Baking precursor product

Abstract

The invention relates to a baking precursor product comprising a dough which is surrounded by a membrane that is produced from a membrane dough. This contains gelatinised, optionally fermented starch and, for example, salt; the membrane can consist, for example, of salt dough, which makes it particularly stable. The dough can contain, in particular, a sourdough.

Description

[0001] BAKING PRE-PRODUCT

[0002] The invention relates to a baking intermediate, i.e., a product which can be used for baking bread or similar products. It relates in particular to an intermediate for baking sourdough bread.

[0003] There are various ways to make sourdough bread. Particularly good results are achieved using a so-called "sourdough mother" (also called "starter" or "mother dough") made from spontaneous sourdough, which serves as the base dough. The disadvantage is the considerable effort required to prepare and regularly feed (also called "refreshing") the sourdough mother. Preparing the dough before the actual baking process is also complex and time-consuming. Furthermore, sourdoughs, especially spontaneous ones, generally require several stages of revitalization before they can be used effectively. For all these reasons, inactive dried sourdoughs or dried active sourdough cultures, which are readily available, are often used. However, in terms of leavening power and bread flavor, these cannot match those of undried spontaneous sourdough.

[0004] Dried or liquid sourdough (often also called sourdough extract) purchased in grocery stores is generally microbiologically dead and only serves an aromatic and acidifying function, possessing no leavening power whatsoever. Doughs processed with this seasoning agent must always have yeast added. A novel concept for the industrial production of bread and pizza products has been published in WO 2015 / 026896 Al. This concept is based on the understanding that the bread crust and the bread crumb have different requirements. Based on this, WO 2015 / 026896 Al proposes producing the crust and the crumb from separate doughs optimized for these purposes.Several methods are proposed for creating a bakeable structure consisting of a shell made from a first dough (for the crust) and a filling made from a different second dough (for the crumb). Among other things, it is mentioned that the first dough can be exposed to high or low temperatures before being filled with the second dough so that it retains its shape during the filling process. If the first dough is exposed to high temperatures, gelatinization (also called 'gelatinization') or at least partial gelatinization of the starch occurs. However, the high temperatures also have the consequence that any yeast or other biologically active organisms present in the first dough would die and / or the gluten would be denatured or at least partially denatured. Therefore, in a subsequent baking process, the first dough cannot rise and remains only an elastically stretchable shell.Therefore, this embodiment is generally unsuitable, depending on the elasticity of the first dough, for structures with a filling (a 'second dough') with high leavening power, such as an active sourdough. Furthermore, the procedure according to WO 2015 / 026896 Al necessarily requires that the structure with casing and filling already contains all the essential ingredients of the baked product, since the casing is intended to form the crust on the finished product. The teaching of WO 2015 / 026896 Al is therefore not suitable for products that are assembled and then baked by the customer.

[0005] It is an object of the present invention to provide a precursor for the production of baked goods that overcomes at least some of the disadvantages of the prior art, is easy to handle, and enables the reliable production of high-quality baked goods. This object is achieved by a baking precursor containing a dough, in particular a sourdough starter. The dough is suitable as a leavening agent, i.e., it is capable of initiating a fermentation process when mixed with flour and liquid. A leavening agent is required to make the dough rise and to allow the baked goods (generally bread) to rise before and during baking. However, sourdough generally serves not only as a leavening agent but also as an acidifying agent and flavoring agent. It also keeps the bread fresh, prevents mold, and, in particular, makes rye flour suitable for baking by acidifying the dough.

[0006] The baking pre-product is a baking pre-product for use in a process in which it is mixed with flour and water—and optionally other ingredients—and kneaded to form a baking product dough. In this baking product dough, the dough itself serves as the leavening agent—in particular, as the sole leavening agent or possibly supplemented by an additional leavening agent added separately from the baking pre-product. Besides the dough itself, the baking pre-product also contains the casing, which, depending on the specific formulation, consists of gelatinized and / or fermented flour and can significantly contribute to the aroma and freshness of the baking product.

[0007] For dough to be suitable as a leavening agent, it must contain the lactic acid bacteria and yeasts required for fermentation as active microorganisms. To initiate a fermentation process in the dough for baked goods (e.g., bread dough), only flour and generally liquid need to be added – the addition of another leavening agent, such as baker's yeast, is not excluded, but also not necessary.

[0008] The baking pre-product is characterized by the fact that the dough is surrounded by a membrane (shell) made of a membrane dough. The dough is therefore not wrapped in plastic film, but in a membrane formed by a membrane dough, which, for example, allows for liquid exchange and / or a certain degree of gas exchange with the environment.

[0009] The baking pre-product is not a ready-to-bake product in the sense that it simply needs to be put in the oven (i.e., it is not a finished baked product). Rather, it is intended to be combined with flour and liquid (and optionally other ingredients) and kneaded into a baked product dough. The dough of the baking pre-product, which is suitable as a leavening agent, then serves as the leavening agent in a subsequent fermentation process of the baked product dough. The baking pre-product is therefore a pre-product for producing a baked product by adding flour and liquid to a baked product dough, then allowing the dough to rest and ferment, and finally baking the fermented baked product dough.The fermented baked product dough consists in particular of a single dough, in contrast to a dough structure with several separate dough components of different composition that are distinguishable within the baked product. The inventive process, when the dough suitable as a leavening agent is a sourdough, offers a solution to the need to provide a dough starter for baking high-quality baked products—by forming a dough with the baking precursor and other ingredients mixed with it—without having to first prepare and then constantly maintain a sourdough. It thus solves a completely different problem than the process described in WO 2015 / 026896 Al, which concerns the crust of the baked product, which is obviously neither intended nor suitable for being mixed with other ingredients to form a baked product dough.The membrane dough, and for example the entire baking pre-product, consists in particular of baking ingredients, i.e., edible ingredients approved for food production and especially for the production of baking products.

