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ASB Conference 2014 Getting more out of the dough. V2
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Getting more out of your DOUGH
natural solutions for shelf life extensionand securing food safety
Baking without boundaries
Alister Ong Technical Service Manager DSM Food Specialties
October 29, 2014Melbourne, Australia
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Bread staling remains responsible for huge economic losses to both the baking industry and the consumer
DSM has natural solutions for shelf life extension and securing food safety
Our mission is to create brighter lives for people today and generations to come.
We connect our unique competences in life sciences and materials sciences to create solutions that nourish, protect and improve performance.
27% of world’s edible food wasted• Extension of shelf life• Change life styles with shift to retail
and convenience
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Bread staling is a complex process involving a combination of physical, chemical and sensory changes making the product less acceptable to consumers.
It is a process like aging:
27 72 yrs
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What is Bread staling?• Bread staling can be split up in:
– Crumb firming
– Crust staling (thickening of crust, decrease of crust crispiness)
– Organoleptic staling (loss of fresh bread flavour and increase of off-flavour during shelf-life)
– Growth of spoiling microorganisms
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Which factors are most important for consumer?
– Crumb firmness is the ageing attribute most commonly recognized by the consumer.
• Consumers associate tender, elastic and cohesive crumb that is soft to touch with bread freshness
– Microbial spoilage
• Mold & yeast
The measurement of the increase in crumb firmness is the most widely used indicator of staling.
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Causes of crumb firming • Role of starch retrogradation?• Role of hemicellulose?• Role of lipids?
• Influence of process factors?
• Influence of storage conditions?
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Wheat! our raw material and its composition
Sugars 1 - 2
Non-starch polysaccharides 1 - 3
Proteins 8 - 15
Lipids 1.5 - 3
Minerals 0.5
Water 12 – 15
Starch 65-70
Wheat flour components %
Present in granules:Amylose 25% largely linearAmylopectin 75% branched
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• Starch granules are inert sand-like particles (90%) in dough during the fermentation stage
• Damaged starch (10%) can be hydrolyzed by amylases and consumed by the yeast
• During baking the gelatinization process is taking place, resulting in crumb setting during cooling
• During storage the retrogradation process is taking place resulting in crumb firming
Bread crumb formation and stalingStructure of a starch granule
Role of starch
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- Overview product portfolio
Alpha AmylaseBakeZyme® P 500 BG… our “first in line” solution based on classic fungal -amylase…
Maltogenic AmylaseBakeZyme® MAM 10.000… solution based on maltogenic amylase formulated onmaltodextrins…
Bacteria AmylaseBakeZyme® AN 301… the classic solution for general softness enhancement based on a smart combination of fungal and bacterial -amylase…
Solutions for Softness in Bread
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-amylase hydrolyzes starch to dextrin… – resulting in reduction of viscosity and increase of the
gelatinization temperature improving loaf volume.• …and forms an increasing number of reaction sites for -amylase
Working mechanism fungal –amylaseBakezyme® P500 BG
Possible reactions sites of -amylase
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-amylase hydrolyzes starch and dextrin into maltose• Maltose is fermentable by bakers yeast and contributes in
Maillard reaction improving crust color and taste & flavour
Cooperation between and -amylase
Possible reactions sites of -amylase
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• During baking bacterial -amylase hydrolyzes starch to dextrin after starch gelatinization.
• Due to the random endo-activity the structure of the amylopectin is lost• Consequently also crumb resilience is lost.
Working mechanism Bacterial AmylaseBakezyme® AN 301 BG
Possible reactions sites of bacterial -amylaseAmylopectin
Dextrins are formed Amylopectin broken down
1 2
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• During bread storage the outer branches of amylopectin reassociate to one another and tend to develop double helix crystallites
• Maltogenic amylase removes these outer branches so crystallization is avoided and staling prevented
• The amylopectin structure remains in tact and consequently crumb resilience is preserved
Working mechanism Maltogenic AmylaseBakezyme MAM® 10.000
Area sensitive to retrogradation
Possible reactions sites of maltogenic-amylase
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• During bread storage the outer branches of amylopectin reassociate to one another and tend to develop double helix crystallites
• Maltogenic amylase removes these outer branches so crystallization is avoided and staling prevented
• The amylopectin structure remains in tact and consequently crumb resilience is preserved
Working mechanism Maltogenic Amylase
Area sensitive to retrogradation Possible reactions sites of maltogenic-amylase
1 2
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Amylopectin after reactionReaction: maltose is formed
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• At increasing dosage crumb softness improves• At increasing dosage crumb resilience improves• True anti staling effect• Consequently bread remains fresh longer
…a sustainable solution reducing returns, waste and CO2 emissions…
BakeZyme® MAM 10.000 in bakingOpen top tin bread
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Causes of crumb firming • Role of starch retrogradation?• Role of hemicellulose?• Role of lipids?
