Production process and product of instant pre-steamed frozen raw dough steamed buns

Abstract

This invention relates to the field of food processing technology, specifically to a production process and product for instant steamed pre-proofed frozen dough buns. The process includes 1000g of medium-high gluten flour, 8-20g of dry yeast, 8-20g of baking powder, 5-30g of pre-proofed frozen dough improver, 20-150g of white sugar, and 440-520g of water. The dough is kneaded, relaxed, folded and rolled at 90° angles 5-20 times, shaped, pre-proofed to 1.5-1.9 times its original volume (50-90%), rapidly frozen to a core temperature of -10 to -18°C, and then rapidly packaged at low temperature (1-15°C / 30 minutes) and frozen. The resulting product, once removed from the frozen state, requires no thawing or secondary proofing and can be directly steamed for consumption. The steamed product is large in volume, white in color, soft and chewy in texture, non-sticky, non-shrinking, and has no dead dough, with a shelf life of up to 30 days. This invention resolves the contradiction between the immediate steaming quality and frozen storage stability of pre-proofed frozen buns by precisely quantifying the proofing degree and establishing coordinated coordination of process parameters across the entire chain. This significantly improves production efficiency and product quality while reducing energy consumption and the threshold for end-user operations.

Description

Technical Field

[0001] This invention relates to the field of food processing technology, specifically to a production process and product for instant steamed, pre-proofed, frozen raw buns. Background Technology

[0002] Steamed buns, as a traditional Chinese staple food, are loved by consumers. With the fast pace of life and the development of chain restaurants, the market demand for frozen steamed buns is increasing. In particular, there is a demand for a ready-to-eat product that can be taken out of the freezer and eaten directly after steaming without thawing or a second proofing, in order to minimize the equipment investment and personnel technical requirements of terminal stores.

[0003] Currently, frozen steamed bun products on the market can be mainly divided into the following two categories:

[0004] 1. Quick-frozen cooked buns

[0005] The production process is as follows: weighing ingredients - kneading dough - pressing dough - shaping - proofing - steaming - cooling - quick-freezing - packaging - finished product. This type of product has the following shortcomings:

[0006] (1) Poor quality of finished products: The buns are steamed twice (first steaming at the factory + second steaming at the terminal). For meat buns, the filling juice is absorbed by the fully fermented bun skin, resulting in insufficient juice; for vegetable buns (especially green vegetables), the color turns yellow after steaming, quick freezing and second steaming, and cannot restore the bright green color of fresh buns; the bun skin absorbs soup, and the appearance is less intact after second steaming, the chewiness is weaker, and the stickiness is stronger, especially the innermost side that is in contact with the filling.

[0007] (2) High energy consumption: It requires steaming equipment and professional operators to control the steaming pressure and time. The location of the production workshop is limited by the source of steam.

[0008] (3) Low production efficiency: After steaming, the buns need to be cooled to room temperature before they can be frozen quickly. Depending on the weight and output of the buns, the cooling process takes 1 to 2 hours, resulting in a long production cycle.

[0009] II. Pre-formed frozen raw buns

[0010] The production process is as follows: weighing ingredients - kneading dough - pressing dough - shaping - quick-freezing - packaging - finished product. These products need to be thawed and proofed at the store before steaming. Its drawback is:

[0011] (1) Cumbersome terminal operation: Stores need to be equipped with defrosting and proofing equipment, which takes up space and money.

[0012] (2) High dependence on technical personnel: The degree of thawing and proofing needs to be controlled by experience. Improper operation can easily lead to fluctuations in product quality and an increase in the defect rate.

[0013] (3) Poor quality stability: It is difficult to maintain consistent thawing and proofing conditions for different operators and different batches, which affects the consistency of the final product.

[0014] (4) Low production flexibility: Staff need to predict the amount of products needed for the day in advance and calculate the thawing and proofing time in order to meet the demand for sales, making it difficult to produce meals flexibly.