[0010] The membrane dough can differ, in particular, from a gluten dough and from a wheat protein isolate (WPI) dough. According to one aspect of the invention, a baking pre-product is thus provided which comprises a dough suitable as a leavening agent and which is characterized by a membrane surrounding the dough, wherein the membrane is made from a membrane dough consisting of baking ingredients and which differs from a gluten dough, a wheat protein isolate (WPI) dough, and a gluten dough supplemented with WPI.

[0011] According to one aspect of the invention, the membrane dough contains gelatinized starch and / or at least 2% salt.

[0012] The salt added to the membrane dough can, for example, correspond to at least 2.5% or at least 3.5% of the amount of flour contained in the membrane dough.

[0013] Starch gelatinization occurs when starch is exposed to heat, and possibly also shear, in contact with water. This allows the starch to absorb larger quantities of water and acquire a different consistency, exhibiting both plastic and elastic properties, through swelling and dissolution of the natural starch granules. It has been shown that gelatinized starch is well-suited as a membrane for dough used as a leavening agent, as the membrane remains physically and chemically stable and is not, for example, disintegrated by the active bacteria and / or fungi naturally present in the dough. The flour used for the membrane dough can be fully gelatinized, meaning that the flour contained in the membrane dough can be heated together with water to a temperature above the gelatinization temperature, e.g., to a temperature of at least 55 °C, at least 67.5 °C, at least 80 °C, or even at least 90 °C.However, it is also possible that the membrane dough contains ungelatinized flour in addition to the gelatinized flour. For example, the membrane dough as a whole (in this text, all proportions refer to mass, i.e., 10% is 10% by mass; the percentages, as usual unless otherwise stated, refer to the total quantity, here the total quantity of the membrane dough) contains at least 10%, at least 20%, or at least 30% gelatinized flour and, for example, at most 65% or 60% gelatinized flour, which, depending on the type of flour, results in a content of approximately at least 7%, at least 15%, or at least 20% and, for example, at most 50% gelatinized starch. In practical examples, the amount of gelatinized flour in the membrane dough can also be significantly above 35%, for example between 40% and 50%, and the content of gelatinized starch can be between 30% and 45%.

[0014] The gelatinized starch of the membrane generally originates from flour to which water is added and heat is applied; that is, either hot water can be added, and / or the resulting dough can be heated. It is possible (though not necessary in many applications) for the flour to undergo further processing before gelatinization, for example, a process in which the starch is enriched or isolated from other flour components. Another possible process to which the membrane dough can be subjected before gelatinization is fermentation. This proves particularly advantageous in certain applications, which will be discussed in more detail below. The gelatinized starch of the membrane dough also has a positive influence on the properties of the baking product dough subsequently created with the baking precursor and on the baked product made from it.The dough's structure during proofing is improved, and the baked product generally has a longer shelf life due to the dough's increased water absorption. The amount of gelatinized starch can be adjusted accordingly to suit the specific dough being prepared.

[0015] The flour used for making membrane dough can generally have any composition suitable for dough production, particularly for gelatinizing the starch contained in the flour. It can be, for example, wheat flour, such as white flour (e.g., type 550). It can also contain spelt flour, for example, by being a mixture of wheat and spelt flour. Adding spelt flour gives the membrane dough additional elasticity.

[0016] The flour used to make the membrane dough can also contain micronized (crushed, e.g., ground) bran; that is, it can consist of micronized bran or be a mix of micronized bran and other flour, e.g., white flour and / or added starch. This allows for the production of a hybrid wholemeal flour. For example, the membrane can contain all components of the grain, i.e., the outer layers of the endosperm and bran fragments, which must be added to a semi-white flour (e.g., type 550) to obtain a wholemeal flour. Thus, the finished product not only provides leavening power—through the dough's suitability as a leavening agent—and freshness, and offers dough rheological advantages (if it contains gelatinized starch), but also specifically influences the ash content (mineral content) of the final baked product.

[0017] In addition to or as an alternative to the gelatinized flour, the membrane also contains a substantial amount of salt (i.e., at least 2% salt), for example, at least 2.5%, at least 3% salt, or at least 4% salt, at least 6% salt, or even 8% salt or more, and for example, a maximum of 30% salt.

[0018] With respect to the amount of flour in the membrane dough, the salt content in the membrane can be at least 3%, at least 4%, at least 6%, at least 8%, or at least 10% or at least 12%, and, for example, a maximum of 80% or a maximum of 50%. The ratio of flour to salt (m«:ms) can specifically be between 20:1 or 10:1 (corresponding to a salt content of 10% of the flour content) and 1.5:1, in particular between 8:1 and 2:1 or between 7:1 and 3:1, for example, between 6:1 and 4.2:1.

[0019] A dough with a salt content of 2% or more, especially at least 3% or even at least 4%, is too salty to be baked directly into a finished product (the salt content in the finished product will then be somewhat higher due to water loss during the baking process). However, this is not a problem in this case, as the pre-baked product is mixed with other ingredients, namely flour and liquid, before baking. As long as the salt content of the resulting dough is not too high, there is no restriction on the salt content of the membrane dough, which makes up only a small fraction of the total dough mass of the finished product.

[0020] The salt content of the entire solid mass in the membrane dough (which consists, for example, of flour and salt, possibly with the addition of other ingredients such as semolina or wheat germ) can range from 4% to 50%, and particularly from 6% or 8% to 40%. The substantial amount of salt in the membrane dough has the significant advantage of contributing to the membrane's malleability and stability. In particular, the salt helps prevent leavening bacteria and fungi from attacking the flour in the membrane dough and prevents external germs from penetrating the baked product (microbiological protection) – both of which have a beneficial effect on the long-term stability of the baked product. Adding salt also reduces the... w -value (the so-called water activity) of the membrane.