• Influence of process factors?
• Influence of storage conditions?
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Arabinoxylan in wheat flour
• AX make up 75% of the endosperm NSP
• 25-30% is water extractable (WE)
• 70-75% is water un-extractable (WU)
• NSP have a major effect on water
absorption of flour in a dough
Components %Starch 65 – 70
Sugars 1 -2
NSP 1.2 – 2.4
Proteins 8 - 15
Lipids 1.5 - 3
Minerals 0.5
Water 12 - 15
Wheat
NSP (Non Starch Polysaccharides)
Role of Non Starch Polysaccharides
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• Wheat flour contains 1.2-2.4% Non Starch Polysaccharides
• Up to 75% of wheat endosperm cell walls is composed from arabinoxylans
• NSP have a mayor influence on dough rheology and baking performance, …– …they have a function in water absorption of the flour– …they disturb the gas retaining properties of the dough– …they disturb the visco-elastic properties of the gluten network
Hemicellulases are the most effective enzymes in optimizing handling properties and product quality.
DSM offers the widest range of hemicellulases in the market
Role of Non Starch Polysaccharides
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Process type
HemicellulasesBakeZyme® HSP/BXP/FXP positioningEnables perfect choice for any situation
Incr
easi
ng B
read
Vol
ume
Incr
easi
ng D
ough
Sti
ckyn
ess
BakeZyme®
BXP
BakeZyme®
FXP
WU-AX
WE-AX
Flour type Whole mealHigh extraction flour
Strong / composite flours(South) East Europe
West Europe
Long fermentations Short processesCBP
Frodo
Soft floursLow resistance to extension
BakeZyme® HSP
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Four pieces closed top tin bread Chorleywood Bread Process (UK)
20 ppm BakeZyme®
HSP 6000 BG10 ppm BakeZyme® HSP 6000 BG10 ppm BakeZyme® FXP 1500 BG
20 ppm BakeZyme®
FXP 1500 BG
1 2 3
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Causes of crumb firming
• Role of starch retrogradation?• Role of hemicellulose?• Role of lipids?
• Influence of process factors?
• Influence of storage conditions?
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Wheat! our raw material and its composition
Sugars 1 - 2
Non-starch polysaccharides 1 - 3
Proteins 8 - 15
Lipids 1.5 - 3
Minerals 0.5
Water 12 – 15
Starch 65-70
Wheat flour components %
Wheat flour lipids composition:
Triglycerides : 0.9 –1.2 %
Phospholipids : 0.4 – 0.6 %
Galactolipids : 0.4 – 0.6 %
• 0.7 <> 0.9 % starch lipids
• mainly polar lyso-phospholipids
• 1.3 <> 2.1 % non-starch lipids
• 40 % neutral triglycerides
• 40 % phospho- and galactolipids21
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Working mechanism Phospholipase
• Phospholipase hydrolyse polar phospholipids (lecithin) into lyso-phospholipds and water.
• Also polar glycolipids function as substrate.• Lyso Phospho lipids and Galacto Monolipids have a strong stabilizing and
volume effect in baking
Possible reaction sites for phospholipaseFormation of lyso-phospholipid
PhospholipidLyso-Phospholipid
Free Fatty Acid
+ H2O
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Working mechanism Lipase
• Lipase hydrolyses triglycerides and produce di- and/or monoglycerides
• Lipase is able to produce in situ bio-emulsifier
Possible reaction sites for lipase
Tri-GlycerideMono-Glyceride
Free Fatty Acid
Formation of Mono-Glycerides
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BakeZyme® L 80.000B… True lipase hydrolizing dough lipids and forming mono glycerides in situ…… Specially for improving softness in pan breads and buns…
Panamore™ Golden… Our industry changing Phospolipase for DATEM replacement…… The worlds most effective enzyme for the improvement of dough and baking characteristics, suitable for all wheat flours, according to customers…
Panamore™ Spring… The sustainable solution for the replacement of CSL and SSL…… Specially formulated for improvement of all crumb rich and soft breads…
- Overview Lipid degrading products
Sustainable solutions for superior bread quality
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Reference 100% 0.5% SSL 104% 40 ppm Panamore® Spring 104%
20 ppm Panamore GoldenDATEM (0.3%)
Reference
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0
200
400
600
BLANK 50 ppm BakeZyme MAM 40 ppm BakeZyme MAM & 10ppm Panamore Golden
Har
dnes
s (g
)
day 1
day 4
day 7
Bread with Softness that LastsDutch tin bread lean recipe (short shelf-life)
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• 800,000 tons of Bakery Waste (UK)• 1.5 billion €
DSM has natural solutions for shelf life extension with:
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Which other factor is important for consumers?
