Industrial butter with gel structure

Abstract

An industrial butter having a gel structure is proposed, which can be obtained by: (a) heating a commercially available butter to a degree to which it is plasticized but not melted; (b) cooling the plasticized butter thus obtained; and (c) adding a structure-forming component selected from the group consisting of carbohydrates, lipids and proteins and mixtures thereof to the cooled butter.

Description

Technical Field

[0001] This invention relates to the field of dairy products, and specifically to a new type of industrial butter with increased hardness, its production method, its use in the production of special baked goods, and the corresponding baked goods. Background Technology

[0002] Puff pastry and similar products are among the most popular baked goods, such as croissants or Danish pastries. Puff pastry (also known as feuilletage) is a multi-layered, sheet-like dough. Butter, or less commonly, other sheet fats like margarine, is added to a base dough made of flour, salt, and water through repeated rolling and folding—a process known as "laminating." During baking, the dough expands, becoming light and crumbly. The heat of the oven causes the moisture in the dough to evaporate, causing the puff pastry to expand and rise. The fat layers act as a barrier, preventing steam from escaping and holding it within the dough layers until the dough structure is baked firm. The dough's expansion (increase in volume) is entirely due to water vapor generated within the dough itself, not from additional leavening agents or yeast. This is why this production method is called "physical relaxation."

[0003] Based on the flavor of the fat used, puff pastry generally has a neutral texture and no added sugar is added during the production process. This makes it suitable for both sweet and savory pastries. Puff pastry can be distinguished by the method of adding butter or fat:

[0004] German puff pastry: The fat layer is located inside and is wrapped in the base dough (according to the German Food Code for fine baked goods, every 100 kg of cereal products must contain at least 62 kg of butter, dairy products, margarine or fat with almost no water).

[0005] French puff pastry: A fat layer encases the base dough. Its advantage is that, because the fat layer is on the outside, the dough doesn't dry out or form a hard crust.

[0006] Dutch puff pastry: Fat is cut into cubes (cold) and kneaded into the dough without resting (hence the name "quick puff pastry"). Most importantly, because fat doesn't expand easily, it's used to form the base of the puff pastry. Due to its dense structure, Dutch puff pastry holds a special place because it can still be cut after baking. This compact structure makes the dough ideal for making special pastries such as prasselkuchen (crispy cakes), cake bases, and cake toppings.

[0007] The main difference between puff pastry and other layered pastries, such as Danish pastries or croissants, lies in the dough. Puff pastry does not contain yeast, while Danish pastries use yeast as a leavening agent. Depending on the requirements and recipe, the dough may also contain sugar, milk, and other ingredients. Yufka, filo, or masouka doughs are also layered and widely used in Turkish, Greek, and Arabic cuisine, and are very similar to puff pastry. In addition, some variations with added oil or yeast are known.

[0008] Importantly, the finished pastry should not taste directly like butter or fat, but rather retain an overall creamy flavor—both visually and in taste—because this is seen by consumers as a sign of quality.

[0009] The market segment for puff pastry baked goods is highly homogenized, with limited product variety. Sales success hinges entirely on quality and price. Consumers are certainly interested in baked goods with additional sensory or flavor characteristics. However, the choices are limited: these are typically croissants or similar products filled with chocolate cream or jam. This is because these products are almost entirely machine-made, as the rolling pin must be aligned with millimeter-level precision to create a uniform dough and achieve a high-quality product after baking. For these processes, the addition of extra ingredients that must withstand the baking process is, if possible, only to a very limited extent.

[0010] The properties and amount of butter used have a significant impact on the sensory quality of puff pastry products. Traditional industrial butter is produced through butter curdling—heating and subsequently cooling butter to form a semi-crystalline plastic substance—and subsequent buttering, resulting in a hardness of approximately 1 N. Because heat is introduced into the dough during the stacking process, using this low-hardness butter can easily lead to it becoming oily, sticking to the conveyor belts of highly automated baking production lines, or causing the dough to slip on the conveyor belt—both of which can cause production interruptions. As for the dough itself, this can lead to an interruption of the butter phase, preventing the dough from relaxing during baking and resulting in defective products.