[0021] A similar effect (reduction of a wThe membrane dough (with a specific value) undergoes fermentation before gelatinization with, for example, sourdough; that is, fermentation by lactic acid bacteria and yeast. In some formulations, the starch contained in the membrane dough is fermented. If the membrane dough is prepared with flour, meaning the starch in the membrane dough is or includes starch from the flour, as is the case in many formulations, the fermentation will affect not only the starch but also other components of the flour; the membrane dough may, for example, be fermented entirely.

[0022] Fermentation leads to a decrease in pH. This reduced pH of the membrane dough (depending on its composition, this can be described as a membrane made from a sourdough-salt cooked starter) provides additional microbiological protection. Furthermore, fermentation can improve the membrane's structure and rheology and reduce starch retrogradation in the cooked starter. The latter can significantly contribute to the membrane's stability. Ultimately, this fermentation breaks down the fermentable substances in the flour, which means they are no longer available for fermentation later on. This reduces or completely prevents secondary fermentation in the interface between the leavening dough and the membrane. Although the fermented membrane is no longer leavening in the final bread dough due to the thermal treatment (for gelatinization), it can still significantly contribute to flavor development.In these production methods, the membrane undergoes fermentation, during which the activity of the yeasts and lactobacilli produced is killed by thermal treatment (e.g., during extrusion). This fermentation aims to lower the membrane's pH (for shelf life), influence the dough rheology of the membrane material, and control the aroma. After the baked product is manufactured from the pre-baked product, the membrane dough material becomes part of the final dough by being mixed with the leavening agent, the added flour and water, and any other ingredients. Therefore, in these production methods, the dough material undergoes a double fermentation—a first fermentation before the membrane is produced and a second after the final dough is made, with the leavening agent being responsible for the latter.This approach with double fermentation is also novel.

[0023] Depending on the pH value, it is possible to completely dispense with the addition of salt to the membrane in a membrane dough with gelatinized starch, as the membrane is sufficiently stable even without the addition of salt if the membrane dough was sufficiently fermented before gelatinization and is therefore sufficiently acidic.

[0024] An unavoidable certain amount of salt diffusion from the membrane dough into the dough surrounded by the membrane – which can be minimized by the optional addition of protein, by suitable management of the sourdough, and / or by adding salt to the dough suitable as a leavening agent (e.g., sourdough) – can also have a positive effect on shelf life – cf. Monheimer Salzsauer.

[0025] A particularly favorable balance is achieved when the difference in salt content between the sourdough and the membrane, calculated based on their respective total weights, ranges from 3% to approximately 18%, especially between 4% and 12%. At salt concentrations higher than approximately 16%, increased water diffusion occurs from the sourdough (which consequently dries out) into the membrane (which consequently becomes slippery). At salt concentrations lower than approximately 6%, the... w The value is relatively high, so resistance to microorganisms is lower. This can be particularly advantageous if the a w The value is not higher than 0.92 or 0.9, e.g., not higher than 0.88. The a w The value of the membrane dough can, for example, be between 0.7 and 0.92.

[0026] If the membrane dough contains both gelatinized starch and a substantial amount of salt, then the membrane dough is a gelatinized salt dough ('salt boiled dough').

[0027] Membrane dough, unlike dough surrounded by a membrane, is generally not capable of leaving a leavening effect.

[0028] In addition to or as an alternative to adding salt, the membrane dough can be pasteurized if it contains gelatinized starch. Pasteurization also kills germs present in the flour, meaning it is a particularly beneficial option if the membrane dough contains no salt or only a relatively small amount. Suitable (high-temperature) pasteurization for membrane dough occurs, for example, when the dough is briefly heated to a temperature of 121°C or higher during extrusion. The extrusion technique, for example, using a cooling die, ensures that the membrane dough cools down rapidly after exiting the die, which is essential for the pasteurization process.

[0029] Besides flour and salt, the membrane dough also contains water. The amount of water is chosen according to need to achieve a suitable, for example, chewy-elastic, consistency of the membrane. The flour-to-water ratio in the membrane dough can be between 1.5:1 and 1:2, especially between 1.3:1 and 1:1.5.

[0030] Particularly through extrusion or generally mechanical mixing processes, the water content and thus the firmness of the membrane dough can be adjusted so that the membrane is easily formable, stable, and storable. In one embodiment, no water is added during the extrusion process, but only liquid sourdough and salt, or liquid sourdough and a salt-flour mixture. This allows a relatively liquid, easily pumpable sourdough, for example, with 1 part flour and 1 part water, to be pumped directly into the extruder, and the flour in the membrane is then largely or even 100% fermented.

[0031] A small amount of crystalline citric acid can optionally be added to the membrane dough to improve its elastic properties and lower the pH (providing additional microbial protection). The amount must not negatively affect the taste or rheology of the final baked product.

[0032] The membrane thickness can range from 1 mm to 15 mm or more, particularly from 2 mm to 12 mm, for example, from 5 mm to 10 mm. Generally, the membrane thickness can vary over a wide range, with thin membranes of no more than 1-2 mm functioning well, although these impart a less stable shape to the baked product as a whole compared to thicker membranes of, for example, 8 mm or more. Similarly, the ratio between the membrane dough mass and the mass of the dough suitable as a leavening agent can also vary widely, for example, between 1.5:1 or 1.2:1, or 1:1 and 1:5, or even 1:10 or 1:15. In general, the membrane dough mass and the mass of the dough suitable as a leavening agent can be selected based on functional and economic criteria, since the inventive method allows for selection within a very broad parameter range.

[0033] The dough suitable as a leavening agent in the baking pre-product can be completely enclosed by the membrane – as a single portion or divided into multiple portions. However, the fact that the dough is enclosed by the membrane does not preclude cracks in the membrane, which can occur, for example, if the dough continues to ferment while enclosed. Such cracks are particularly unproblematic and well-tolerated if the dough has a low fluidity, for example, due to a dough yield (TA) of no more than 200.

