Maltogenic Alpha-Amylase Premix for Longer-Lasting Flat Bread Freshness
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Solution Overview
Problem
Flat breads harden quickly after baking, reducing their quality and freshness, and existing enzyme solutions require longer baking times, making them unsuitable for rapid baking processes.
Innovation Solution
A method involving the use of a first and second maltogenic alpha-amylase, each with specific substitutions, and the addition of sugar to the dough, to improve the freshness of flat breads, specifically pita, baladi, Lebanese, and other flat breads, by enhancing foldability, eating properties, and softness up to 7 days post-baking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional amylases are used to improve freshness of flat breads, then starch modification is achieved, but baking time must be extended which is incompatible with rapid flat bread baking
Solution Approach 1:
The patent modifies the amino acid sequence of maltogenic alpha-amylase by introducing specific substitutions (S194Y, N375S, D261G, T288P) to change the enzyme's kinetic parameters. These parameter changes enable the enzyme to achieve sufficient starch modification at lower temperatures and shorter times, resolving the contradiction between freshness improvement and baking time reduction.
Solution Approach 2:
The patent combines multiple enzyme variants (first and second maltogenic alpha-amylase with different amino acid substitutions) to create a composite enzymatic system. This composite approach synergistically enhances starch modification efficiency, allowing effective freshness preservation within the rapid baking timeframe without requiring extended processing.
2Productivity
If flat breads are stored for extended periods, then distribution and automation are enabled, but quality and softness deteriorate rapidly
Solution Approach 1:
The improved maltogenic alpha-amylase is incorporated into the dough before baking, performing preliminary starch modification during the baking process. This preliminary action creates a starch structure that resists retrogradation during storage, enabling flat breads to maintain quality over extended periods and facilitating distribution without quality deterioration.
Solution Approach 2:
The enzyme's modified amino acid structure changes its catalytic parameters to produce a specific starch modification pattern that stabilizes the bread crumb structure. This parameter change in enzyme function directly translates to improved storage stability, allowing productivity gains through distribution while maintaining quality.
3Productivity
If rapid baking is used for flat breads, then productivity is increased, but insufficient starch modification occurs leading to fast hardening
Solution Approach 1:
The patent introduces specific amino acid substitutions in maltogenic alpha-amylase that optimize its activity parameters for rapid processing. These parameter changes increase enzymatic efficiency and temperature tolerance, enabling sufficient starch modification to occur during rapid baking cycles, thus maintaining freshness without sacrificing productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly improves the freshness and quality of flat breads by maintaining softness and foldability for up to 7 days, allowing for storage and distribution using automated processes.
Implementation Method 1
adding to flour or to a dough comprising a flour, a first maltogenic alpha-amylase having at least 70% identity to SEQ ID NO: 1, and compared to SEQ ID NO: 1 comprising the substitutions D261G, T288P, and F188L; and a second maltogenic alpha-amylase having at least 70% identity to SEQ ID NO: 1, and compared to SEQ ID NO: 1 comprising the substitutions D261G, T288P, F194Y, and N375S
Data Source
AI summary
A method for improving the freshness of flat breads comprising a) adding to flour or to a dough comprising a flour, a first maltogenic alpha-amylase having at least 70% identity to SEQ ID NO: 1, and compared to SEQ ID NO: 1 comprising the substitutions D261G, T288P, and F188L; and a second maltogenic alpha-amylase having at least 70% identity to SEQ ID NO: 1, and compared to SEQ ID NO: 1 comprising the substitutions D261G, T288P, F194Y, and N375S; and b) making flat breads from the dough.