[0015] Neither quick-frozen cooked buns nor pre-formed frozen raw buns can meet the market demand for "ready-to-steam" products. If a pre-proofing process is added after shaping, allowing the buns to proof before leaving the factory, end users can steam them directly. However, pre-proofed frozen raw buns face a core technological bottleneck in practical applications:

[0016] The precise control of the proofing degree is crucial. Insufficient proofing (below 50%) results in a small volume, tough texture, stickiness, and insufficient softness after steaming, leading to a short shelf life. Over-proofing (above 90%) damages the gluten network and deactivates the yeast due to excessive gas production during quick-freezing and frozen storage, causing shrinkage, collapse, and staleness in the steamed product, also resulting in a short shelf life. Finding the precise balance between "sufficient proofing to ensure immediate steaming quality" and "moderate proofing to ensure frozen storage stability" is a key challenge hindering the industrialization of this technology.

[0017] In addition, even if a suitable proofing level is found, the following supporting issues still need to be addressed: How to select flour and yeast suitable for a pre-proofing freezing system? How to preserve the proofing results completely during frozen storage and achieve a stable shelf life of up to 30 days through the coordinated use of process parameters (dough temperature, rolling method, quick-freezing conditions, and packaging conditions)? Existing technologies have not yet provided systematic solutions to the above problems. Summary of the Invention

[0018] To address the shortcomings of existing technologies, this invention provides a production process and product for pre-proofed frozen steamed buns that can be steamed immediately. By precisely controlling the proofing degree and establishing a coordinated system of process parameters across the entire chain, the product can be steamed directly after being taken out of the frozen state without thawing or secondary proofing. The steamed product is large in volume, white in color, soft and chewy in texture, does not stick to teeth, does not shrink, and does not have any dead buns. It also has a shelf life of up to 30 days.

[0019] This invention is achieved through the following technical solution:

[0020] A production process for instant-steaming pre-proofed frozen raw buns is provided, including the following steps:

[0021] S1. Ingredients: 1000g all-purpose flour, 8-20g dry yeast, 8-20g baking powder, 5-30g pre-proofed frozen dough improver, 20-150g sugar, 440-520g water; the protein content of all-purpose flour is 9%-13%, and the wet gluten content is 25%-35%;

[0022] S2. Kneading the dough: Mix the above ingredients together, first stir slowly for 4 to 10 minutes, then stir quickly for 1 to 8 minutes, and control the dough temperature to 18 to 28℃.

[0023] S3. Relaxation: Let the kneaded dough rest for 1-15 minutes;

[0024] S4. Pressing the dough: Fold and roll the relaxed dough at 90° 5-20 times.

[0025] S5. Shaping: Divide the rolled dough into portions, wrap the filling, and shape them into bun blanks. The weight of the bun skin is 56~60g, the weight of the filling is 24~28g, the total weight of a single bun is 80~88g, and the weight ratio of skin to filling is 2.0~2.5:1.

[0026] S6. Pre-proofing: Place the shaped bun dough in a temperature of 28~38℃ and a relative humidity of 70%~85% for 15~35 minutes to proof, controlling the proofing degree to reach 1.5~1.9 times the original volume, that is, proofing to 50%~90%.

[0027] S7. Rapid freezing: Rapidly freeze the pre-proofed bun dough at -30℃ to -45℃ for 10 to 60 minutes, so that the center temperature of the bun reaches -10℃ to -18℃.

[0028] S8. Packaging: Under ambient temperature conditions of 1~15℃, complete the sealing and packaging within 30 minutes from the end of rapid freezing;

[0029] S9. Frozen storage: Freeze the packaged product at -18°C or below.

[0030] The resulting frozen raw buns do not need to be thawed or proofed a second time; they can be steamed directly and eaten immediately.

[0031] Preferably, in S1, the amount of dry yeast is 12g, the amount of pre-proofed frozen dough improver is 10g, the amount of white sugar is 50g, and the amount of water is 480g.

[0032] Preferably, in S1, the dry yeast is highly active dry yeast, and fresh yeast is not used.

[0033] Dry yeast is more suitable for this process than fresh yeast because the amount of yeast added for pre-proofing frozen dough buns is 1.2 times that of normal products, and the dough temperature is controlled at around 24℃. If the proofing speed of fresh yeast is too fast, it will be difficult to control the proofing speed and result in poor product quality stability.

