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SITHPAT014 Produce yeast-based Bakery products  2 V1 260423 SITHPAT014 Produce yeast-based bakery products  3 SITHPAT014...

SITHPAT014 Produce yeast-based Bakery products  2 V1 260423 SITHPAT014 Produce yeast-based bakery products  3 SITHPAT014 Produce yeast-based bakery products Student’s Name: Student No.: Teacher’s Name: Contact No.: Email: @angliss.edu.au 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  4 Project Base William Angliss Institute 555 La Trobe Street Melbourne 3000 Victoria Tel: (03) 9606 2111 Fax: (03) 9670 1330 Acknowledgements Project Manager: Paul Hughes Writer: Paul Hughes DTP/Production: Cheryl Xiao © William Angliss Institute 2014. All text and images unless otherwise stated. All rights reserved. This booklet was produced by William Angliss Institute to be used as resource material for its enrolled students only; and as such they have the authority to print out this material. Any further copying or communicating of this material in any format or via any means may only be done so with the prior documented permission of William Angliss Institute. William Angliss Institute does not have the authority to give permission for third party materials that may be included in this resource.. Disclaimer Every effort has been made sure that this booklet is free from error or omissions. However, you should conduct your own enquiries and seek professional advice before relying on any fact, statement or matter contained in this book. William Angliss Institute is not responsible for any injury, loss or damage as a result of material included or omitted from this course. Information in this module is current at the time of publication. The time of publication is indicated in the date stamp at the bottom of each page. Cover Image: © William Angliss Institute 2014. V1 260423 SITHPAT014 Produce yeast-based bakery products  5 Table of Contents William Angliss Institute 6 Theory Ingredients and their functions 7 Session 1 39  White Dough 39  Cobbs and Vienna loaves 39 Session 2 43 Wholemeal, honey, sultana and oat bread 43 Focaccia 43 Session 3 New York style rye and caraway seed Bagels 50 Session 4 Baguette and Rolls 58 Session 5 Assessment - Baguette and rolls 62 Session 6 Hot Cross Buns 64 Session 7 Assessment - Hot Cross Buns 68 Session 8 Danish Pastry 74 Session 9 Assessment - Danish 83 Session 10 Croissant 88 Session 11 Brioche (Catch-n-grab) assessment 92 Glossary of Terms 104 Resource List 114 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  6 William Angliss Institute William Angliss Institute was named after the late Sir William Angliss, MLC, whose generous donations and personal efforts were instrumental in the foundation of the Institute, which opened as the William Angliss Food Trades School in 1940. The Institute provided training in pastry cooking, retail butchery and smallgoods, bread-making and baking, as well as cookery and waiting. In the late 1960s the school expanded into training for the hospitality industry, and in the late 1980s into the broader tourism-related courses. Today, William Angliss Institute is a national and international provider of education and training programs, consultancy services and human resource development solutions for the tourism, hospitality and foods industries. The Institute is the largest single-purpose government educational institute of its kind in Australia, offering short courses, apprenticeship, certificate, diploma, advanced diploma, degree and graduate courses. William Angliss Institute’s portfolio of skill and career development programs spans a diverse range of hospitality, tourism and foods-related disciplines. This includes generalist and specialist programs with options for delivery in the workplace, on-campus and online. Educational and industry expertise includes:  tourism  coffee making and barista training  retail travel  patisserie  hospitality management and operations  bakery  hotel management  butchery and meat retailing  ecotourism  confectionery manufacturing  meeting and event management  food science and technology  resort management (spa, dive and marine)  business and retail management  professional cookery  marketing and human resources In addition to over 1000 international students enrolled at William Angliss Institute in Melbourne and off-shore campuses, a comprehensive network of government, industry and education partnerships provide students and Institute staff with a world of opportunities. Recognition of Prior Learning (RPL) If you’ve got previous qualifications or relevant work/life experience, you may be eligible for exemptions in your course through our RPL process. For more information, check out our RPL brochure available from the Information Centre. For further information: Phone: (03) 9606 2111 Fax: (03) 9670 0594 Web: www.angliss.edu.au Unit Competency Refer to www.training.gov.au for more information on the unit. V1 260423 SITHPAT014 Produce yeast-based bakery products  7 Theory Ingredients and their functions 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  8 Flour Wheat flour is the fine, clean product that is derived from or separated during the milling process of wheat, and is one of the most important ingredients used in the production of bread dough’s and yeast-raised products. While wheat is the most common base for flour, flour can also be produced from vegetables, grasses, nuts and many other grains including Rye, Spelt, Rice, Corn, and Barley. Botanically, wheat is classified as a grass, and like all grasses there are many different varieties of wheat with each one have different characteristics, according to the locality in which they are grown, soil fertility, rainfall and the amount of sunshine it receives while growing. This can have a direct impact on the on the hardness of the wheat and the quality and quantity of protein as well as water absorption rate. Chemical composition of wheat flour Starch 65 - 70% Water 13 - 15% Proteins 8 - 14% Fat 1 - 1.5% Sugars 1.5 - 2% Minerals 0.3 - 0.6% Proteins Almost all flours contain starch, water, proteins, sugars, oil, mineral salts and a small percentage of acid, with proteins being regarded as the most valuable. The type and percentage of the proteins influence the capabilities of flour to such an extent that they are the dominant factors in determining the abilities of the flour. The higher the proteins content of the flour the better the volume of the baked goods and higher dough water absorption. There are five distinctive proteins in flour; the first three, albumin, globulin and protease occur in very small amounts while glutenin and gliadin make up the bulk of the proteins in the flour. Glutenin and gliadin are insoluble in water. It is because these two proteins are water insoluble that they combine with the water to form and produce gluten. There are roughly equal quantities of glutenin and gliadin present in the flour.  