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UNIT7 VARIETYBREADS

Structure 7.0 Objectives 7.1 Introduction 7.2 Whole 7.3 BrOWI1Bread 7.4 Flat Bread

7.5 High Fiber Bread 7.6 Multi Grain Bread 7.7 and Rolls 7.8 Let Us Sum Up 7.9 KeyWords 7.10 Answers to Check Your Progress Exercises 7.11 Some Useful References 7.0 OBJECTIVES

After reading this unit you would be able to: • understand the differences among the variety of other than routinely prepared , bread etc. • explain the basic requirements of different varieties of nontraditional breads. • gain basic knowledge about the non-traditional variety breads. 7.1 INTRODUCTION One of the needs for the sustainable growth of industry isto produce different varieties of bakery products. Varieties of bakery products having different taste and texture provide wide choice to consumers which in turn increases the turn over, resulting into faster growth of the industry. Hence varieties of breads are being produced worldwide. These varieties are produced either by (i) adding new ingredients (ii) changing their preparation of ingredients (iii) changing the processing conditions (iv) altering shape and size etc. It is known that just by changing shape and size, 200 varieties of breads are produced in . In contrastto tbis very limited varieties of breads are available to Indian bakery consumers. Hence, there is ample scope to diversify, by producing varieties of bread keeping in mind palate ofIndian consumers; This in turn would expand the market, resulting into growth ofthe Indian industry. Some of the varieties of breads which could be popularized in India are: • • • Flat bread • High fiber bread • Multi grain bread 20 • Buns and rolls Variety Breads 7.2 WHOLEWHEATBREAD It is very well known that whole-wheat (100% extraction) is nutritionally much superior to commonly used white flour (72% extraction). During production of white flour (refined ), germ and portions of wheat grain get removed. In wheat the majority ofB-group vitamins and minerals are found located in bran and germ. As these two (germ and bran) parts of wheat grain get removed, the nutritive value of refined wheat flour reduces. In view of greater demand for whole-some nutritious products, whole wheat bread is the ready answer. The bread made from whole-wheat flour is not only more nutritious but also has typical pleasant wheatish aroma. Whole-wheat flour contains the wheat germ and bran. Since most of the in the germ is polyunsaturated, the shelflife of whole-wheat flour depends on the storage conditions. Warm and high humid storage conditions promote rancidity, developing a bitter taste with time. Therefore, must not on ly avoid overstocking, but must also watch that oldest wheat flour must be used first. Among the different type ofrnills, hammer type mill has been found to be more suitable for grinding of wheat into whole-wheat flour. Finer the particles offlour better the quality of bread. While finalizing the recipe of whole wheat bread the bakers are required to keep following points in mind. • Whole-wheat flour requires more water to prepare . This dough should be slightly softer. It stiffens slightly during fermentation because of bran in it. • Whole-wheat flour requires shorter fermentation time of 1to 1.5 hour, because dough ripens quickly by enzymes from aleurone layers. Proteolytic action may be greater iffermentation is longer. This weakens the dough. The gluten in this dough is not as strong as that in white bread, and over fermentation will cause tearing of gluten with a loss in volume. • Higher amounts of oxidants such as Azodicarbonamide and Ascorbic acid improve the quality of whole wheat bread. • The coarse ground whole wheat needs more time to hydrate than the finely ground flour. • The finely ground whole wheat flour performs more like white flour than the coarse whole wheat , thus produce larger loaf volumes with the same amount of vital wheat gluten added to the dough. Medium and coarse whole- wheat flour requires about 5% wheat gluten for sufficient loaf volume. Fine whole wheat flour will produce the same loaf volume with only 3% wheat gluten and with 3 to 4% extra water. • Use enough dusting flour to prevent the dough from sticking or tearing during makeup. • Whole wheat flour dough lack cohesiveness and tend to tear during sheeting operation therefore, sheeting rolls should be more open for whole wheat compared to dough for wh ite pan breads. • Give the bread o/.s th proofbefore baking • Allow a small amount of steam to enter the before loading the bread and continue the steam until the over spring has been completed and the crust starts to show signs of colour. • Bake at215°C or215°C (4200P) for slightly longer than white bread. • Remove from the tins (depaning) immediately on withdrawal from the oven to

avoid sweating. 21 Fundamentals of Typical whole wheat bread formulations for (A) Method and Bread Making .(B) No-Time Dough Method are given below .

