A short time sponge and dough process

Abstract

Provided is a process for producing a yeast-leavened product. The process comprises combining into a dough (a) flour; (b) yeast; (c) yeast food; (e) about 0.015 to 0.25 parts food acid per 100 parts flour; and (d) water, which shortens fermenting the dough in the process of dough making. Also provided are dough improvers, individual food acids and sources of food acids added to the dough that bring about the proper changes in gluten structure and dough properties in the fermented dough, which occur during fermentation and other dough processing steps. Eliminated is the sponge fermentation that leads to the development of the Short Time Sponge and Dough process, which produces natural and better quality breads in about 2 hour processing time than a sponge and dough bread.

Description

[0001] A SHORT TIME SPONGE AND DOUGH PROCESS

[0002] BACKGROUND OF THE INVENTION

[0003] I. Field of the Invention

[0004] The research disclosed in the inventor’s US RE36,355 Fl (‘355 Fl) found that the acetic acid produced during yeast fermentation acts as a dough oxidant / improver, which produces properly oxidized / developed gluten protein structure in the fermenting dough. Due to the acetic acid produced in the fermented sponge, the use of different amounts of ascorbic acid as an oxidant in the Canadian sponge-and-dough baking test (40 ppm) and Canadian short process baking test (150 ppm) at www.grainscanada.gc.ca confirmed the study results reported in the ‘355 Fl patent.

[0005] The successful Short Time Sponge and Dough process must be able to bring about the proper changes in gluten protein structure and dough properties in the fermented dough, which occur during fermentation and other dough processing steps. The present invention is related to a Short Time Sponge and Dough process that brings about the proper changes in gluten structure and dough properties, and provides interacting partners of functional wheat gluten proteins, metal ion-food acid complexes to the fermented dough. Specifically, the present invention discloses a Short Time Sponge and Dough process, which uses the inventor’s newly developed dough improver. When flours used in making breads are treated with food acids and sources of food acid listed in claims 5 and 10 of the ‘355 Fl patent, bakers achieve their objective of eliminating sponge fermentation.

[0006] Based on the new findings disclosed in the ‘355 Fl patent, the inventor submitted Citizen’s Petition (Docket No. FDA-2006-P-0017) for the ban of carcinogenic potassium bromate used in the breadmaking process to the U.S. Food and Drug Administration (FDA) on April 24, 2006. The email received from the FDA dated August

[0007] I I, 2020 stated that "let us know within 30 days if you are still interested in pursuing the petition." To support the inventor’s citizen petition in the letter of intent, the inventor submitted Chapter 3 of the inventor’s Book titled "Mechanisms of Oxidants Used in Flour Treatments" to the FDA on August 23, 2020, because the inventor believes that the content of Chapter 3 allows the FDA to grant the inventor’s citizen petition filed on April 24, 2006. Combining the study findings of food acids as dough oxidants in the ’355 Fl patent with the contents of the inventor’s Book titled “ Wheat Chemistry and Dough for Breadmaking: Understanding How Functional Gluten Proteins, Wheat Starch, and Lipids Govern Gluten Functionality. Functional Glutenin and Gliadin Proteins, Starch, and Lipids in Baking Performance and for Bread Structure”, the inventor has discovered that treating flours with the examples of preferred embodiments disclosed in A Short Time Sponge and Dough process not only eliminates the sponge fermentation, but it also produces the final baked bread that, is natural and better quality than sponge fermentation by reducing the cost of bread production through energy usage, processing time, labor, and higher dough yield that are required to produce quality breads.

[0008] As based on the study findings detailed in the inventor’s Book, the mechanism by which oxidizing agents act on flour proteins in the fermenting dough (Chapter 3) and a greater understanding of yeast fermentation that contributes to the development of fermented dough structure with the viscoelastic properties from flour (Chapters 4 and 7-8) have resulted in the production of natural and better quality breads in about 2 hour processing time, developing the most cost-effective Short Time Sponge and Dough process in this breakthrough breadmaking process.

[0009] 2. Description of the Prior Art

[0010] The lengthy Sponge and Dough process was empirically developed by ancient bakers, who noted that dough that had been allowed to ferment for a certain time not only was easier to process during dividing and moulding than freshly mixed dough, but also produced the unique viscoelastic fermented dough that retains the gas produced by yeast, producing bread that was well aerated and more flavorful. They observed that yeast fermentation is essential to bread quality by changing the cohesive properties of wheat dough formed during mixing, as the fermented sponge becomes soft and loses much of its gluten elasticity during lengthy fermentation. The stiff and inelastic dough matrix formed by mixing (Johannson and Cooke, 1971) acquires smoother and glossier appearance that is greatly pliable, extensible, and elastic fermented dough in the production of quality breads.

[0011] Thus, over many millennia, the production of yeast-leavened breads was firmly founded on a basic procedure in which fermentation of the dough may be said to have been an essential step, as the function of fermentation food acids produced during fermentation brings about the proper changes in gluten structure, and produces the functional gluten proteins in the fermenting dough that govern gluten functionality (Figure 21). However, to eliminate sponge fermentation that has an improving effect on gluten proteins by properly developing gluten structure in the sponge fermentation, changes in the structure of gluten proteins have been achieved by the use of liquid ferment or brew, the application of mechanical energy imparted into the dough during mixing, and the use of chemical additives. Short Time Bread processes that do not bring about the proper changes in gluten structure that occur during sponge fermentation produce structurally different gluten proteins in the fermenting dough (Chapter 7), affecting bread structural features, loaf volume, crumb grain, and shelf life.

[0012] 2.1. Continuous Mix Process in the U. S

[0013] The Do-Maker process introduced by Baker (1954) and Amflow process (Anon, 1958) are the principal continuous mix process used in the U.S. To replace sponge fermentation, fermentation in liquid ferments or brew with intense mixing action is introduced to both processes. After ferments or brews are prepared, continuous mix process is blending ferments or brews with flour and other ingredients to form dough. Mixing the loosely mixed mass by intense mixing in a closed chamber differ from those in the fermented sponge, and the dough is then directly extruded into the pan. It produced good bread, but not identical with sponge dough bread due to differences in structural changes of proteins and starch between sponge fermentation and ferments or brews with other ingredients by intense mixing.

[0014] Fermentation in liquid ferments or brews with or without flours is conducted for about 2 to 2.5 hours. As a result of yeast activity and ethyl alcohol fermentation that produces acetic acid, the pH drops to 4.7. The pH of the fermented sponge and of the liquid ferment has a final value of about 4.7, indicating that wheat proteins undergo partial unfolding induced by H+in liquid ferments or brews. However, the liquid sponge or brew cannot replace the fermented sponge in the Sponge Dough process, because due to differences in the amount of water, fermentation time, and dough processing methods between the Sponge Dough process and Continuous Mix Process, structurally different gluten proteins are produced between two processes. The fermented sponge produces the functional gluten proteins and liquid ferment or brew produces the specialized gluten proteins. As all protein functions are dependent on their structure, this structural difference contributes to differences in bread structural features.

[0015] 2.2. Chorleywood Bread Process in Great Britain

[0016] The Do-Maker process introduced by Baker (1954) is further modified to suit British breads by British Baking Industry Research Association in 1958. Investigators have found that when sponge fermentation in dough was replaced by mechanical modification, the quality of bread was related to the amount of work applied to the dough and the time span over which the kneading action was performed. Chamberlain et al. (1961) found that optimum results of mechanical dough modification were achieved, when the optimum energy input was 5 -watt hour per pound of dough and the amount of energy had to be put into the dough within five minutes. This amount of energy is five to eight times greater than required in mixing dough intended for sponge fermentation.

