Sourdough Pre-Dough From Staled Bread Using Starter Culture
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Solution Overview
Problem
The challenge lies in recycling residues from wheat bakery products into the baking process while avoiding visible stains in bread, which is often hindered by hygiene standards and the potential for spoilage, especially with existing methods that rely solely on mechanical swelling of bread residues.
Innovation Solution
A method utilizing a starter culture containing Lactobacillus paracasei BSB 2 DSM 28104 and Lactobacillus gallinarum BSB 1 DSM 28103, along with other lactobacilli and yeasts, to produce a fermented pre-dough that initiates controlled fermentation, degrading bread components and lowering pH, thereby preventing spoilage and achieving natural storage stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If return bread is added via mechanical swelling only, then the process is simple and quick, but visible bread particles remain in the crumb causing stains and defects
Solution Approach 1:
The patent transforms the physical-chemical state of return bread by introducing fermentation parameters (pH reduction to 3.8-4.2, temperature control at 20-35°C, extended time of 12-48 hours) that convert insoluble bread particles into a fine, homogeneous pre-dough structure that cannot be seen as defects in the final product
2Ease of operation
If return bread is stored at room temperature, then processing is convenient, but spoilage germs multiply rapidly
Solution Approach 1:
The patent applies preliminary anti-action by introducing starter cultures (Lactobacillus and yeast) that preemptively occupy the nutritional niche and lower pH before spoilage organisms can multiply, creating a protective acidic environment that inhibits harmful bacteria while allowing convenient room temperature processing
Solution Approach 2:
The patent converts the potential harm of room temperature storage (spoilage risk) into a benefit by using the warmth to accelerate fermentation of the starter culture, which in turn produces acids that prevent spoilage, transforming a risk factor into a process advantage
3Loss of substance
If legal proportions of return bread (3-3.5% wheat bread) are recycled, then resource utilization improves, but hygiene standards and spoilage prevention become more difficult to maintain
Solution Approach 1:
The patent introduces starter cultures as intermediary organisms that mediate between return bread and the final product, transforming the bread through controlled fermentation into a stable pre-dough that meets hygiene standards while maximizing the utilization of legal return bread proportions
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 approach results in a pre-dough with extended natural storage stability up to 96 hours, inhibiting spoilage organisms and ensuring a stable, high-quality bread product without visible bread particles, adhering to hygiene standards and enhancing the utilization of return bread.
Implementation Method 1
A method utilizing a starter culture containing Lactobacillus paracasei BSB 2 DSM 28104 and Lactobacillus gallinarum BSB 1 DSM 28103, along with other lactobacilli and yeasts, to produce a fermented pre-dough that initiates controlled fermentation, degrading bread components and lowering pH
Data Source
AI summary
A starter culture for making sourdough is disclosed, comprising a mixture of Lactobacillus paracasei BSB 2 DSM 28104 and Lactobacillus gallinarum BSB 1 DSM 28103. Likewise disclosed is a method for producing a starter dough as a constituent of doughs for baking baked wheat products using a wheat bread contingent, including the following steps: a) In a first stage, preparing a sourdough by mixing around 100 parts by weight wheat flour with 100-200 parts by weight water and inoculating the mixture with a starter thickened with milled cereal products and obtained from a culture of lactic acid bacteria, more particularly as a mixed culture of at least two complementary Lactobacillus species and yeast with a 20-35°C temperature range, and ageing the resulting first mixture for a period of 12-36 hours. b) In a second stage, producing a mixture of wheat flour, a wheat bread contingent and water, comprising an amount of 75-135 parts by weight, preferably 75-120 parts by weight wheat flour; including 15-75 parts by weight, preferably 30-75 parts by weight wheat bread contingent, which is mixed with 150 parts by weight water for a time in particular of 10-120 minutes, preferably 30-60 minutes, with stirring in two steps, the product having a temperature in a range of 20-35°C; c) mixing part of the sourdough obtained in the first stage as per step a) with a greater part of the second mixture for initializing the fermentation of the second stage, d) ageing the combined mixture obtained in step c) for a period of 24-60 hours, to give a starter dough as a constituent of doughs for making baked wheat products. Starter dough as a constituent of doughs for making baked wheat products, obtainable by the method of the invention.