Production method of leavened cocoa bakery products, semi-finished product for food preparations of leavened cocoa bakery products to be used in said method, production method of said semi-finished product

Abstract

The invention relates to a production method of a leavened cocoa bakery product, comprising the following operating steps : a) kneading at least soft wheat flour, yeast, egg yolk, preferably egg mixture, with water to obtain a main dough; b) adding at least one sweetener, preferably sucrose, and egg yolk, preferably egg mixture, to said main dough in one or more stages, creating a uniform mass; c ) adding fat matter of butter origin and / or vegetable origin to said main dough already containing said at least one sweetener and egg yolk, preferably egg mixture, creating a uniform mass; d) reducing the main dough mass into portions and letting them rise; e ) baking the leavened portions of said main dough, obtaining a leavened bakery product from each one. The method comprises a step f ) of adding cocoa to said main dough before step d). The cocoa is added to the main dough as a component of a semi-finished product consisting of a fluid carrier mixture comprising at least cocoa, water and at least one water activity stabiliser Aw. The fluid carrier mixture is added to said main dough after the completion of step a) and before step c).

Description

"PRODUCTION METHOD OF LEAVENED COCOA BAKERY PRODUCTS ,SEMI-FINISHED PRODUCT FOR FOOD PREPARATIONS OF LEAVENED COCOA BAKERY PRODUCTS TO BE USED IN SAID METHOD , PRODUCTION METHOD OF SAID SEMI-FINISHED PRODUCT" DESCRIPTIONField of application

[0001] The present invention relates to production method of leavened cocoa bakery products , to a semi- finished product for food preparations of leavened cocoa bakery food products to be used in said method, as well as to a production method of said semi- finished product .Background art

[0002] In the preparation of naturally leavened bakery food products , e . g . , such as panettone , pandoro , and colomba, it is known to enrich the mixture of ingredients with cocoa powder to give a dark colour and a typical cocoa taste and aroma to the final product .

[0003] Generally, the cocoa powder is added to the other ingredients at the first step of kneading, i . e . , it is mixed directly with the wheat flour, natural yeast , egg mixture ( egg yolk and white from fresh chicken eggs ) and water and other minor ingredients . The subsequent steps in the preparation process ( in particular, the addition of sugar, egg mixture and butter, leavening and subsequent baking) are similar to those involved in theproduction of leavened bakery products not enriched with cocoa .

[0004] Leavened cocoa bakery products obtained in this manner already exhibit good organoleptic characteristics per se and maintain a good level of internal moisture and fluffiness throughout their shelf life.

[0005] However, compared with similar naturally leavened bakery food products, cocoa-enriched products tend to be less moist and fluffy throughout their shelf life.

[0006] Thus, there is a need to improve leavened cocoa bakery food products in terms of maintaining internal moisture and fluffiness throughout the shelf life. Overview of the invention

[0007] Therefore, it is the main object of the present invention to eliminate, or at least reduce, the above- mentioned problems related to the known technique by providing a production method of leavened cocoa bakery products, which makes it possible to obtain products which, under the same storage conditions, maintain more internal moisture and fluffiness throughout their shelf life than leavened cocoa bakery products obtained by a traditional production process.

[0008] It is a further object of the present invention to make available a production method of leavened cocoa bakery products, which makes it possible to obtainproducts comparable to similar products obtained by a traditional production process in terms of organoleptic properties .

[0009] It is a further obj ect of the present invention to make available a production method of leavened cocoa bakery products that is economically sustainable .

[0010] It is a further obj ect of the present invention to make available a production method of leavened cocoa bakery products that is operatively easy to implement .Description of the drawings

[0011] The technical features of the invention may be clearly found in the content of the claims presented below and the advantages thereof will become more apparent from the following detailed description, made with reference to the accompanying drawings , which show one or more embodiments thereof , merely given by way of non-limiting examples , in which :

[0012] - figure 1 shows a flow chart of a production method of leavened cocoa bakery products according to a preferred embodiment of the invention ;

[0013] - figure 2 shows a table in which results of comparative tests for relative moisture ( % ) , water activity (Aw) , pH, and titratable acidity are collected, which are conducted on a cocoa pandoro made according to a traditional production process and a cocoa pandoro madeaccording to the invention; and

[0014] - figure 3 shows the trend over time of moisture % measured for a cocoa pandoro made according to a traditional production process (curve a) and for a cocoa pandoro made according to the invention (curve b) . Detailed description

[0015] The present invention relates to a production method of a leavened cocoa bakery product.

[0016] In particular, the method relates to the production of naturally leavened bakery products, i.e., which involve the use of sourdough starter. Particularly favourite examples of these products are panettone, pandoro and colomba.

[0017] The method according to the invention further relates to bakery products leavened by using only brewer's yeast, or even a mixture of the two (sourdough starter and brewer's yeast) .

