Frozen Dough Quality Using Instant Active Dry Yeast
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The baking potential and organoleptic characteristics of frozen doughs deteriorate over time and with freeze-thaw cycles, requiring higher yeast dosages and additives, making them economically unviable and less desirable for producers, while instant active dry yeast is sensitive to cold shock and not commonly used in frozen doughs.
Innovation Solution
A method for producing fully fermented frozen doughs using instant active dry yeast at low concentrations, eliminating the need for additives and proofing steps, involving mixing, kneading, proofing, and freezing, with optional flattening to optimize storage, allowing for direct baking without loss of quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If higher yeast dosage and additives are used to maintain quality during frozen storage, then the organoleptic characteristics and baking potential are preserved, but the production cost increases and economic viability decreases
Solution Approach 1:
The patent changes the yeast form parameter from conventional compressed or liquid yeast to instant active dry yeast (IADY), which has different physiological properties including higher viability and cold tolerance. This parameter change allows the dough to maintain quality during frozen storage without requiring excessive yeast dosage or additives, thereby reducing production costs while preserving reliability
Solution Approach 2:
The patent applies preliminary freezing protection by using IADY that is pre-adapted to withstand cold shock. The yeast is selected and prepared in advance to survive the freezing process, eliminating the need for post-freezing proofing and reducing the requirement for additional protective additives, thus lowering production costs while maintaining quality stability
2Ease of manufacture
If instant active dry yeast is used in frozen doughs, then the process is simplified and cost is reduced, but the yeast is sensitive to cold shock and fermentation performance deteriorates
Solution Approach 1:
The patent changes the yeast form parameter to instant active dry yeast (IADY) which has distinct physiological characteristics including higher viability, different cell wall structure, and improved cold tolerance compared to conventional yeast forms. These parameter changes enable IADY to withstand cold shock during freezing while maintaining fermentation performance, simplifying the process and reducing costs without sacrificing reliability
3Productivity
If frozen storage time is extended or freeze-thaw cycles are increased to improve logistics and distribution, then the availability and convenience are improved, but the baking potential and organoleptic characteristics deteriorate
Solution Approach 1:
The patent applies preliminary freezing protection by using IADY that is pre-adapted to withstand cold shock and maintain viability during extended frozen storage and multiple freeze-thaw cycles. This preliminary adaptation ensures the yeast remains functional even after prolonged storage, allowing extended logistics time and improved availability without deteriorating baking potential or organoleptic characteristics
Solution Approach 2:
The patent provides beforehand cushioning against the harmful effects of extended freezing and freeze-thaw cycles by selecting IADY with inherent cold tolerance. This cushioning effect protects the fermentation system from damage during logistics, enabling extended storage and distribution while maintaining quality and baking potential
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 high-quality bakery products with outstanding volume and oven development, comparable to direct-baked products, reducing production time and costs by eliminating the need for proofing equipment and additives, while maintaining freshness and quality.
Implementation Method 1
preparing a dough by mixing at least flour, water and a IADY; proofing the dough until complete proofing has been achieved
Implementation Method 2
freezing the dough
Data Source
AI summary
The present invention relates to a new method for preparing fully fermented frozen dough, formulation of the ingredients and process to produce different type of bakery product. The fully fermented frozen doughs obtained using this method do not require the addition of any additives and allow baking off the fermented frozen dough without an additional proofing step thereby providing high quality bakery products.