[0017] They concluded that brew or preferment, which brings about structural changes in proteins, is not necessary in the Chorleywood Bread process. However, to offset the lack of the dough development by fermentation food acids produced in the fermented sponge, flours are treated with additional usages of dough improvers and yeast, which bring about structural changes in proteins during about 2-hour processing time. To supplement the structural changes of gluten proteins induced by hydrogen ions (H+) during fermentation in liquid ferments or brews, the Chorleywood Bread process introduced in 1961 is specified the addition of 75 ppm potassium bromate or ascorbic acid, the use of moderately high melting point fat, about 3.5% higher water absorption, and an increase in yeast level by 50 to 100% to maintain to final proof times comparable with those used for fermented sponge. Bach mixers operated at 350-400 r.p.m. under reduced pressure for two to four minutes to supply constant work input increase electric power usage, but it produces bread with finer crumb grain than that produced by sponge fermentation.

[0018] In fact, mechanically modified protein structure in the Chorleywood Bread process is not able to replace the fermentation development achieved with fermentation food acids during the Sponge Dough process. The development of viscoelastic structure in the fermented dough that retains gas during fermentation cannot be achieved by mechanical work imparted into the dough during mixing, which brings about changes in the molecular weight distribution of proteins (Skerritt et al. 1999). The proper changes in gluten structure during intermediate proofing before moulding, the final stages of proofing, and the early stages of baking play the essential roles in the development of viscoelastic fermented dough (Figures 21, 24, 27, and 33), contributing to the final bread quality. Hence, the Chorleywood Bread process is not regarded as the No-Time dough process, because additional usages of dough improvers, yeast, and water yield mechanically modified dough properties with similar machineabilities that can be processed on the same plant as fermented sponge. Specifically:

[0019] 1. The proper changes in gluten structure achieved by additional dough improvers and yeast produce the specialized gluten proteins in the fermenting dough and also provide metal ion-food acid complexes as interacting partners of specialized gluten proteins.

[0020] 2. Hard fat is required to achieve adequate increases in loaf volume, due to the structural differences in the form of the protein produced in the fermented dough between two processes.

[0021] 3. Additional water should be added to adjust the dough consistency to be comparable with that from a lengthy fermentation stage, as enzymatic hydrolysis in the fermenting sponge brings about changes in dough fluidity during early baking stages.

[0022] In sum, to bring about structural changes in gluten proteins and many complex reactions that occur during sponge fermentation, depolymerization of glutenin macropolymers and starch molecules is achieved by the application of mechanical energy imparted into the dough during mixing. Since the proper changes in gluten structure in freshly milled flour are essential for the production of quality breads, additional usage of dough improvers, yeast, and hard fat made good breads that are different from sponge dough bread, because mechanically modified gluten structure does not bring about properly developed gluten structure and dough properties that occur during sponge fermentation.

[0023] 2.3. Chemical Dough Modification

[0024] Another short time bread process is chemically modified dough structure by making the use of chemical additives. Hydrated glutenin polymers first depolymerize into smaller units by reducing agents and undergo the molecular rearrangement of protein molecules in cohesive dough during further mixing of dough. It does not require intense mixing, but fermentation is reduced to about 40 minutes (Tsen, 1970) because chemically modified dough does not bring about the required structural changes in gluten proteins and dough properties during fermentation, as chemical dough modification introduced in the U.S. in 1962 modified the dough structure through the reducing action of L-cysteine plus oxidizing action of potassium bromate. However, the combined use of reducing and oxidizing agents is unable to achieve the many changes that take place during lengthy sponge fermentation, and fails to produce comparable quality breads produced from the Sponge Dough process.

[0025] 2.4. No-Time Dough Process

[0026] Short time bread process called No-Time Dough process that requires about 2 hours from mixing to baking has become important in many countries around the world. The dough is not subjected to sponge fermentation, but total dough fermentation still occurs during floor time, final proofing, and the early stage of baking. For the NoTime Dough process, all the ingredients are mixed using optimum water absorption and mixing time by blending them together into homogeneous mass, and the dough is then relaxed for 15 to 40 minutes. The reason for this floor time is needed for stiff and inelastic dough to ensure hydration of gluten proteins and starch, and also to improve handling properties of dough during subsequent processing steps. The dough is then divided and goes through the usual processing steps. Due to the lack of sponge fermentation, no-time dough bread has short shelflife during storage. Hearth breads and rolls that are consumed within a day or two are produced.

[0027] Moreover, to produce breads with “no-time” doughs in the mid-1950s has its obvious advantages, but such doughs become never popular because of the inferior quality of the bread they produced. Due to the acetic acid produced in the fermented sponge, 40 ppm ascorbic acid as an oxidant is needed in the Canadian sponge-and-dough baking test, but 150 ppm ascorbic acid as a dough improver is added to bring about proper changes in gluten structure. In addition to the need for higher amount of ascorbic acid that induces structural changes of gluten proteins in freshly milled flour, the amounts of yeast and yeast food are also increased in the No-Time Dough process, so final proof time comparable with about 55 minutes with Sponge Dough process dough is maintained.

[0028] From the turn of the century until the present time, the Sponge Dough process produces the majority of breads. The idea for making bread in the shortest time is to eliminate sponge fermentation, but speeding up the process has been approached to bring about unknown changes in the gluten structure during fermentation by using liquid ferments or brew and chemical additives and applying mechanical work into dough during mixing. Then, to counteract the fermentation effects on structural changes in gluten proteins and dough properties during sponge fermentation, the formula adjustment is required to produce quality breads in the No-Time Dough process:

[0029] 1. Additional dough improvers are needed to bring about the proper structural changes of gluten proteins in freshly milled flour to offset the lack of the sponge fermentation.

[0030] 2. Yeast activity is accelerated by higher levels of yeast and yeast food, increasing the production of CO2 and alcohol that serves as the raw material for acetic acid in the fermenting dough.

[0031] 3. Fermentation food acids, acetic acid provides H+that bring about structural changes in gluten proteins, while its anions provide interacting partners of metal ion-acetate complexes that interact with the specialized gluten proteins developed in the fermented dough (Figures 16-17, 24, and 27).

[0032] In sum, despite making an ongoing effort that evolves over many millennia and ingredient development, the Sponge Dough process developed by ancient bakers remains basically the same, because we do not have a deeper understanding how sponge fermentation develops the fermented dough.

[0033] SUMMARY OF THE INVENTION

[0034] The present invention is achieved through developing new dough improvers disclosed in the ‘355 Fl patent, which replace the acetic acid produced during lengthy sponge fermentation. The present invention is further related to previously unknown subjects for the function of dough improvers on gluten proteins in the fermenting dough and dough development that occurs during a fermentation processing step. In sum, a greater understanding of both subjects is imperative to the development of a Short Time Sponge and Dough process, most cost-effective Sponge Dough process:

[0035] 1. Mechanisms of oxidizing agents used in flour treatments improve the baking performance of gluten proteins in freshly milled flour by bringing about structural changes in proteins through pH-induced conformational changes or salt effects on conformational stability in the fermenting dough. 2. Fermentation dough development is attributed to fermentation food acids produced in the fermenting dough that bring about the structural changes in gluten proteins through protein unfolding.

[0036] 3. The proper changes in gluten structure that are achieved during fermentation and by dough improvers produce the partially unfolded structures of functional and specialized gluten proteins in the fermenting dough that govern the baking performance of flour and hence gluten functionality.

[0037] The inventor has thus found that food acids and sources of food acid listed in claims 5 and 10 of the ‘355 Fl patent bring about the proper changes in gluten structure and provide interacting partners of functional and special wheat proteins, metal ion-food acid complexes during A Short Time Sponge and Dough process, whereas treating flours with ascorbic acid or potassium bromate do not provide interacting partners of functional gluten proteins developed in the fermented dough.