[0018] According to a general embodiment of the invention, as shown in the flow chart in figure 1, the production method of a leavened cocoa baked product comprises the following operational steps:

[0019] a) kneading at least soft wheat flour, yeast, egg yolk, preferably egg mixture, with water to obtain a main dough;

[0020] b) adding at least one sweetener, preferablysucrose, and egg yolk, preferably egg mixture, to said main dough in one or more stages, creating a uniform mass ;

[0021] c) adding fat matter of butter origin and / or vegetable origin to said main dough already containing said at least one sweetener and egg yolk, preferably egg mixture, creating a uniform mass;

[0022] d) reducing the main dough mass into portions and letting them rise;

[0023] e) baking the leavened portions of said main dough, obtaining a leavened bakery product from each one.

[0024] Said method comprises a step f) of adding cocoa to said main dough before step d) of reducing the main dough mass into portions.

[0025] Preferably, sourdough starter is used in step a) . Alternatively, only brewer's yeast, or even a mixture of the two (sourdough starter and brewer's yeast) can be used .

[0026] "Egg mixture" means a mixture of egg yolk and egg white from chicken eggs, preferably fresh eggs.

[0027] "Sweetener" means a natural substance (e.g., sucrose, glucose, fructose, or other sugars) capable of imparting sweet flavour to a food or beverage.

[0028] Preferably, in step a) the ingredients are mixed according to the following percentages by weightreferring to the final dough before step d) : wheat flour25-29%; yeast 6-10%; egg yolk, preferably egg mixture, 7- 11%; water 6-10%.

[0029] Preferably, step a) can be performed in several rounds, each of which specifically involves adding a portion of the total amount of flour needed for the dough .

[0030] Preferably, in step b) the sweetener and the egg yolk, preferably the egg mixture, are added to the main dough according to the following percentages by weight referring to the final dough before step d) : sweetener 12-16%; egg yolk, preferably egg mixture, 7-11%.

[0031] Part of the sweetener, preferably less than 20% by weight of the total sweetener provided, may be introduced directly in step a) if brewer's yeast is added in that step in order to make the yeast itself grow.

[0032] Preferably, in step c) , the fat matter is added to the main dough according to the following percentages by weight referring to the final dough before step d) : 12- 16% .

[0033] Advantageously, at least one emulsifier can be introduced into the dough in step a) , with a percentage by weight (referred to the final dough before step d) ) comprised between 0.5% and 1.5%. For example, monoglyceride can be used as an emulsifier.

[0034] According to a first aspect of the present invention, as shown in the flow chart in figure 1 , the cocoa is added to the main dough as a component of a semi- finished product consisting of a fluid carrier mixture comprising at least cocoa, water and at least one water activity stabiliser Aw .

[0035] According to a further aspect of the present invention, said fluid carrier mixture is added to said main dough after completing step a ) and be fore step c ) .

[0036] Step a ) is to be considered complete when the gluten network has formed completely . A person skilled in the art can determine when the gluten network formation is complete . Indicatively, this occurs when the main dough appears as a compact , smooth mass which detaches completely from the walls of the kneading container .

[0037] The invention sparks from the observation made by the applicant that the inclusion of potashed cocoa powder, as a characteri zing ingredient in a chocolate dough, has a main problem : when cocoa is found on its own it is , as a rule , added in the first step of kneading, thus entering in direct competition with the flour for water absorption, thereby subtracting an amount thereof useful for the gluten formation . This ef fect is mainly related to the high percentage of fibre that are contained in potashed cocoa powder . The result of thisnegative competition will be drier and less fluf fy doughs , both at time zero and throughout shelf li fe .

[0038] Cocoa in its powdered state has five times the absorbing power of wheat flour (used for making leavened products ) by virtue of its high fibre content ( 29 g per 100 g of cocoa powder ) . Therefore , the applicant concluded that including cocoa powder directly in step a ) would impair the formation of the gluten network, subtracting water from the flour to the extent of forming drier and less fluf fy doughs .

[0039] The addition of cocoa to the main dough as a component of a semi- finished product consisting of a fluid carrier mixture makes it possible to postpone the step of including this ingredient to the moment of its use in the dough .

[0040] In this manner, it is achieved that :

[0041] - cocoa is no longer added on its own but within a richer composition ( semi- finished product ) , and

[0042] - cocoa is added after the complete formation of gluten ( gluten network) , avoiding competition with flour for water .

[0043] Therefore , according to the invention, it is crucial to appropriately choose when to include the semi- finished product containing cocoa in the main dough . This choice is essential not only so as not to hinder the formationof the gluten network, but also so as not to deteriorate it once formed.

[0044] In more detail, it was observed that the inclusion of the cocoa semi-finished product during step a) would not allow the proper formation of the gluten network, not only because of the presence of cocoa, but also because of the temperature increase resulting from the longer kneading time required to allow the absorption of the semi-finished product ingredients into the main dough. In particular, the presence of the sweetener would impose a significant increase in the kneading time thereof, leading the dough to exceed the final temperature of 35°C, and thus to deteriorate.