[0034] Preferably, in step S2, the slow mixing time is 6 minutes, the fast mixing time is 3 minutes, and the dough temperature is 24°C; in step S3, the relaxation time is 8 minutes.

[0035] Preferably, in S4, the 90° folding and calendering is performed 12 times.

[0036] Preferably, in step S6, the proofing temperature is 35°C, the relative humidity is 80%, the proofing time is 22 minutes, and the proofing degree is 1.7 times the original volume, that is, 70% proofed.

[0037] Preferably, in S7, the rapid freezing temperature is -35°C, the freezing time is 30 minutes, and the center temperature of the bun reaches -15°C.

[0038] Preferably, in step S8, the packaging environment temperature is 1~5℃, and the sealing and packaging are completed within 10 minutes from the end of rapid freezing.

[0039] Preferably, in S1, the medium-high gluten flour has a protein content of 11.5% and a wet gluten content of 30%.

[0040] The present invention also provides an instant-steaming pre-proofed frozen raw bun produced by a production process of instant-steaming pre-proofed frozen raw buns.

[0041] The beneficial effects of this invention are:

[0042] 1. Instant steaming operation, zero barriers to entry for end users.

[0043] This invention achieves a precise balance between "sufficient proofing to ensure adequate volume and fluffiness for immediate steaming" and "moderate proofing to prevent collapse during freezing" by precisely controlling the proofing process to 1.5 to 1.9 times the original volume. Simultaneously, it uses 1.2 times the normal amount of dry yeast to compensate for yeast activity loss during freezing, ensuring sufficient gas production after freezing. Combined with controlled dough temperature (24℃), the yeast remains in its optimal activity range, resulting in a stable and controllable proofing process. After being removed from -18℃ frozen storage, the product requires no thawing or secondary proofing; it can be directly steamed to obtain plump, fluffy buns. Retail stores do not need proofing boxes or thawing equipment, nor do they require professional technicians to assess the proofing level, making operation extremely convenient and significantly reducing equipment investment and personnel training costs.

[0044] 2. The product quality is excellent, and the freshness is greatly improved.

[0045] Because it only undergoes one final steaming process (unlike the two steaming processes of traditional quick-frozen cooked dough), the juices from the meat filling are not absorbed by the loose and porous dough, resulting in a rich juiciness; the vegetable buns (especially those with green vegetables) are bright green, comparable to fresh buns.

[0046] By folding and rolling the dough 12 times at 90°, the gluten proteins are arranged in an orderly manner along a specific direction, forming a dense and elastic three-dimensional network structure, with a significantly better gas-holding capacity than ordinary rolling methods. Combined with medium-high gluten flour (25%~35% wet gluten, optimal 30%) and a suitable dough temperature (18~28℃, optimal 24℃), the gluten is fully formed and has moderate extensibility. Rapid freezing to a core temperature of -15℃ results in fine and uniform ice crystals, minimizing damage to the gluten network. The final product has a smooth, white surface after steaming, a soft and chewy texture, and exhibits no stickiness, shrinkage, or stale filling. The sensory quality of the product is highly similar to freshly made buns, overcoming the industry pain point of traditional frozen buns where "the taste deteriorates and the color darkens after re-steaming."

[0047] 3. Production efficiency has been significantly improved.

[0048] This invention eliminates the steaming and lengthy cooling processes (cooling takes 1-2 hours) required in traditional quick-freezing pre-frozen dough production. After shaping and pre-proofing, the dough is directly subjected to rapid freezing, significantly shortening the production cycle. For the same production capacity, the production cycle is reduced by more than 40%, output per unit time is significantly increased, and equipment turnover efficiency is improved.

[0049] 4. Energy consumption is significantly reduced.

[0050] This invention eliminates the need for a steam cooking process, avoiding boiler steam consumption and investment in related equipment. The quick-freezing process uses precise parameters of -35℃ / 30min to avoid energy waste caused by over-freezing. Overall energy consumption is reduced by more than 50% compared to traditional quick-freezing cooked embryo processes, and the production workshop location is not limited by the steam source, increasing the flexibility of plant construction.