[0011] Existing technology

[0012] Industrial butter with increased hardness is known from EP 35 42 636 B1 (DMK), which can be obtained by heating commercially available butter to a degree that makes it plastic but not melted, and then cooling it under mechanical load.

[0013] EP 35 69 061 B1 (DMK) describes an industrial butter with increased hardness, which is obtained by separating raw milk into a skimmed milk portion and a cream portion; separating the cream portion into a milk phase and a protein-lactose aqueous phase with the addition of water; adding hard fat to the milk phase and homogenizing it; and cooling the homogenate under shear.

[0014] Purpose of the invention

[0015] Therefore, the primary objective of this invention is to provide an industrial butter specifically for the production of puff pastry, having a hardness in the range of about 2 to about 5 N, particularly about 3 to 4.5 N, and which is not prone to oil leakage when used on a conveyor belt.

[0016] The second task is to produce butter with as little technical effort as possible, especially by eliminating the time-consuming curing process after butter is pounded. Summary of the Invention

[0017] The first object of the present invention relates to an industrial butter having a gel structure, which can be obtained by the following method:

[0018] (a) Heat commercially available butter to a degree that it is plasticized but not melted;

[0019] (b) Cooling the resulting plasticized butter; and

[0020] (c) Adding a structural component, selected from carbohydrates, lipids and proteins and mixtures thereof, to cooled butter.

[0021] Surprisingly, it has been found that commercially available industrial butter, such as butter specifically used in the production of baked goods like puff pastry, can prevent oil separation by heating it to its plastic temperature, cooling it, and then adding structure-forming components—carbohydrates, lipids, and especially proteins or mixtures thereof. These structure-forming components impart the consistency of a solid oil gel to the butter, preventing any liquid components from escaping even under conditions suitable for use on long baking production lines.

[0022] The term "commercially available" should be interpreted in the broadest sense, including conventionally produced industrial butter with a correspondingly low hardness. The required low hardness refers to a hardness in the range of approximately 0.5 to 1.5 N, preferably approximately 1 N.

[0023] plasticizer

[0024] Plasticization refers to the heating process where butter, before it has liquefied, becomes easier to knead and shape. This temperature range may vary depending on the fat content of the butter, but is typically between 18 and 25°C.

[0025] cool down

[0026] Butter can also be cooled under load. The term "cooling under load" refers to cooling plasticized butter as described above in one or at least two scraper-type heat exchangers connected in series, the final product being "hardened" industrial butter with a hardness in the range of about 2 to about 5 N, preferably about 3 to about 4.5 N. During cooling under load, two processes occur simultaneously: first, particularly small crystals are obtained, and then these crystals interlock to form a particularly stable lattice, which corresponds to higher hardness.

[0027] Structure forming components

[0028] The structure-forming component can be selected from polysaccharides, lipids, particularly monoglycerides, and proteins, especially hydrophobic proteins. Examples of polysaccharides include xanthan gum, guar gum, agar, alginate, tylosin, ethyl cellulose, carboxymethyl cellulose, and hydroxyethyl and hydroxypropyl cellulose. In a preferred embodiment, the structure-forming component is a protein. Besides milk proteins, plant prolysins are also particularly suitable for this application. Typically, the amount of the structure-forming component added is from about 0.1 to about 15% by weight, preferably from about 0.5 to about 10% by weight, especially from about 1 to about 8% by weight, based on the weight of butter.

[0029] Preparation method

[0030] Another subject of the present invention relates to a method for producing industrial butter having a gel structure, the method comprising or consisting of the following steps:

[0031] (i) Separate the raw milk into a skim milk portion and a cream portion;

[0032] (ii) partially cook the butter in a manner known per se;

[0033] (iii) Whip the matured butter portion in a manner known per se;

[0034] (iv) Heat the commercially available butter obtained therefrom to about 18 to about 25°C;

[0035] (v) Cool the heated butter, if necessary, under mechanical load;

[0036] (vi) Adding and incorporating structure-forming components; and

[0037] (vii) The butter obtained therefrom is made into industrial butter.