[0045] It was also observed that the inclusion of the cocoa semi-finished product either during or after step c) (i.e., once the fat matter is added to the dough) would lead to the deterioration of the newly structured and well bound gluten network; this would result from the need to prolong the kneading time in order to allow the absorption of the semi-finished product ingredients into the dough.

[0046] In more detail, industrial tests were conducted which involved the introduction of the semi-finished cocoa product during or after phase c) (i.e., once the fat matter was added to the dough) . In all cases, oncethe semi-finished product was completely absorbed into the dough that had been previously added with fat matter, the latter - which after phase a) had reached a consistency that allowed its processing - completely lost its structure, resulting in complete disaggregation. This was already evident upon manual inspection; in particular, the dough no longer formed the classic "veil", an indication of a correct and complete development of the gluten network and the dough itself. This deterioration of the dough characteristics is attributable to the introduction of the semi-finished product during or after phase c) (i.e., once the fat matter was added to the dough) . Confirmation of this comes from the fact that, being the dough characteristics equal, the introduction of the semi-finished product before phase c) did not, however, cause such deterioration.

[0047] Therefore, according to the invention, said fluid carrier mixture (cocoa semi-finished product) is added to said main dough after completing step a) and before step c) .

[0048] Preferably, as shown in the flow chart in figure 1, the fluid carrier mixture is added to said main dough before step b. This facilitates the absorption of the cocoa semi-finished product. Indeed, immediately afterstep a) (gluten network formation) and before the subsequent steps that involve the addition of sugars (and egg yolk, preferably egg mixture) , the main dough is low in sugars and ready to absorb the sugars of the semifinished product; postponing the inclusion of the cocoa semi-finished product (which also contains sugars) , after other steps of adding sugar, would reduce the ease of absorption of the same semi-finished product due to a dough that, in this case, is already rich in sugar.

[0049] Advantageously, to facilitate the absorption of the cocoa semi-finished product into the main dough, it is not necessary for the dough to be sugar-free, but the dough should preferably be low in sugar. This condition is achieved when less than 20% by weight of the total amount of sugar required is added in step a) .

[0050] However, the cocoa semi-finished product can also be included after step b) or during step b) .

[0051] Another essential aspect of the invention (already highlighted) is the presence of a water activity stabilizer Aw in the semi-finished product.

[0052] Indeed, it has been verified that stabilizing the activity of the water present in the semi-finished product significantly reduces the risk of bacterial growth and thus the consequent risk of gluten network deterioration.

[0053] More in detail, microbial growth is one of the most important and dangerous causes of alteration (in the sense of undesired spontaneous transformation) of food. Microorganisms absolutely need water to multiply in addition to appropriate conditions of temperature, acidity, presence (or absence) of oxygen. The presence of water, not much in terms of quantity but in terms of the availability of the water itself, can therefore determine the perishability of a food product.

[0054] It follows that the cocoa semi-finished product needs proper balancing in order to remain stable over time (it must not deteriorate) and not compromise the leavening of the finished product. Adding an altered semi-finished product to the dough would affect the structure of the gluten network and thus leavening.

[0055] Therefore, reference is made to the water activity (Aw) tests as a control parameter for shelf life and effectiveness in (naturally) leavened products.

[0056] It is known that water activity is a concept in food processing and preservation technologies which indicates the relationship between the water vapor pressure in a given material and the vapor pressure of pure water. It is an index relating to the amount of water which, in a given product, is free from particular bonds with other components, i.e., the amount of water (expressed at adimensionless value comprised between 0 and 1 ) available for chemical and biological reactions .

[0057] Preferably, said fluid carrier mixture has a water activity Aw not greater than 0 . 86 , measured with an electrolytic res istive hygrometer using the electrolytic resistive method .

[0058] Thus , it could be veri fied that the method according to the invention makes it possible to obtain leavened cocoa bakery products , which, under the same storage conditions , retain more internal moisture and fluf finess throughout their shel f li fe than leavened cocoa bakery products obtained by a traditional production process .

[0059] It was also possible to veri fy that the method according to the invention makes it possible to obtain leavened cocoa bakery products which are comparable in terms of organoleptic properties to similar products obtained by a traditional production process .

[0060] Preferably, said fluid carrier mixture is added to said main dough at a temperature not lower than 20 ° C . In this manner, the complete absorption of the cocoa semifinished product ingredients into the main dough is promoted; absorption is further promoted when the semifinished product is introduced into the dough before step b ) , i . e . , before the addition of sweetener and egg yolk, preferably egg mixture .

[0061] Preferably, the aforesaid at least one water activity stabil i zer Aw consists of a sweetener, preferably sucrose .

[0062] Preferably, the fluid carrier mixture ( cocoa semifinished product ) comprises at least one anticrystalli zing agent of the sweetener .

[0063] In particular, said at least one anti-crystalli z ing agent of the sweetener is glucose syrup . The presence of glucose syrup helps preventing the formation of sugar crystals when preparing bakery products . Glucose also reduces the freezing point of the cocoa semi- finished product , improving its storage at negative temperature .