[0038] Hence, flours used in making breads are treated with food acids, which act as better dough improvers in a Short Time Sponge and Dough process. Moreover, among the food acids studied, citric acid provides colloidal, aquo-metal ion-citrate complexes that act as excellent emulsifiers in the fermented dough and effective crumb softeners during bread aging. Importantly, citric acid is a natural product that is produced by vegetative fermentation of sugars. Breads made with citric acid in a Short Time Sponge and Dough process can be thus labelled as “natural”, which has a desirable attribute for the consumer. Even with eliminating lengthy fermentation, the final bread has better quality than traditional 4-hour fermentation time by reducing the cost of bread production through energy usage, processing time, and labor that are required to produce quality breads.

[0039] DETAILED DESCRIPTION OF THE INVENTION

[0040] 1. Gluten Protein Functionality in Breadmaking

[0041] Wheat storage proteins are the quality determinants of the breadmaking quality of flour (Delcour et al. 2012), although millers or bakers are acknowledged in early years that freshly milled flours require proper treatments with oxidizing agents to produce quality breads (Huebner et al. 1977; Kulp, 1981; Fitchett and Frazier 1986; Weegels et al. 1996; Grosch and Wieser, 1999; Demiralp et al. 2000; Goesaert et al. 2005). For the full functional performance of flour, fermentation and dough improvers bring about the proper changes in gluten structure that are required for the production of quality breads, indicating that functional and specialized wheat proteins produced in the fermenting dough govern the baking performance of flour (Figures 21, 24, and 27). In fact, it is not the primary structure of gluten proteins in wheat grains that determine the baking potential of flour. As optimally mixed dough undergoes further structural changes in gluten proteins during fermentation and by dough improvers through protein unfolding, partially unfolded structures of functional glutenins and gliadins produced in the fermenting dough play a pivotal role in governing gluten functionality and hence baking performance (Figure 21). Since a quality determinant of the baking potential of flour is related to partially unfolded gluten proteins in the fermenting dough, wheat cultivars with similar gluten protein content exhibit different protein functionality in breadmaking performance.

[0042] 2. Mechanisms of Oxidizing Agents Used in Flour Treatments

[0043] To realize the full functional potential of freshly milled flour, dough oxidizing agents are widely used to make quality breads. To improve the functional performance of wheat proteins in freshly milled flour (col. 1, 11. 31-42 of the ‘355 Fl patent), oxidizing agents have different rates of reaction during dough production. Kulp (1981) stated that as the dough requires strengthening by oxidation, bakers can combine fast oxidizing agents, ascorbic acid with a slow acting oxidant, potassium bromate to provide adequate dough strength at various stress points of the entire manufacturing process. As effects of oxidizing agents on flour proteins have currently built on theories, they do not explain differences in the rate of reactions of oxidizing agents during dough processing steps (Fitchett and Frazier 1986; Demiralp et al. 2000; Goesaert et al. 2005; Delcour et al. 2012). Despite the earlier premises to the contrary, the inventor’s Book in Chapter 3 detailed how oxidants bring about structural changes in gluten proteins in the fermenting dough and produce the properly oxidized / developed gluten structures that are required for the production of quality breads.

[0044] New evidence in the experimental findings has now shown that the improving effects of oxidizing agents on dough quality should be explained by changes in gluten structure during dough processing (Figure 21). The study on the effect of different food acids as dough improvers in breadmaking processes disclosed in the ‘355 Fl patent and detailed in the inventor’s hardcopy of printed Book of Chapter 3 has found that the oxidizing / improving effects of ascorbic acid, fermentation food acids, or potassium bromate / iodate on gluten proteins arise from structural changes in gluten proteins through protein unfolding in the fermenting dough. When they are ionized in water or dough (Ayres, 1968; Tsao, 1997; ‘355 Fl patent), ascorbic acid and food acids bring about the proper changes in gluten structure induced by H+in the fermenting dough. Through pH-induced protein unfolding (Kasarda et al. 1968; Rudy and Audrey Haschemeyer, 1973), ascorbic acid and fermentation food acids improve the functional performance of gluten proteins in freshly milled flour.

[0045] On the other hand, potassium bromate and potassium iodate are known to liberate bromide / iodide ions in acidic solution (Ayres, 1968). To understand the improving effect of potassium bromate or potassium iodate on dough properties and loaf volume, this is likely to be the case in the acidic conditions of fermenting and proofing doughs. Moreover, liberation of bromide / iodide ions is used to standardize thiosulfate solutions, and titrations in slightly acidic solution have shown that the reaction is somewhat slower with potassium bromate than it is for potassium iodate (Ayres, 1968). When used as dough improvers in breadmaking process, differences in their rate of liberation of bromide and iodide ions play their role in deciding the reaction rates of potassium bromate / iodate during dough processing steps. Iodide ions generated in the fermenting dough are faster than bromide ions - the iodide ion generated in the fermenting dough makes potassium iodate to be functional during the early stages of proofing, while the bromide ion generated in the proofing and baking makes potassium bromate to be functional during the later stages of proofing and early stages of baking. Through salt effects on protein structure (von Hippel and Schleich, 1969), their improving effect on the baking performance of gluten proteins in freshly milled flour and bread quality is thus due to liberated iodide / bromide ions inducing conformational changes in proteins in the fermenting dough.

[0046] In sum, the study on the effect of different food acids as dough improvers in breadmaking processes disclosed in the ‘355 Fl patent and in the inventor’s Book has found that “strengthening dough with oxidation” should be defined as “proper changes in gluten protein structure” in the fermenting dough, as the reactions of oxidizing agents in the dough bring about structural changes in gluten proteins through either pH-induced conformational changes or salt effects on conformational stability during dough processing. Now it is established that oxidizing agents bring about changes in gluten structure during breadmaking processes. Either inadequate changes (insufficient oxidation) in protein structures or extensive changes (excessive oxidation) in protein structures are equally damaging to dough properties and bread quality. In contrast, addition of an effective amount of food acids produces a properly oxidized dough (col. 7, 11. 26-32 in the ‘355 patent) in which gluten structure is properly developed by H+through protein unfolding, and food acids having chelate-forming properties provide negatively charged metal ion-food acid complexes that interact with functional gluten proteins developed in the fermented dough (Figure 16-17, 21, and 24).

[0047] 3. Dough Development by Yeast Fermentation

[0048] One of important functions of yeast fermentation is dough development during breadmaking processes, as structural changes in wheat proteins during fermentation produce the functional and specialized gluten proteins in the fermenting dough, which govern gluten functionality and hence the breadmaking performance of freshly milled flour. Fermentation dough development by yeast thus means that dough fermentation results in the production of ethyl alcohol in fermenting and proofing doughs. The alcohol by bacteria’s action in flour is further transformed to acetic acid that provides H+by ionizing and exerts an improving effect on the baking potential of flour through protein unfolding, while acetate anions affect the strength of fermented dough and crumb grain by providing negatively charged metal ion-acetate complexes (Figures 16-17 and 24), which interact with positively charged groups on the surface of the functional gluten proteins developed in the fermented dough.

[0049] As detailed in the inventor’s Book on the effect of food acids in breadmaking processes, they improve the functional performance of freshly milled flour through pH-induced unfolding in the fermenting dough. By lowering the pH from 5.3 to 4.7 in the fermented sponge (Selman, 1948), the fermentation food acids produced in the fermenting dough and the food acids added as dough improvers are partially ionized in aqueous solution and in dough (Ayres, 1968; ‘355 Fl patent), and this contributes H+that partially unfold gluten structure (Figure 21) and protonate specific amino acid residues in proteins that acquire positive charges in the fermented dough, while their anions contribute negatively charged metal ion-food acid complexes that interact with functional and specialized gluten proteins developed in the fermented dough (Figures 16-17, 21, 24, and 27).