. (A) Sponge and Dough Formula for whole wheat bread:

Ingredient Bakers Remarks Percent (i) Sponge Whole wheat flour 65 Sponge temperature (74-77 OF)23.5°C to 25°C Vital wheat gluten 5 Fermentation time 3.5 to 4 hours at (84°F) 29°C Mineral food 0.5 Sodium Stearoyl Lactylate 0.5 Compressed yeast 2.5 Ascorbic acid 90ppm water 43 (ii) Dough

Whole wheat flour 30 Dough temperature (78-80°F) 25.6°C to 26.7°C Brown 8 Floor time 10 to 15 minute Milk solid non fat 2 2 Shortening/fat 3 Water lice 20 (variable)

(B) No-Time Dough formula for whole wheat bread: Ingredient Bakers Remarks percent Whole wheat flour 95 Mix to full gluten development Vital wheat gluten 5 Dough temperature (82°F) 27.8°C

Brown sugar 8 Milk solid non-fat 2 Salt 2 Sodium Stearoyl Lactylate 0.5 M ineral yeast food 0.5 Shortening/fat 3 Compressed yeast 3.5 Ascorbic acid 90ppm Water/ice 66 22 Variety Breads 7.3 BROWN BREAD

Most bakers have been in the habit of adding a proportion ofwhite flour in whole wheat bread formula with the object of getting a larger loaf having finer crumb structure. Such breads are called brown bread. Brown breads are normally made by using white flour (maida) and whole wheat flour in the ratio of 50: 50. Further extract, brown sugar or caramel are used to get brown colour and to improve the flavour of bread. The processing conditions are the same as whole wheat bread. The volume of brown bread is generally better than whole wheat bread.

Some authors refer brown bread as malted brown bread. Depending upon the proportion of malt inthe bread formulation they classify itas (i) Lightly malted brown bread and (ii) Heavily malted brown bread.

Generally non-diastatic malt extract is used in brown bread

7.4.

Flat breads in America are Arepa, corn and wheat flour torti Has,pizza and many other types of local and ethnic flat breads. The flat breads consumed in includes Baboli, English mufin, , pizza etc. In the countries of North Africa, baladi, Khobz el-daar, kisra, injera and shams are examples of a wide range of such breads that are consumed dai ly,

The , also known as the roti in Northern India, is a flat unleavened baked product. It is widely consumed by population in the Indian subcontinent. There are several culinary variations of the chapatti. The important ones being the parotha, stuffed parotha, tandoori roti, phulka and puri. The other culinary variations include nan, South Indian parotha and roomali roti.

7.4.1 Classification of Flat Breads

Flat breads can be classified into two major groups according to their cross section. a) Single-layered flat bread b) Double-layered flat bread

The single-layered flat breads are sub-classified as : i) Unleavened or chemically leavened single- e.g. Chapati, Parotha, layered flat breads Tortillas Arepa, iI) Leavened single-layered flat breads

The leavened single layered flat breads are again sub-grouped as i) Dough type leavened single-layered such as e.g. Barbari, Nan, Tandoor roti and breads etc. iI) Batter type leavened single-layered flat breads e.g. Dosai, lnjera, Crepe, Pancake etc.

23 Fundamentals of The following figure will give overall view of above classification of flat breads. Bread Making Flat Breads I Single •layered Double la••yered (Leavened; Sour doubh yeast) + + e.g. Arabic (Pita) Baladi Leavened Unleavened ( or yeast) or chemically leavened e.g. Chapati, Parotha, Tortillas, Arepa

Dough type Batter type e.g. , Tandoor, e.g. Dosai, lnjera, Barbari, , etc. Pancake, Crepe etc.

7.4.2 Methods of Production of Flat Breads

The methods of production for the varieties of flat breads popular in Indian subcontinent are described hereafter

7.4.2.1 Chapati

The method for preparation of chap atis involves three important steps, viz., i) Preparation of Dough ii) Sheeting iii) Baking-cum-puffmg

The main ingredients used in are whole-wheat flour or resultant atta and water. The water level varies from 65 to 75%, depending on the type of wheat and the milling method.

In households, and even inrestaurants, the dough is kneaded by hand to a consistency that is stiffer than bread dough. In large canteens suitable mechanization is followed in dough preparation. The dough is mixed for complete development of gluten. It is then, given rest for a period ranging from 30 to 120 minutes. Th is resting is necessary for proper hydration and for stress relaxation. Which enableseasy sheeting with minimal stickiness?