[0064] More in detail , glucose syrup is a puri fied and concentrated aqueous solution of food carbohydrates , preferably obtained from starch or potato starch, having :

[0065] - a dry matter content not lower than 70% by weight ;

[0066] - a dextrose equivalent not lower than 20% by weight of dry matter, expressed as D-glucose .

[0067] Preferably, glucose syrup is chosen so that it has low sweetening power to avoid interfering with the organoleptic properties of the final product .

[0068] In more detail , it can be indicated that glucose has about 25-30% lower sweetening power than sucrose (normal cooking sugar ) which, in turn, has about 30% lower sweetening power than fructose ( simple fruit sugar ) ;therefore, a dextrose equivalent not lower than 20% by weight on the dry matter means that this substance must not have less than 20% of glucose (the rest are complex carbohydrates, such as starch) and all the glucose present is not a powerful sweetener.

[0069] In particular, glucose syrup has a sulphated ash content not higher than 1% by weight of dry matter.

[0070] Advantageously, the fluid carrier mixture may comprise natural flavourings.

[0071] Preferably, the fluid carrier mixture is obtained by mixing its components together until a homogeneous mass is obtained and pasteurizing the homogeneous mass thus obtained before introducing at least a part thereof into the main dough.

[0072] The heat treatment during the step of pasteurization of the cocoa semi-finished product actively binds the insoluble fibres contained in cocoa, no longer affecting the liquid parts of the natural leavened product. This is because among the insoluble fibres in cocoa is cellulose (which makes up about 9% of the total fibres in cocoa itself) ; it has marked hygroscopic properties, i.e., it can absorb up to 10 times its weight in water. Specifically, cellulose consists of a large number of glucose molecules joined together by a p- (l-4) bond; these form chains, arranged mutually parallel, which arevery long and difficult to dissolve (fibres) . These long- chain fibres have a pronounced ability to chemically bind water resulting in high viscosity solution. By virtue of the heat treatment of pasteurization of the cocoa semifinished product, these insoluble fibres solidify making the water, present in the semi-finished product itself, already chemically bound, indissoluble.

[0073] According to a preferred embodiment, the fluid carrier mixture is obtained by mixing the following ingredients together:

[0074] - caster sugar: between 20% and 44% by weight, preferably between 30.0% and 34.0%;

[0075] - cocoa powder: between 12% and 32% by weight, preferably between 21.0% and 23.0%;

[0076] - glucose syrup: between 11% and 26% by weight, preferably between 17.5% and 19.5%;

[0077] - optionally, natural flavourings: between 1% and 4% by weight, preferably between 2.2% and 2.8%;

[0078] - water: between 15% and 35% by weight, preferably between 24.5% and 25.5%,

[0079] wherein the % values are referred to the total weight of the fluid carrier mixture.

[0080] In particular, caster sugar is obtained from sugar beet or sugar cane and has a sucrose level of over 99.7% purity .

[0081] In particular, the cocoa powder has a maximum water content of 9% by weight .

[0082] Preferably, said cocoa powder is potashed cocoa powder, having a pH comprised between 6. 0 and 8 . 0 .

[0083] In particular, the aforesaid natural flavourings consist of a Vanilla flavouring solution defined by a mixture of ethyl alcohol ( 96 ° ) and vanilla / vanillin flavouring at 0 . 1 % .

[0084] The various ingredients of the fluid carrier mixture that forms the semi- finished cocoa product are introduced according to predefined weight ranges aimed at preventing the introduction of the semi- finished cocoa product into the dough from causing deterioration of the already formed gluten network .

[0085] The set of ingredients according to this preferred embodiment constitutes a closed set that excludes the presence of :

[0086] - powdered substances ( other than cocoa ) that can act as competitors to cocoa in water absorption ( such as flours , starches , powdered milk, powdered barley malt ) , thus preventing the "neutrali zation" of the cocoa within the semi- finished product in terms of residual water absorption capacity, thereby leaving at least a portion of the cocoa as a direct competitor to the flour in water absorption within the dough, with consequent at leastpartial deterioration of the gluten network previously formed;

[0087] - fat matter ( such as butter, oil , margarines , milk, cocoa butter, hazelnut paste ) that can hinder the proper dispersion of the semi- finished product in the dough, requiring additional mixing which can also cause the deterioration of the gluten network .

[0088] The presence of the various ingredients within the aforementioned weight ranges helps to reduce the risk of alterations in the formation and / or maintenance of the gluten network in the dough intended to receive the semifinished cocoa product .

[0089] In more detail , the following is observed :

[0090] - the % of water ( in relation to the % of cocoa ) is functional to provide the amount of water necessary to hydrate the cocoa, guaranteeing its "neutrali zation" in terms of water absorption capacity;

[0091] - the % of sugar is functional to guarantee a suf ficient amount of sugar to ensure the stabili zation of water, however avoiding excesses that would impose , once the semi- finished product is introduced into the dough, additional mixing that can cause the deterioration of the gluten network .