[0051] 5. Shelf life up to 30 days

[0052] The proofing process is precisely quantified to avoid under-proofing or over-proofing; dry yeast is used, and the amount is 1.2 times that of ordinary products to compensate for freezing damage and avoid the uncontrolled proofing caused by fresh yeast; 90° folding and rolling (optimal 12 times) forms a dense and orderly gluten network, enhancing gas retention stability during frozen storage; medium-high gluten flour (25%~35% wet gluten, optimal 30%) has moderate gluten strength, balancing gas retention and taste, avoiding the collapse of low-gluten flour or the shrinkage of high-gluten flour; rapid freezing to -15℃ in the center produces fine and uniform ice crystals without damaging the gluten structure. It simultaneously inhibits yeast metabolism without causing its inactivation, ensuring re-steaming activity; low-temperature rapid packaging (1~5℃ / 10min) prevents surface thawing from causing ice crystal recrystallization, avoiding product sticking and quality deterioration; the pre-proofed frozen dough improver retains an appropriate amount of water, maintaining the dough's moisture distribution and preventing drying and cracking during frozen storage; under -18℃ frozen storage conditions, the product quality remains stable for 30 days, and after steaming, all sensory indicators (volume, color, taste, and presence of shrinkage or dead packaging) are not significantly different from freshly made products, meeting the needs of commercial distribution and terminal inventory turnover.

[0053] 6. Simplified formula, controllable cost

[0054] Unlike existing technologies that employ complex compound additives such as multiple enzymes, emulsifiers, and modified starches, this invention uses only a single pre-proofed frozen dough improver (0.5%~3%, optimally 1%), without adding lard, shortening, or other fats. It achieves its quality goals through precise synergy of process parameters rather than excessive additives. This results in lower raw material costs, a cleaner formula, alignment with health-conscious consumption trends, and easier standardization and replication of the production process. Attached Figure Description

[0055] Figure 1 Comparison photos of the appearance of raw buns and steamed buns at different proofing stages.

[0056] Figure 2 Comparison of the shapes of raw and finished buns under different proofing ratios. Detailed Implementation

[0057] To clearly illustrate the technical features of this solution, the following detailed implementation method will be used to explain the solution.

[0058] This invention, through extensive experimentation, has discovered that dividing, weighing, and shaping the dough into buns, then placing them in a proofing room for pre-proofing (controlling the pre-proofing ratio between 1.5 and 1.9 times), followed by rapid freezing, yields the optimal frozen dough state and final product texture. Figure 2 As shown, under pre-proofing ratios of 1.5, 1.6, 1.7, 1.8, and 1.9 times, the frozen raw dough and the steamed finished product exhibited significant morphological differences:

[0059] 1. Observation of the morphology of the green body (upper half of the image):

[0060] As the pre-proofing ratio increases, the volume of the frozen green body gradually increases, and the fullness and gloss of the green body's appearance show a trend of first increasing and then decreasing. When the pre-proofing ratio is 1.5 to 1.6 times, the green body skin is relatively dense, the volume is small, and the gloss is poor; when the pre-proofing ratio reaches 1.7 to 1.8 times, the green body skin expands significantly, the volume increases, the gloss improves, and the overall shape is more stretched and full; when the pre-proofing ratio reaches 1.9 times, the green body skin exhibits problems such as rapid freezing shrinkage, reduced firmness, and decreased gloss.

[0061] 2. Observation of the finished product's shape (bottom half of the image):

[0062] The steamed buns maintain a high degree of consistency in shape with the raw dough. Steamed buns with an appropriate pre-proofing ratio (such as 1.7 times or 1.8 times) have a smooth and round appearance after steaming, with a full and upright shape, clear pleats, and a bright white color with good luster.

