ENZYMES in TORTILLAS and FLAT BREADS

Dilek Austin, Ph.D. Baking Technical Services Novozymes North America, Franklinton, NC TIA 2016 Annual Convention and Trade Exposition May 19th, 2016

Agenda

Introduction to Enzymes

Enzymes in FLOUR tortillas

Enzymes in CORN tortillas

Enzymes in FLAT BREADS

Q&A

Introduction to Enzymes

Where do the enzymes come from ?

4

An example: Enzymes can increase efficiency, profit, and reduce waste

Enzymes are natural

Active proteins

In all living organisms

• Plant

• Animal

• Microorganisms-fungal, bacterial

Specific

Works under mild conditions

Can replace/reduce chemicals

How enzymes work

pH Temperature Contact time Water Enzyme

dosage Substrate Stabilizers

Inhibitors Oxygen

pH effect Temperature effect

Important process parameters for enzymes

Enzymes maintains tortilla freshness Stale tortillas/flat breads are firm and they crack when folded, become unacceptable to consumers

Enzymes can; • Extend shelf-life

• Improve dough handling and machinability

• Enhance mixing tolerance

• Can replace/reduce chemicals

Enzymes in FLOUR tortillas

FLOUR tortillas

Short baking time

Stale fast

Maintenance of flexibility is important

Shortenings, emulsifiers, vital gluten, dough relaxers are critical

Consumers desire less ingredients Clean label is vital

Enzymes used in FLOUR tortillas

Fresh keeping Maintenance of softness, flexibility and moistness of tortillas up to six months

Enzymes Alpha-amylase

Ingredient reduction/replacement L-cystein/SMS Gums Emulsifiers Vital gluten

FLOUR tortillas

Six weeks-old tortillas

With enzymes: Flexible, no cracking

Without enzymes: Undesirable cracks

Novozymes internal data

Novozymes NEW enzyme maintains the flexibility for FIVE-months

Alpha-amylase No enzyme

Novozymes internal data

Novozymes NEW ALPHA-AMYLASE -INCREASING dosages INCREASES extensibility

Novozymes internal data

4 weeks 45

70 74 76

0

20

40

60

80

100

without enzyme 225 ppm Alpha-amylase

315 ppm Alpha-amylase

410 ppm Alpha-amylase

%ex

ten

sib

ility

mai

nte

nan

ce

Four week-old flour tortillas % maintained mechanical extensibility compared to freshly

baked

Equipment: TA.XT2-Tortilla Burst Rig

Novozymes NEW enzyme makes tortillas STRONGER and MORE EXTENSIBLE at four week-storage

-100

-50

0

50

100

150

200

250

300

350

400

10 20 30 40 50

Fo

rce

4 weeks

Time/sec

New

en

zym

e N

o e

nzy

me

Novozymes internal data

Strong and more extensible

Breaks easily, not extensible

Alpha-amylase maintains high rollability scores during four-week storage

5

4.2

3.4

2.5

2.1

1.5

5 5 5

4.6 4.5 4.5

1.0

2.0

3.0

4.0

5.0

1 3 7 14 21 28

Ro

llab

ility

sco

res

(1 to

5)

Storage days

without enzymes Alpha-amylase

Flexible

NOT flexible

A study by Texas A&M University. Determining the Role of Starch in Flour Tortilla Staling Using α-Amylase J. Novie Alviola and Ralph D. Waniska. Cereal Chemistry. May/June 2008, Volume 85, Number 3

4 weeks

Four-week old tortillas INCREASING dosages INCREASES FLEXIBILITY

3.7

4.5 4.8

5.0

1.0

2.0

3.0

4.0

5.0

without enzyme 150 ppm Alpha-amylase

250 ppm Alpha-amylase

350 ppm Alpha-amylase

Rol

lab

ility

sco

res

(1

-5)

