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Fermentation-Biotechnology for Better Baked Goods

C o n t i n u o u s L i q u i d S p o n g e P r o d u c t i o n

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A Well-Rested Dough

Improves the Quality

Decisive Reasons for the Use of a ContinuousLiquid Sponge System from Reimelt:

‡ Ensures a constant quality‡ Liquid sponge is available on demand‡ Production scheduling and post-production is

possible at any time‡ A hygienic production - due to the closed

system‡ Flexibility due to adjustable process para-

meters

‡ Optimal utilization of production capacity‡ Later extension of the production capacity

possible‡ Low space requirements‡ Easy to operate‡ Reduction in active ingredients

Wheat Flour with the Addition of Yeast

For this liquid sponge, wheat flour, water andyeast are homogeneously mixed. The addedyeast, better the enzyme Zymase, produces car-bon dioxide CO2 and ethanol that are aromaand flavour components. The volatile alcoholand the gaseous carbon dioxide leave the fer-mentation tank. A portion of the CO2 is conver-ted to a water solution and lowers the pH value.The fermentation time is approx. 2-4 hours. Asthe dough is to be pumped, the DY should beapprox. 200 with an added amount of approx.0,5% yeast.

Liquid Sponge with the Addition of StarterCultures

By this process the operator attempts to achie-ve something between liquid sponge and sour-dough. Here the flavour providing acid is de-sired in addition to the soaking of the flour andthe yeast activity. A combination of wheat flour,water and starter culture is used to make a mix-ture with an approx. DY of 200. With a fermen-tation time of approx. 4-6 hours at a tempertureof 22-24°C, a mild acidification of approx. 6-7acidity level is achieved.

The Process

Wheat Flour Soaking

The flour constituents are soaked-through and begin to swell through the mixing of flourand water. The water surrounds the agglomer-ates and is absorbed especially by the proteins.The gluten strands begin to form at a DY of 180-200 and a temprature of approx. 25°C.This generates the gluten framework, which is definitely necessary for the forming of thedough.A ripening time of approx. 12-18 hours is possi-ble. This dough process is to be considered withcaution because the flour’s own flora can leadto faulty fermentation results over longer periods of time. Unwanted byproducts from the flora can influence the taste and aroma.Development of taste is not of primary impor-tance during the wheat flour soaking process.

Reimelt FoodTechnologie A division of Reimelt Henschel GmbHMessenhäuser Straße 37-45 63322 Rödermark, GermanyTel. +49 6074 691- 0Fax +49 6074 691- 208email: info@reimelt.dewww.reimelt.de

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C o n t i n u o u s L i q u i d S p o n g e P r o d u c t i o n

Quality Through Continuity

Decisive Reasons for the Use of Liquid Sponge:

‡ Presoaking of the flour constituents‡ Kneadable dough‡ Better processing qualities‡ Natural fermentation‡ Remains fresh longer‡ Milder, well-balanced taste‡ Soft, elastic crumb‡ Higher dough-yield volume‡ Reduction in the dough resting period

Products:‡ Wheat baked goods‡ Baguettes‡ Ciabatta‡ Pita bread‡ Brioches‡ Hamburger buns‡ Toast bread‡ Pizza‡ Yeast dough baked goods

The quality of wheat dough baked goods is de-termined by the raw materials and to a certainextent by the application of liquid sponge. Theuse of liquid sponge is essential in order to meetthe increasing high quality standards of the con-sumer. By the use of liquid sponge a natural ba-king additive is developed that ensures that thebaked goods have a crispy crust, taste more fla-vourful, remain fresh longer and have an exten-ded shelf-life.

the storage tank, the dough is cooled by travel-ling through a heat exchanger in order to haltthe fermentation process. The liquid sponge isthen ready to be taken for the production lines.

The Operation Concept

The operation and monitoring of the system isof great importance for the production of liquidsponge. Reimelt systems need only a very limi-ted operator interaction. All relevent data is stored in the PLC. The operator can performchanges to the recipes within the allowed tol-erances at any time. The PLC-system monitorsthe production, storage and metering to the usepoints. The required liquid sponge amounts canbe automatically calculated or entered from ex-ternal sources. The production of liquid spongecan be set to match actual requirements so thatunnecesarry delays, especially on the weekend,are prevented.Anyone can operate the system and there is nospecial IT knowledge required. Exceeded tole-rances are shown on the display and enable theoperator to react accordingly.

Flour Feeding

‡ Integrated flour use bin- Flour supply from existing silo system

‡ Gravimetric flour metering- Metering exactly according to recipe- Adjustable metering capacity

Water Mixing Unit

‡ Connection to city, hot and cold water lines- Adjustable mixed water temperature- Easy installation

‡ Automated, precise recipe metering- Inventorying of the water component- Adjustable metering capacity

Yeast Suspension

‡ Agitated hopper with hinged lid- Easy to clean- Suitable for dry or liquid yeast

‡ Suspension is cooled- Storage at approx. 5-7°C and a constant

quality‡ Automated process

- Automatic and exact metering of the desired amount of yeast

‡ Use of liquid yeast- More economical yeast purchase

Liquid Sponge Mixer

‡ Vertical construction- Gravity aids the mix effect

‡ Continuous mixing of the raw materials- No deviation from recipe

‡ Lump-free dough production- No blockages in hopper outlet and piping

‡ Short mixing time- Only slight increase in temperature

‡ Any components are mixable- Free recipe composition

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‡ Lateral filling of fermenter- First-in, first-out

‡ Adjustable fermentation time- Production of different liquid sponges

(pH-value, °Acidity)‡ No inner mechanical components

- Very easy to clean‡ No agitator

- Liquid sponge without damage to wheat gluten

- Constant gluten development for a constant dough quality

Cooling

‡ Cooling to approx. 10°C- Storage also possible over the weekend

‡ Cooling to under 10°C- Dough production without addition of ice

‡ Plate heat-exchanger- Highly effective degree of cooling

Storage

‡ Vertical stainless steel storage tank- Space-saving construction

‡ High availability- Liquid sponge can be stored for many hours

‡ Cooled liquid sponge- On demand use

Cleaning

‡ Cleaning of the piping and tanks- Protection from microorganisms

‡ Selectable cleaning program- Monitored by PLC

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For the continuous production of liquid spongewater, wheat flour and yeast suspension are metered gravimetrically and volumetrically intothe continuous mixer and immediately mixedtogether. A homogenous dough is produced al-ready after a short time which is then pumpedfrom the mixer to the fermentation tank. The“first-in, first-out” principle ensures a con-stantly high quality and freshness of the dough. When the fresh liquid sponge is pumped into