The dough is then divided into pieces weighing around 35-40 g and then rounded. The rounded dough piece is sheeted to a circular shape of about 15 centimeter in diameter and 1.5-2.0 mm in thickness. Dusting with flour is done to reduce the .stickiness. The sheeted round shape dough is then baked on each side on a heated shallow iron plate (200-220 QC)for a total time of 1-2 minutes. For getting a puffed product the surface ofthe chapati is gently pressed with a clean dry cloth during final stages of baking of the second side ofthe chapati. Alternatively, puffing can also be done by placing the chapati immediately after baking on a gas flame or live glowing coals for few seconds. The hot chapati is served either as such or after smearing the surface with fat, preferably ghee or butter. 24 Sheeting of dough with the use of a rolling pin, requires experienced persons to produce the uniform chapati. Secondly it is atime consuming job. Now a day's suitable mechanization for like, chapati press, roller press, rotary cutters; roti maker etc. could be used for large scale production of chapatis. 7.4.2.2 Phulka

The ingredients and method of preparation for phulka are similar to those of chapatis. Here more water is used in dough preparation. Secondly around 0.5% salt and 4-6% oil is used in the dough preparation. This-helps in sheeting the dough very thinly (0.8-1.0 mm thick circular shape of about 8-12 cm in diameter). The resulting phulka will have a softer texture, and it remains mold free for about 5-6 days; due to presence of salt and oil in it.

7.4.2.3 Puri Puri is a deep-fat fried product. Here whole-wheat flour of85-90% extraction rate is used. Flour is rubbed with oil and then dough is prepared by flour and water. Dough is divided into pieces of20-30g and rounded. The rounded dough is sheeted to a thickness of 1.5-2 mm and a diameter of 10-12 cm using a rolling pin or chapati press. It is then deep fat fried in oil maintained at 180-200 QCfor about one min. with intermittent turning. During frying intermittent pressing of puri with a perforated ladle improves puffing. The fried puri isthen removed from oil bath and served hot. " .

7.4.2:4 Parotha The dough for parotha is made by rubbing fat (2-5%) into whole-wheat flour, then salt and water (65-70%) is added and a stiff dough is prepared. It is then divided into piecesof35-45 g and sheeted to circular shape of 10 cm-diameter. Then oil (1- 2g) is applied on top surface and folded in to a semicircle, and oil isagain uniformly applied over the surface. The semicircle is then folded into a quarter circle. This laminated piece of dough (the quarter shaped) is then sheeted into the shape of a triangle having thickness of2-3 mm and sides of 15-18 cm in length. It isthen baked on a heated shallow iron plate or on electric hot plate, forabout 1-2 min until the colour become light brown. Oil is applied to both sides while baking. 7.4.2.5 Stuffed Parotha

Stuffed parotha are parotha-having filling with vegetables, & spices.

The dough of stuffed parothas is prepared in the same manner as like for parothas. A typical parotha filling includes:

Boiled, peeled mashed potato 100g Chopped onion 25 g Salt 1 g Green Chillies (crushed) 5g or Red chilly powder . 0.5 g Black 'pepper powder . As desired Green (crushed) leaves As desired Fundamentals of The above ingredients are mixed well and slightly loose vegetable mixture is Bread Making prepared. A portion (about 20 g) of this vegetable is placed on the center of the sheeted parothadough (5 cm diameter). The dough is folded Over this vegetable filling to make a dough ball. The dough ball is then sheeted into a circular shape (12-15 cm. diameter). It is then baked on a hotplate by smearing oil, butter or ghee to both side. Theingredients ofthe above filling could be changed depending upon the availability of vegetables and preferences of consumers e.g. Radish, carrots, cauliflower, fenugreek leaves etc.

Spicy parothas without filling are prepared by mixing mashed spiced vegetables in the dough itself. Then it is sheeted and parothas are prepared in the normal manner. 7.4.2.6 Roomali Roti

Maida (refined wheat flour), milk or milk powder, fat, salt and water are used for preparing dough for Roomali Roti, The chapati like loose dough is prepared and rested for 30-60 min. A dough ball of 100-200 g is prepared. It is pressed and then stretched through fingers. Stretching with fingers iscontinued to get a very transparent sheet of 0.5-0:8 mm thickness and a diameter of 60-90 cm. This transparent dough sheet is then placed on a heated (350-360 0C) inverted shallow iron plate and baked for 60-90 seconds. The baked roomali roti is smeared with ghee and then it is folded into cylindrical shape. It is cut into 5-7 cm pieces and served hot. 7.4.2.7 Tandoor Roti

