Food or edible material: processes – compositions – and products – Packaged or wrapped product – Packaged product is dough or batter or mix therefor
Reexamination Certificate
1999-09-16
2001-11-27
Tran, Lien (Department: 1761)
Food or edible material: processes, compositions, and products
Packaged or wrapped product
Packaged product is dough or batter or mix therefor
C426S094000, C426S106000, C426S312000, C426S316000, C426S319000, C426S404000, C426S486000, C426S496000, C426S498000
Reexamination Certificate
active
06322830
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a ready-to-bake, shelf-stable cake dough and the process for its manufacture.
2. Description of Related Art
Liquid doughs are known which require chemical conservation and low temperatures for suitable storage stability. German patent DE 36 32 567 discloses liquid doughs which can be stored for about six weeks under cooling after having been pasteurized at temperatures up to 75° C.
German patent DE 37 26 577 discloses a dough which can be kept for long periods without preservatives and without cooling due to its low water activity of between 0.60 and 0.80. This dough should contain 30-40% enzyme deactivated flour and a rather high proportion of 20-30% of dried starch and only 5-10% water. Therefore this dough is not pourable but must be rolled and cut into pieces and due to the required low water content it is impossible to incorporate whole eggs because this would cause a too high water content.
It has been one object of the present invention to provide a ready-to-bake, shelf-stable cake dough which is sufficiently liquid to be pourable and which can contain a high amount of liquid whole eggs as is required for certain cakes.
SUMMARY OF THE INVENTION
According to the present invention a ready-to-bake, shelf stable cake dough consisting essentially of flour, fat, sugar, eggs and water and usual dough additives is provided, which dough has a shelf-stability at ambient temperature of at least four months, preferably of four to six months and most preferably of 9 to 12 months. The dough of the present invention has a water activity of below 0.85, preferably of 0.81-0.83, and an overall water content of 18-25%, preferably of 20-23%. The dough according to the invention is packed in an essentially gas-impermeable pouch in an atmosphere of an inert gas containing less than 4%, preferably less than 2% residual oxygen.
DETAILED DESCRIPTION OF THE INVENTION
The cake dough according to the present invention consists essentially of (all percentages based on the final dough composition):
15-25%
fat
15-30%
whole egg (liquid)
3-6%
glycerol
20-30%
sugar
10-15%
flour
10-15%
starch.
Preferably the fat to be used in the invention is a hydrogenated, highly saturated vegetable fat containing no lauric acid and with a free acid content below 0.3%, preferably below 0.1% (calculated as oleic acid), an iodine value (Wijs) of 66-75 g/100 g, preferably 68-73 g/100 g, a peroxide value of max. 1.2, preferably max. 1.0 meg O
2
/kg and a melting point of 20-35° C., preferably 32-35° C.
The egg component used according to the invention preferably is a pasteurized liquid whole egg composition which, for example, has been pasteurized at 65° C. for 3 minutes. A commercial composition of this kind usually has a dry matter content of 23%, i.e. a humidity of up to 77%.
The dough according to the invention contains 3-6% glycerol in order to control the required water activity of the dough.
The dough contains sugar not only for organoleptic reasons, but a high level of sugar is also used in order to lower the water activity.
Special care must be taken in the selection of the enzyme-inactivated flour. The alpha-amylase activity (determined by an accelerated Visco-test) should be essentially zero, the lipase activity (determined by the method of Purr: Nahrung 9, 445-454 (1965)) should be essentially zero and the peroxidase activity (determined by the modified Guaiacol assay according to Schwimmer: Food Enzymology, 207-208 AVI Publ. Comp. Westport USA (1981)) should be reduced by more than 90%. Preferably the flour has also no lipoxygenase activity (determined by Williams: Food Technology 40, 130-140 (1986)).
It was found that during the enzyme-inactivation of the flour by heat-treatment a pregelatinisation of the starch must be avoided because this may cause difficulties in the spreading characteristics of the dough. Therefore, as far as heat-treatment is applied, this has to be done without any pregelatinisation.