[0038] Butter is a spreadable fat typically made from milk cream, which, according to EU regulations, contains at least 80% milk fat. During buttermaking, the cream is churned. This breaks down the fat globules in the milk fat. The fat membranes rupture, releasing the contained fat. The fat molecules can now stick together. In this process, some fat membranes, water, and some milk proteins are encapsulated. The liquid water-in-fat emulsion becomes a solid water-in-fat emulsion. By this point, most of these fat-free components (whey) have been released in the form of buttermilk. The butter itself is ultimately kneaded into a smooth, uniform mass, then shaped and packaged. In this respect, steps (i) through (iii) are standard procedures well known to those skilled in the art.

[0039] Butter production begins with the cream fraction separated during the extraction of skim milk from raw milk or whole milk. This cream fraction typically contains approximately 37.5% by weight of fat, which can be adjusted to this value by standardization, i.e., by adding external cream.

[0040] The butter is pasteurized or sterilized, and then undergoes a process known as ripening. This process involves alternating heating and cooling, which forms a lattice and increases the viscosity of the product. At this stage, butter cultures may be added to produce aroma, or the butter may be acidified.

[0041] Next comes the actual churning, in which the ripened butter is whipped and churned in a mixer equipped with a rotating drum at approximately 10°C. After separating the buttermilk, commercially available butter is obtained, with a hardness of approximately 0.5 to 1.5 N, preferably 1 N.

[0042] According to the invention, the fat content of the butter phase obtained in this manner is preferably in the range of about 80% to about 88% by weight, particularly about 81% to about 85% by weight.

[0043] Further preferably, the fat-free dry matter (FFDM) content of this butter phase is in the range of 1 to 3% by weight, preferably about 2% by weight. The total content of fat and dry matter is equal to 100%, of which the water content must not exceed 16% by weight; otherwise, it will no longer be considered butter according to EU regulations.

[0044] Next, the softened butter is heated to plasticize it, allowing it to be reshaped and kneaded without liquefying. This is typically achieved in a temperature range of about 18 to 25°C. Cooling is then performed, and repeated, especially under load, i.e., under shear force. Scraper heat exchangers, or particularly at least two, preferably two to five, connected in series, also referred to in this apparatus as a "combiner," are particularly suitable for this purpose. In such an assembly, the product to be cooled is pumped into the lower end of a vertical heat exchanger and flows through a cylinder. The product is continuously agitated by a scraper and removed from the cylinder wall. The heating or cooling medium flows in an annular gap between the heat exchange cylinder and the insulating shell. Industrial butter, in this way, is removed as a product at a temperature of about 10 to 16°C at the end of the exchanger, with a hardness in the range of about 2 to about 5 N, particularly about 3 to about 4.5 N.

[0045] The cooled butter is treated with structural components. These components can be spread in layers or added through a kneading process.

[0046] Industrial application

[0047] Another subject of the present invention relates to baking food prep materials, which comprise or consist of the following ingredients:

[0048] (i) Dough phase and

[0049] (ii) Industrial butter as described above.

[0050] The dough composition is preferably the standard puff pastry as described at the beginning.

[0051] Another subject of the present invention relates to a method for producing baked goods, preferably croissants, comprising the following steps:

[0052] (i) Provide the dough phase;

[0053] (ii) Provide industrial butter as described above;

[0054] (iii) Cover the dough phase with industrial butter to obtain the baking food blank;

[0055] (iv) Bake the blank.

[0056] Alternatively, the dough can be folded several times before baking to create a layered structure, as is common in puff pastry.

[0057] Finally, the present invention also includes the use of the above-mentioned industrial butter in the production of baked goods, particularly puff pastry baked goods, and most preferably croissants. Detailed Implementation

[0058] Example 1

[0059] Industrial butter is produced using milk proteins.