The dough for Tandoor Roti is prepared as like the dough for chapati, using whole- wheat flour or refined wheat flour, salt, and water. A dough ball of 40-60 g is prepared. It isthen flattened by beating and pressing between the palm to a thickness of 4-6 mm and a diameter of 15-18 cm. It is then placed on a wet cloth pad and pasted to the heated walls of the tandoor oven (The tandoor oven is a hollow drum having inner sides plastered with clay. It is heated prior to use by burning wood or coal in the bottom) Upon completion of baking (60-90 seconds depending on the temperatureof the tandoor oven), the Tandoor roti separates from the side of the wall and falls on the bottom. It is then taken out, using a long L-shaped iron rod. The freshly baked Tandoor Roti is smeared with ghee or butter and served hot. 7.4.2.8 Nan

The dough for Nan is prepared using refined wheat flour i.e. maida (100 g), milk (6 g), curd ( 12 g), salt (1 g), baking soda (0.5 g), fat (4 g), egg (3 g) and water (50- 60 g). Smooth dough is prepared and allowed to ferment for 3-4 hours. 80 g of fermented dough is sheeted to a thickness of2.5 mm using a rolling pin. It is then baked in a Tandoor oven maintained at 350-365 QCfor 60 seconds. It is served hot after applying ghee if desired.

7.5 HIGH-FIBERBREAD \, In view of nutritional advantages of dietary fibers in rt(d~~ing diet related diseases, more and more emphasis is given to bread with high~. Dietary fibers are not digested in human body and thus do not contribute any energy. However fibers in the diet reduces the risk of some cancers and contribute beneficial effect on diseases like heat diseases and diabetes. The food items contain two types offibers viz. insoluble and soluble fibers. The insoluble fibers from wheat bran, cellular materials, oat hulls etc. reduce the risk of some colon cancers. The soluble fibers such as 26 those present in vegetable gums (gum arabic, gum karaya, gum tragacanth etc.), Variety Breads microbial gums, marine products (Alginates, t\gar, Carrageenan etc.) and Pectin (in fruits) have therapeutic value for diseases like diabetes and heart diseases. Fibers in general give reliefin problem of constipation.

Some bakers add a high content of dietary fiber in bread. As fiber does not contribute any calories, such high fiber breads are some time advertised as "Calorie reduced breads". To claim this there must be at least:' 5% reduction in calorie ofthe product as compared to standard reference product.

Bakers are now able to choose various fiber ir-gredients containing varying levels of fiber content. There are various types of fiber ingredients such as: i) Bran fiber :

Wheat bran bran Corn bran

Oat bran

Soy bran ii) Cell wall material:

Fruits and citrus fibers

Pea fiber iii) Seed material: Guarflour Locust bean flour iv) Tree extrudates: Gumarabic Gum karaya Gum tragacanth v) Microbial gums: Xanthan vi) Marine products: Agar Alginates Carageenan vii) Cellular products : Carboxy Methyl Cellulose (Ci\1C)

Micro crystaline cellulose (MeC) viii) Psy.lliumseed husk (lsabgol husk) 27 Fundamentals of Before a chooses a fiber ingredient, he is required to conduct pilot baking Bread Making trials; so as to get acceptable product.

When these are used at significant levels (5% or more) they influence loaf volume and some other bread characteristics. The magnitude of effect varies with the type and amountoffiber ingredient used.

In general all fiber ingredients absorb more water thus requires use of more water while preparation of bread dough.

To overcome the problem of reduction in volume of high fiber breads some bakers add vital wheat gluten and a 0.5 to 1 % gum in such breads. Some fibers require longer time to hydrate properly. They give specked appearance to crust and crumb. Such ingredients could be added at sponge stage (to provide longer time for hydration) instead of at the dough stage.

Most of gums contain 70 to 85% soluble fiber. In spite oftheir high dietary fiber content theses alone are not suitable for reducing the calorie content in bread because, they are used at very low level (0.5 to 1% ofthe flour weight). Even though at low levels of their use along with the other fiber ingredients (bran fiber, cell wall material) may increase the loafvolume of high fiber bread. ~Use ofhigh levels of gum may lead to higher oven spring followed by shrinkage. High levels of gums change the rheology ofdoughs. The dough becomes stiff and require more water. Such dough become moist and sticky and thus are difficult to process.

Use of sponge dough method and incorporating surfactants like sodium stearoyl lactylate improve the quality of bread. Higher levels of oxidants and yeast (to shorten fermentation time) further improve the bread qualities. (soften the texture).

The high fiber bread dough requires more water as compared to white pan bread. Therefore, such bread should be baked slightly longer, and at a lower temperature than white pan bread.