– Crumb firmness is the ageing attribute most commonly recognized by the consumer. • Consumers associate tender, elastic and cohesive crumb that
is soft to touch with bread freshness– Microbial spoilage
• Mold
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Natural Preservation solutionOur Mission
To help customers to protect in a sustainable way food & crop products against harmful micro-organisms and contaminants.
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Current food protection portfolio
• Natural preservatives – DELVO®CID to prevent yeast and fungi– DELVO®NIS to prevent bacteria– DELVO®ZYME to prevent bacteria
• Ripening solutions– DELVO®COAT coatings – Pack-Age™ ripening bags
• Antibiotic residue testing dairy– Delvotest® broad spectrum testing– Delvotest® fast tests
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Food spoilage - solutions
The food spoilage market can be split into physical, chemical and microbial spoilage.Microbial spoilage solutions are natural, synthetic ingredients or physical methods.
Food spoilage
Physical spoilage Chemical spoilage Microbial spoilage
Anti-oxidantsPackaging Physical methodsIngredients
NisinNatamycinLysozymeCultures
BacteriophagePlant extracts
Sorbate/ sorbic acidBenzoate/ benzoic acid
NitratePropionateLactatesSulfites
Synthetic antimicrobialNatural antimicrobialHot PasteurizationCold pasteurization
UV treatment
Source: Frost & Sullivan research 2012
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Our product offeringOverview of applications, solutions and markets
Delvocid®
A product based on Natamycin.
Prevents spoilage by mould and yeast.
Delvo®nisA product based on
Nisin.
Prevents spoilage against gram-positive
and Pathogenic bacteria.
Delvozyme®
A product based on Lysozyme.
Prevents spoilage during food processing, where it breaks down bacteria cell walls.
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About Delvo®Cid
Delvo®Cid prevents spoilage against mold and yeast.
The active ingredient Natamycin, was first discovered by DSM in 1955 in a soil sample in the Natal province of South Africa.This ingredient is based on the bacterium Streptomyces Natalensis.
Today this material is produced by DSM and sold in many industries as a food protection ingredient under the name “Delvo®Cid”.
Natamycin approval is in CFR 21, 172.155. It is allowed on or in cheese up to 20ppm.
Where does it come from?
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How does it work?
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Preservation in Baking
The shelf life of baking is restricted due to staling of the products (getting dry) and freshness of the product (no mold contamination).
For both problems, DSM offers solutions. Enzymes that increase shelf life by preventing staling and preservation solutions to prevent mold problems.The anti-mold preservation solution is called Delvocid®.
During the baking process most molds are killed by the heat, but spores are able to survive. Also contamination after production is a risk.Since baking products are typically high moisture products, this is the perfect environment for a mold to grow.
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About Delvocid® in BakingWhy and how much to apply in Baking
Delvocid® is a good solution to extend shelf life and solve mold problems in Baking products like bread, cakes, pies and buns.
Baking products that contain high moisture content are receptive to spoilage by mold. Delvocid® is an effective and natural and solution to solve your spoilage problems due to molds in bread, cake, pies or buns.
Today often propionate propionates and sorbate are as preservative systems. These ingredients can generate off-flavors and will effect the baking yeast in your system. The Delvocid® solutions, you will only effect the molds, but will not effect the yeast and will not have a taste effect.
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About Delvocid® in BakingWhy and how much to apply in Baking
Delvocid® is most effective when applied as a surface treatment after baking with a fine spray solution. Alternatively it can be applied in the dough before baking.
Suggested dosage:200-500 ppm Delvocid®+ when applied on the surface with a fine mist spray. 20-40 ppm Delvocid® when applied in the dough.
Spray application: Prepare a solution of Delvocid® + in tap water to a final natamycin concentration of 200 – 500 ppm. Apply the suspension on the freshly baked cake as soon as possible after baking by spraying/misting the solution homogeneous over the complete surface of the cake.
Dough solution:Add the Delvocid® Instant powder to the dough together with the water during the blending of the ingredients.
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Bread staling remains responsible for huge economic losses to both the baking industry and the consumer
DSM has natural solutions for shelf life extension and securing food safety
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Your contact Person:
DSM Food Specialties
Kris Ferguson Christian PetersenOffice: +61 2 87789800 Office: +65 65358066Mob: +61 (0) 423568773 Mob: +65 92302741Email: [email protected] Email: [email protected]
Or check out more information on:www..dsm.foodspecialties.comwww.protectionyoucantrust.com
Questions & future contact
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While making reasonable efforts to ensure that all information in this presentation is accurate and up to date, DSM makes no representation or warranty of accuracy, reliability, or completeness of the information. The information provided herein is for the informational purposes only.
This publication does not constitute or provide scientific advice and is without warranty of any kind, express or implied. In no event shall DSM be liable for any damage arising from the reader’s reliance upon, or use of, this presentation. The reader shall be solely responsible for any interpretation or use of the materials contained herein.