[0034] It is also possible that the baking pre-product consists of several portions – for example, two – each enclosed in a membrane, containing doughs of different compositions, with at least one of the doughs being suitable as a leavening agent. This can allow for optimization of the final baked product, including in terms of taste.

[0035] The dough used as a leavening agent in the baking pre-product may contain sourdough. Such a dough contains, in addition to flour and water, a culture of lactic acid bacteria and yeasts. The homofermentative (lactic acid-producing) and heterofermentative (lactic and acetic acid-producing) lactic acid bacteria, and possibly also acetic acid bacteria, cause fermentation, which produces lactic acid and possibly (in smaller quantities) acetic acid. The pH value of the sourdough is generally between 3 and 5, particularly at least 3.2, 3.5, 3.6, or 3.8 and at most 4.4 or 4.3, for example, between 3.9 and 4.2. In the present process, up to 3.5% salt may be added to the sourdough to improve its properties. An addition of 3.5% salt to the sourdough, with a flour to water ratio of 1:1, corresponds to an amount of 7% calculated on the amount of flour in the sourdough.For reference: The new method of the Monheim salt sourdough, after adjustments in 1971, specifies a maximum amount of 2.5% based on the weight of the flour in the sourdough, i.e. a significantly lower addition; previously a maximum amount of 5% of the sourdough flour quantity was recommended.

[0036] The properties of sourdough (acidity) can be controlled not only by the amount of water but also by using single- or multi-stage fermentation at different temperatures. Slightly higher temperatures, for example 30-35°C, are ideal for the development of homofermentative bacteria, cooler temperatures of 20-27°C for heterofermentative bacteria, and temperatures around 25-26°C for yeast. Sourdoughs fermented at higher temperatures are more lactic acid-dominant and generally milder than those fermented at lower temperatures, which are more acetic acid-dominant.

[0037] Instead of sourdough, or as a component thereof, the dough suitable as a leavening agent can also contain wild yeast (which is obtained from so-called yeast water, which in turn is obtained, for example, from fruit). The inventive approach can also be useful for producing a wild yeast baked product from, for example, yeast water.

[0038] Encapsulated flour can be added to the dough within the membrane, which is suitable as a leavening agent. This flour dissolves slowly over time, continuously feeding the sourdough starter. A suitable flour capsule can be designed, in particular, to dissolve slowly within the dough. Embodiments with such a flour addition to the dough surrounded by the membrane may, under certain circumstances, be suitable for even longer storage.

[0039] In addition to the actual sourdough, the dough suitable as a leavening agent can, in various embodiments, include the addition of protein, in particular gluten and / or WPI (wheat protein isolates); non-wheat-based proteins are also suitable as additions, e.g., soy proteins. Specifically, the addition can be wheat gluten, spelt gluten, or ancient spelt gluten. As an alternative to gluten, treated or untreated wheat protein isolates (WPIs) are also suitable for protein addition. Like wheat gluten, these are wheat proteins. However, with a protein content of typically 90%, they have an even higher protein content; in comparison, the protein content of dried gluten is at least 75%, typically around 80%. A commercially available wheat protein product is GernPro® Plus or GemPro® Prime-E from the Manildra Group (USA).

[0040] The fact that the protein is present as an additive to the sourdough in certain embodiments means that it is present in addition to the proteins that are already present in the grain and thus in the flour from which the sourdough is made. The protein content of the dough suitable as a leavening agent, made from the sourdough and the added protein, can be, in particular, at least 25%, at least 35%, at least 50%, or even at least 70% higher than the protein content of the sourdough without the added protein; that is, also at least 25%, at least 35%, at least 50%, or at least 70% higher than a mixture of the flour and water present in the sourdough. The protein content can, for example,The protein content must be at least 15% or at least 20% of the solid mass of the dough product (generally the cumulative mass of all components excluding added water) and / or at least 10% of the total mass of the dough product, which is significantly higher than the protein content of untreated flour or bread dough. The addition of dried gluten to strengthen the dough, relative to the amount of flour, corresponds to at least 10%, at least 15%, or even at least 20% or at least 25%, for example, approximately 30%, which is significantly higher than the usual amounts of dried gluten added to baking flours for quality control, which are typically a maximum of 5%. This results in a gluten-flour mixture with a protein content at least 80% higher and usually at least twice as high as that of conventional baking flours and / or, for example, at least 50% higher than that of the flour in sourdough before the gluten is added.

[0041] The addition of protein to the sourdough starter has a particular impact on the stability of the dough, which is suitable as a leavening agent. It allows for improved shaping of the baking starter, which enhances its shelf life, portionability, and ease of handling. The addition of gluten (or WPI) results in virtually no fermentation in the already fermented sourdough starter; that is, it provides little to no nourishment for the dough and does not restart the fermentation process after its addition. A certain degree of co-fermentation of the gluten also has a beneficial effect on the subsequent dough rheology (of the baked product dough made with the baking starter) and the flavor.

[0042] Adding protein has the further advantage of strengthening the gluten network of the dough suitable as a leavening agent. This allows doughs, especially sourdoughs, with a significantly higher liquid content (i.e., a significantly higher dough yield after fermentation) to become considerably firmer and subsequently stored as leavening dough surrounded by the membrane. Furthermore, the addition of protein, particularly gluten, provides additional protection against drying out. When gluten is used for protein addition, the declaration of the flour and / or bread does not need to be expanded – the dough product is free of additives, with the possible exception of additives that are already present in the flour used and are approved for use in flour, such as barley malt flour, acerola powder, or other suitable foods with a high natural ascorbic acid content.

[0043] Another advantage of adding protein, especially gluten, is that the protein structure prevents excessive salt from penetrating the dough. High salt concentrations can negatively impact the shelf life of the sourdough and thus its leavening power. Therefore, adding gluten is particularly beneficial when combined with the option described below of producing a salt-enriched membrane dough.