[0063] Comparative analysis of product morphology under different pre-proofing ratios reveals that a pre-proofing ratio of 1.7 to 1.8 times is the optimal range for this process. Within this range, the dough undergoes sufficient relaxation and expansion, ensuring not only the freeze-dried dough's resistance to cracking and preventing shrinkage after quick-freezing, but also resulting in steamed buns with a smooth and plump appearance, excellent fluffiness, whiteness, gloss, and a delicate, soft, and moderately chewy texture. Simultaneously, it ensures the filling is juicy and fresh. If the pre-proofing ratio is too low (<1.6 times), the finished product will shrink, be smaller in size, and have a denser texture, resulting in poor overall sensory quality. If it is too high (>1.9 times), the steamed buns may exhibit bubbling, collapse, shrinkage, juice leakage, and a sticky texture, and the product's shelf life stability will also be affected.

[0064] Based on the above experimental findings, specific embodiments of the present invention are provided below. Embodiment 1 uses 1.7 times (70%) as the optimal proofing degree, and combines it with other preferred parameters to form a complete process scheme.

[0065] Example 1:

[0066] Ingredients: 1000g medium-high gluten flour (protein content 11.5%, wet gluten content 30%), 12g dry yeast, 12g baking powder, 10g pre-proofed frozen dough improver, 50g sugar, 480g water.

[0067] Kneading: 6 minutes on slow speed, 3 minutes on fast speed, dough temperature 24℃.

[0068] Relaxation: 8 minutes.

[0069] Pressing: Fold and roll 12 times at 90°.

[0070] Shape: 84g / bun, bun skin 58±2g, filling 26±2g.

[0071] Proofing: Proof at 35℃ and 80% humidity for 22 minutes, until the volume is 1.7 times (70%) of the original volume.

[0072] Rapid freezing: Freeze at -35℃ for 30 minutes until the center temperature of the buns reaches -15℃.

[0073] Packaging: Seal the package within 10 minutes at 1~5℃.

[0074] Frozen storage: below -18℃.

[0075] The resulting product has a shelf life of up to 30 days. After steaming, the product is large in volume, white in color, soft and slightly chewy in texture, without stickiness, shrinkage, or dead packaging.

[0076] The following examples verify the key role of each process parameter by comparing it with Example 1 using a single variable.

[0077] Example 2: (Comparison of low-gluten flour)

[0078] The difference from Example 1 is that low-gluten flour (9% protein content, 25% wet gluten content) is used.

[0079] Results: Low-gluten flour exhibited shrinkage and a shorter shelf life after quick-freezing. This is because the gluten is damaged during the quick-freezing process. After quick-freezing and frozen storage, the gas-holding capacity of the gluten network in low-gluten flour weakens, making it prone to shrinkage.

[0080] Example 3: (Comparison of high-gluten flour)

[0081] The difference from Example 1 is that high-gluten flour (protein content 13%, wet gluten content 35%) is used.

[0082] Results: High-gluten flour that was flash-frozen and then steamed directly exhibited shrinkage, a chewy texture, and excessive chewiness. This was because the high-gluten flour had excessively strong gluten, which affected the chewiness and resilience of the texture.

[0083] Example 4: (Comparison with fresh yeast)

[0084] The difference from Example 1 is that 30g of fresh yeast is used instead of 12g of dry yeast.

[0085] Results: The fresh yeast fermented too quickly. When producing 25kg of flour (to make 40kg of dough), the first and last dough pieces were in very different states. Under the same fermentation conditions, the fermentation time was shortened to 12-15 minutes. The production process had a low tolerance for error, resulting in unstable quality of the finished product.

[0086] Example 5: (Yeast dosage was too low)

[0087] The difference from Example 1 is that the amount of dry yeast used is 8g.

[0088] Results: The proofing time was slightly extended by 2-3 minutes, and the shelf life was significantly shortened, with the ideal shelf life being only 1-3 days.

[0089] Example 6: (Yeast dosage was too high)

[0090] The difference from Example 1 is that the amount of dry yeast used is 20g.

[0091] Results: The proofing time was shortened to 12-15 minutes, the error tolerance in the production process was low, and the quality of the finished product was unstable.