[0050] As the proper changes in gluten structure during fermentation and by dough improvers are required for full functional potential of freshly milled flour, mechanically and chemically modified doughs that undergo further changes in gluten structure by dough improvers and during proofing and the early stages of baking produce the specialized wheat proteins in the fermenting dough. Due to way of dough treatments during mixing, structural differences in each specialized protein led to different protein functions that determine bread structural features. Fermentation food acids produced in sponge yield partially unfolded structures of the functional gluten proteins through protein unfolding, which are different from the gluten structures produced from both the mechanically and chemically modified doughs that yield specialized gluten proteins (Figures 21 and 27). Structural differences among gluten proteins produced in the fermenting dough thus contribute to differences in bread structural features.

[0051] Moreover, the correct level of mechanical work imparted into the dough during mixing is not the critical step in developing dough, as evidenced by the fact that relatively stiff, rough sponge at the end of mixing undergoes fermentation and develops dough structure with thin, elastic, and extensible films that retains the gas produced during fermentation (Figure 20). The Chorleywood Bread process is thus not a successful example of properly developed dough by mechanical modification. In fact, structural changes in gluten proteins through protein unfolding and the complex reactions that occur in the fermenting sponge are not replaceable by the mechanical work imparted into the dough during mixing, which brings about the changes in the molecular weight distribution of gluten proteins.

[0052] In sum, all protein functions are dependent on their structure, as the amino acid residues in distinct structures of functional and specialized gluten proteins determined by dough processing methods take part in interactions with each other and with other flour constituents and components in the fermenting dough. Structural differences between the functional and specialized gluten proteins contribute to the specificity and affinity of protein interactions in the fermented dough that have a large impact on bread attributes, loaf volume, crumb grain, texture, and shelf life.

[0053] 4. Development of Viscoelastic Dough from Flour During mixing, gluten proteins form a continuous network in the dough, giving it the viscoelastic dough that is suited for use in breadmaking. Contrary to this consensus view, the stiff and inelastic dough mass that is almost incapable of expansion by gas is produced during mixing (Johannson and Cooke, 1971). To explain the viscoelastic properties of wheat dough, there were heated discussions on the subject of dough development theories (Belton and Dobraszczyk, 2006; MacRitchie, 2007; Belton, 2007; Vliet and Hamer, 2007), but the study findings have now shown that the distinctive viscoelastic property, which makes wheat dough suitable for breadmaking, occurs during fermentation. As a result of fermentation dough development (Figure 20), the fermented dough becomes extensible and elastic, so thin web structure retains entrapped gas in fine bubbles and not coalesces during the rapid expansion that occurs in the oven, contributing to the final bread quality.

[0054] The relevance of wheat flour to breadmaking quality is attributed to cohesive properties of wheat dough and the development of viscoelastic structure in the fermented dough that retains the gas produced by yeast, when the optimally mixed wheat dough formed by mixing undergoes further structural changes in gluten proteins during fermentation and by dough improvers in the fermenting dough. Fermentation food acids produced during fermentation and dough improvers added bring about structural changes in cohesive properties of wheat dough that improve its ability to retain gas during proofing and baking, as functional glutenin and gliadin proteins produced in the fermenting dough interact with each other and with other flour constituents and engage in varied networks during various stages of breadmaking (Figure 21). Hence, the primary structure of gluten proteins fails to explain its viscoelastic property of dough from flour, as partially unfolded structures of functional and specialized gluten proteins in the fermenting dough contribute to the development of the gluten structure in the viscoelastic fermented dough that is required for good baking performance of flour.

[0055] It is generally accepted that differences between flours in baking quality are largely due to variation in gluten protein composition, but all components of wheat flour have an effect on the final bread quality through protein interactions and networks, finding that starch and lipids are other flour constituents accounting for the ability of wheat grain to be processed into quality breads. Elasticity in the fermented dough is attributed to where functional high molecular weight glutenin subunits (HMW-GS) interact with each other and with starch and lipid and extensibility is where functional low molecular weight glutenin subunits (LMW-GS) and functional gliadin proteins interact with each other and with starch and lipids, but not HMW glutenin to gliadin ratio. The elastic HMW glutenin networks linked to the extensible LMW glutenin and gliadin networks through noncovalent interactions contribute to the development of viscoelastic structure in the fermented dough that is required for gas retention in the production of quality breads (Figures 21 and 24).

[0056] Mixing that involves the application of mechanical energy imparted into the dough is not a critical step in developing the dough into viscoelastic structure with gas retention. The reason is that as mixing progresses, homogeneous dough with cohesive properties is produced where the protein structure in wheat dough interact with each other and with other flour constituents. The study on the effect of food acids in breadmaking processes found that fermentation is a critical processing step in developing viscoelastic dough from flour, as relatively stiff, rough sponge at the end of mixing undergoes fermentation (Figure 20) and then, how the functional gluten proteins produced in the fermenting dough interact with each other and with other flour constituents and engage in varied networks leads to the proper development of the gluten structure in the viscoelastic fermented dough that maximizes gas retention in the production of quality breads (Figures 21 and 24).

[0057] In sum, there are differences in rheological properties between wheat dough and fermented dough. The most important function of yeast in breadmaking is attributed to fermentation food acids produced, which bring about structural changes in cohesive properties of wheat dough. The proper changes in gluten structure during dough fermentation produce functional and specialized wheat proteins in the fermenting dough that govern gluten functionality in breadmaking. Interactions of functional and specialized gluten proteins with each other and with other flour constituents determine the balance between elasticity and extensibility developed in the fermented dough that is required for optimal breadmaking quality. The viscoelastic structure in the fermented dough that is essential for gas retention is developed in the process of breadmaking, linking the elastic HMW glutenin networks to the extensible LMW glutenin and gliadin networks through noncovalent interactions (Figure 21).

[0058] 5. Strength and Stability of the Gluten Structure in Viscoelastic Fermented Dough To prevent coalescence of gases during the rapid expansion that occurs during oven rise, adequate dough strength throughout the entire process produces quality breads with loaf volume and crumb structure. Bakers are aware that dough made without added oxidizing agents does not produce acceptable loaf volume and strengthening dough with oxidation is required to increase loaf volume, as the addition of oxidizing agents strengthens dough in breadmaking (Wieser, 2003). Contrary to old assumptions, the study findings have shown that oxidants added to bread mix bring about structural changes in gluten proteins in the fermenting dough through protein unfolding, and the strength and stability of the gluten structure in the viscoelastic fermented dough is achieved by noncovalent bonds (Figures 24 and 33), but not disulfide bonds playing a major role in the strength of dough.

[0059] When ionized in dough, the H+released from food acids bring about structural changes in gluten proteins through pH-induced unfolding and protonate specific amino acids in proteins that acquire positive charges in the fermented dough and their anions provide interacting partners of negatively charged metal ion-food acid complexes (Figures 16-17). Noncovalent interactions between positively charged groups on the surface of functional gluten proteins and negatively charged metal ion-food acid complexes involve electrostatic forces that contribute to the strength and stability of the gluten structure in the viscoelastic fermented dough (Figures 27 and 33), while the noncovalent bonds that bring the cysteine residues into close proximity permit the formation of new disulfide bonds, which serve as additional means for increasing the stability of the functional gluten protein structure.