A typical "High fiber bread" recipe is outlined below:

Ingredients Bakers percent

(a) Sponge: Flour 70 Wheat Gluten 8 Mineral yeast food 0.5 Compressed yeast (Fresh/Wet yeast) 2.8 Water 80% of sponge flour High Fiber ingredients 5%

Note: Sponge temperature (74-78°F) 23.5°C- 25.6°C and Fermentation time 3-4 hours

(b) Dough: Flour 30 Sugar 6 Salt 2 Gum 0.5 to 1% 28 Sodium Stearoyallactylate 0.3 Variety Breads Glycerol monostearate 0.2 Ascorbic acid 90-100 ppm Water As required Note: • Mix dough at (78-80 OF)25 .6°C- 26.7°C with full gluten. development • Give floor time of 10-15 minutes • Proofat (1 10°F) 43.3°C for 55 to 60 minutes

• Bake at (425°F) 218°C • Depan immediately after unloading from oven to avoid sweating and cool it. 7.6 MULTIGRAINBREAD

In white bread only flour from wheat grain is used. Whereas, the "" contain in addition to flour (wheat) other grain components (flour, grits, meal etc.) Some of the grain components used in multi-grain bread are mentioned below: • Barley (milled) • Corn (milled) • Flaxseed (milled form) • Millet (hulled) • Oat (milled) • Poppy seeds (whole) • Rye (milled) • (whole) • Triticle(milled) • Sunflower seed (Hulled) In USA most of the bakers prefer to use commercially available multi grain mixes. The baker may opt to prepare and use a unique blend of various grains. In general, the multi grain breads contain 20 to 30 % non-wheat grain flour and 70 to 80% wheat flour. The wheat flour (maida) contains gluten-forming proteins (glutenin and gliadin) which contributes loaf volume. The non-wheat grain components do not contain gluten and hence their addition in bread reduces volume of the bread. To overcome this problem 3 to 5% vital wheat gluten is used in multi-grain breads. The multi-grain breads are generally dense as whole wheat breads andhence their pan size must be smaller than the traditional pans used for white bread of same weight. In contrast to this, while baking such multi-grain breads in routinely used bread pans, the scaling .weight is increased. Such breads are baked at lower temperature for slightly longer time than that followed for white bread. The grits/mealst coarse ingredients) are blended with water for 5 minutes and allowed to soak for 6-8 hours. The dough is then mixed with other ingredients. The dough is given 30 minutes floortime and baked at 205°C (400°F) for 25-30 minutes. 29 Fundamentals of Bread Making 7.7 BUNS AND ROLLS

7.7.1 Buns Buns dough normally contains more sugar, fat and water than normal bread doughs. As these are baked on flat baking trays, strong flour is preferred so as to retain shape. The quality of flour required is similar to that required for bread.

The formulas for the preparation of differ widely from baker to baker; however regular bread dough could be used to make buns. The popularly known and Hot Dog Buns formulations require some changes compared to white pan bread. Some of these are listed below. 1. Flour with slightly higher protein is preferred. In case oflow protein flour vital wheat gluten could be used to meet this requirement. 2. Increase sugar and fat and thus this formula become richer compared to white pan bread. 3. Increase yeast. The yeast activity reduces in rich formula dough and hence more yeast requirement. 4. Slight increase in crumb softeners. The buns and rolls being smaller in size,they dry at faster rate than breads. Secondly to make them softer, it is necessary to increase crumb softness such as Glycerol mono stearate. 5. Slight decrease in water. This is necessary to ease the make up process. 6. Keep floor time to a minimum. Make up of Hamburger Buns Divide the fermented dough into pieces of desired weight (60 to 100 g). Separate each dough piece by dusting very lightly with flour. Takeone unit inthe palm of each hand. Press down gently and move the hand in circular motion. The right hand moves clockwise and the left counterclockwise. Keep the units enclosed in the palm ofthe hand until round. Use dusting flour if the unit sticks to palm and round the unit until it get smooth surface. Then, place it on baking tray 2-3 inches apart, proofit and bake it.

In case of mechanical bun rounding, the dough of desired weight is placed in the tray of divider cum rounder. The mechanical rounding produces buns with uniform round shape.

7.7:2 Rolls

Rolls are delightful parts of meals. Their attractive shapes provide enjoyment while eating. Some bakers divide rolls into three categories (i) rolls (ii) Dinner rolls and (iii) Tea rolls. The breakfast rolls should be unsweetened and not heavily enriched. These are enjoyed withjam, marmalade or honey. The dinner rolls should be of the Vienna type crisp; so that they can be broken and enjoyed with soup vegetables or meat products.

The tea rolls are ideal for buffet purposes. These are prepared from rich formulas using egg, fat and milk products. 30 Rolls belong to hearth type breads strong wheat flour is required because the rolls Variety Breads should retain the shape during proofing and subsequent baking.