[0092] Example 7: (Baking powder dosage was too low)

[0093] The difference from Example 1 is that the amount of baking powder used is 8g.

[0094] Results: The product volume and softness decreased slightly, while the chewiness increased, making it less acceptable to consumers who prefer a softer texture.

[0095] Example 8: (Too much baking powder)

[0096] The difference from Example 1 is that the amount of baking powder used is 20g.

[0097] Results: The product is prone to bursting at the top, has a slightly alkaline taste, develops an astringent taste after being left for 1 week, and has a yellowish skin color.

[0098] Example 9: (Sugar dosage is too low)

[0099] The difference from Example 1 is that the amount of white sugar used is 20g.

[0100] Results: The proofing time was shortened by 3-5 minutes, the shelf life was short, and the product quality stability was difficult to control.

[0101] Example 10: (Sugar dosage is too high)

[0102] The difference from Example 1 is that the amount of white sugar used is 150g, and the amount of water added is adjusted to 450g.

[0103] Results: The dough was more elastic and the proofing time increased by 3-5 minutes; the product tasted sweeter, which was difficult for consumers in the north to accept; the chewier texture was more difficult for consumers in the south to accept.

[0104] Example 11: (Insufficient amount of modifier)

[0105] The difference from Example 1 is that the amount of pre-proofed frozen dough improver used is 5g.

[0106] Result: The product's water retention was reduced, affecting the dough's moisture distribution and the product's shelf life.

[0107] Example 12: (High dosage of improver)

[0108] The difference from Example 1 is that the amount of pre-proofed frozen dough improver used is 30g.

[0109] Result: The product's water retention was significantly improved, which may affect the dough's water absorption characteristics and moisture distribution, resulting in the finished product being sticky.

[0110] Example 13: (Water addition was too low)

[0111] The difference from Example 1 is that the amount of water added is 450g.

[0112] Results: The dough was highly elastic, but the proofing speed was slow. The gluten protein could not be fully formed, resulting in shrinkage. The finished product was not soft enough and had a short shelf life.

[0113] Example 14: (Water addition too high)

[0114] The difference from Example 1 is that the amount of water added is 520g.

[0115] Result: The dough was soft, rose quickly, and the buns were flat, affecting the product's appearance and reducing its shelf life.

[0116] Example 15: (Dough temperature is too low)

[0117] The difference from Example 1 is that the dough temperature is 18°C.

[0118] Results: The dough had poor extensibility, was prone to breakage during rolling, and the finished product was prone to shrinkage, resulting in a short shelf life.

[0119] Example 16: (Dough temperature is too high)

[0120] The difference from Example 1 is that the dough temperature is 28°C.

[0121] Results: The first and last dough pieces had very different states during production, the proofing time was shortened to 12-15 minutes, the production process had a low error tolerance, and the quality of the finished product was unstable.

[0122] Example 17: (Relaxation time is too short)

[0123] The difference from Example 1 is that the relaxation time is 2 minutes.

[0124] Result: The dough is highly elastic and prone to shrinkage, resulting in small finished product volume, poor gloss, shrinkage, and short shelf life.

[0125] Example 18: (Long relaxation time)

[0126] The difference from Example 1 is that the relaxation time is 10 minutes.

[0127] Results: Increased dough temperature resulted in poor dough uniformity, poor finished product quality stability, and short shelf life.

[0128] Example 19: (Insufficient number of calendering cycles)

[0129] The difference from Example 1 is that it is folded and rolled 5 times at 90°.

[0130] Results: The gluten was not fully developed, resulting in shrinkage, small volume, strong chewiness, and short shelf life of the finished product.

[0131] Example 20: (Too many calendering cycles)

[0132] The difference from Example 1 is that the 90° folding and rolling is repeated 25 times.

[0133] Result: The product has too high extensibility, the dough is too soft, and the buns have poor uprightness, which affects the uprightness and shelf life of the finished product.

[0134] Example 21: (Comparison of calendering methods)

[0135] The difference from Example 1 is that continuous calendering is used instead of 90° folding calendering.

[0136] Results: The gluten was not fully developed, resulting in poor gloss on the finished product surface, easy shrinkage, and short shelf life.