[0060] Essentially, to produce a properly oxidized / developed dough structure in bread production, ascorbic acid or food acids added at a proper level bring about the proper changes in gluten structure through pH-induced conformational changes, while an optimum amount of potassium bromate or potassium iodate brings about the proper changes in gluten structure through salt effects on conformational stability. As presented in Figures 16-17, 24, and 27, the functional / specialized wheat proteins and their interacting partners of metal ion-food acid complexes are developed in the fermented dough. Noncovalent bonds between charge-charge interactions contribute to the strength and stability of the elastic and extensible dough films, which surround the gas cells in the fermenting dough during proofing and baking, but not disulfide bonds playing a major role in strengthening dough or the HMW glutenins imparting dough strength.

[0061] Proteins encounter many potential interacting partners in the dough. The bread produced from old sponge has proven that interacting partners produced in the fermented dough are negatively charged metal ion-acetate complexes, as the study has already shown that “old sponge” produces bread with “open, uneven, streaky grain” (Cotton and Ponte, 1973). As disclosed in the ‘355 Fl patent and presented Figures 16- 17 and 24 in the inventor’s Book, the study on the effect of different food acids in breadmaking revealed that due to non-colloidal metal ion-acetate / tartrate complexes in the fermented dough, excessive acetic acid in the old sponge and tartaric acid added to bread mix produce breads with coarse crumb grain, whereas citric and malic acids provide the negatively charged colloidal, aquo-metal ion-citrate / malate complexes. Thus, Hamburger Buns made from ascorbic acid combined with citric / malic acid at Coldwater Bakery in Michigan on July 10, 1996 improved crumb structure with finer crumb grain than regular production batch that had monodiglycerides.

[0062] Due to the side-chain structures of amino acid residues, proteins rarely act alone. In dough, proteins interact with each other and with other molecules to form complexes or networks that undertake the baking performance of flour. As all flour constituents are embedded in protein matrix during mixing, the flour strength of wheat dough is attributed to where the protein structure in wheat dough interacts with each other and with other flour constituents, starch and lipids during mixing (Figures 13-14 and 23), but not the HMW glutenins imparting dough strength. The strength of fermented dough is attributed to where electrostatic interactions between functional gluten proteins and metal ion-food acid complexes strengthen and stabilize the gluten structure in the viscoelastic fermented dough, as fermentation food acids produced and “a food acid added in an effective amount” produce positively charged groups on the surface of functional / specialized gluten proteins and negatively charged metal ion-food acid complexes developed in the fermented dough.

[0063] In sum, the major components responsible for gas cell stability and gas retention in the viscoelastic fermented dough are the functional and specialized wheat proteins, starch, lipids, emulsifiers, and metal ion-food acid complexes (Figures 16-17, 21-22, and 24). The dough film surrounding gas cells is the continuous phase of viscoelastic dough films that is formed by the functional gluten protein-wheat starch / lipid interactions in the fermented dough (Figure 21), causing the gas cell film to set and become rigid and extensible long enough to hold entrapped gases but does not collapse and thus giving structure to the bread. The strength and stability of the gluten proteins in the viscoelastic structure result from the binding of functional / specialized gluten proteins to metal ion-acetate / citrate / tartrate complexes developed in the fermented dough (Figures 24 and 27). These interactions support the structure of the leavened dough during the rapid expansion that occurs in the proof box and oven, contributing to the production of quality breads.

[0064] 6. Development of a Short Time Sponge and Dough Process

[0065] The successful Short Time Sponge and Dough process must be able to bring about the proper changes in gluten protein structure and dough properties in the fermented dough that occur during fermentation and other dough processing steps - it must be able to achieve the proper changes in the gluten protein structure and dough properties that occur during sponge fermentation, and also the bread must be satisfactory to the consumer. The development of a Short Time Sponge and Dough process is achieved by the key findings of a functional replacement of fermentation food acids produced in the fermenting dough that act as dough improvers and a greater understanding of dough development that occurs during fermentation in bread production. Hence, when flours used in making breads are treated with new dough improvers, food acids that bring about the proper changes in gluten protein structure in freshly milled flour produce the functional glutenin and gliadin proteins in the fermenting dough and also provide interacting partners of functional gluten proteins, metal ion-food complexes to the fermented dough that are essential for the production of quality breads (Figures 21, 24, and 27).

[0066] To eliminate lengthy sponge fermentation that has an improving effect on gluten proteins by properly developing dough structure in the sponge through protein unfolding, the structural changes in gluten proteins have been achieved by the use of food acids and a source of food acids listed in the claims 5 and 10 of the ‘355 Fl patent. Knowing how the acetic acid produced in lengthy sponge fermentation and food acids added to bread mix function in the fermenting dough has led to the development of a Short Time Sponge Dough process. Moreover, citric acid that brings about a much greater change in gluten structure in freshly milled flour is a natural product produced by vegetative fermentation of sugars and provides negatively charged colloidal, aquo-metal ion-citrate complexes. Thus, even with a shorter processing time, the final bread is natural and better quality than traditional 4-hour fermentation time by reducing the cost of bread production through energy usage, processing time, and labor that are required to produce quality baked bread products.

[0067] In sum, as “a food acid added in an effective amount” to bread mixes properly develops gluten structure, fermentation dough development is thus achieved by the use of food acids, but not sponge fermentation during dough processing. It has been found that when flours used in making breads are treated with the effective amount of food acid as a dough improver, bakers achieve the objective of eliminating sponge fermentation, as food acids produce the properly developed gluten structure that is induced by H+through protein unfolding and have chelate-forming properties that provide metal ion-food acid complexes as interacting partners of functional gluten proteins in the fermented dough.

[0068] 7. Embodiments of a Short Time Sponge and Dough Process

[0069] The proper changes in gluten protein structure in freshly milled flour are required for improvements in the baking performance of wheat grains and loaf volume. As the inventor’s study findings are that food acids act as dough improvers during dough processing and the wheat dough is developed during a fermentation processing step, food acids and a source of food acids listed in the claims of the ‘355 Fl patent are chosen to shorten the Sponge and Dough process - the required changes in the structure of gluten proteins have been achieved by the use of food acids and a source of food acids, i.e., citric acid produced by vegetative fermentation of sugars and in citrus fruits, malic acid in apple juice, tartaric acid in raisin juice concentrate, and acetic acid in grain vinegar. However, as food acids partially unfold gluten structure in the fermenting dough and provide colloidal or non-colloidal metal ion-food acid complexes to the fermented dough, improvements in bread quality such as specific loaf volume, crumb grain, and shelf life, depend primarily on which food acid is used / chosen in a Short Time Sponge and Dough process.

[0070] For the acetic acid produced during sponge fermentation, the study with 20% liquid vinegar (0.2% acetic acid) was presented in col. 7, 11. 14-19 of the ‘355 Fl patent, describing that “Bread volume was good to excellent, but slightly coarse grain.” The study on the effect of different food acids in breadmaking processes revealed that the acetic acid in old sponge and tartaric acid added produce breads with coarse crumb grain due to non-colloidal metal ion-acetate / tartrate complexes in the fermented dough, whereas citric and malic acids provide the negatively charged colloidal, aquo-metal ion- citrate / malate complexes to the dough matrix. Thus, Hamburger Buns made from ascorbic acid combined with citric / malic acid at Coldwater Bakery in Michigan on July 10, 1996 improved crumb structure, producing finer crumb grain than regular production with monodiglycerides.

[0071] 7.1 Use of an Effective Amount of Food Acids Combined with Dough Improvers

[0072] When treated flours with ascorbic acid, ascorbic acid contributes H+by ionizing in the fermenting dough, but food acids that provide H+and metal ion-food acid complexes as interacting partners of functional wheat proteins act as better dough improvers than ascorbic acid or potassium bromate. When ascorbic acid is used in a Short Time Sponge and Dough process during commercial bread production, the beneficial impacts on the gluten protein structure are:

[0073] 1. Bringing about structural changes of gluten proteins induced by H+through pH-induced protein unfolding (Figure 21).