Typical formulas for hard and soft rolls are mentioned below;

Ingredients (%) Variety Hard Rolls Soft Rolls

Flour 100 100

Water 50-60 60-65

Compressed yeast 1-3 2-4.5

~ineralyeastfood 0-0.5 0-0.75

Salt 1.5-2.25 1.75-2.5

Sugar 0-4 6-16

Fat 0.5-5 5-10

Milk solids 0-6 0-6

Malt 0-2 0-2

Calcium propionate 0-0.35 0-0.35

Bromatesl Ascorbic acid 20-50 ppm 20-50 ppm

The general steps followed for Hamburger and hot dog buns and bread rolls are outlined below. These steps are almost similar to bread production.

1. Mixing

Mix dough to high degree of extensibility to make it soft, shiny and very pliable. This improves the scaling rounding and moulding operations Dough temperature should be cool to normal.

Generally followed dough temperature could be 24.5°C-26. 7°C (76 to 80°F). Too high a temperature will cause dough to ferment too rapidly and yield products with sour or yeasty taste. On the other hand, in case of cool dough, it produces heavy and tough product as these are baked in open trays.

2. Fermentation

The fermentation time needed depends upon the amount of yeast and richness of the formula. Higher sugar level decreases yeast activity, thus requires longer fermentation time for proper ripening of the dough.

3. Scaling and shaping

Accurate scaling of dough and skilled manipulation of it is required for forming variety of shapes. The seal ing weight could he 40 to 60 g per piece. Make up of constitute major step in production The variety of shapes possible with soft and hard rolls is almost endless.

Some ofthe shapes that are given to bread rol.s are summarized below:.

Rounded rolls

Here the divided dough piece is moulded into a round shape. It may be given a single cut after proofing. 31 Fundamentals of Batons Bread Making The rounded dough piece is moulded in a sim ilar manner to a Swiss bun. It may be baked uncut or after giving a series of oblique cuts. Suitable dusting with flour after wash ing and before proofing provides excellent effect and added flavour. Points Points is a product prepared after moulding the rounded dough piece into long cylindrical shape. It has rounded points at both ends. Knots Here the rounded dough piece is moulded to get a shape like rope of about 20-22 cm length. Then it is folded into a knot shape. Here single knot is given. Double knots These are similar to single knot rolls. Here dough piece is moulded to get 25-30 cm length. Then it is folded into double strands. Snail rolls Here the rounded dough piece is moulded into rope shape of about 20-22 cm length. Then it is folded into snail shape. There are numbers of shapes which are given to bread rolls e.g. Owl-eye shape, Braiding shape, S-shape, 8 shape, shape etc. 4. Proofing Since buns and rolls we considerably smaller in size thanbread proofing time and conditions am very critical. Therolls should be proofed until about doubled in volume from make-up size. Over proofing may cause blisters on the surface or flatten during Q baking. Proofing is generally done at 43.3-46 C (110° to lIS OF)temperature and 90-95 % relative humidity for 40 to 60 minutes. Too low relative humidity during proofing will produce ball shaped dough piece and too high relative humidity will produce white spots on the crust. 5. Baking

Baking temperature could. be between 224 QC-24 IQC(435 to 465 OF),depending on richness of formula and it requires 7,to 10 minutes baking time. Short time baking aids shelf life, especially lesser moisture loss during baking. Brown Nserve Rolls is a product, which is particularly baked, to the point when the rolls hold their shape but have no (white) crust colour. The partially baked rolls are Q held in refrigerator at 4.5 C (40°F) up to one week. The consumers are required to do second baking at home at the mealtime to establish colour and to serve hot baked rolls. The brown 'N' serve rolls formula contains more mold inhibitors; so as to avoid problem ofmold growth. ' Manyauthors consider health breads as rolls oftypical shape. Hence the basic information about such health breads is summarised hereunder: Although there are wide variety of hearth breads on the market, French, Italian and Vienna breads are the most popular breads. They are normally made by lean formula. True French and Italian breads are made from the basic four ingredients: Flour, Water, Yeast and Salt. The usually contains some shortening, milk and eggs. Some time potato flour is used in Vienna bread dough to soften the bread crumb. 32 Nowadays bakers add shortening and sugar even to the French and Italian breads Variety Breads for extending shelfli fe and to improve eating quality. Thus the only real difference between these three popu lar hearth-baked breads is prirnari ly their make -up and appearance. These hearth breads have had th ick crust, and open texture.