Gliadin provides extensibility and volume to the dough  Glutenin provides elasticity to the dough. The protein in flour is measured as a percentage of the flour weight and can range from 8% to 14%. Some specialty flours may even be higher. Starch Wheat flour contains starch, which plays an important role in the production of breads and yeast- raised products. It acts as a filler in the baked product, and it helps to keep the gluten strands apart to form a fine network, resulting in the fine even cell structure in the baked loaf. V1 260423 SITHPAT014 Produce yeast-based bakery products  9 During the milling process some of the starch granules are damaged, this damaged starch performs two main functions in baked goods. One: During fermentation, the damaged starches are attacked by the flours diastatic enzymes alpha and beta-amylase and are broken down into simple sugars. This process sustains the yeasts metabolism and allows fermentation to continue. Two: Damaged starches absorb higher water levels then undamaged starch and during baking helps to set (Gelatinise) and maintain the structure of the baked goods. Starch accounts for the largest amount of materials found in wheat flour. Starches are classified as polysaccharides; this means they are made up from large glucose based complex carbohydrate molecules. Fat All flour contains natural fat in small quantities. Wholemeal flours, which contain the germ of the wheat grain are much richer in fat, Fat plays an important part in flour maturity. As flour ages it undergoes a natural maturing action. This ageing is the result of the developing of fatty acids from the oxidation of the natural flour fat, these fatty acids are said to alter the properties of the gluten. Sugar It is very valuable during fermentation for it provides immediate food for the yeast and so keeps the yeast going until the flour enzymes have had time to make sugar from the flour starch. Mineral content Very small amounts of Potash, Magnesia, Calcium, Iron and Alumia, Phosphoric Acid, Sulphur Trioxide, Chlorine are contained in flour. But this mineral matter has a directly beneficial effect upon fermentation because it promotes vigorous yeast and enzyme activity. Moisture content Although flour feels dry to touch it contains a small percentage of water, which can vary from time to time. The moisture content of flour can have a marked effect on the amount of liquid dough will hold. The moisture content of flours can change with the weather, as well as with the condition and method of storage. In a warm dry store flour will lose moisture quicker than in a cool dry store. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  10 The grain of wheat V1 260423 SITHPAT014 Produce yeast-based bakery products  11 Types of flour used in the bakery industry In this industry there are many different types of flour that are used for creating a variety of products. Below are the most common flours used: Strong flour (Bakers) 11 - 14% gluten – Bread and bun goods Medium flour (Biscuit) 9 - 11 % gluten – Puff pastry, scones, Madeira cakes and fruitcakes Soft flour (Cake) 7 - 9% gluten – Shortbread goods, biscuits, slab cakes HR flour (High ratio) 8% gluten – Emulsified sponge. High ratio cake. Bakers flour is the most commonly used flour in the production of yeast goods and bread products due to its high levels of gluten forming proteins. How to simple identify various types of flour Take a small sample of baker’s flour, cake flour and high ratio cake flour. It is possible to compare these flours by sight and feel.  The higher protein flour (e.g. bakers), has a creamy colour and when compressed in the hand, will not form a ball or lump.  The lower protein flours appear whiter in colour, and will compress into a lump in the hand. The easier it is to compress, the lower the protein level, and so, the higher the starch level.  High ratio flour is usually whiter, due to bleaching, and more compressible than soft cake flour. Use these simple observations to check that you are using the correct flour in your baked goods. Salt Actual salt flavour is not usually detected in a baked product. Salt not only provides its overall flavour, but also helps to bring out the natural flavour of ingredients associated with it; Bread and yeast goods made without salt would be almost flavourless. Common salt (sodium chloride) is one of the basic ingredients in bread and yeast goods. Salt performs the following functions:  Flavour – salt brings out the natural flavour of foods.  Dough stability – salt has a toughening and strengthening effect on gluten.  Control of fermentation – salt acts upon and strengthens gluten; it restricts the build-up of unwanted acids; it steadies the rate of yeast fermentation; it lowers the water absorption rate.  Antiseptic action (killing unwanted bacteria)  Enhancement of crumb colour  Helps to retain moisture, lengthening the shelf life of baked goods. Experienced patissiers or bakers can detect that salt has been left out of dough by one of the following characteristics:  The dough “flows” – it has a low degree of firmness.  The dough lacks elasticity.  The dough shows signs of uncontrolled fermentation. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  12  The dough is sticky and wet.  Proofing tolerance is greatly reduced.  The volume of the finished product is small and pale in colour.  