Baking Problems Solved Related Titles Steamed Breads: Ingredients, Processing and Quality (ISBN: 978-0-08-100715-0) Cereal Grains, 2e (ISBN: 978-0-08-100719-8) Cereal Grains for the Food and Beverage Industries (ISBN: 978-0-85709-413-1) Baking Problems Solved Second Edition Stanley P. Cauvain Woodhead Publishing is an imprint of Elsevier The Officers’ Mess Business Centre, Royston Road, Duxford, CB22 4QH, United Kingdom 50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States The Boulevard, Langford Lane, Kidlington, OX5 1GB, United Kingdom Copyright r 2017 Elsevier Ltd. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions. This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress ISBN: 978-0-08-100765-5 (print) ISBN: 978-0-08-100768-6 (online) For information on all Woodhead Publishing visit our website at https://www.elsevier.com/books-and-journals Publisher: Nikki Levy Acquisition Editor: Rob Sykes Editorial Project Manager: Karen Miller Production Project Manager: Laura Jackson Designer: Vicky Pearson Esser Typeset by MPS Limited, Chennai, India Contents Preface to the First Edition xxxi Preface to the Second Edition xxxiii Woodhead Publishing Series in Food Science, Technology and Nutrition xxxv 1. Introduction to problem solving techniques 1.1 How to problem solve 2 1.1.1 Low-bread volume 3 1.1.2 Keyholing 4 1.2 The record 6 1.3 The analysis 9 1.4 Modelling techniques 12 1.5 Matching patterns and visualising changes 14 1.6 The information sources 16 1.6.1 Personal 17 1.6.2 Written 17 1.6.3 Constructing knowledge trees and knowledge fragments 23 1.6.4 Knowledge (computer)-based systems 26 1.6.5 The ‘Web’ 27 1.7 New product development 27 1.7.1 Concept 28 1.7.2 Product development investigation À prototype product 29 1.7.3 Scale-up to commercialisation assessment 30 1.7.4 Prototype trials on the plant 30 1.7.5 Pre-launch trials 30 1.7.6 Launch 30 1.7.7 On-going product maintenance/handover 31 1.8 Conclusions 31 References 31 2. Raw materials 2.1 Wheat and grains 33 2.1.1 Can you explain the functions of the different compo- nents in the wheat grain and, after milling, their contributions to the manufacture of baked products? 33 2.1.2 We understand that millers often use a mixture of different wheats to manufacture the flours that they supply to us. Can you explain why they do this? 36 v vi Contents 2.1.3 Why are there so many varieties of wheat and how are they classified? 37 2.1.4 We have heard several experienced bakers talking about the ‘new harvest effect’ and the problems that it can cause. Can you explain what is behind this phenomena and how we can mitigate its effects? 39 2.1.5 We are a bakery working with a local farmer and miller to produce a range of local breads and want to use some different varieties and forms of malted grains that we are producing. Can you advise us on any special issues that we should be aware of? 40 2.1.6 Can we mix oats or oat products with our wheat flours to make bakery products? If so, are there any special issues that we should be aware of? 41 2.1.7 What is micronized wheat? 42 2.2 Flours 43 2.2.1 Can you explain what the ash content means and should we ask for it to be determined on our flours? 43 2.2.2 What does the term grade colour figure mean in flour specifications? How is it measured? What are the implications for bread quality? 45 2.2.3 We have the water absorption capacity of our flour assessed regularly but find that this is different to the actual water level that we use in the bakery. What are the reasons for this difference and is it important for breadmaking? 47 2.2.4 What effects will variations in flour protein content have on baked product quality? How is the property measured? 50 2.2.5 There are many references to protein and gluten quality in the technical literature, how important are these properties for bread and other baked products? 52 2.2.6 I have seen that there are several different methods which can be used to assess flour protein quality, which one gives the most meaningful results? 53 2.2.7 We have been using a flour ‘fortified’ with dry gluten for breadmaking. The bread is satisfactory when made on a high-speed mixer but so less when we use a low-speed mixer. What is ‘dry gluten’ and can you explain why we get different results when we change mixers? 55 2.2.8 Why is the protein content of wholemeal bread flour typically higher than that of white flours but the bread volume is commonly smaller with the former? 56 2.2.9 We get a significant variation in the quality of our wholemeal bread and rolls depending on which flour Contents vii we purchase. What characteristics should we look for in a wholemeal flour specification to get more consistent results? 57 2.2.10 What is the Falling Number of a flour, how is it measured and what values should we specify for our flour miller? 58 2.2.11 What is damaged starch in flour? How is it damaged and how is it measured? What is its importance in baking? 59 2.2.12 What characteristics should we specify for white bread flour and why? 61 2.2.13 As enzymes such as alpha-amylase are inactivated by heat during baking, is it possible to use heat treatment of flour to inactivate the enzymes in low Hagberg Falling Number flours before baking? 63 2.2.14 We are considering making traditional German-type rye breads and have researched the recipes and production methods. Do you have any suggestions as to what characteristics we should have in the rye flour? 64 2.2.15 We wish to add non-wheat fibres to some of our baked products to increase their healthiness. What fibres can we used, in what products and what potential technical problems should we be aware of? 65 2.2.16 Why is flour particle size important in cakemaking? 67 2.2.17 What is heat-treated flour and how can it be used? 68 2.2.18 What is chlorinated flour and how is it used? 69 2.2.19 What characteristics should we specify for cake flour? 71 2.2.20 We have had some wholemeal flour in stock for a while and noticed that it has passed its use by date. Can we still use it? And what are there any related issues with white flours? 72 2.2.21 What are the active components in self-raising flour? 73 2.2.22 We have changed suppliers of our self-raising flour and find that we are not achieving the same product volume as before. If we adjust the recipe by adding more baking powder we, find that the products tend towards collapse. Can you explain why and how do we overcome the problems? 74 2.2.23 What are ‘organic’ flours, how do they differ from other flours and what will be the differences to the baked product? 75 2.2.24 What characteristics should we specify for our biscuit and cookie flours? 76 viii Contents 2.3 Fats 77 2.3.1 What are the critical properties of fats for making bread, cakes and pastries? 77 2.3.2 Can you explain the different terms used to describe bakery fats? What are the functionalities of the different forms in baking? 79 2.3.3 Our bread doughs prove satisfactorily but they do not rise in the oven. On some occasions, they may even collapse and blisters form on the dough surface in the corners of the pans. What is the cause of these problems? 81 2.3.4 What is the role of fat in the manufacture of puff pastry? 83 2.3.5 Our puff pastry fails to rise sufficiently even though we believe that we are using the correct level of fat.