[0137] Example 22: (Short proofing time)

[0138] The difference from Example 1 is that the proofing time is 10 minutes.

[0139] Results: Insufficient proofing resulted in products that were small in size, tough in texture, lacked softness, and had a short shelf life after steaming.

[0140] Example 23: (Prolonged proofing time)

[0141] The difference from Example 1 is that the proofing time is 30 minutes.

[0142] Result: Over-proofing caused the product to easily wrinkle and shrink, resulting in a short shelf life.

[0143] Example 24: (Short freezing time)

[0144] The difference from Example 1 is that the quick-freezing time is 10 minutes.

[0145] Result: Insufficient freezing resulted in the products being thawed before packaging, causing them to stick together after packaging and affecting product quality.

[0146] Example 25: (Flash freezing time is too long)

[0147] The difference from Example 1 is that the quick-freezing time is 50 minutes.

[0148] Results: Over-freezing resulted in the surface temperature of the buns dropping below -18°C, making the products prone to cracking, resulting in a tough texture, insufficient softness, short shelf life, and excessive energy consumption, increasing production costs.

[0149] Based on the analysis and research of the above embodiments, the summary analysis of the impact of key parameters on product quality is shown in Tables 1 and 2:

[0150] Table 1: The impact of proofing degree on product quality 30-40% (less than 10%) 10min Small (≤1.5 times) Tough, sticky, and lacks softness No shrinkage 1-3 days 22 70% (optimal) 22min Larger (≥2.5 times) Soft and chewy, not sticky No shrinkage, no dead sac ≥30 days 1 More than 90% (excessive) 30min medium Insufficient chewiness Wrinkle, shrink 7~14 days 23

[0151] As shown in Table 1, the product has the largest steamed volume, the best taste, and the longest shelf life when it is 70% proofed, which is the optimal proofing degree.

[0152] To visually demonstrate the impact of proofing degree on the final product quality, Figure 1 The images provide a comparison of the appearance of raw steamed buns and the finished products at different proofing stages. From left to right, the images show:

[0153] Figure 1 A: Appearance of raw dough that has risen to 30-40% (less than 40%): smaller in size and slightly shriveled on the surface; after steaming, the finished product is small in size, has a dull surface, and may have dead skin on the bottom.

[0154] Figure 1 B: Appearance of raw dough that has risen to 50% (critical lower limit): The volume has increased slightly and the surface has begun to become full; the finished product after steaming has a medium volume, a slightly tough texture, and poor softness.

[0155] Figure 1 C: Appearance of raw dough that has risen to 70% (optimal): The volume is about 1.7 times the original volume, the surface is full and round, and the texture is elastic; after steaming, the finished product has a large volume, a white and shiny surface, even and delicate air holes, a soft and chewy texture, and no shrinkage or dead buns.

[0156] Figure 1D: Appearance of raw dough that has risen more than 90% (over-proofed): It is too large in volume, has high surface tension, and feels soft but lacks elasticity; although the finished product is large in volume after steaming, it is prone to shrinkage and collapse after freezing, the surface gloss decreases, and the shelf life is significantly shortened.

[0157] Table 2: Defect Statistics for Each Process Parameter Deviation from Optimal Value

[0158] As shown in Table 2, 70% proofing (approximately 1.7 times) is the optimal balance point: insufficient proofing (≤50%) results in small product volume, tough texture, and short shelf life; excessive proofing (≥90%) leads to poor frozen storage stability, shrinkage, and collapse. Only with precise control at around 70% proofing can excellent immediate steaming quality and a frozen storage shelf life of up to 30 days be achieved simultaneously.

[0159] The production formula and process for instant-steaming pre-proofed frozen raw buns provided by this invention are suitable for industrial mass production. The resulting products can be transported and stored under cold chain conditions. When used in terminal stores or homes, they can be directly taken out from the frozen state and placed in a steamer for steaming without the need for thawing and secondary proofing. The operation is extremely simple and suitable for promotion and application in convenience stores, breakfast shops, canteens and homes.

