Frozen Dough Production for Cream-Filled Bread
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Solution Overview
Problem
Conventional methods for producing bread with fillings face challenges in maintaining the soft texture and freshness of bread, especially when using frozen or refrigerated dough, as the crispiness is short-lived and the texture can become hardened over time.
Innovation Solution
A method for producing frozen dough for bread with fillings, involving the preparation of a first sponge dough and a second dough, followed by fermentation, shaping, and quick freezing to preserve the dough, which can then be thawed and baked at a bakery outlet to produce cream-filled bread with a retained soft texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bread is baked based on watery dough, then crispy mouth feel is achieved, but crispiness does not last long due to moisture
Solution Approach 1:
The dough is prepared in advance with optimized water content and frozen before baking. The preliminary freezing action allows the dough to be stored and transported while maintaining the water content necessary for crispy texture, which will be activated during the baking process at the retail outlet
Solution Approach 2:
The water content parameter of the dough is precisely controlled at 67-73% (higher than conventional dough) to ensure crispy texture after baking. The dough is then frozen at -18°C or lower, changing its physical state to preserve this parameter during storage and transport
2Duration of action of stationary object
If bread is baked based on water-reduced dough, then texture remains stable over time, but crispiness is low and bread becomes hardened
Solution Approach 1:
The dough is prepared with high water content (67-73%) in advance and frozen, allowing the retail outlet to bake fresh crispy bread daily. The preliminary freezing preserves the high water content without causing the bread to harden during storage
Solution Approach 2:
The water content is increased to 67-73% and the temperature is reduced to -18°C or lower for freezing, creating a state where the dough maintains high moisture without becoming stale, enabling crispy texture after baking
3Ease of operation
If paste-type dough is supplied to retail bakers, then distribution is simplified, but bread product quality becomes inconsistent
Solution Approach 1:
The dough is frozen at -18°C or lower, which standardizes its physical properties and maintains consistent quality during distribution. The freezing process preserves the dough's water content and structure, ensuring uniform baking results at different retail outlets
Solution Approach 2:
The dough is quickly frozen and distributed in this state, allowing retail bakers to skip the time-consuming dough preparation process while maintaining consistent quality. The frozen dough can be directly used for baking after simple thawing
4Ease of operation
If frozen dough is used at retail outlets, then bread can be freshly baked, but the quality may not be maintained compared to centrally baked bread
Solution Approach 1:
The dough is frozen at -18°C or lower to preserve its quality parameters during storage and transport. This freezing process maintains the dough's water content, gluten structure, and yeast activity, enabling consistent bread quality when baked at retail outlets
Solution Approach 2:
The dough is prepared with optimized ingredient ratios and water content (67-73%) in advance and frozen, so that when baked at retail outlets, it produces high-quality fresh bread. The preliminary preparation ensures consistent quality regardless of where the bread is baked
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 ensures that bread can be freshly baked and maintained in quality even when supplied as frozen dough to retail outlets, while retaining the soft texture of cream-filled bread without becoming hardened over time.
Implementation Method 1
subjecting the first dough to fermentation at room temperature for 1 to 3 hours
Implementation Method 2
quickly freezing the filling-containing dough at a temperature of -18°C
Implementation Method 3
secondly fermenting the thawed dough for 60 to 70 minutes in a fermentation room conditioned at a temperature in a range of 28 to 35°C and humidity of 70 to 95%
Implementation Method 4
baking the second fermented dough at a temperature in a range of 150 to 230°C for 6 to 10
Data Source
AI summary
The present invention relates to a method of producing frozen dough for bread containing a filling and a method of producing cream-filled bread by employing the frozen dough. More particularly, the present invention relates to a method of producing cream-filled bread, which can produce soft textured bread even by employing frozen/refrigerated dough, and can maintain soft bread texture even after a long period of time.