Flour, Bread and Pastry Industry
The quality of flour, as the main raw material in bread production, is of great importance to bakery product manufacturers. Due to climate changes, weather conditions, and variations in wheat quality, the produced flour differs throughout the year and across regions. This discrepancy negatively impacts production performance and the quality of bakery products.
Enzymes in the Flour, Bread, and Pastry Industry
The quality of flour, as the main raw material in bread production, is of great importance to bakery product manufacturers. Due to climate changes, weather conditions, and variations in wheat quality, the produced flour differs throughout the year and across regions. This discrepancy negatively impacts production performance and the quality of bakery products. In the past, various additives were used in this industry to improve flour quality. Recently, enzymes have emerged as a natural alternative to chemical additives and are widely used in the flour, bread, pastry, and chocolate industries, with positive effects on production processes and quality parameters of final products. Enzymes offer flexible and more efficient solutions for bakery product manufacturers, and their use in the flour, bread, pastry, and chocolate industries is steadily increasing. Enzyme solutions, in addition to improving the production process, can serve as a sustainable and cost-effective approach, enhancing the quality of bakery products.
Enzyme Solutions for Enhancing Production Processes and Improving the Quality of Bakery Products
Enzyme Solutions for Enhancing Production Processes and Improving the Quality of Bakery Products
Enzyme Solutions for Enhancing Production Processes and Improving the Quality of Bakery Products
Modification and Improvement of Flour Quality
A consistent challenge in flour mills is maintaining steady flour quality despite variations in wheat quality. If the natural Amylase activity in flour is low, it can be improved by adding the enzyme Alphaamylase, which produces fermentable sugars for yeast. Yeast consumes these sugars, providing enough Carbon dioxide to help the dough rise. The metabolic activity of yeast on sugars created by Alpha-amylase during the Maillard reaction produces desirable color and aroma in bread.
Increasing Bread Shelf Life
Maintaining freshness is the main concernfor consumers when it comes to bread. Bread staling is caused by changes in the starch structure of the flour, which begin immediately after baking. Starch naturally starts to recrystallize right after baking, causing bread to dry out and stale. Enzymes, as natural catalysts, can delay this recrystallization process. Using Maltogenic Alpha-amylase can alter the starch structure to increase bread shelf life.
Improving Dough Handling
Xylanase or Hemicellulase enzymes play an important role in the baking process. These enzymes enhance certain dough properties, such as machinability and gas retention leading to optimized production time, increased volume, and a better texture in the fina product.
Strengthening the Gluten Network
In bread production, a strong Gluten network is necessary to withstand the pressure and stretching during dough kneading, to retain the gas formed during fermentation, and to give the loaf good volume. The enzymes Glucose oxidase and Lipase help strengthen the Gluten network’s strength and potential. These enzymes improve dough stability, making it easier to work with and resulting in a loaf with better volume and appearance
Key benefits of enzymes for improving Gluten network structure include:
- Increased dough stability
- Reduced need for Ascorbic acid
- Replacement of Potassium bromate and other chemical oxidizers
- Reduced need to add Gluten to the flour
Better Quality for Biscuits, Crackers, and Wafers
Weak flours with low protein content have low elasticity and water absorption, making them suitable for producing biscuits and crackers, as they easily take shape and allow for desired designs. By using a suitable combination of Protease and Xylanase enzymes, these characteristics can be achieved, even eliminating Sodium metabisulfite, a chemical often used to weaken the Gluten network. Sodium metabisulfite is associated with cancer risks in many scientific studies.
Key benefits of using enzymes in biscuit, cracker, and wafer production:
- Improved flavor, color, and texture of products
- Reduced breakage in final products
- Enhanced machinability and suitability for different flour types
Improved Quality for Noodles, Pasta, and Macaroni
By using enzymes, producers can overcome the natural variations in the quality of raw materials used in pasta and noodle production to achieve consistent, desirable quality. A chewy texture is key to consumer enjoyment of foods like pasta and noodles. Traditionally, pasta is made from high-quality Durum wheat, which yields firm and non-sticky products. Formulations with lower-quality wheat flour can result in a softer texture and reduced cooking tolerance. With enzyme solutions, manufacturers can address these challenges.
Benefits of using enzymes in noodle, pasta, and macaroni production:
- No need to add Gluten during production
- Prevention of cracking in the final product
- Prevention of dark specks
- Suitable firmness and a uniform, clear appearance in dried pasta and noodles
- Reduced stickiness in cooked noodles and pasta
- Whiter and more color-stable products
Production Issues in the Flour and Bread Industry and Enzymatic Solutions
| Product Name | Application | Benefits | Dosage |
|---|---|---|---|
| Lipase |
|
|
5 – 50 ppm |
| Maltogenic Alpha-Amylase |
|
|
5 – 20 ppm |
| Xylanase |
|
|
5 – 15 ppm |
| Protease |
|
|
5 – 50 ppm |
| Glucose Oxidase |
|
|
5 – 40 ppm |
| Fungal Alpha -Amylase |
|
|
5 – 10 ppm |
| Glucoamylase |
|
|
5 – 30 ppm |
| Protease and Xylanase Mix |
|
|
50 – 300 ppm |
| Maltogenic Alpha- Amylase and Lipase Mix |
|
|
10 – 100 ppm |
Production Issues in the Flour and Bread Industry and Enzymatic Solutions
| Defects and Shortcomings of Bread and Flour Products | Possible Causes | Enzymatic Solution |
|---|---|---|
| Dough Resistance and Lack of Volume Increase in Final Bread Stage |
| Use of Amylase and Xylanase enzymes |
| Side Cracking of Bread |
| Use of Amylase and Xylanase enzymes |
| Unsatisfactory Bread Volume |
| Use of Amylase, Lipase, and Glucose oxidase enzymes |
| Pale and Dull Bread Crust |
| Use of Amylase enzyme |
| Overly Dark Bread Crust Color |
| Use of Lipase and Glucose oxidase enzymes |
| Unsatisfactory Bread Shape |
| Use of Lipase and Xylanase enzymes |
| Collapsing Sides in Toast Bread |
| Use of Lipase and Glucose oxidase enzymes |
| Dark Interior of Bread (Uneven Interior Color) |
| Use of Lipase and Glucose oxidase enzymes |
| Irregular and Uneven Bread Texture |
| Use of Xylanase, Lipase, and Glucose oxidase enzymes |
Dry and Brittle Bread Interior and Staleness |
| Use of Lipase and Maltogenic amylase enzymes |
| Weak Taste and Flavor |
| Use of amylase enzyme |
Poor Shape of Biscuits and Crackers |
| Use of Protease enzyme |
| Stickiness of Cooked Pasta and Noodles |
| Use of Lipase enzyme |
| Cracking and Brittleness of Dried Pasta and Noodles |
| Use of Lipase enzyme |