Cold Sponge Bread Making with Freezing Storage
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Solution Overview
Problem
Conventional bread-making methods, particularly the sponge dough method, face challenges in maintaining consistent quality due to temperature and time fluctuations during fermentation, leading to under- or over-ripened dough, which is costly and inefficient, and unsuitable for mass production and franchise systems.
Innovation Solution
A method involving a cold sponge process, followed by freezing storage, thawing, and a second fermentation process, where the dough is mixed at specific temperatures and humidity levels to create a stable gluten network, improving texture and flavor, and extending shelf life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the first fermentation process is performed at low or high temperature for a relatively short time, then the fermentation speed is increased, but the texture and volume of bread deteriorate
Solution Approach 1:
The patent changes the temperature parameter from conventional high/low temperature short-time fermentation to a specific low temperature range (2-4°C) with extended duration (15-18 hours), creating optimal conditions for gluten development and yeast activity that simultaneously improve texture and volume while maintaining fermentation speed
Solution Approach 2:
The patent performs preliminary mixing and ingredient preparation at controlled temperatures (15-17°C) before the main fermentation process, ensuring proper gluten network formation and ingredient distribution that will positively affect the final bread texture and volume during the extended low-temperature fermentation
2Loss of time
If the first fermentation process is performed under conventional temperature and time conditions, then the production cycle is shortened, but the dough becomes under-ripened or over-ripened due to temperature fluctuations, causing costly waste
Solution Approach 1:
The patent establishes a specific low temperature range (2-4°C) and extended time period (15-18 hours) for the first fermentation process, which provides stable and reliable ripening conditions that prevent both under- and over-ripening, thereby reducing waste while maintaining efficient production cycles
Solution Approach 2:
The patent prepares the dough mixture with precise ingredient ratios and controlled initial temperature (15-17°C) before fermentation, creating a buffered system that is less sensitive to temperature fluctuations during the extended low-temperature fermentation process, thus ensuring consistent ripening and reducing waste
3Ease of manufacture
If conventional bread-making methods are used, then the process is simple, but the quality of bread is inconsistent and cannot meet the requirements of franchise systems
Solution Approach 1:
The patent implements specific controlled parameters including temperature (15-17°C for mixing, 2-4°C for fermentation), humidity (90-95%), and time (15-18 hours) that ensure consistent and high-quality bread production, making the process suitable for franchise systems while remaining manufacturable
Solution Approach 2:
The patent performs preliminary mixing and ingredient preparation under controlled conditions before the main fermentation process, ensuring consistent gluten development and ingredient distribution that produce uniform bread quality while maintaining a relatively simple overall process structure suitable for franchise operations
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 results in bread with enhanced texture, flavor, and extended shelf life, ensuring consistent quality and increased productivity, even in the face of temperature fluctuations, and allows for differentiated product offerings in franchise systems.
Implementation Method 1
the dough produces various aromatic substances by alcohol fermentation, lactic acid fermentation, and fermentation with other organic acids after proper ripening
Implementation Method 2
the resulting dough pieces of the dough process are frozen at −38° C. for 40 minutes, wrapped in plastic, and stored at a temperature of less than −18° C.
Data Source
AI summary
A bread making method including: a cold sponge process where strong flour, dried yeast, yeast food, salt, an improver, and water are mixed, stirred at low speed, stirred at high speed, and then fermented at a temperature and relative humidity; a dough process in which the resulting mixture of the cold sponge process is mixed with strong flour, sugar, salt, dried milk, dried yeast, margarine, and water, and the to resulting mixture is given a floor time and then divided into pieces; a freezing storage process in which the dough is frozen, wrapped in plastic, and stored at a temperature of less than −18 degrees C.; a thawing process in which the resulting dough pieces of the freezing process are thawed; and a second fermentation process in which each of the resulting dough pieces is molded and subjected to a second fermentation.