[0044] The increase in the dough's pH value caused by the addition of protein, compared to pure sourdough, also has the advantage of positively influencing its shelf life. At the same time, the increase in pH value is small enough that the pH remains within a range in which the sourdough remains microbiologically robust.

[0045] The addition of gluten has no negative impact on dough quality or baking performance; in fact, it is even advantageous when mixed with and used in conjunction with untreated flour. Gluten does not need to be declared as an additive in untreated flour.

[0046] Gluten has a significantly higher pH value than sourdough, which is why the pH value of the dough suitable as a leavening agent in embodiments with added protein is somewhat higher than the pH value of the sourdough, for example between 3.4 and 5.4, particularly at a value of at least 3.6 or at least 3.8 or at least 4.0 and at most 4.7 or 4.5, for example between 4.0 and 4.4. The ratio of flour to water in a sourdough can vary considerably and, for example, in an Italian biga sourdough, can range from 100:40 (flour to water), which corresponds to a dough yield (TA) of 140, to 100:120, i.e., TA 220, in highly hydrated sourdoughs. The latter can be used to produce sourdough breads with a soft, fine crumb and a very mild flavor. In particular, the former (i.e., doughs with lower hydration and lower dough yield) can be sufficiently stable within the membrane even without the addition of protein, which is why it is optional.

[0047] Since baking the product from the pre-baked dough, as well as from any additional flour, liquid, and possibly other baking ingredients, requires the addition of salt anyway, any salt already present in the membrane dough is perfectly usable and desirable. To create a dough for the baked product, it may only be necessary to combine flour, water, and the pre-baked dough in a container and mix and knead them together. The subsequent steps for creating the baked product (bulk fermentation, proofing, baking) can be carried out as is generally known for baked products, especially sourdough baked goods.

[0048] The baking starter can be used, for example, as an all-in-one product, as a complete or, for accelerating dough fermentation, partial replacement for, or addition to, baker's yeast (Saccharomyces cerevisiae). As mentioned, it can optionally contain the total amount or a portion of the salt required to create the finished bread dough with the amount of flour specified in the application instructions, in addition to the total salt in the membrane and, if applicable, the salt in the dough suitable as a leavening agent. In terms of fermentation tolerance, oven spring, flavor and aroma development, crumb and crust quality, freshness, and digestibility, sourdough is superior to baker's yeast. The only difference is that the required dough resting time is generally longer for pure sourdough breads, depending on the dosage. However, this corresponds to a clear trend in the baking industry and home baking and also offers recognized advantages in relation to a low-FODMAP diet (i.e.,This entails a diet with as few fermentable saccharides in the digestive tract as possible, by potentially reducing the oligosaccharide content through long dough fermentation.

[0049] The total mass of the baking pre-product can range from 100 g to 400 g, and in particular from 200 g to 350 g, depending on the intended use (producing baking dough with 0.5 kg flour, with 1 kg flour or more). In any case, the mass of the baking pre-product is significantly less than the mass of the final baked product.

[0050] A process for producing the baking pre-product using a sourdough starter as a dough suitable as a leavening agent includes, for example, the following steps:

[0051] • Natural fermentation of sourdough based on a pre-produced sourdough, e.g. with 5 parts flour, 5 parts water and a part of the pre-produced sourdough (as is known in the first place, a part of the sourdough can be used as pre-produced sourdough (leavening agent) for the subsequent sourdough production);

[0052] • Optional: Monitoring of fermentation by determining the pH value or acidity of the sourdough;

[0053] • Optional: Adding salt and / or gluten to the sourdough and subsequent optional fermentation. Salt and gluten can be added simultaneously or at intervals, and in the order salt, gluten or gluten, salt.

[0054] • Optional: Cooling the sourdough to extend its shelf life before filling the membrane and to slow down or stop the fermentation process; • Optional: Fermentation of the flour used to make the membrane dough in the subsequent membrane dough production process (this step can also be done after mixing the membrane dough ingredients, but must necessarily take place before heating for gelatinization);

[0055] • Production of the membrane dough from flour, salt and water, wherein the water or the water with the dissolved salt is heated before addition and / or the entire flour-water-salt mixture is heated;

[0056] • Production of the membrane from the membrane dough, for example by extrusion or rolling;

[0057] • Filling the membrane with the dough to complete the baking pre-product;

[0058] • Optional: Placing the baking pre-product in a transport and storage container (e.g. as part of a package).

[0059] The ingredients used and / or subsequently the baking pre-product as a whole can be cooled, with the exception, of course, of the membrane dough production step, which requires heating in between.

[0060] The steps of manufacturing the membrane and filling the membrane with the dough can take place sequentially one after the other or simultaneously in a single process step.

[0061] Membrane dough can be produced in various ways, for example by extrusion on a single- or twin-screw extruder with a perforated, flat, or annular die. Production in a suitable cooker is also possible, whereby the cooker, especially at low water contents, should have a suitable agitator to prevent the membrane dough from boiling. After this process, it is a standard cooked dough in the industry; if the cooked dough is enriched with salt, it is called a "salt cooked dough."

[0062] For filling, the extruded membrane can then be placed around the dough, which is in lump form.

[0063] Alternatively, using co-extrusion with ring dies, the dough can be filled into the resulting "dough tube" and then sealed in portions. In this case, the dough would be co-extruded into the membrane formed by the extruder's ring die and crimped into dough packages. So-called "pillow crimpers" are downstream devices commonly used for this purpose in co-extrusion. However, separation can also be achieved using other devices, such as twisting (similar to the end of a sausage) or cutting, etc.