Novozymes internal data

4 weeks

NOT flexible

Flexible

Enzymes in CORN tortillas

CORN tortillas

Short baking time

Stale faster than flour tortillas

Maintenance of flexibility is important

Gums are critical

Consumers desire STRONG and FLEXIBLE tortillas

Enzymes used in CORN tortillas

Fresh keeping Maintenance of softness and flexibility of tortillas Reduction of masa stickiness Processing ease

Enzymes Alpha-amylase Lipase

CORN tortillas

Ten day-old tortillas

With enzymes: Flexible, no cracking

Without enzymes: undesirable cracks

Two-week old corn tortillas

Maltogenic amylase improves corn tortilla strength during storage

Maltogenic amylase help to decrease the CMC in the formula

Combining Maltogenic Amylase with CMC or Wheat Gluten to Prevent Amylopectin Recrystallization and Delay Corn Tortilla Staling Francisco J. Bueso , Lloyd W. Rooney , Ralph D. Waniska , and Laura Silva. Cereal Chemistry. September/October 2004, Volume 81 (5)

Stronger

762.2

899.5

500

700

900

40 ppm Alpha-amylase 40 ppm Alpha-amylase

day 5 day 11

Force to break the tortilla with Texture Analyzer

1.2

2.3 2.3

1.0

2.0

3.0

4.0

5.0

without enzyme 0.5% CMC 0.25% CMC+30 ppmAlpha-amylase

Ro

llab

ility

sco

res

(1-5

) at

ro

om

tem

per

atu

re

Masa dough

Less sticky and softer corn masa obtained with an Alpha-amylase and a Lipase

Sticky dough

Non-sticky dough

50

30 40 40 35

0

20

40

60

80

100

without enzyme 20 ppm Alpha-amylase

40 ppm Alpha-amylase

20 ppm Lipase 40 ppm Lipase

Dough stickiness (g)

Hard dough

Soft dough

Novozymes internal data-Equipment: TA.XT2

75

61 70

0

20

40

60

80

100

without enzyme 20 ppm Alpha-amylase 40 ppm Lipase

Firmness (g force)

Enzymes in FLAT BREADS

FLAT BREADS

Difficult to retain softness even for one day

Quickly becomes stale and chewy

No technology offers longer freshness

Reheating of frozen flat bread results in a very dry and elastic bread

Maintenance of softness is important Enzymes can help to retain the softness

Enzymes used in FLAT BREADS

Fresh keeping Maintenance of softness and flexibility of flat breads Bacterial alpha-amylase Lipases

Enzymes Alpha-amylase Lipases

Alpha-amylase maintains and improves flat bread softness for three days

Very flexible

Breaks

5

6.2 6.8

5

7.2

8.3

1

3

5

7

9

without enzyme 5 ppm Alpha-amylase 10 ppm Alpha-amylase

Day 1 Day 3

Novozymes internal data

Softer

Firmer

Softer

Firmer

A Lipase makes softer Naan dough; softer final product at four-hour after baking

Novozymes internal data

5

8

0

2

4

6

8

10

without enzyme 250 ppm Lipase

Naan dough softness

100

128

0

20

40

60

80

100

120

140

without enzyme 250 ppm Lipase

Naan instrumental softness (% softness compare to without enzyme)

FROZEN Naan -A lipase gives 22% more mechanical and sensorial softness compared to those without enzymes after 40 days of storage under frozen condition at -20 0C

Softer

Firmer

Softer

Firmer

5

7

0

2

4

6

8

10

no enzymes 250 ppm Lipase

100

122

0

20

40

60

80

100

120

140

no enzymes 250 ppm Lipase

Novozymes internal data

Chapatti made with a Lipase showed excellent dough property and better softness

546 585

393 391

0

100

200

300

400

500

600

700

30 min after baking 3 hrs after baking

no enzymes 250 ppm lipaseFirmer

Softer

Novozymes internal data

Enzymes are natural

Enzymes can Maintain freshly baked quality of tortillas/flat breads Improve dough handling and machinability

Enhance mixing tolerance

Replace/reduce chemicals

http://www.aaccnet.org/publications/store/pages/27885.aspx

A good source for enzymes and tortillas