[0092] Therefore , the formulation of the semi- finished cocoa product (both in terms of choosing a closed set ofspecific ingredients and in terms of their weight ranges) is aimed at avoiding interferences and / or alterations in the gluten network of the dough by the semi-finished product. Maintaining an intact gluten network is fundamental to preserve the internal moisture and softness of a leavened baked product obtained from a dough added with the aforementioned semi-finished cocoa product during its shelf-life. The characteristics of the aforementioned formulation therefore synergistically contribute to the same result.

[0093] Preferably, the fluid carrier mixture has a viscosity comprised between 5.5 and 4.5 Pa*s measured with a rotational viscometer (Viscotester iQ Thermo Scientific, Haake) at 20°C, with a creep limit (shear stress) of 160 + / - 1 Pa. In more detail, data were extrapolated according to Casson's laws after a ramp with velocities from 5 to 70 s-1 (over 10 points) . The semifinished product behaves as a plastic fluid and its behaviour follows Casson's laws; the ramp means that the data were taken after passing an initial stress, beyond which fluids in this category behave as superplastic fluids .

[0094] Preferably, the fluid carrier mixture is added to the main dough with a dosage comprised between 5% and 30% by weight on the dough as it is, more preferably between10% and 15% .

[0095] Preferably, the fluid carrier mixture is added into the main dough by mixing for a time comprised between 100 and 120 seconds with powers of 19kW .

[0096] It is an obj ect of the present invention to provide a semi- finished product to be incorporated in food preparations for the production of leavened cocoa bakery products .

[0097] According to the invention, the semi- finished product consists of a fluid mixture compris ing at least cocoa, water and at least one water activity stabiliser Aw .

[0098] In particular, the semi- finished product corresponds to the cocoa semi- finished product ( fluid carrier mixture ) described in connection with the method according to the invention and described above .

[0099] The advantages associated with the use of the semifinished product have already been described above in connection with the aforesaid method .

[0100] In particular, the aforesaid at least one water activity stabil iser Aw consists of a sweetener, preferably sucrose .

[0101] Preferably, said semi- finished product comprises at least one anti-crystallising agent of thesweetener .

[0102] In particular, said at least one anticrystallizing agent of the sweetener is glucose syrup.

[0103] The semi-finished product may comprise natural flavourings .

[0104] Preferably, the semi-finished product has a viscosity comprised between 5.5 and 4.5 Pa*s measured with a rotational viscometer (Viscotester iQ Thermo Scientific, Haake) at 20°C, with a creep limit (shear stress) of 160 + / - 1 Pa.

[0105] According to a preferred embodiment, the semifinished product comprises the steps of:

[0106] - caster sugar: between 20% and 44% by weight, preferably between 30.0% and 34.0%;

[0107] - cocoa powder: between 12% and 32% by weight, preferably between 21.0% and 23.0%;

[0108] - glucose syrup: between 11% and 26% by weight, preferably between 17.5% and 19.5%;

[0109] - optionally, natural flavourings: between 1% and 4% by weight, preferably between 2.2% and 2.8%;

[0110] water: between 15% and 35% by weight, preferably between 24.5% and 25.5%,

[0111] wherein the % values are referred to the total weight of the semi-finished product.

[0112] Preferably, said semi-finished product has awater activity Aw not greater than 0 . 86 , measured with electrolytic resi stive method with electrolytic res istive hygrometer .

[0113] It is an obj ect of the present invention to provide a method for the production of a semi- finished product to be integrated into food preparations for the production of leavened cocoa bakery products .

[0114] In particular, the semi- finished product obtained by the aforesaid method is the semi- finished product according to the invention, as described above .

[0115] According to the invention, the method comprises the following operative steps :

[0116] - preparing ingredients consisting of at least cocoa powder, water and at least one water activity stabiliser Aw;

[0117] mixing said ingredients together until a homogeneous mass is obtained; and

[0118] pasteurising such a homogeneous mass thus obtained .

[0119] Preferably, the aforesaid at least one water activity stabil iser Aw consists of a sweetener, preferably sucrose ( caster sugar ) .

[0120] Advantageously, the ingredients may comprise at least one anti-crystallising agent of the sweetener,preferably glucose syrup.

[0121] The ingredients may comprise natural flavourings .

[0122] According to a preferred embodiment, the ingredients consist of:

[0123] - caster sugar: between 20% and 44% by weight, preferably between 30.0% and 34.0%;

[0124] - cocoa powder: between 12% and 32% by weight, preferably between 21.0% and 23.0%;

[0125] - glucose syrup: between 11% and 26% by weight, preferably between 17.5% and 19.5%;

[0126] - optionally, natural flavourings: between 1% and 4% by weight, preferably between 2.2% and 2.8%;

[0127] water: between 15% and 35% by weight, preferably between 24.5% and 25.5%,

[0128] the % values referring to the total weight of the fluid carrier mixture.

[0129] Preferably, said cocoa powder has a maximum water content of 9% by weight.