Hearth bread formula has a lower water requirement than white bread. Around 59% water in hearth bread in contrast to 64% water in white bread. A lower water addition in dough will prevent pan flow. Pan flow is not desired in hearth breeds. Because hearth breads are baked without bread pans, the dough piece must retain its shape without much flow. Hearth breads are mixed to a lesser degree to avoid much extensibility. This again prevent unwanted pan flow.

The sheeting rolls for hearth breads must be ooen with a wide gap between them as compared to white pan bread. This is desired as the dough of hearth breads is stiffer. While moulding it requires little dusting to get better seal. Secondly dough piece should be tightly moulded with no seams. A seam on a hearth type product causes bursting of loaf in the oven. Therefore the seems should be down on the pan or screen. The relative humidity for these breads should be lower than the panned product. The lower R.H. will prevent pan flow, unwanted in hearth breads. Too dry a proof box will cause skin formation, which may cause unwanted bursting of bread in the oven. Before load ing into the oven the loaves can be docked or cuts looking to the type of hearth breads viz. Italian, French, Vienna etc. Wash ing with water or egg-water solution can be done to prevent bursting. This is essential while baking in oven in absence of steam. The typical recipe for hearth bread is given below:

Sponge Dough Flour 60-80 Flour 40-20 Water 60 Wheat 55-58 Compressed yeast 1.5 Salt 2.0 Malt 0.5 Sugar 1-3 Fat 0-2 Yeast Optional Malt 0-2

The recipe is low in sugar, fat and milk solids. Sponge fermentation may vary from 3 to 5 hour. Sponge flour also can vary 60-80f~,O.The high protein flour with gluten content ranging from 12-13% is desirable. The dough should be made tight by reducing at least 2% water from the water absorption. Final proofing should be done at lower RH and after proofing docking is done with knife to give weak point for expansion of gas Surface is bru shed with water or egg solution to get glaze. It could be topped with seeds. The French bread is generally shaped into long rnd narrow loaves. The Italian bread is usually made either as a round or as an oblong loaf with pointed ends. This type of 33 Fundamentals of make up yields larger slices suitable for . The make-up of Vienna bread Bread Making is usually in the oblong shape. To prevent wild break, all three types of breads are cut in the top crust prior to loading in oven. The French bread is cut four times diagonally across the loaf. The round shaped Italian loaves receive two parallel cuts across the first two cuts. The oblong shaped Italian loaves are given one off-centered lengthwise cut or are given widthwise three to four straight cuts.

The Vienna bread (oblong shaped with round edge) is also given three or four cuts diagonally across the top. Vienna bread may also be topped with poppy or sesame seeds and no cut is given to such breads.

The Italian bread is baked without steam, which results into thick and dull crust formation. Such thick crust contributes good taste of this bread. In contrast to the Italian breads the French bread and Vienna bread are baked under initial few minutes oflow pressure steam. The steam should be turned into the oven a few minutes prior to baking operation and continue steaming until the loaves are well set. This steaming assures that these bread have a nice bloom and possess crispy crust.

7,.8 LET US SUM UP

Baking isan aIt associated with science. As like cooking, manipulation in formulation and processing conditions alter the overall characteristics of the finished product. Bakers are required to do suitable alterations, looking to the prevailing conditions with an ultimate aim of meeting the requirements of the consumers.

7.9 KEYWORDS Absorption The property offlour to absorb and hold liquid. Bran Skin or outer covering of the wheat grain. Caramelised Sugar Dry sugar heated with constant stirring until melted and dark in colour, used for flavouring and colouring. Crusting Formation of dry crust on surface of dough/product due to evaporation of water from the surface Dough The thickened uncooked mass of combined ingredients for breads, rolls etc. Dusting Distributing a film of flour on pans or product to avoid sticking of dough/product Fermentation The biochemical changes occurring due to action of yeast and bacteria, which produce gas for leavening. 34 Flour Extraction: Proportion of wheat that become flour Variety Breads

Formula In baking a recipe giving ingredients, amounts to be used. and the method of preparing the finished product.

Gluten The elastic protein mass that isformed when the protein material of the wheat flour combines with water.

Hearth The heated baking surface or the floor of an oven Humidity Usually expressed as relative humidity which is an expression of percent of moisture in air related to the total moisture capacity ofthat air at a particular temperature.

Leavening Raising or lightening ofthe bakery product by air, steam or gas

Make-up Manual or mechanical manipulation of dough to provide a desired size and shape

Malt extract A syrupy liquid obtained from malted flour, a product obtained as a res' tit of conversion of starch into sugar' Proofing A process of dough rising between moulding and baking Rounding Shaping of dough pieces into a ball to seal end and prevent bleed and escape of gases ~ Scaling Apportion ing/d ividing dough or better according to unit of desired weight Vienna bread : A hearth-type bread with heavy crisp crust, sometimes finished with seed topping.