The crust of the finished product is hard and brittle, and it splinters.  The baked product has uneven cell structure.  The finished product tastes bland. Crumb colour Without salt, dough may exhibit the following characteristics:  The dough “flows”– It has a low degree of firmness;  The dough lacks elasticity;  The dough shows signs of uncontrolled fermentation;  Proofing tolerance is greatly reduced;  The finished product is pale in colour;  The crust of the finished product is hard and brittle and it splinters  The baked product has uneven cell structure;  The finished product tastes bland. Yeast Baker’s yeast, Saccharomyces cerevisiae, is manufactured specially for the production of bread doughs and yeast goods. It is a single-celled micro-organism classified as a fungus. Yet each microscopic cell contains a multitude of enzymes capable of carrying out the most intricate series of chemical reactions. Because it is a living organism, baker’s yeast is very perishable and must have optimum storage conditions. Compressed yeast should be stored in dark and cool conditions; it is best used for up to two weeks after manufacture, as it slowly loses its strengths. Yeast produces carbon dioxide and Ethyl alcohol, by changing sugars. Yeast activity is destroyed at temperatures above 60°C and may be severely impaired at temperatures above 50°C. Being a single cell micro-organism, each cell can reproduce itself identically, under the right conditions. This process, called budding, and usually takes approximately three hours to complete. The bud will continue to grow over time and eventually break away from the host – mother cell to create a new cell. For normal growth, yeast requires warmth, moisture, food and time. The ideal temperature range for this growth is 25°C to 28°C. At lower temperatures, growth slows down. At temperatures above 35°C, the weaker yeast cells may die off with all the yeast being killed at approximately 55 - 60°C. The principle food of yeast is simple sugar (glucose and fructose). In its short life, a yeast cell consumes many times its own weight of sugar (although too much sugar can kill the yeast). Yeast can survive on its own for a long period of time by feeding on the sugar in the enzymes in the structure of the internal cell of the yeast. Dried yeast can be stored indefinitely if in a vacuum sealed pack. When the dry yeast spores are re- hydrated, they then begin to reproduce and grow. V1 260423 SITHPAT014 Produce yeast-based bakery products  13 The fermentation or ripening of the yeast can be regarded as decomposition (decay) of sugars by successive stages, into waste carbon dioxide and alcohol, both bi-products of the growth of the yeast cell. Enzymes within the yeast cell bring about these changes. Enzymes are proteins that act as biological catalysts (a catalyst is an agent which creates change without being changed itself). In addition to the carbon dioxide and the alcohol produced during fermentation, there are numerous other complex chemical compound bi-products of the fermentation process which are not fully understood even today, and which are responsible for the unique flavour that yeasty creates. This is also why long fermentation process breads have greater taste than short fermentation breads. Too much yeast creates a larger amount of carbon dioxide and alcohol, which then breaks down the gluten structure because it is unable to hold this excess gas. The oversupply of yeast also consumes the sugar in the dough more quickly than usual, leaving no consumable sugars and so stopping the gassing process earlier in the fermentation/proving process, perhaps preventing full dough development. Too little yeast in a dough results in a lack of enough carbon dioxide and alcohol to lift the gluten structure and a rapid exhausting of the yeast life, leading to underdeveloped doughs, giving dense heavy breads with poor loaf volume. Types of yeast used in the industry are:  Fresh yeast or compressed yeast – commonly used by bakers, comes in a block and must be kept refrigerated and has a shelf life of about 2-3 weeks  Instant dry yeast - commonly used by bakers, comes in a vacuum pack and has a shelf life of about 2-3 months when opened and can be added directly to the dough.  Cream yeast – used by large volume production bakeries. It is delivered by a truck in a tank and pumped into storage vats that are plumbed into the bakery.  SAF – osmotolerant dry instant yeast. It is used in very sweet or acidic doughs as it is able to tolerate the effects of sugar and acidity that may slow down fermentation.  Wild – commonly cultivated in the making of a sourdough starter. If is found naturally in the environment Factors that influence yeast fermentation  Amount of yeast used in the dough  Dough temperature  Amount of salt  Amount of sugar  Dough pH 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  14 Reproduction When conditions are favourable yeast reproduces itself by a vegetative process called budding. The cytoplasm enriches itself and a small nodule or ‘bud’ develops in the cell wall. As the bud grows and fills with cytoplasm the nucleus replicates itself, each new nuclei being identical to the original. One of the new nuclei moves into the bud. When the bud reaches the required size new cell wall tissue develops and seals it off from the parent. The bud then detaches from the parent and is now a functional mature cell which will itself propagate by budding. This process is repeated over and over. V1 260423 SITHPAT014 Produce yeast-based bakery products  15 Water Water is one of the four essential ingredients required to produce doughs and yeast products. It can be introduced into a formula via moisturising ingredients such as liquid milk or fresh egg. In the production of yeast goods and bread doughs, water serves the following functions:  Hydrates the gluten forming proteins (Gliadin and Glutenin)  Dissolves and disperses salt and sugars and carries sugars to the yeast which it can only use in liquid form  Provides moisture for yeast to grow  Hydrates dry yeast and disperses both dry and compressed  Controls dough temperature  Controls dough consistency  Wets and swells starch during baking (gelatinisation) — makes it available to amylase enzymes  Controls enzyme activity (enzymes are active only in liquid or semi liquid mediums  Increases shelf life  Contributes to eating qualities.  