The starch, which is also incorporated into the dough of the present invention, preferably is a native wheat starch.
The dough of the present invention also contains a leavening system.
The leavening system may comprise an encapsulated chemical raising system which is stable during the storage of the dough. Preferably sodium bicarbonate, which is encapsulated with cotton seed oil, is used. This system is stable at ambient temperature and acts as a raising system only at higher temperatures which means only during baking, when the coating melts at temperatures above 60° C.
Preferably the leavening system also comprises an inert gas which is partially soluble in the dough, e.g. N
2
O. During preparation of the dough this gas solubilizes into the dough and partly forms gas bubbles. The dough density is then between 0.5 and 0.7 g/ml, but during storage density increases up to about 1 g/ml. When the dough is baked, this gas contributes to the volume increase and the shape of the cake.
N
2
O is preferred as such inert gas because it does not change the acidity and the taste of the product.
The dough of the present invention must be packed in an essentially gas-impermeable pouch in an atmosphere of inert gas containing less than 4%, preferably less than 2% residual oxygen.
Suitable pouch materials are commercially available. Preferably the pouch material is a laminate of different materials with low gas permeation rates. A preferred laminate is a polyester-aluminum-polyethylene laminate.
It is essential that during the manufacturing process oxygen is completely removed from the dough and the dough is stored in an atmosphere which is as far as reasonably possible free from oxygen. This goal is it obtained by a repeated sequence of applying vacuum and breaking the vacuum by an inert gas, which is preferably nitrogen. A vacuum of −0.5 bar (−0.05 MPa) might be sufficient.
In a preferred process for the manufacture of the ready-to-bake, shelf-stable cake dough according to the present invention
a)
10-15% (based on the final dough composition) of an enzyme-inactivated flour,
10-15% starch, preferably native wheat starch,
20-30% sugar (sucrose),
0.1-0.7% of an encapsulated chemical raising system, salt and optionally xanthan gum
are homogeneously mixed
b) 15-25% fat pressurized with an inert gas, preferably nitrogen, are placed into a mixer, whereafter vacuum is applied and a liquid mix of 15-30% liquid, pasteurized whole eggs and 3-6% glycerol is sucked into the mixer in which the fat and the liquids are intensively mixed under vacuum to create an emulsion and remove the oxygen, whereafter the vacuum is broken with inert gas, preferably nitrogen;
c) the premix powder of step a) is added to the emulsion of step b) and mixed with the emulsion under vacuum for several minutes, preferably 10-12 minutes;
d) several, preferably 3, successive phases of injection of inert gas followed by vacuum during mixing are applied, to ensure a content of oxygen as low as possible;
e) the vacuum is broken with an inert gas which is at least partly soluble in the dough, preferably N
2
O, and the dough is pressurized with said gas up to 1-2 bar (0.1-0.2 MPa) and mixed under this atmosphere for another 20-30 minutes;
f) whereafter the dough is packed in an essentially gas-impermeable pouch which is flushed with inert gas before it is sealed.
The packaged ready-to-bake dough according to the invention does not need any chemical preservative for shelf-stability, although it may contain some potassium sorbate. Moreover, the packaged dough according to the present invention does not need a pasteurization or another heat-treatment step to obtain an excellent shelf-stability of 4-6 months and even more at ambient temperature.
REFERENCES:
patent: 4904493 (1990-02-01), Petrizzelli
patent: 5366744 (1994-11-01), Drummond et al.
patent: 5549922 (1996-08-01), Juchem
patent: 145 550 (1983-11-01), None
patent: 156 573 (1985-10-01), None
patent: 488 012 A2 (1991-11-01), None
patent: 510 320 A1 (1992-02-01), None
patent: 666 028 A1 (1995-08-01), None
patent:
LeFlecher Rene
Robson Peter
Bestfoods
Norris & McLaughlin & Marcus
Tran Lien
LandOfFree
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