[0130] Preferably, said cocoa powder is potashed cocoa powder and has a pH comprised between 6.0 and 8.0.

[0131] Preferably, all ingredients are taken from the respective storage warehouses, weighed according to the established recipe and put into a mixer; after this preliminary operation, they are mixed at a constant anddefined speed to obtain a homogeneous mass. Once this step is completed, the mixture is pasteurised to ensure its healthiness and shelf life according to the data sheet .

[0132] In particular, the packaging is done aseptically within different packaging solutions as needed; thus, it can be placed in tubs, made of PE, of 15 kg each or in tanks, made of AISI 304 stainless steel, of 1000 kg each.

[0133] Acceptance inspections of cocoa-based semifinished products are:- Water activities aw- Dry residue (% @ 105°C)- Viscosity- Total bacterial load- Yeasts and moulds- Organoleptic inspection.Experimental Test

[0134] The applicant conducted a series of tests on different products (panettone, pandoro, and colomba) comparing the characteristics of the product made by the traditional production method (cocoa powder added during the flour kneading step) and the production method according to the invention (use of cocoa semi-finished product) .

[0135] The following are the results that emerged from the comparison between:

[0136] - pandoro made by the traditional production method (cocoa powder added during the flour kneading step) , hereafter referred to as reference pandoro;

[0137] - pandoro made by the production method according to the invention (use of cocoa semi-finished product) , hereafter referred to as pandoro according to the invention.

[0138] The same tests were carried out with panettone and colomba, obtaining similar comparison results as those obtained in relation to pandoro.

[0139] In more detail, the reference pandoro was produced by mixing the following ingredients according to the following sequence of steps with the amounts given in % referring to the final dough before step d) :

[0140] Step 1) Natural yeast (6.6%) , flour (4.3%) , water (1.8%) ; mix for 120 seconds at slow speed + 240 minutes at high speed;

[0141] Step 2) Step 1 dough (12.7%) ; flour (7.9%) ; egg mixture (3.5%) ; sugar (1.5%) ; brewer's yeast (0.4%) ; mix for 120 seconds at slow speed + 240 minutes at high speed;

[0142] Step 3) Step 2 dough (26.0%) ; flour (16.2%) ; egg mixture (9.2%) ; water (4.3%) ; monoglyceride (1.1%) ;cocoa powder (2.2%) ; minor ingredients (0.2%) ; mix for420 seconds at high speed;

[0143] Step 4) Step 3 dough (59.2%) ; sugar (4.6%) ; water (1.9%) ; chocolate powder (0.9%) ; mix for 110 seconds at high speed;

[0144] Step 5) Step 4 dough (63.5%) ; sugar (2.2%) ; water (0.9%) ; mix for 85 seconds at high speed;

[0145] Step 6) Step 5 dough (66.6%) ; sugar (5.8%) ; egg mixture (1.7%) ; mix for 85 seconds at high speed;

[0146] Step 6) Step 5 dough (74.1%) ; sugar (5.8%) ; egg mixture (1.7%) ; mix for 85 seconds at high speed;

[0147] Step 7) Step 6 dough (81.5%) ; butter (18.5%) ; mix for 200 seconds at high speed.

[0148] The pandoro according to the invention was produced by mixing the following ingredients according to the following sequence of steps with the amounts given in % referring to the final dough before step d) :

[0149] Step 1) Natural yeast (6.5%) , flour (4.3%) , water (1.8%) ; mix for 120 seconds at slow speed + 240 minutes at high speed;

[0150] Step 2) Step 1 dough (12.6%) ; flour (7.8%) ; egg mixture (3.5%) ; sugar (1.6%) ; brewer's yeast (0.4%) ; mix for 120 seconds at slow speed + 240 minutes at high speed;

[0151] Step 3) Step 2 dough (25.9%) ; flour (16.0%) ;egg mixture (9.1%) ; water (3.0%) ; monoglyceride (1.1%) ; minor ingredients (0.2%) ; mix for 420 seconds at high speed;

[0152] Step 4) Step 3 dough (55.3%) ; cocoa semifinished product (11.6%) ; mix for 110 seconds at high speed;

[0153] Step 5) Step 4 dough (66.9%) ; sugar (5.7%) ; egg mixture (1.7%) ; mix for 85 seconds at high speed;

[0154] Step 6) Step 5 dough (74.3%) ; sugar (5.7%) ; egg mixture (1.7%) ; mix for 85 seconds at high speed;

[0155] Step 7) Step 6 dough (81.7%) ; butter (18.3%) ; mix for 200 seconds at high speed.

[0156] The semi-finished product according to the invention was introduced into the dough with a dosage on finished product (panettone, pandoro, and colomba) of 11.6%.

[0157] The semi-finished product used has the following composition: caster sugar 32.0% by weight; cocoa powder 22% by weight; glucose syrup 18.5% by weight; natural flavourings 2.5% by weight; water 25.0% by weight; % values being referred to the total weight of the semi-finished product.