It binds dry ingredients together Bread improvers Bread improvers also known, as dough conditioners are a mixture of additives mixed with the flour to improve the function of the dough and baked goods. Bread improvers are used to speed up the rate of fermentation of the dough and to improve the strength and workability. They play an important role in today’s bakeries and kitchens allowing for a loaf of bread to be produced within 2 hours. The down side to this is that doughs that have a shorter fermentation time have less flavour. Bread improvers have a common dual function being: 1. To contribute to the gluten condition and to maximize its functionality during mixing, fermentation and baking – To maximise the gas retaining properties of the dough 2. To ensure that the dough contains sufficient sugars to maintain adequate gas production at all stages of fermentation – To help with the break down the starches in the flour into simple sugars allowing the yeast to ferment quickly. Bread improvers usually contain oxidising agents, reducing agents, enzymes and mineral salts. Oxidising agents are gluten straighteners, which work by promoting new bonds within and between gluten molecules. Ascorbic acid is the oxidising agent used. Reducing agents weaken gluten by breaking the disulphide bonds between and within gluten molecules. Enzymes help to improve the process characteristics of the dough. Yeast naturally contains enzymes in the form of amylases and proteases but additional enzymes can be added by using bread improvers. Amylase is responsible for the breakdown of the starches into simple sugars allowing yeast to ferment. There are two types, alpha-amylase and beta-amylase. Alpha-amylase hydrolyses the bonds of the large starch molecules and is also responsible for the starch to lose its gelling properties. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  16 Beta-amylase releases the sugar maltose from the shorter fragments caused by the alpha-amylase activity. Protease helps to improve the extensibility of the dough by breaking down the peptide bonds within the gluten molecules. They are generally not required in bread improvers, but because they are companion enzymes in amylase preparations most improvers have a protease component. Bread improvers are usually shown in a formula as MRU, which stands for “Manufactures Recommended Usage”. *Note – Dietary information – Some bread improvers may contain ingredients that are from animals. Gluten The addition of dry gluten to baked products is sometimes necessary to give increased volume and increase the amount of protein present in the flour. High Protein or Starch reduced Bread is produced by the same recipe, and this is to increase the gluten protein content (and thus reduces the starch percentage) of the dough Breads like Multigrain, Wholemeal and Rye often require Gluten additions to produce bread with the volume and crumb characteristics normally expected in Yeast goods.  Where wet and dry gluten is added to doughs, or a flour or starch reduced standard is used, then the mixing time will need to be increased by 25% over the normal time for mixing white bread doughs.  The strengths of flour are determined not only by the quantity of gluten protein but also by the quality of the protein. Some flours of high protein content require less mixing time than flours that have slightly lower protein content. The reason for this lies in the nature and character of the protein in the flour.  If the quality of the protein in the flour is good, then it is true to say that as we quantity increase, so also will the mixing time. The higher the protein content, the greater will be the water absorption of the flour. To incorporate the extra water and develop the additional protein present, the dough must be given a longer period of mixing than is necessary for flours that have a lower protein content.  The better the protein quality, the more water, the longer the mixing time. The effects of gluten when added to bread dough:  Improves cell and dough structure and dough tolerance  Supplements the natural flour protein  Balances the recipes in protein strengths when high levels of enriching agents are used in dough making  Increase moisture absorption by 1.5% for each 1% of vital wheat gluten added, which results in: - Increased volume - More resilient crumb - More stability of dough - Lighter texture. V1 260423 SITHPAT014 Produce yeast-based bakery products  17 Enriching ingredients Enriched doughs are doughs that have had other ingredients add to the formula to enhance the flavour, texture and eating qualities of the baked goods. These ingredients usually include butter, sugar, eggs, milk powder, fruits and nuts etc. Fats and oils The addition of fat to Yeast Goods will improve bread quality and although fat is not an essential ingredient; it is important assisting in the slicing of the product especially when slicing bread by lubricating the slicer blades. Fat contributes to the volume, softer texture, brighter crumb colour and better keeping qualities. There are many fats available to the baking industry and some are specially manufactured to contain other compounds such as emulsifiers (TEM and SSL) some fats contain sugar and others may contain water. It should always be remembered that butter provides better flavour to the product when deciding upon what type of fat to use. Effects of fats  Improves slicing  Softer crumb  Softer crust  Better keeping qualities  Increases volume  Shorter eating crust  Emulsified fats retard crumb  Enhances firmness Sugar The proportion of sugar added usually depends on the type of product, and in particular, the amount of dried fruit used, as this will greatly influenced the sweetness of the product. Castor sugar is the best suited to most doughs, which ensures that it will dissolve in the mixing process. Perhaps the most important factor related to the amount of sugar in the dough formula is its effect on yeast activity and final proof rate. Sugar addition above 5% of the flour weight may slow fermentation appreciably while more than 10% sugar will require maximum yeast in the dough. Because sugar is hygroscopic, it tends to draw up dough water rapidly, depriving yeast of the moisture required to dissolve the sugars on which if feeds. It acts in a similar manner to salt, affecting the process of ‘osmosis’, or the manner in which it feeds. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  18 How sugar affects bread making Fermentation Yeast produces gas to leaven dough by fermentation of sugar. This may be the natural sugar from the flour or add sugar. Yeast ferments best in low concentrations of sugar. Fermentation rate may be slowed down if the sugar concentration is above 5% and will be severely slowed by more than 10% sugar. Baking Crust colour is darkened by the ‘browning’ reaction of sugar with other compounds within the dough. The presence of too much sugar raises the temperature of the starch gelatinisation and so interferes with the setting of baking dough. This effect changes the character of the crumb in several ways. Most noticeable is the tenderness and lack of resilience. Effects of sugar in bread dough:  Sweetens the bread  Feeds the yeast  Assists bread colour. Effects of high sugar content on bread:  Slow fermentation and rising of the dough  Too dark a crust colour unless the oven temperature is lowered.  Soft but fragile crumb structure  Greater retention of moisture in the baked product  Natural flavour. Eggs Eggs can be purchased as follows:  Shell egg  Liquid egg or egg pulp  Frozen egg pulp  Dried. Effects of eggs are:  Moistening  Enriching due to fat in the yolk.  Increased nutritional value  Emulsifying, due to lecithin in the yolk, therefore better keeping qualities  Aids structure, due to the proteins, which coagulate at 65 to 70°C  Better colour and appearance to baked product.  Better eating qualities  Better keeping. V1 260423 SITHPAT014 Produce yeast-based bakery products  19 As egg is added to a formula, water has to decrease (in re-formulations). Milk and milk powder Effects of milk powder in baked products:  Brighter and softer crumb  Reddish-brown (foxy) crust colour, due to lactose (milk sugar), which cannot be used by yeast as food  Increased nutritional value and flavour  Greater volume (due strengthening of Gluten Strands by the casein protein)  Slight sweetness (due to lactose). Effects of Skim Milk powder when added to bread doughs:  Reduced fermentation speed  Increased mixing times  Higher water absorption  Bread improver requirement. Remedies to overcome retarding influences of skim milk powder are:  Increased yeast, increase by 25% for normal strength flour  Increased bread improver  Addition of a sugar additive, e.g. malt flour, sugar Addition of shortening, 2% and above  Increased water  Increased mixing time, by 25%. Fresh pasteurised milk or untreated milk powder used bread products will result in products with lower volume, due to Serum protein, which weakens the dough structure Fruit and nuts Almost any dried fruit or nut can be added to bread and yeast goods. Most commonly dried fruit used are sultanas, currants, raisins, mixed peel and dates. Most commonly used nuts are hazelnuts, walnuts and peanuts. Nuts have a very high fat content. Large amounts used in bread making need the addition of extra yeast and also extra gluten. Dried fruit should be washed and well drained before fruit is added to the dough. This will reduce water absorption from the dough, increasing the yield, improve eating quality, and increase the volume by producing more steam in the product during baking. Fruit should always be washed first and be mixed into the dough on low speed as not to damage it. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  20 Functions of ingredients In ‘Scratch Dough’ or basic bread dough, each of the main ingredients has a function to carry out in the process of making the final product. It is important to have an understanding of the ingredients the way that they interact with each other. Here are the basics and their chief functions. Ingredient Main function Flour Main body-Structure Natural sugars Protein content Salt Flavour Fermentation control Gluten toughening Improver Gluten conditioning Yeast stimulation Enzyme supplementation Fat/Oil Keeping qualities Crumb softness Volume and texture Yeast Carbon dioxide gas Leavens bread Flavour-aroma Dough maturity Water Hydration Dough consistency Finished dough temperature Dry Gluten Increases protein content Retains gas produced by yeast Increases bread volume Adds nutritional value Sugar Sweetens the bread Feeds the yeast Assists bread colour Milk Powder Add food value Enriches the bread Improves texture and sheen Enhances bloom and colour Assists in crust crispness V1 260423 SITHPAT014 Produce yeast-based bakery products  21 The production process There are many different way to produces dough but the most common methods are:  Bulk fermentation process  Rapid/instant dough  Preferment process Stages of manufacture This shows the typical dough making process. This schedule can be applied to different bread making process but the bulk fermentation is adjusted to suit the needs of the dough. 1. Selecting and weighing of ingredients 2. Pre-ferment – optional stage used in pre-ferment dough process 3. Dough formation and development – mixing 4. 1st fermentation (Bulk proof) 5. Dividing the dough 6. Scaling/weight of the dough into the required sizes 7. Pre-shaping 8. 2nd fermentation (Intermediate proof) 9. Final shaping 10. Tray up – placing the product onto or into prepared tins and trays 11. 3rd fermentation (Final proof) 12. Oven loading 13. Baking – oven spring 14. Cooling Storage/Packaging/bagging/labelling Baked yeast-based products will need to be stored correctly to prolong the shelf life of the product and delay the staling process. Storage conditions will vary depending on the finished product and whether the product is finished or filled with ingredients that shorten the shelf life such as creams or fresh meats. After baking and cooling, baked products begin to stale though the process of moisture migration. Moisture migrates from the centre of the product to the surface and evaporates. This process will vary depending on the hydration rate of the product and can take as long as 12 hour before any noticeable change has occurred. Staling cannot be prevented as it is natural for baked products to change as it ages, however steps can be taken to slow down this process. Before storing, baked yeast goods will need to be cooled first to prevent the product from sweeting and becoming wet. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  22 Packaging serves the following purposes:  Protects the bread from contamination and damage  Makes for ease in handling and transportation  Retains moisture and flavour of bread Materials used for packaging include:  Polybags or other plastic films  Cellulose films  Waxed or plain paper bags Notes concerning packaging If pre-packed bread is for sale the baker has to comply with the legislation for pre-packed articles. This Act is looked after by Trade Measurement Victoria. It states that any pre-packed article ready for sale requires labelling. This label should read with the following information:  Name and premises address of the packer  Measurement of the article, either in units or in weight – usually single units, like a loaf of bread, are labelled with the weight. If more than one unit is packed, the unit number is labelled. Under the Food Act, it is also required that all ingredients be identified and labelled, whereas quantity of such is not required. All this is not required if bread is sold loose, not pre-packed. Bulk fermentation process Straight dough In this process all the ingredients are weighed and checked. The yeast and water are added to the dry ingredients and the dough is mixed on low speed until the dough has formed a clear mass. The dough is then mix on a higher speed until the gluten is fully developed. Once the dough has reached peak development it is allowed to rest for 1 – 5 hours, this is known as “Bulk Fermenting Time”. It is best to keep the dough covered during this time to prevent skinning or chilling. At approximately 1/2 – 2/3 of the fermentation time, the dough is knocked back, this:  Evens up dough temperature  Expels carbon dioxide  Stretches gluten (improves quality of structure)  Allows yeast to continue to ferment. Scale and process the dough as per the stages of manufacture. Effects of the bulk fermentation process are: V1 260423 SITHPAT014 Produce yeast-based bakery products  23  Improved flavour with longer processes  Maturing is natural and takes place by the enzymatic activity, occurring during the bulk fermentation of the dough  More space is required for fermentation in the dough room. The dough temperature, amount of yeast used and the quantity of salt control the rate and length of the bulk fermentation. Instant dough or rapid dough process This process is almost the same as the bulk fermentation process with the difference being bread improver added and the bulk fermentation time cut down to about 10 – 30 minutes. The effects of the rapid dough process are:  Yeast level from 3% upwards, depending on size of product  Requires A.D.D. bread improver – active dough development  Warmer dough temperatures 28-30°C. Gluten tougheners are used to enable the process to be effective.  The gluten structure is modified by chemicals to produce a mature dough as it is taken from the machine  Ascorbic Acid strengthens (matures)  L Cysteine or Metabisulphite softens (mellows)  Space Saving — dough room/mixing area  Increased bread yield — doughs do not slacken and can include more water as well as no fermentation weight loss.  Divider accuracy improved — less gas evolution than in other types of dough  Labour Saving, due to production efficiency and no Knock Back and BFT.  Loss of flavour, due to the production process  Increased cost of products (improver). This process is the most commonly used in the industry. Pre-ferment dough process This process requires an addition stage of mixing up a pre-ferment. Pre-ferments are doughs that are made from a portion of the total formulas flour, water and yeast (wild or commercial) and allowed to ferment for a period of time before adding to the final dough. Pre-ferments are a valuable tool and an inexpensive way to improve the quality of the baked goods The effects of this process are:  No bread improvers are required  Improved flavour, colour, volume and texture  Maturing is natural and takes place by the enzyme activity during fermentation  Better keeping qualities  More room is required in the kitchen to allow for storage of the pre-ferments  Labour intensive 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  24 Types of preferment’s There are many different types of preferment that are used and each one provides different characteristics within the baked product. Preferment dough or old dough could be any kind of dough that has had a minimum of 3 hours fermentation before being used in the final dough. It was first developed to improve the quality of bread using the straight dough process and a short bulk fermentation time and is used in a wide range of products. Poolish is a liquid preferment that has 100% hydration and using commercial yeast that is calculated based on the fermentation time. The Poolish is one of the first preferment’s elaborated using commercial yeast and was invented by the Polish bakers although it was later used in other countries Sponge is a preferment that has a hydration rate of approximately 60-63%. It was first used British bakers to improve tin breads but can also be used in sweet dough and other products. Biga was first used by the Italian bakers to improve quality and strength of their dough. It is a very stiff preferment with a hydration rate of 50% with 1% yeast and allowed to ferment for 18 hours at room temperature. It is used in a wide range of products. Sourdough is a preferment that uses wild yeast and bacteria to ferment the final dough and has a consistency that can be either liquid or stiff and is sometimes referred to as a Levain. It was the first leavening agent used in bread and can be date as far back as 4000BC. A sourdough preferment is perpetuated from day to day and can be kept alive for many years. It is used in a wide range of products to improve the quality of the baked goods. Purpose of mixing 1. The first function of the mixer is to thoroughly and evenly distribute the yeast cells, salt and other additives throughout the dough mass. 2. The second function of mixing is to form gluten from the gliadin and glutenin proteins in the flour and added liquid. 