[0074] 2. Protonating specific amino acid residues in proteins that acquire positive charges in the fermented dough (Figures 16-17).

[0075] When effective amounts of food acids and a source of food acids are commercially used in a Short Time Sponge and Dough process to produce properly developed dough structure and to strengthen the gluten structure in the viscoelastic fermented dough, the beneficial impacts on the proper dough development that lead to the best quality breads are:

[0076] 1. Changing AA from a fast oxidant to a slow oxidant that is functional throughout the entire bread manufacturing process by slowing down the oxidation of AA to DHAA through binding copper and iron ions in the dough.

[0077] 2. Replacing the function of potassium bromate in breadmaking by producing the properly developed gluten structure through pH-induced unfolding of proteins in the fermenting dough. 3. Producing partially unfolded structures of functional and specialized wheat proteins in the fermenting dough that govern the baking performance of flour.

[0078] 4. Providing positively charged groups on the surface of functional and specialized wheat proteins and negatively charged aquo-metal ion-food acid complexes to the fermented dough.

[0079] 5. Strengthening and stabilizing the gluten protein structure in the viscoelastic fermented dough through noncovalent interactions between positively charged groups in functional / specialized gluten proteins and negatively charged metal ion-food acid complexes.

[0080] 6. Contributing to the development of fermented dough with the viscoelastic structure that is required for gas retention in the production of quality breads with increased loaf volume, fine crumb grain, texture, and extended shelf life.

[0081] 7. Preserving the "as-baked" quality of fresh bread during storage by binding water molecules through aquo-metal ion-food acid complexes in the fermented dough.

[0082] Fermentation dough development in a Short Time Sponge and Dough process is thus achieved by the use of about 0.015 to 0.25 parts food acids combined with effective amounts of other dough improvers such as ascorbic acid, which bring about structural changes in wheat proteins through protein unfolding, but not lengthy fermentation in sponge. However, the preferred embodiments of a Short Time Sponge and Dough Process are the use of only food acid, particularly the use of citric acid / malic acid added in an effective amount during bread manufacturing processes. Among food acids studied, citric acid is a tricarboxylic acid that has three carboxyl functional groups (-COOH) and citrate anions, bringing about a greater change in protein structure and being a more effective chelator with metal ions and hence a more effective dough improver than dicarboxylic malic acid. The use of citric acid produced by vegetative fermentation of sugars or citric acid in fruit juices is thus the best example of dough improvers in a Short Time Sponge and Dough process.

[0083] 7.2. Use of Effective Amount Food Acids as Dough Improvers

[0084] The elimination of lengthy fermentation from the Sponge and Dough process is successfully achieved by a greater understanding of yeast fermentation and dough improvers, which bring about the proper changes in gluten structure through protein unfolding, and then, the functional gluten proteins produced in the fermenting dough govern the baking performance of flour. Fermentation dough development in a Short Time Sponge and Dough process is thus achieved by the use of about 0.015 to 0.25 parts food acids, which bring about the proper changes in gluten protein structure through pH-induced unfolding and also provide interacting partners of functional gluten proteins in the fermented dough. This breakthrough Short Time Sponge Dough process will finally revolutionize the bread manufacturing process throughout the world and provide consumers with natural, better quality breads at a reasonable price. The use of ascorbic acid combined with citric / malic acid was successfully tested at Coldwater Bakery in Michigan on July 10, 1996 by making Hamburger Buns, compared with regular production with monodiglycerides.

[0085] Bakers achieve A Short Time Sponge and Dough Process with or without using variable amounts of other dough improvers combined with food acids or a source of food acids listed in the claims of the ‘355 Fl patent. Example 1 is given with variable amounts of dough improvers, food acids, citric acid and acetic acid, which bring about the proper changes in the gluten protein structure and dough properties that occur during sponge fermentation and A Short Time Sponge and Dough Process.

[0086] Example 1

[0087] Ingredient (in baker’s %) Short Time Sponge Dough Process

[0088] Flour 100

[0089] Water (variable)

[0090] Compressed Yeast 2.5

[0091] Yeast food 0.3

[0092] Salt 2

[0093] Sugar 6

[0094] Oil 3

[0095] Other dough improvers (variable)

[0096] Dough improver as citric acid 0.015 - 0.1 Dough improver as acetic acid 0.015 - 0.25

[0097] 7.3. Mixing

[0098] Flour, water, and other ingredients are mixed using optimum water absorption and mixing time by blending them together into homogeneous mass. The importance of proper mixing is to produce cohesive dough with optimum consistency for desirable handling properties during subsequent processing steps. The dough relaxation period of 8-12 minutes is needed to recover from the stresses incurred during mixing, which the mechanical work is imparted into the dough. As cohesive wheat dough undergoes fermentation development that is achieved by effective amounts of food acids or a source of food acids added as dough improvers and with or without variable amounts of other dough improvers, it attains viscoelastic structure in the fermented dough that is required to retain gases during proofing and baking (Figure 21).

[0099] The improving effect of food acids on gluten proteins in A Short Time Sponge and Dough process is attributed to H+and their anions that bring about the proper changes in gluten structure and provide metal ion-food acid complexes, as sponge undergoing fermentation produces fermentation food acids in the fermenting dough. However, the Short Time Sponge and Dough process does not develop the increase in fluidity of dough structure at the early stages of baking, as the Sponge and Dough process has taken place. Thus, when making the dough during mixing, other benefits of A Short Time Sponge Dough Process produce higher bread yield, as bakers add about 3-4% additional water to adjust the optimum consistency of dough structure during the early stages of baking, and also wheat flours with 9 to 10% protein contents are well-suited for making quality breads.

[0100] 7.4. Dough Development during Proofing and Baking

[0101] After undergoing intermediate proof, the pans containing the moulded dough are conveyed to proof box at temperature of 95 to 110° F and relative humidity of 80 to 85% for the fermentation in the proofing stages. The proper dough development of the structure of gluten proteins occurs in the fermenting dough, as the H+provided by food acids added in an effective amount to bread mixes and the acetic acid produced during proofing and the early stages of baking lower the pH that brings about structural changes in proteins through protein unfolding, and positively charged groups on the surface of functional and specialized wheat proteins are developed in the fermented dough in the process of A Short Time Sponge and Dough Process.

[0102] Proteins exist with distinct structures and conformational states determined by the pH and temperature in a given environment. After yeast is inactivated at about 140° F, heat in the oven increases the temperature and pH by volatilization of acetic acid, bringing about structural changes in proteins through heat-induced unfolding and refolding in the fermented dough. The HMW glutenins and gliadins are not the essential determinant for the development of viscoelastic dough from flour, as starch forms hydrogen bonds with proteins and lipids form hydrophobic interactions with proteins (Figures 14 and 23). Thus, the balance between elasticity and extensibility developed in the fermented dough that is required for optimal baking quality arise from the interactions of functional gluten proteins with each other and with starch and lipid (Figure 21). As protein networks arise from the interactions among different molecules (Petersen et al. 2012), the elastic HMW glutenin networks linked to the extensible LMW glutenin and gliadin networks through noncovalent bonds contribute to the development of viscoelastic structure with gas retention in the fermented dough.