[0158] In both cases, the final dough was then subjected to the following two steps:

[0159] - reducing the main dough mass into portionsand letting them rise;

[0160] - baking the leavened portions of said main dough, obtaining a leavened bakery product from each one.

[0161] Shelf-life checks were conducted on these products, which included a series of analytical and organoleptic evaluations. The two samples were made on the same day and tasted, in blind test, by a group of trained panelists at different times: 7 - 30 - 60 - 90 - 120 - 180 days (natural aging) ; the following tests were carried out on a batch of the same samples at different times: 7 - 30 - 60 - 90 - 120 - 180 days:- Relative moisture (%)- AW- pH- Titratable acidity.

[0162] Relative moisture (%) was measured with a thermobalance at 125°C for 10 minutes.

[0163] The water activity Aw was measured with theNOVASINA aWmeter instrument;

[0164] The pH was measured with pH meter on a solution of 10g of sample dissolved in 250ml of distilled water.

[0165] The titratable acidity was measured as follows: solution of 10g of sample dissolved in 250ml of distilled water, brought to pH 8.30 with 0. IN KOH titrant solution, measured by reading the value of the titrant solution ona graduated burette.

[0166] The results of these tests are shown in the table in figure 2 (where "semi-finis (hed) " means the sample produced according to the invention and "powder" means the sample produced according to the known process) . The graph in figure 3 shows the trend in moisture % over time of the reference pandoro (curve a) and of the pandoro according to the invention (curve b) .

[0167] It can be seen from the graphs that at the same aW, the two samples have different moisture values; i.e., there is a higher water content in the samples made according to the invention; however, all the extra water is bound (same aW values) , and this attests to the fact that the product is moister throughout its shelf life by virtue of the present invention.Panelist organoleptic evaluations

[0168] The sample made from the semi-finished product according to the invention appears softer to touch and palate, showing, in addition, a greater cocoa aroma.

[0169] These evidences are confirmed until the last step of tasting.Analytical Tests

[0170] As can be seen in the graph in figure 3, the moisture % values 7 days after production already show a difference of 0.623 points: 22.313% for the productaccording to the invention (semi-finished cocoa) vs. 21.690% for the reference product (with only cocoa powder) .

[0171] This gap is maintained throughout shelf life, being reduced only after 120 days.

[0172] The evaluations on the other analytical parameters (Aw; pH; acidity) show substantial overlap, which stands for non-alteration of the product over time by the cocoa semi-finished product.

[0173] The results of the tests conducted confirm that the use of a semi-finished cocoa product, in food preparations of leavened bakery food products (in particular, in naturally leavened large bakery products, such as panettone, pandoro, colomba) , as a substitute for the use of cocoa alone as a typical ingredient, facilitates the kneading steps, characterises the finished product, making it more pleasing to palate and taste, and makes it moister and fluffier during its shelf lif e .

[0174] The invention allows obtaining several advantages that have been explained in the description.

[0175] The production method of leavened cocoa bakery products according to the invention makes it possible to obtain products which, under the same storage conditions, retain more internal moisture and fluffiness throughouttheir shelf life than leavened bakery products made by a traditional production process.

[0176] The production method of leavened cocoa bakery products according to the invention makes it possible to obtain products that are comparable to similar products made by a traditional production process in terms of organoleptic properties.

[0177] The production method of leavened cocoa bakery products according to the invention is cost sustainable and operationally simple to implement.

[0178] Therefore, the invention thus devised achieves the set objects.

[0179] Obviously, in practice, it may also take shapes and configurations different from the one disclosed above, without because of this departing from the present scope of protection.

[0180] Furthermore, all details may be replaced by technically equivalent elements, and any size, shape, and material may be used according to needs.

Claims

CLAIMS1 . Production method of a leavened cocoa bakery product , comprising the following operating steps : a ) mixing at least soft wheat flour, yeast , egg yolk, preferably egg mixture , with water to obtain a main dough; b ) adding at least one sweetener, preferably sucrose , and egg yolk, preferably egg mixture, to said main dough in one or more stages , creating a uni form mas s ; c ) adding fat matter of butter origin and / or vegetable origin to said main dough already containing said at least one sweetener and egg yolk, preferably egg mixture , creating a uni form mass ; d) reducing the main dough mass into portions and letting them rise ; e ) baking the leavened portions of said main dough, obtaining a leavened bakery product from each one , wherein said method comprises a step f ) of adding cocoa to said main dough before step d) , characterised in that said cocoa is added to the main dough as a component of a semi- finished product consisting of a f luid carrier mixture comprising at least cocoa, water and at least one water activity stabiliser Aw and in that said fluid carrier mixture is added to saidmain dough after the completion of step a ) and before step c ) .2 . Method according to claim 1 , wherein said fluid carrier mixture is added to said main dough before step b ) .

3. Method according to claim 1 or 2 , wherein said fluid carrier mixture is added to said main dough at a temperature not less than 20 ° C .4 . Method according to claim 1 , 2 or 3 , wherein said at least one water activity stabiliser Aw consists of a sweetener, preferably sucrose .5 . Method according to claim 4 , wherein said fluid carrier mixture comprises at least one anti-crystal lising agent of the sweetener .