[0064] If the membrane is produced as a flat layer – for example, by extrusion with a flat die or by rolling (provided the limited plasticity of the membrane dough allows this) – a filling method similar to that used for making Maultaschen (a type of filled pasta) is also suitable: the dough is applied in portions to a first layer and then covered with a second layer, whereupon the first and second layers are pressed together at the points between the sourdough portions and the portions are separated from each other simultaneously or subsequently.

[0065] Another possibility is to shape the membrane dough and inflate it into a balloon-like structure by injecting the dough. The baking pre-product may be intended specifically for refrigerated storage, transport, and / or shipping, for which purpose it may also be labeled accordingly (e.g., "keep refrigerated").

[0066] The baking pre-product can be specifically designed for the preparation of a particular baking product – e.g., a light or dark wheat sourdough bread, a rye mixed bread, a spelt sourdough bread, sourdough croissants, etc. – as indicated in the information.

[0067] In addition to the baking pre-product and a method for its production, the present invention also relates to the use of the baking pre-product for the production of a baked product – e.g., sourdough bread. For production, the baking pre-product is mixed as a whole with flour and water and optionally other ingredients to form a baked product dough, whereupon the baked product dough is allowed to rest – as is known per se, possibly in several phases, interrupted by kneading and possibly portioning and / or placing in a mold or shaping it as desired – and then baked.

[0068] Exemplary embodiments of the invention are described below with reference to the drawings. In the drawings, identical reference numerals denote identical or analogous elements. The drawings are schematic and partially show corresponding elements in different sizes from figure to figure. They show:

[0069] Fig. 1 shows a baking pre-product;

[0070] Fig. 2 shows a cross-section of a transport and storage container with a plurality of baking ingredients; Fig. 3 shows a view of another transport and storage container;

[0071] - Fig. 4 shows a stack of transport and storage containers with baking ingredients; and

[0072] - Fig. 5 shows another transport and storage container in cross-section.

[0073] An example of a baking pre-product 1 is shown in Figure 1. The baking pre-product 1 comprises a dough 3 which is completely enclosed by a membrane 5 in the example shown. The dough is, in particular, a sourdough product, namely a sourdough with added protein.

[0074] Dough 3 is in particular a spontaneous sourdough that can be fermented without restrictions, optionally enriched with added salt and / or protein.

[0075] Dough 3, for example, can be prepared as follows:

[0076] First, a starter culture, a milled grain product (e.g., wheat flour, type 550), and water are placed in a fermenter. The ratio of starter culture to milled grain product to water can be, for example, 1:1:1. The mixture ferments in the fermenter at a temperature Ti, with this fermentation process lasting, for example, a predetermined time Zn or until a predetermined pH value pHti is reached. Of course, combinations are also possible, such as fermentation over a predetermined period with additional pH control Ii, where fermentation is stopped if a specific first pH threshold is undershot during this period and / or fermentation continues beyond the time Zn if a second pH threshold is exceeded after its expiry. The parameters Ti, Zn, and / or pHi can be optimized depending on the starter culture, as well as on requirements and preferences.Tn can be, for example, at a value between 20°C and 27°C, especially between 22° and 25°, Zn at a value between 6 hours and 24 hours, for example between 12 hours and 20 hours, and pHn at a value between 3.2 and 4.2, for example between 3.5 and 4.

[0077] Following fermentation, a quantity of the product is placed in a mixing bowl, either at room temperature or chilled, and optionally mixed with gluten and / or salt while kneading, e.g., ms sourdough with IHG dried gluten. The ms:mo ratio can range from 18:1 to 4:1, particularly between 10:1 and 5:1.

[0078] The kneading process typically takes only a few minutes, resulting in a very slight temperature increase. The addition of the dried gluten raises the pH of the product. The pH can optionally be measured again and compared to a target value. The target pHsi for the resulting sourdough product immediately after mixing can be between 3.9 and 4.6. The sourdough product is then either cooled immediately or left to stand for a further period Zβ, e.g., at room temperature, to allow it to ferment further (post-fermentation). Afterward, it is allowed to stand, for example, at approximately 4°C, under refrigeration. This further period Zβ typically lasts a few hours, e.g.,2-6 hours; after this further fermentation, another pH measurement can be carried out, whereby the target pHs2 for the sourdough product after the post-fermentation may be somewhat lower than the target pHsi immediately after mixing, e.g., between 0.05 and 0.25 lower than pHsi and, for example, at a value between 3.8 and 4.5. In the example shown, the membrane dough is a cooked dough enriched with salt.

[0079] The membrane dough can be prepared as follows: First, a quantity of flour (e.g., white wheat flour) is mixed with a quantity of salt (e.g., iodized and / or fluorinated) in a mixer. The flour-to-salt ratio can be between 20:1 and 1.5:1, particularly between 10:1 and 2:1, between 8:1 and 4.2:1, or between 6.2:1 and 5.2:1.

[0080] The flour and salt together form the membrane dough solid, which can be premixed or, alternatively, dosed separately in the following steps. This is dosed, for example, gravimetrically in an extruder, mixed with a quantity of water (mw) or, if the salt is not present in the solid, with brine, and heated to a target temperature (TE) at the point of exit from the extruder nozzle, generally with low shear and with additional housing temperature control. The flour-to-water ratio (mw:mw) is, for example, between 1.4:1 and 1:1.4, while the flour-to-salt ratio is chosen in the range described above. The target temperature (TE) is at least the gelatinization temperature of the starch contained in the flour, i.e., at least 55°C, and in particular at least 67.5°C (the temperature at which starch paste forms in wheat starch).An upper temperature limit is determined by the requirement that the membrane dough should remain plastic after cooling; in some embodiments, this limit can be 125 °C, 121 °C, HO °C, or at the boiling point. In other embodiments, the target temperature is at least 80 °C, particularly between 90 °C and approximately 110 °C or the boiling point (100 °C at standard atmospheric pressure at sea level). A target temperature TE above the gelatinization temperature of the starch applies regardless of the type of mechanical treatment (extrusion in the described embodiment). The gelatinization temperature for a specific type of starch can be looked up or determined experimentally if necessary.