[0060] Ten kilograms of commercially available butter, with a fat content of 84% by weight, a non-fat dry matter content of 2% by weight, and a hardness of 1 Newton, was heated to 25°C with stirring to obtain a plasticizer, but without releasing any liquid. The plasticized butter was continuously fed into a series of four APV (Automatic Ventilation Vehicle) Gerstenbeck- A combination unit consisting of a scraping-type heat exchanger. This combination unit has four reheating zones, namely from 17°C to 21°C, back to 17°C, and back to 12°C, with an operating pressure of 18.5 bar. Subsequently, 1 kg of milk protein is added to the butter and mixed by kneading. Industrial butter with a strong gel structure and a hardness of 3.2 N is obtained.

[0061] Use this butter to make puff pastry, and bake in a preheated oven at 220°C (425°F) for 20 minutes. No oil seepage was observed.

[0062] Comparative Example V1

[0063] Production of industrial butter without milk protein

[0064] Ten kilograms of commercially available butter, with a fat content of 84% by weight, a non-fat dry matter content of 2% by weight, and a hardness of 1 Newton, was heated to 25°C with stirring to obtain a plasticizer, but without releasing any liquid. The plasticized butter was continuously fed into a series of four APV (Automatic Ventilation Vehicle) Gerstenbeck- A combination unit consisting of a scraping-type heat exchanger. This combination unit has four recirculation zones: from 17°C to 21°C, back to 17°C, and back to 12°C, with an operating pressure of 18.5 bar. Industrial grease with a solid crystalline structure and a hardness of 3.3 N is obtained.

[0065] Use this butter to make puff pastry, and bake in a preheated oven at 220°C for 20 minutes. After only 15 minutes of baking, tiny oil droplets can be observed on the surface of the dough, and after baking, a film of oil forms on the entire surface.

Claims

1. An industrial butter with a gel structure, which can be obtained by the following method (a) Heat commercially available butter to a degree that it is plasticized but not melted; (b) Cooling the resulting plasticized butter; and (c) Adding a structural component, selected from carbohydrates, lipids and proteins and mixtures thereof, to cooled butter.

2. The industrial butter according to claim 1, wherein the commercially available butter used has a hardness in the range of about 0.5 to 1.5 N.

3. The industrial butter according to claim 1, wherein the commercially available butter is heated to a temperature of about 18 to about 25°C.

4. The industrial butter according to claim 1, wherein the plasticized butter is cooled in one or at least two scraper-type heat exchangers connected in series.

5. The industrial butter according to claim 1, wherein milk protein is added thereto as a structural forming component.

6. The industrial butter according to claim 1, wherein the amount of the structure-forming component added is from about 0.1 to about 15% by weight, based on the weight of the butter.

7. A method for producing industrial butter with a gel structure, comprising or consisting of the following steps: (i) Separate the raw milk into a skim milk portion and a cream portion; (ii) partially cook the butter in a manner known per se; (iii) Whip the matured butter portion in a manner known per se; (iv) Heat the commercially available butter obtained therefrom to about 18 to about 25°C; (v) Cool the heated butter, if necessary, under mechanical load; (vi) Adding and incorporating structural components; as well as (vii) The butter obtained therefrom is made into industrial butter.

8. The method of claim 7, wherein the cream used has a fat content of at least 37.5% by weight.

9. The method of claim 7, wherein the cream portion is matured by alternating heating and cooling.

10. The method of claim 7, wherein the heated cream in step (iv) is cooled in one or at least two scraper-type heat exchangers connected in series.

11. The method according to claim 7, wherein the resulting industrial butter has a hardness of about 2 to about 5 N, preferably about 3 to about 4.5 N.

12. A baking dough, comprising or composed of the following ingredients: (i) Dough phase and (ii) The butter according to claim 1.

13. The baking food prep according to claim 12, characterized in that... The dough is a standard puff pastry.

14. A method for producing baked goods, comprising the following steps: (i) Provide the dough phase; (ii) Providing industrial butter according to claim 1; (iii) Cover the dough phase with industrial butter to obtain the baking food blank; (iv) Bake the blank.

15. Use of industrial butter according to at least one of claims 1 to 6 or the method according to at least one of claims 7 to 11 for the production of baked goods, particularly puff pastry baked goods.