6. Method according to claim 5 , wherein said at least one anti-crystallising agent of the sweetener is glucose syrup .7 . Method according to any of the preceding claims , wherein said fluid carrier mixture comprises natural flavourings .8 . Method according to any one of the preceding claims , wherein said fluid carrier mixture is obtained by mixing its components together until a homogeneous mass is obtained and pasteurising such a homogeneous mass thus obtained before introducing at least a part thereof intothe main dough.

9. Method according to any one of the preceding claims, wherein said fluid carrier mixture is obtained by mixing the following ingredients together:- caster sugar: between 20% and 44% by weight, preferably between 30.0% and 34.0%;- cocoa powder: between 12% and 32% by weight, preferably between 21.0% and 23.0%; glucose syrup: between 11% and 26% by weight, preferably between 17.5% and 19.5%;- optionally, natural flavourings: between 1% and 4% by weight, preferably between 2.2% and 2.8%; water: between 15% and 35% by weight, preferably between 24.5% and 25.5%, the % values referring to the total weight of the fluid carrier mixture.

10. Method according to claim 9, wherein said cocoa powder has a maximum water content of 9% by weight.

11. Method according to claim 9 or 10, wherein said cocoa powder is potashed, having a pH comprised between 6.0 and 8.0.

12. Method according to any one of the preceding claims, wherein said fluid carrier mixture has a viscosity comprised between 5.5 and 4.5 Pa*s measured with a rotational viscometer at 20°C, with a yield point of 160+ / - 1 Pa .

13. Method according to any one of the preceding claims , wherein said fluid carrier mixture has a water activity Aw not greater than 0 . 86 measured with electrolytic resistive method with electrolytic resistive hygrometer .14 . Method according to any one of the preceding claims , wherein said fluid carrier mixture is added to the main dough with a dosage comprised between 5% and 30% by weight on the dough as is , preferably between 10% and 15% .15 . Semi- finished product to be integrated in food preparations for the production of leavened cocoa bakery products , characterised in that it consists of a fluid mixture comprising at least cocoa, water and at least one water activity stabiliser Aw .

16. Semi- finished product according to claim 15 , wherein said at least one water activity stabiliser Aw consists of a sweetener, preferably sucrose .17 . Semi- finished product according to claim 15 or 16 , comprising at least one anti-crystallising agent of the sweetener .18 . Semi- finished product according to claim 17 , wherein said at least one anti-crystallising agent of the sweetener is glucose syrup .

19. Semi- finished product according to any one of claims15 to 18, having a viscosity comprised between 5.5 and4.5 Pa*s measured with a rotational viscometer at 20°C, with a yield point of 160 + / - 1 Pa.

20. Semi-finished product according to any one of claims 15 to 19, comprising:- caster sugar: between 20% and 44% by weight, preferably between 30.0% and 34.0%;- cocoa powder: between 12% and 32% by weight, preferably between 21.0% and 23.0%; glucose syrup: between 11% and 26% by weight, preferably between 17.5% and 19.5%;- optionally, natural flavourings: between 1% and 4% by weight, preferably between 2.2% and 2.8%; water: between 15% and 35% by weight, preferably between 24.5% and 25.5%, the % values referring to the total weight of the semifinished product.

21. Semi-finished product according to any one of claims 15 to 20, wherein having a water activity Aw not greater than 0.86 measured with electrolytic resistive method with electrolytic resistive hygrometer.

22. Production method of a semi-finished product to be integrated in food preparations for the production of leavened cocoa bakery products, characterised in that it comprises the following operating steps:preparing ingredients consisting of at least cocoa powder, water and at least one water activity stabiliser Aw;- mixing said ingredients together until a homogeneous mass is obtained; and- pasteurising such a homogeneous mass thus obtained.

23. Method according to claim 22, wherein said at least one water activity stabiliser Aw consists of a sweetener, preferably sucrose (caster sugar) .

24. Method according to claim 22 or 23, comprising among the ingredients at least one anti-crystallising agent of the sweetener, preferably consisting of glucose syrup.

25. Method according to any one of claims 22 to 24, wherein the ingredients consist of:- caster sugar: between 20% and 44% by weight, preferably between 30.0% and 34.0%;- cocoa powder: between 12% and 32% by weight, preferably between 21.0% and 23.0%; glucose syrup: between 11% and 26% by weight, preferably between 17.5% and 19.5%;- optionally, natural flavourings: between 1% and 4% by weight, preferably between 2.2% and 2.8%; water: between 15% and 35% by weight, preferably between 24.5% and 25.5%, the % values referring to the total weight of the fluidcarrier mixture.

26. Method according to any one of claims 22 to 25, wherein said cocoa powder has a maximum water content of 9% by weight.

27. Method according to any one of claims 22 to 26, wherein, said cocoa powder is potashed and has a pH comprised between 6.0 and 8.0.

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