3. The third duty of mixing is to develop this gluten and disperse it evenly through the dough. The gluten forming proteins are in fine even particles mixed with the starch in the flour. In the dry state they have no coherence and no ability to form a mesh-like network capable of holding gas. The ability to do so comes when the correct quantity of liquid is added, and the dough is mixed for the required length of time. At the beginning of mixing, lumpy dough is formed which is short, rough and sticky. As mixing continues, the dough begins to take on distinct characteristics. True gluten formation is taking place. The gluten particles at first are short and of little coherence, they then begin to adhere to each other to form rough rope-like strands of many shapes and sizes. Mixing is continued to develop these strands to definite shapes and size. We cannot hope to produce a real loaf of bread unless we develop the gluten strands during mixing. Mixing should continue until the dough mass is smooth or in other words, until the dough has cleared. V1 260423 SITHPAT014 Produce yeast-based bakery products  25 Different mixing techniques  Short  Improved  Intensive  Double hydration Short mix This style of mixing would suit the bulk fermentation process or the pre-fermented dough process. It utilises first speed only on a machine to closely replicate the characteristics of hand mixing. Short mixing incorporates the ingredients and does very little gluten development resulting in underdeveloped doughs. As a result a long first fermentation time is required (min 3hrs) with 2 – 4 punch and fold (knock back) given to develop strength in the dough. These are given at regular intervals over the fermentation period. Because good extensibility is needed to fold the dough a soft dough consistency is required. Due to the long fermentation time a smaller amount of yeast is used in the dough. At the shaping stage the dough is gassy and soft but easy to work with. Effect of short mixing on the final product.  Open and irregular crumb structure  Creamy crumb colour.  Smaller volume  Complex flavour  Longer shelf life Intensive mix With the availability of two speed mixers, bakers realised that the more intensive the development of the gluten enabled them to shorten the first fermentation time. This was a benefit to the bakers – the more bread produced one shift meant more sleep for the baker. Also people at the time enjoyed bread with a large volume and whiter crumb and this lead to the creation of the Intensive mix and the development of modern day bread improvers. This process would best suit the Instant dough or rapid dough process. Intensive mixing,  Longer mixing time and shorter first fermentation  Uses 1st speed to incorporate ingredients and 2nd speed to fully develop the gluten.  The dough has a stiffer consistency.  Lack of extendibility – strong dough Effects on the final product;  Tighter crumb structure 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  26  Whiter crumb colour  Bigger volume  Blander flavour  Shorter shelf life People started to notice that bread was lacking flavour and staling was happening at a much faster rate with the introduction of this mixing process. By mixing the dough until full development on the mixer two major factors were created that compromised the bread quality. The first was over oxidisation of the dough, which gave the bread a whiter crumb and blander flavour. ≠The second was related to the fermentation activity of the dough. By reducing the bulk fermentation time of the dough to almost zero, acidity was not given time to develop, there is less alcohol produced, this leads to aromas not being created and the self-life is a lot shorter. Improved mix An Improved mix was developed and is a compromise between short and intensive mixed doughs. The baker is able to achieve more of the efficiencies of the intensive mix while retaining most of the product qualities obtained with a short mix. This process would best suit the bulk fermentation process and some pre-fermented doughs. An Improved mix has a shorter mixing time to that of an Intensive mix.  Uses 1st speed to incorporate the ingredients and 2nd to develop the gluten;  A medium soft dough consistency is required.  Gluten is not fully developed  Medium length of time for the first fermentation Effects on the final product,  Crumb structure is open and irregular  Good crumb colour  Medium volume  Good flavour  Good shelf life Double hydration This method is used in the production of super hydrated doughs such as Ciabatta. The water is added to the dough in two stages. First enough water is added at the start to form the dough to a medium consistency. The dough is mixed to form the gluten then on a higher speed to develop the gluten. Once the gluten has reach about 2/3s maximum development the remaining water is added in small addition until it is well incorporated. These types of doughs can have water percentages up to and exceeding 100% of the flour weight. V1 260423 SITHPAT014 Produce yeast-based bakery products  27 Factors that influence gluten development 1. Type and speed of mixer used; 2. Dough size; 3. Energy input; 4. Dough temperature; 5. Flour type and strength; 6. Quality and quantity of gluten and gluten forming proteins; 7. Formula selection, that is, ingredient selection; 8. Type of bread improver used; 9. Use of artificial gluten modifying agents; 10. Quantity of salt in formula. If dough is under mixed you will notice: 1. under mixing has a retarding effect upon fermentation; 2. Gluten is not formed, so the dough has poor gas retaining powers, and low water absorption; 3. Finished dough temperatures are often low; 4. The dough has poor moulding characteristics; 5. The finished product has a “Woolly” texture with grey crumb colour; 6. The finished product has poor keeping qualities. If dough is over mixed you will notice: 1. Sticky doughs cause poor handling qualities; 2. Excessive elasticity; 3. The dough has poor moulding qualities; 4. Excessive volume in slightly over mixed dough because the FDT is high; 5. Flowing of doughs in final proof; 6. The finished product has grey crumb with crumb tearing; 7. The finished product has poor keeping qualities. