Malted Barley Flour Dough for Artisanal Frozen Pizza Texture
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Solution Overview
Problem
The challenge lies in creating a frozen pizza that mimics the appearance and texture of a hand-made, artisanal pizza while maintaining cost-effectiveness and efficiency in high-speed, automated manufacturing processes, as existing frozen pizzas lack the unique shape and texture characteristics of artisanal products.
Innovation Solution
Incorporating malted barley flour at higher levels than typically used (1.0% to 3.0% by flour weight) into the dough, combined with specific processing steps such as shorter fermentation times and the use of unique die press plates to create irregular shapes and uneven crust topography, allows for the production of pizzas with an artisanal appearance and texture using industrial equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hand-made processes are used to create irregular shape and textured appearance, then product quality and aesthetic appeal are improved, but manufacturing time and cost increase
Solution Approach 1:
The patent changes the chemical composition parameters of the dough by incorporating malted barley flour (1-10% of total flour weight) and specific enzyme combinations (amylases, proteases, lipases) to alter dough behavior during automated processing, enabling irregular shapes and textures to form naturally during high-speed manufacturing rather than requiring manual shaping
Solution Approach 2:
The patent replaces manual mechanical shaping with a controlled chemical system where enzymes and malted barley flour naturally guide dough formation into irregular shapes and textured surfaces during automated processing, eliminating the need for hand-made mechanical manipulation while achieving similar aesthetic effects
2Manufacturing precision
If longer fermentation times are used to develop flavor and texture, then product quality is improved, but manufacturing time and productivity decrease
Solution Approach 1:
The patent changes the chemical environment parameters by adding malted barley flour (1-10% of total flour weight) which contains natural enzymes and nutrients that accelerate yeast activity and dough development, allowing high-quality flavor and texture to be achieved in shorter fermentation times (30-120 minutes) compared to traditional long fermentation processes
Solution Approach 2:
The patent introduces malted barley flour and specific enzymes as intermediary substances that mediate between the yeast and flour, facilitating faster and more efficient dough development, gas production, and flavor formation, thereby reducing the required fermentation time while maintaining or improving product quality
3Productivity
If standardized automated processes are used for mass production, then manufacturing efficiency and cost are improved, but product appearance and texture uniformity worsen
Solution Approach 1:
The patent changes the dough's rheological parameters through malted barley flour (1-10% of total flour weight) and enzyme additions, creating a dough formulation that is sufficiently responsive to minor variations in automated processing while still producing consistent desirable outcomes, thereby maintaining appearance and texture consistency across high-volume production
Solution Approach 2:
The patent creates a composite dough system combining multiple flour types (wheat, barley, rye, oats), malted barley flour, and various enzymes that work synergistically to produce a dough with optimized properties for automated processing, achieving both manufacturing efficiency and consistent product quality through the combined effects of multiple ingredients
Data Source
AI summary
The present disclosure relates to food products having a dough component with a unique appearance and texture. The food product may be a pizza product. In a general embodiment, the dough component of the food product includes malted barley flour in an amount greater than 1% to about 3%, which helps to create and maintain the unique appearance and texture of the food product. Methods for making a dough-based food product are also provided and include mixing a dough having malted barley flour in an amount from about 0.5% to about 3.0%, fermenting the dough, pressing the dough with a die having unique characteristics, and baking the dough to form a baked dough.