[0081] Following extrusion, the membrane dough is cooled, for example via a cooling die or by leaving it in a cool environment. It can be stored in a refrigerator until needed, for example at approximately 3 °C.

[0082] The pre-product shown in Fig. 1 is produced from the membrane dough and the dough (sourdough product in its final state), for example, by forming dough balls from the sourdough product and the extruded membrane dough using a suitable co-extrusion machine. The size of the dough balls depends on the amount of flour the baking pre-product is intended for in the baked product to be manufactured. For example, if the baking pre-product is intended for a flour quantity of 500 g, it can contain approximately 80 g of sourdough product encased in approximately 70 g of membrane dough; for a flour quantity of 1,000 g, it will contain twice that amount.

[0083] The baking ingredients can then be placed in a suitable transport and / or storage container, which is optionally flooded with CO2 before and after filling (oxygen displacement, creation of a protective atmosphere) to reduce the oxygen content in the packaging to ideally below 2%, and stored at a maximum temperature of approximately 5 °C until use. The transport and / or storage container can be moisture-proof and / or oxygen-proof, e.g., airtight.

[0084] To complete the baked product, the baking starter is mixed and kneaded with the specified amount of flour, water, and, if necessary, additional salt and / or other ingredients to form a dough. Particularly in commercial use, the dough may contain a larger quantity of flour and water, and a number of portions of the baking starter adjusted to the amount of flour. It is also possible that the baking starter is not supplied as a single portion, but rather in the form of a membrane dough tube filled with the dough suitable as a leavening agent, i.e., in the form of a long 'sausage'. Such a baking starter 'sausage' can be provided as an endless tube, i.e., a tube without a predefined length, in which case portioning is achieved by cutting off a piece of the appropriate length.It is also possible that a baking pre-product 'sausage' has a defined length and is therefore already pre-portioned for a specific - large - quantity of dough.

[0085] The kneaded dough is left to rest for a certain period, typically several hours (bulk fermentation). Then it is generally kneaded again and subsequently, possibly after being portioned, shaped into the baked product, left to rest briefly (final proof), after which it is baked.

[0086] Figure 2 shows, very schematically and in cross-section, an example of a transport and storage container 10 containing a plurality of baking pre-products 1 of the type described above. Since the transport and storage container in the illustrated example holds several baking pre-products 1, each in a separate unit, it can also be referred to as a 'container' in this example. The transport and storage container has a base body 11 with recesses (cavities) for each of the baking pre-products 1. The base body 11 can be made, for example, of a paper fiber casting or another material that is obtained in a recycling process and / or is recyclable. If the material of the base body, as is the case with paper fiber casting, can absorb water, the base body can be coated on the inside with a barrier, for example, a barrier coating commercially available for this purpose.Additionally or alternatively, the fiber casting can be made hydrophobic using a suitable, preferably natural and food-safe agent (e.g., waxes) or can consist directly of hydrophobic fibers. Besides the base body, the transport and storage container 10 has, for example, an airtight seal, such as one made of heat-sealable paper or a plastic film.

[0087] The transport and storage container 10 can, for example, be provided as a recyclable, single-use container. Its dimensions can be selected according to requirements, e.g., 60x40 cm or 40x30 cm.

[0088] Another packaging option is to wrap the portions in PE or aluminum-coated paper. The latter is available with very thin aluminum layers and is then considered a mono-material that can be completely recycled with waste paper.

[0089] In some embodiments, the transport and storage container can also be made of a plastic, e.g. a transparent plastic, e.g. polyethylene (PE).

[0090] After the baking ingredients 1 are placed in the cavities, the base body 11 of the transport and storage container can be fitted with a sealing film 12 (see Figure 5), also made of plastic, for example, possibly the same plastic as the base body 11, so that each cavity forms an enclosed space containing the baking ingredients 1. The transport and storage container then forms an outer package for the baking ingredients 1. It is also possible to subsequently divide the transport and storage container into individual portions or groups of portions of the baking ingredients with outer packaging (pre-separation points 23 in Figure 5). The cavity formed by the two films (base body 11, sealing film 12) can be pressurized or vacuum-sealed and, if required, insulated with a protective gas.The sealing (top) film 12 can be designed as a peelable film, which significantly facilitates the opening of individual packages. The peelable film and the tear lines can be designed so that individual packages or the entire package unit can be opened by pulling on the peelable film.

[0091] Figure 3 shows a schematic view of a transport and storage container 10 of the type shown in Figure 2. The transport and storage container 10 additionally has a downward-projecting stacking rim 21 on each of two sides, allowing multiple transport and storage containers 10 to be stacked on top of each other, as shown in Figure 4.

[0092] Example 1: Baking pre-product with high gluten addition to sourdough

[0093] To produce a salt-based membrane dough, 20 kg of flour and 5.6 kg of iodized salt are mixed in a mixer (membrane dough solids). The membrane dough solids are gravimetrically fed into an extruder, mixed with 20 kg of water, and heated to a target temperature of 95°C at the extruder nozzle under low shear and with housing temperature control. The extruded membrane dough is optionally cooled via a cooling nozzle and then stored in a cooler at 4°C until further use. The salt content of the resulting membrane dough is 12.3%.

[0094] To produce a gluten sourdough starter (sourdough product) suitable as a leavening agent, a starter culture, a grain milling product, and water in equal proportions are placed in a fermenter and fermented at room temperature for 18 hours, or until the pH reaches 3.74. Following fermentation, an appropriate amount is transferred to a mixing bowl, for example, 10 kg of sourdough starter with 1.44 kg of dry gluten, and mixed with a mixer for 3 minutes and 30 seconds. The kneading process results in a very slight temperature increase. The pH is then measured, which should be approximately 4.33. The dough is then left to stand at room temperature for 3 hours, after which another pH measurement is taken, targeting 4.23. The dough is then placed in a cooler, where it can cool to 4 °C and is left to stand for at least 18 hours.