Yeast A microorganism which reproduces by budding and causes fermentation and produce carbon dioxide and alcohol.

Check Your Progress Exercise 1 Note: a) Use the spaces given below for your answers. b) Check your answers with those given at the end of the unit.

1. Whole-wheat flour bread contains ------% white flour and ------% whole-wheat flour.

2. Brown bread contains around ------% whole-wheat flour. 3. The finely ground whole wheat flour is preferred to coarse ground whole wheat flour to improve volume of whole wheat bread (Tick the Answer)

a. True ------b. False _

4. Whole wheat doughs have less mixing tolerance

a. True ------

b. False -,------35 Fundamentals of 5. Bran present in whole-wheat flour has a cutting action on dough structure, Bread Making which is responsible for lower volume ofloaf.

a. True ------

b. False ------6. Vital wheat gluten is added in whole wheat bread to improve loaf volume.

a. True ------

b. False ------7. Malt extract, brown sugar and caramel are used in brown bread formulations to improve colour and flavour

a. True ------

b. False ------8. The.pan size for whole wheat bread should be smaller than the pan sizes for white bread.

a. True ------

b. False --~--- 9. As compared to white bread the whole wheat breads and brown breads are baked at lower temperature for longer time

a. True ------

b. False ------10. Steaming is desired for producing good whole wheatlbrown breads

a. True ------

b. False ------Check Your Progress Exercise 2

1. List ingredients used in the preparation of chapati ?

2. List ingredients used in the preparation ofPhulka ?

36 3. Explain the process for preparation ofpuri? Variety Breads

4. Give brief information about preparation ofParotha ?

5. Mention fiber rich ingredients which are used in high fiber bread?

7.10 ANSWERS TO CHECK YOUR PROGRESS EXERCISES

1. 1. 0%,100%

2. 50% 3. True 4. True 5. True 6. True 7. True 8. True 9. True

10. True

2. 1. Whole wheat flour or resultant atta and water 2. Whole wheat flour or resultant atta, water, salt and oil 3. Rub oil in flour, Add water and khead itto prepare dough. Divide dough in to pieces each weighing 20-30 g. Round them. Sheet to 1.5-2 mm thickness and get a circle shape. Do deep fat frying for one min in fat maintained at 180-200 "C.

4. Fat is rubbed in whole-wheat flour. Salt and water is added and dough is prepared. (Parotha dough should be slightly stiffer to chapati dough). It is 37 Fundamentals of divided into pieces of35-45 g and sheeted to a circular shape. Then oil is Bread Making applied on top surface. It is folded into semi circle shape. Oil is applied again and folded into quarter circle shape. This laminated dough piece is sheeted in to triangle shape and baked on heated iron plate or on electric hot plate. Oil is applied on both surfaces while baking.

5. Bran (from wheat, barley, corn, oat, soy), cell wall materials (from fruits; pea etc.), seed material (Guar flour, locust bean flour), Tree extrudes (gum arabic, gum karaya, Gum tragacanth), microbial gum (Xanthan), Marine products (Agar, Alginate, Carageenan) Cellular Products (CMC, MCC), Psyllium seed husk etc.

7.11 SOME USEFUL REFERENCES

I. Anonymous, Baking Science and Technology (A course manual), Pub. by International School of Milling Technology, Department of Flour Milling, Baking and confectionary Technology, Central Food Technological Research Institute, Mysore-5700 13

2. Anonymous, Information Booklet on Baking, Pub. by Wheat Associates USA, New Delhi

3. A. R. David (1953), Bakery Materials and Methods, Pub. Maclaren & sons Ltd., London

4. P. Haridas Rao and R. Sai Manohar (2003), Chapatis and Related Products "Published in Encyclopedia of Food Science and Nutrition) pp 1034-1044. Elsevier Science Ltd.

5. Qarooni J (1996), Flat breads. In: Flat Bread Technology. Ed. Quarooni 1., Chapman & Hall International Thomson Publishing, Newyork.

6. Wilfred lames Fance (1960). Breadmaking and Flour Confectionery, Pub. by Routledge and Kegan Paul.London.

7. W. 1. Fance and B. H. Wragg (1968). Up-Ta-Date Breadmaking, Pub. Maclaren and Sons Ltd, London

8. Wull Doerry (1995), Breadmaking Technoloy - Volume 1, Pub. by Americal Institute & Baking, Manhattam, Kansas"-66502, USA.

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