caracterise en ce que Ton uti- lise une farine fortif iee avec une farine de gluten de ble. 15 11. Procede de preparation de produits de panifica- tion, caracterise en ce que Ton place dans un four sans decongelation prealable les morceaux congeles de pate a pain prepares selon I'une quelconque des revendications precedentes et 20 on les cuit.

12. Procede selon la revendication 1 1 , caracterise en ce que Ton place une longueur de cordon humide sur le morceau de pate congelee en un ou plu- 25 sieurs endroits avant de placer le morceau de pate congele dans le four.

6 EP 0 384 539 B1

intermediate! final fermentation rounding moulding baking mixing in bulk proof I proof

FIG. 1

bake-off r * -a 4 6 7 1 1 / fermentation intermediate! final rounding moulding _^ baki mixing in bulk proof I proof

8- freezing »* thawing

FIG. 2

L fermentation intermediate! final rounding moulding baking mixing in bulk proof f proof

'12 10- Ifreezingh

FIG. 3