[0095] Using a suitable co-extrusion machine, filled dough balls are formed, each containing 180 g of dough as filling and 140 g of membrane dough as the membrane (for units made with 1 kg of flour; for 500 g of flour, the baking precursors are half the weight). They are then placed in a suitable transport / storage container, sealed airtight, and stored at a maximum temperature of 5 °C.

[0096] From such a baking pre-product, a bread dough can be made by adding 1 kg of flour, 700 g of water, and 1.1% salt (dough yield TA 172). Based on the amount of flour, this contains approximately 15% sourdough, with a total salt content of 2.1% of the flour weight including gluten, and 2% of the dry gluten weight. Using a membrane dough, the bread dough contains almost 5% gelatinized flour based on the amount of flour excluding gluten. The gelatinized flour contributes to improved freshness, especially for ancient spelt and spelt baked goods. This makes baking with the pre-product particularly reliable. As already mentioned, in some formulations, baking pre-products can also be produced in which the entire amount of salt is already included. This has the advantage that the user does not need to add any salt, but it also limits the flexibility in adding salt. Example 2: Baking pre-product with highly hydrated, salt-enriched sourdough without added gluten

[0097] To produce a salt-based membrane dough, 20 kg of flour and 3.5 kg of iodized salt are mixed in a mixer (membrane dough solids). The membrane dough solids are gravimetrically fed into an extruder, mixed with 23.5 kg of water, and heated to a target temperature of 95°C at the extruder nozzle under low shear and with housing temperature control. The extruded membrane dough is optionally cooled via a cooling nozzle and then stored in a cooler at 3°C ​​until further use. The salt content of the resulting membrane dough is 7.4%.

[0098] To produce a sourdough starter, suitable as a leavening agent, a starter culture, a grain milling product, and water are combined in equal proportions in a fermenter and fermented at room temperature for 18 hours, or until the pH reaches 3.71. 3.2% iodized salt is added to the dough, which is then placed in a cooler to cool to 34°C and left to stand for at least 18 hours.

[0099] Using a suitable co-extrusion machine, filled dough balls are formed, each containing 160 g of dough as filling and 130 g of membrane dough as the membrane (for units made with 1 kg of flour; for 500 g of flour, the baking precursors are half the weight). They are then placed in a suitable transport / storage container, sealed airtight, and stored at a maximum temperature of 5 °C.

[0100] From such a baking starter, a bread dough can be made by adding 1 kg of flour, 675 g of water, and 9.5 g of salt (dough yield TA 172). Based on the total amount of flour, this contains approximately 15% sourdough, a salt content of 2.1%, and almost 5% gelatinized flour via the membrane dough.

Claims

- 33 - PATENT CLAIMS 1. A baking intermediate comprising a dough (3) suitable as a leavening agent, characterized by a membrane (5) surrounding the dough (3), wherein the membrane is made of a membrane dough containing gelatinized starch and / or at least 2% salt.

2. A baking intermediate according to claim 1, wherein the membrane dough contains at least 3% Contains salt.

3. Baking pre-product according to claim 2, wherein a solid mass of the membrane dough contains at least 4% and at most 40% salt.

4. Baking intermediate product according to one of the preceding claims, wherein the membrane dough comprises a w -value of at most 0.

92.

5. Baking intermediate product according to one of the preceding claims, wherein the membrane dough contains at least 15%, in particular at least 25% gelatinized flour.

6. Baking intermediate product according to one of the preceding claims, wherein the dough (3) which is suitable as a leavening agent has a protein addition.

7. Baking intermediate product according to one of the preceding claims, consisting exclusively of ingredients that are suitable for baking.

8. Baking intermediate product according to one of the preceding claims, wherein the dough (3) which is suitable as a leavening agent contains a sourdough.

9. Baking intermediate product according to claim 7, wherein the pH value of the dough (3), which is suitable as a leavening agent, is between 3.4 and 5.

4.

10. Baking intermediate product according to any one of the preceding claims, wherein the Dough (3) which is suitable as a leavening agent, has an added salt.

11. Baking pre-product according to one of the preceding claims, wherein the membrane dough is pasteurized.

12. Baking intermediate product according to one of the preceding claims, wherein the starch contained in the membrane dough is at least partially fermented.

13. Method for producing a baking pre-product according to one of the preceding claims, comprising the steps: • Preparation of the dough suitable as a leavening agent (3); • Creating a mixture of flour and water for the production of the membrane dough; • Heating the mixture to a temperature above the gelatinization temperature of the flour contained in the mixture; Production of a membrane from the membrane dough; • Filling the membrane with the dough.

14. The method of claim 13, wherein the production of the membrane dough and / or the production of the membrane from the membrane dough is carried out by extrusion.

15. The method of claim 14, wherein the filling of the membrane from the Membrane dough is produced using co-extrusion.

16. Method according to any one of claims 13 to 15, wherein the step of producing the dough suitable as a leavening agent (3) comprises the partial step of adding gluten and / or the partial step of adding salt.

17. Method according to any one of claims 13 to 16, wherein the production of the membrane dough and / or the production of the membrane from the membrane dough comprises heating to a temperature of at least 121°C, thereby pasteurizing the membrane dough.

18. Method according to any one of claims 13 to 17, wherein the production of the membrane dough includes fermentation of at least a part of the starch contained in the flour.

19. Method according to any one of claims 13 to 18, wherein the mixture for the The membrane dough contains salt in addition to flour and water.

20. Use of a baking pre-product according to any one of claims 1 to 12 for the production of a baking product, wherein the baking pre-product is mixed as a whole with flour and water and formed into a baking product dough, after which the baking product dough is left to rest and then baked.

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