[0103] 7.5. Gluten Structure in the Viscoelastic Fermented Dough

[0104] The development of viscoelastic dough from flour is required to retain gas during proofing and baking, as extensible and elastic films in the fermented dough have the ability to retain the CO2 gas produced by yeast (Figure 20). Instead during dough mixing, yeast fermentation plays a key role in developing the viscoelastic structure with gas retention in the fermented dough. Food acids added and fermentation food acids produced bring about structural changes in gluten proteins through pH-induced unfolding and the functional and specialized wheat proteins produced in the fermenting dough govern gluten functionality. The consensus view is that gluten proteins are considered ideal for making breads, but the key study findings are that wheat starch is of utmost importance in imparting excellent baking properties and having good gas retention through the functional gluten protein-wheat starch matrix that forms the continuous phase of the viscoelastic dough film surrounding gas cells in the fermented dough, and the functional gluten protein-polar lipid interactions contribute to gas cell stability and gas retention in the viscoelastic fermented dough The loaf volume of bread is from the continuous phase of elastic and extensible dough for a long enough time during the baking to avoid premature rupture of the dough films surrounding gas cells. Now, it has been shown that the continuous phase of viscoelastic dough films surrounding gas cells is formed by the functional gluten protein-starch / lipid interactions in the fermented dough (Figure 21), becoming rigid and extensible long enough that does not collapse during baking, thus giving structure to the bread and producing increased loaf volume. The strength and stability of the gluten proteins in the viscoelastic dough structure with gas retention result from the binding of the functional gluten proteins to metal ion-acetate / citrate complexes developed in the fermented dough (Figures 24 and 27). These interactions support the structure of the leavened dough during the rapid expansion that occurs in the oven, contributing to the production of quality breads.

[0105] In sum, the key study findings are that instead of the gluten proteins in grain, flour or wheat dough, partially unfolded structures of functional glutenin and gliadin proteins produced through protein unfolding in the fermenting dough play a pivotal role in governing the gluten functionality and hence the baking performance of flour (Figure 21); the acetic acid produced in the fermenting dough acts as a dough improver in the process of breadmaking. Hence, the baking performance of flour in a Short Time Sponge and Dough process is achieved by the proper changes in wheat protein structure induced by the use of the inventor’s newly developed dough improver, food acids or a source of food acids listed in the claims of the ‘355 Fl patent and the acetic acid and metal ion-food acid complexes produced in the fermented dough.

[0106] Additional Embodiments

[0107] 1. Fermentation food acids produced in the fermenting sponge and food acids added to bread mixes act as dough improvers through protein unfolding, when ionized in water or dough.

[0108] 2. Yeast fermentation contributes to the development of fermented dough structure with the viscoelastic properties from flour.

[0109] 3. Principal acetic acid produced in the fermenting sponge and food acids added to bread mixes bring about the proper changes in gluten protein structure through protein unfolding. 4. Food acids that provide the interacting partners of functional and specialized wheat proteins function as better dough improvers than ascorbic acid and other chemical dough improvers used in breadmaking.

[0110] 5. A Short Time Sponge and Dough process is achieved, when flours used in making breads are treated with newly developed dough improvers, about 0.015 to 0.25 parts food acids combined with or without effective amounts of other dough improvers / oxidants added.

[0111] 6. Citric acid is a much more effective dough improver than the principal acetic acid naturally produced during a fermentation processing step.

[0112] 7. Sponge fermentation in the traditional Sponge and Dough Process is eliminated, when flours used in making breads are treated with food acids.

[0113] 8. Flours used in making breads that are treated with new dough improvers, about 0.015 to 0.25 parts food acids provide interacting partners of functional and specialized wheat proteins, metal ion-food acid complexes developed to the fermented dough.

[0114] 9. Optimally mixed dough undergoes further structural changes in gluten proteins during fermentation and by dough improvers, and the functional and specialized wheat proteins produced in the fermenting dough govern the baking performance of flour.

[0115] 10. The elasticity developed in the fermented dough is attributed to where the functional HMW-GS interact with each other and with starch and lipids.

[0116] 11. The extensibility developed in the fermented dough arises from where the functional LMW-GS and gliadin proteins interact with each other and with starch and lipids.

[0117] 12. The elastic HMW glutenin networks linked to the extensible LMW glutenin and gliadin networks through noncovalent interactions contribute to the development of viscoelastic structure in the fermented dough in the process of breadmaking.

[0118] 13. The functional gluten protein-starch matrix developed in the fermented dough forms the continuous phase of viscoelastic dough films, giving structure to the bread. 14. The functional gluten protein-lipids interactions in the fermented dough contribute to gas cell stability and gas retention in the continuous phase of viscoelastic dough films.

[0119] 15. Loaf volume, as measured by baking tests, is determined by the interactions between functional / specialized gluten proteins and interacting partners, metal ion-food acid complexes developed in the fermented dough.

[0120] 16. The final bread quality made from a Short Time Sponge and Dough process is attributed to where electrostatic interactions between the functional / specialized gluten proteins and the metal ion-food acid complexes strengthen and stabilize the gluten protein structure in the viscoelastic fermented dough.

[0121] 17. A Short Time Sponge and Dough Process reduces the cost of bread production and increase dough yield that produces natural and better quality breads than when using traditional 4-hour sponge fermentation.

[0122] 18. This new Short Time Sponge Dough process is a breakthrough development of the bread manufacturing process using food acids or a source of food acids as dough improvers listed in the claims of the ‘355 Fl patent that provide consumers with natural, better quality breads at a reasonable price.

[0123] Core Discoveries

[0124] The successful Short Time Bread process must be able to bring about the proper changes in gluten structure and dough properties in the fermented dough, which occur during fermentation and other dough processing steps. The discoveries, which the acetic acid produced in the fermenting sponge functions as a dough improver that brings about the proper changes in gluten structure during dough processing and fermentation develops the wheat dough with the viscoelastic structure in the fermented dough that retains the gas produced by yeast, have led to the development of the Short Time Sponge and Dough process that produces natural and better quality breads in about 2 hour processing time than the traditional Sponge Dough Process.

[0125] The key study findings are that how food acids bring about the proper changes of gluten structure in the fermenting dough (Chapter 3), and the development of viscoelastic dough from flour (Figure 20) is attributed to fermentation food acids produced in the fermenting dough (Chapters 4 and 7-8). Hence, the elimination of fermentation from the Sponge and Dough process is successfully achieved by the use of food acids added to bread mixes, as H+released from food acids bring about the proper changes in gluten proteins through pH-induced unfolding and the functional gluten proteins produced in the fermenting dough govern the baking performance of flour. The functional gluten proteins interacting with each other and forming networks with starch and lipids develop elasticity and extensibility in the fermented dough in the process of breadmaking, and the elastic HMW glutenin networks linked to the extensible LMW glutenin and gliadin networks through noncovalent interactions develop the fermented dough structure with the viscoelasticity from flour (Figure 21).

[0126] Furthermore, the increase in H+released from food acids that lower the pH protonates specific amino acids in proteins that yield positively charged groups on the surface of functional wheat protein structure developed in the fermented dough, while acetate, citrate, or tartrate anions impart dough strength and crumb grain by providing negatively charged aquo-metal ion-acetate / citrate / tartrate complexes that interact with positively charged groups in the functional gluten proteins in the fermented dough (Figures 16-17). These electrostatic interactions support the structure of the leavened dough during the rapid expansion in the proof box and oven that contributes to the production of quality breads (Figure 24).

[0127] As to the best example of Short Time Sponge and Dough process, citric acid that brings about greater changes in gluten structure induced by three H+and has good chelation power by providing three citrate anions is a much more effective dough improver than the acetic acid naturally produced in fermenting dough. Additional benefits are that citric acid produced by vegetative fermentation of sugars provides colloidal, aquo- metal ion-citrate complexes to the fermented dough proved to be an excellent emulsifier during dough processing and also an effective crumb softener during bread aging, producing the final baked bread that is natural and better quality than when using traditional 4-hour sponge fermentation.

