Fermented Back Dough Stabilization for Bakery Production
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Solution Overview
Problem
The limited utilization of back dough in baking due to its biochemical and microbiological activity leads to inconsistent quality in baked products, especially in line production where precise specifications are required, and existing recycling methods are either time-consuming, energy-intensive, or result in spoilage.
Innovation Solution
A method involving the addition of a starter culture to a sourdough substrate, coarse pre-shredding of back dough, mixing with water and starter, fermentation to achieve a pH below 4.5, and subsequent blending with raw dough to create a stable basic dough for consistent reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If back dough is stored for later use, then production flexibility is improved, but biochemical and microbiological degradation processes increase leading to quality inconsistency
Solution Approach 1:
The back dough undergoes preliminary freezing before storage, which halts biochemical and microbiological degradation processes. This allows the dough to be stored for extended periods without quality deterioration, resolving the contradiction between storage time and quality consistency
Solution Approach 2:
The invention changes the temperature parameter by freezing the back dough at sub-zero temperatures. This parameter change preserves the dough's biochemical composition during storage, enabling both time flexibility and quality consistency
2Productivity
If back dough is directly returned to main dough, then processing time is reduced, but quality control becomes unpredictable due to variable degradation states
Solution Approach 1:
The back dough is pre-freezed and pre-processed into a standardized form before being incorporated into the main dough. This preliminary action ensures consistent quality parameters while maintaining efficient processing when the frozen back dough is later used
Solution Approach 2:
Freezing changes the physical state of back dough, preserving it in a controlled parameter state. This allows the dough to be stored and then used at standardized conditions, ensuring manufacturing precision without sacrificing productivity
3Stability of the object's composition
If back dough is cooled to limit degradation, then quality is improved, but energy costs increase and microbiological spoilage still occurs
Solution Approach 1:
The invention uses freezing (phase transition from liquid to solid) instead of mere cooling. This phase transition completely halts microbiological spoilage and biochemical degradation, providing superior stability that exceeds what refrigeration alone can achieve
Solution Approach 2:
By changing the temperature parameter to sub-zero levels for freezing, the invention achieves complete preservation of dough quality. The energy investment is justified by the complete halt of degradation processes and elimination of spoilage risks
4Loss of substance
If excess back dough is produced and stored, then waste is reduced, but the dough undergoes spontaneous quality changes due to continued biochemical activity
Solution Approach 1:
The back dough is pre-freezed to preserve its quality before long-term storage. This allows excess dough to be produced and stored without undergoing spontaneous quality changes, enabling waste reduction while maintaining reliability
Solution Approach 2:
Freezing changes the temperature parameter to a state where biochemical activity is halted. This allows excess back dough to be stored indefinitely without quality degradation, achieving both waste reduction and quality predictability
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
This method stabilizes the back dough, allowing for flexible and safe reuse with improved quality and longer storage, reducing spoilage and enzymatic effects, enabling up to 24% fat content in doughs and enhancing product freshness and consistency.
Implementation Method 1
a) adding a starter culture to a sourdough substrate and obtaining a starting material... d) fermentation, if necessary homogenization, of the mixture at a temperature of 20 to 38 °C over a period of 6 - 20 h (hours) and obtaining a fermented dough with a pH value of less than pH 4.5
Data Source
AI summary
The invention relates to a method for manufacturing a basic dough for baked products by using fermented residual dough, comprising the following steps: a) inoculating a sour dough substrate with a starter culture and obtaining a starting material, b) coarse comminution and/or separation of a residual dough, c) mixing 20 to 70 parts of residual dough from step b) with 5 to 40 parts of water and 15 to 50 parts of the starting material from step a) and obtaining a mixture, d) fermenting, possibly homogenizing, the mixture at a temperature of 20 to 38 °C over the time interval of 6 – 20 h (hours) and obtaining a fermented residual dough having a pH value of less than pH 4.5; e) mixing 15 to 35 parts of the fermented residual dough with 65 to 85 parts of a raw dough and obtaining a basic dough.