[0160] Of course, the above description is not limited to the examples above. Technical features not described in this invention can be implemented by or using existing technology, and will not be repeated here. The above embodiments and drawings are only used to illustrate the technical solutions of this invention and are not intended to limit this invention. This invention has been described in detail with reference to preferred embodiments. Those skilled in the art should understand that any changes, modifications, additions or substitutions made by those skilled in the art within the scope of this invention do not depart from the spirit of this invention and should also fall within the scope of protection of the claims of this invention.

Claims

1. A production process for instant-steamed, pre-proofed, frozen raw buns, characterized in that: Includes the following steps: S1. Ingredients: 1000g all-purpose flour, 8-20g dry yeast, 8-20g baking powder, 5-30g pre-proofed frozen dough improver, 20-150g sugar, 440-520g water; the protein content of all-purpose flour is 9%-13%, and the wet gluten content is 25%-35%; S2. Kneading: Mix the above ingredients together, first stir slowly for 4 to 10 minutes, then stir quickly for 1 to 8 minutes, and control the dough temperature to 18 to 28℃. S3. Relaxation: Let the kneaded dough rest for 1-15 minutes; S4. Pressing the dough: Fold and roll the relaxed dough at 90° 5-20 times. S5. Shaping: Divide the rolled dough into shapes to make steamed bun dough, wherein: the dough weighs 58±2g, the filling weighs 26±2g, and the ratio of dough to filling is 2.0~2.5:

1. S6. Pre-proofing: Place the shaped bun dough in a temperature of 28~38℃ and a relative humidity of 70~85% for 15~35 minutes to proof, controlling the proofing degree to reach 1.5~1.9 times the original volume, that is, proofing to 50~90%. S7. Rapid freezing: Rapidly freeze the pre-proofed bun dough at -30℃~-45℃ for 10~60 minutes so that the center temperature of the bun reaches -10℃~-18℃; S8. Packaging: Under ambient temperature conditions of 1~15℃, complete the sealing and packaging within 30 minutes from the end of rapid freezing; S9. Frozen storage: Freeze the packaged product at -18°C or below. The resulting frozen raw buns do not need to be thawed or proofed a second time; they can be steamed directly and eaten immediately.

2. The production process of the instant-steaming pre-proofed frozen raw buns according to claim 1, characterized in that: In S1, the amount of dry yeast is 12g, the amount of pre-proofed frozen dough improver is 10g, the amount of white sugar is 50g, and the amount of water is 480g.

3. The production process of instant-steamed pre-proofed frozen raw buns according to claim 1 or 2, characterized in that: The dry yeast is instant, highly active dry yeast; fresh yeast is not used.

4. The production process of the instant-steaming pre-proofed frozen raw buns according to claim 1, characterized in that: In S2, the slow mixing time is 6 minutes, the fast mixing time is 3 minutes, and the dough temperature is 24℃; in S3, the relaxation time is 8 minutes.

5. The production process of instant-steamed pre-proofed frozen raw buns according to claim 1, characterized in that: In S4, the 90° folding and calendering is performed 12 times.

6. The production process of instant-steamed pre-proofed frozen raw buns according to claim 1, characterized in that: In S6, the proofing temperature is 35℃, the relative humidity is 80%, the proofing time is 22 minutes, and the proofing degree is 1.7 times the original volume, that is, 70% proofed.

7. The production process of instant-steamed pre-proofed frozen raw buns according to claim 1, characterized in that: In S7, the rapid freezing temperature is -35℃, the freezing time is 30 minutes, and the center temperature of the bun reaches -15℃.

8. The production process of instant-steamed pre-proofed frozen raw buns according to claim 1, characterized in that: In S8, the packaging environment temperature is 1~5℃, and the sealing packaging is completed within 10 minutes after the rapid freezing ends.

9. The production process of instant-steamed pre-proofed frozen raw buns according to claim 1, characterized in that: In S1, the protein content of medium-high gluten flour is 11.5%, and the wet gluten content is 30%.

10. A steamed pre-proofed frozen raw bun made using the production process of any one of claims 1 to 9.

Images