[0128] In sum, the development of inventor's SHORT TIME SPONGE AND DOUGH PROCESS is achieved by inventor's core discoveries and Figures 10, 11, 14, 16, 17, 21, 24, 25, 26, 27, and 33 presented in the inventor’s Book, Gluten Protein Functionality in Breadmaking, Mechanisms of Oxidizing Agents Used in Flour Treatments, Dough Development by Yeast Fermentation, Development of Viscoelastic Dough from Flour, and Strength and Stability of the Gluten Structure in Viscoelastic Fermented Dough, which not only support by a list of references, but also provide 33 Figures and 8 Tables provided in the inventor's Book.

[0129] Thus, in some embodiments, a process for producing a yeast-leavened product is provided. The process comprises combining into a dough

[0130] (a) flour;

[0131] (b) yeast;

[0132] (c) yeast food;

[0133] (e) about 0.015 to 0.25 parts food acid per 100 parts flour; and

[0134] (d) water. The dough composition comprising dough improvers, individual food acids and source of food acids used and amounts of food acids added, shortens fermenting time in the process of making yeast-leavened dough.

[0135] The food acid in these embodiments can be any acid found in a food. Nonlimiting examples include acetic acid, citric acid, fumaric acid, lactic acid, malic acid, oxalic acid, phosphoric acid, succinic acid, tartaric acid, fruit juice, fruit juice concentrate, vinegar, wine, or any combination thereof. In some embodiments, the food acid is citric acid, for example produced by vegetative fermentation of sugars, or from or in citrus fruits; malic acid, for example from or in apple juice; tartaric acid, for example from or in raisin juice concentrate; and / or acetic acid, for example from or in grain vinegar.

[0136] In some embodiments, the food acid (e.g., citric acid) shortens fermenting the dough and produces natural and better quality breads in about 2 hour processing time than a sponge dough bread.

[0137] As used herein, yeast food that provides essential nutrients for yeast growth is ammonium chloride, ammonium sulfate as nitrogen source. Acid type yeast food has monocalcium phosphate that is useful in high alkaline water, and also calcium carbonate is used to control pH in the brew system.

[0138] Any flour or combination of flours capable of being utilized in a yeast-leavened product can be utilized in the process of these embodiments. Nonlimiting examples of such flours include wheat flour, rye flour, oat flour and soy flour. In some embodiments, the flour comprises wheat flour with 9-14% protein content.

[0139] In some embodiments, the process further comprises adding ascorbic acid and / or potassium iodate to the dough. In some of these embodiments, about 0.001 to 0.03 parts ascorbic acid per 100 parts flour is added, with or without variable amounts of other dough improvers such as potassium iodate.

[0140] In various embodiments, the dough is proofed to develop dough structure with improved gas retention. The proofing can be done under any conditions known in the art, for example at 95-110° F and a relative humidity of 80-85%, room temperature or refrigerator temperature.

[0141] The process of these embodiments can be used to produce any product made from yeast-leavened dough. Non-limiting examples include bread, a bun, a roll, a doughnut, a bagel, and a pastry.

[0142] In additional embodiments, the process further comprises baking the fermented dough to produce the yeast-leavened product.

[0143] Also provided are individual food acids and sources of food acids as described above added to a bread mix. In some of these embodiments, the individual food acids and sources of food acids added are different amounts. In a non-limiting example of these embodiments, citric acid is added at 0.015 - 0.1% and acetic acid is added at 0.015 - 0.25%.

[0144] In some of these embodiments, the food acid added and acetic acid produced in the fermenting dough function as dough improvers in the process of breadmaking.

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[0172] Yoon Ja Kim. Wheat Chemistry and Dough for Breadmaking: Understanding How Functional Gluten Proteins, Wheat Starch, and Lipids Govern Gluten Functionality. Functional Glutenin and Gliadin Proteins, Starch, and lipids in Baking Performance and for Bread Structure, 2nd ed., 2023. von Hippel, P. H.; Wong, K. Y. On the conformational stability of globular proteins: The effects of various electrolytes and non-electrolytes on the thermal ribonuclease transition. J. Biol. Chem. 1965, 240, 3909. van Vliet, T.; Hamer, R. J. Letter to the Editor. J. Cereal Sci. 2007, 46, 98.

[0173] Wieser, H. The use of redox agents. In Bread making Improving quality, Cauvain, S. P., Ed.; Woodhead Publishing: Cambridge, 2003; pp 424.

[0174] In view of the above, it will be seen that several objectives of the invention are achieved and other advantages attained.

[0175] As various changes could be made in the above methods and compositions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0176] All references cited in this specification, including but not limited to patent publications and non-patent literature, and references cited therein, are hereby incorporated by reference. The discussion of the references herein is intended merely to summarize the assertions made by the authors and no admission is made that any reference constitutes prior art. Applicants reserve the right to challenge the accuracy and pertinence of the cited references.

[0177] As used herein, in particular embodiments, the terms “about” or “approximately” when preceding a numerical value indicates the value plus or minus a range of 10%. Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. That the upper and lower limits of these smaller ranges can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.

[0178] The indefinite articles “a” and “an,” as used herein in the specification and in the embodiments, unless clearly indicated to the contrary, should be understood to mean “at least one.”

[0179] The phrase “and / or,” as used herein in the specification and in the embodiments, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements can optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and / or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

[0180] As used herein in the specification and in the embodiments, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the embodiments, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the embodiments, shall have its ordinary meaning as used in the field of patent law.

[0181] As used herein in the specification and in the embodiments, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements can optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and / or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

Claims

What is claimed is:

1. A process for producing a yeast-leavened product, the process comprising combining into a dough(a) flour;(b) yeast;(c) yeast food;(e) about 0.015 to 0.25 parts food acid per 100 parts flour; and(d) water; and shortens fermenting the dough in the process of dough making.

2. The process of claim 1, wherein the food acid is selected from the group consisting of acetic acid, citric acid, fumaric acid, lactic acid, malic acid, oxalic acid, phosphoric acid, succinic acid, tartaric acid, fruit juice, fruit juice concentrate, vinegar, wine, and any combination thereof.

3. The process of claim 1, wherein the food acid is citric acid produced by vegetative fermentation of sugars and in citrus fruits, malic acid in apple juice, tartaric acid in raisin juice concentrate, and acetic acid in grain vinegar.

4. The process of claim 3, wherein the citric acid shortens fermenting the dough and produces natural and better quality breads in about 2 hour processing time than a sponge dough bread.

5. The process of claim 1, further comprising combining about 0.001 to 0.03 parts ascorbic acid per 100 parts flour into the dough, potassium iodate, or a combination thereof.

6. The process of claim 1, wherein the flour is wheat flour with 9-14% protein content.

7. The process of claim 7, wherein the dough further comprises another flour.

8. The process of claim 1, wherein the dough is proofed at 95-110° F and a relative humidity of 80-85%, room temperature or refrigerator temperature to develop dough structure with improved gas retention.

9. The process of claim 1, wherein the product is made from yeast-leavened dough, bread, a bun, a roll, a doughnut, a bagel, a pastry.

10. The process of any one of claims 1-10, further comprising baking the fermented dough to produce the yeast-leavened product.

11. Individual food acids and sources of food acids listed in claim 2 added to a bread mix.

12. The bread mix of claim 11, wherein individual food acids and sources of food acids added are different amounts.

13. The bread mix of claim 12, wherein the citric acid is at 0.015 - 0.1% and the acetic acid is at 0.015 - 0.25%.

14. The bread mix of any one of claims 11-13, wherein the food acid added and acetic acid produced in the fermenting dough function as dough improvers in the process of breadmaking.