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  28 How to calculate the mixing time of dough To know how long you should mix dough for, first you need to know what level of gluten development that is need and the revolutions of the mixer on 2nd speed.  Short mixed dough will have about 30% gluten development and will required approximately 600 revolutions on first speed only. This is after the dough has formed.  Improved mixed dough will have about 70% gluten development and will require approximately 1000 revolution on 2nd speed.  Intensive mix dough will require about 90% gluten development and will need approximately 1600 revolutions on 2nd speed. These mixing times take into account the all the ingredients have been incorporated and the gluten has been formed on low speed first. The formula to calculate mixing times is: Total revolution required ÷ revolutions per minute (RPM) of the mixer = total mixing time. Total revolution required ÷ revolutions per minute (RPM) of the mixer = total mixing time. E.g. intensive mixed dough mixed on a machine with 200 RPM on 2nd speed. 1600 ÷ 200 = 8 Total mixing time on 2nd speed would be 8 minutes. This is on top of the five minutes that is given to form the dough on low speed. Note: Always remember that there are many factors that can influence the level of gluten development and a visual check of the dough should always be done using the window test. V1 260423 SITHPAT014 Produce yeast-based bakery products  29 Dough yield calculations When bakers talk about a “1 kilogram”, dough this weight actually applies to the flour content of the dough only. When all the other ingredients are added, the total dough weight is referred to as the expected yield (from 1 kilo of flour). In calculating the Ingredient weights for a given amount of dough (the required yield) we use the expected dough yield from 1 kilo of flour using the following formula: New base weight of flour = required yield ÷ expected yield Example: Use the following dough formula to calculate the actual quantities of ingredients for the required yield. Final dough Ingredients Bakers % 1kg dough New dough Bakers Flour 100 1.000 4.263 Salt 2 0.020 0.085 Bread improver 0.5 0.005 Yeast 4 0.040 Water 60 0.600 Expected yield 1.665 F.D.T 27°C. Required yield: 3 units @ a scaled weight of 0.520 kg (3 x 0.520 = 1.560 kg) 4 units @ a scaled weight of 0,300 kg (4 x 0.300 = 1.200 kg) 5 units @ a scaled weight of 0.800 kg (5 x 0.800 = 4.000 kg) Gives a total required yield (dough weight) 6.760 kg Include 5% wastage = 6.760 x.05 = 0.338 6.760+0.338 = 7.098 The new required yield including 5% wastage is = 7.098 New base weight of flour = required yield ÷ expected yield 7.098÷ 1.665 = 4.263 4.263 × ingredient % = new ingredient weight 4.263 × 0.02 = 0.085 To ensure that the calculations have been done correctly the new dough column is added up to get a total weight that should equal the required yield. If these figures do not match then the process is repeated to find the error and is corrected. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  30 Activity: Calculate the expected yield and required yield for the following: Ingredients Bakers % 1kg dough New dough Bakers Flour 100 Salt 2 Bread Improver 1 Oil – Fat 2 Water +/- 62 Yeast 3 Expected yield = Production 10 units × 0.350 = ___________ 8 units × 0.450 = ___________ 16 units × 0.080 = ___________ Include 5% wastage Total dough required = ____________ ÷ __________ = ___________ The flour weight for the new dough is ____________ V1 260423 SITHPAT014 Produce yeast-based bakery products  31 Calculating water temperature To consistently produce quality baked products it is necessary for the Patisserie or Baker to be able to control and manipulate the temperatures relevant to all stages of the dough production. Factors, which influence the final temperature of the dough, include:  Temperature of the ingredients used.  Ambient temperature of the kitchen  Friction factor of the mixer being used. This is the amount of heat created by friction during mixing.  Temperature of the water used Ingredients Flour and water are the two main ingredients that contribute to the final dough temperature (FDT). Ambient Dough may lose heat or gain heat from the surrounding atmosphere during mixing. The greater the difference between the ambient room temperature and the desired dough temperature, the great the effect will be. Friction factor The movement of the dough hook through the dough and the moment of the dough against the side of the mixer will generate heat due to the friction created during mixing. The amount of heat produced will depend on the type and speed of the mixer (higher the RPM the more heat), the duration of the mixing (more time the more heat), and the consistency of the dough (the tighter the dough the more heat). To work out the friction factor the first thing that is needed is the amount of degrees (C°) that the dough will rise within one minute of mixing on 2nd speed. This figure is now multiplied by the number of minute that the dough will mix for on 2nd speed. Every machine will have a different friction factor and this should be done with the first dough and recorded. Most spiral dough mixers on average will have a friction factor of 3 to 3.6°C for every minute of mixing. It is also recommended that this test be repeated over time. Water temperature Water in bread doughs and yeast-raised products should not be taken for granted as something just to form the dough mass. The amount of water and its temperature should be carefully controlled, so as the starch and gluten retain the correct amount of water to make a workable dough consistency, and with the correct finished dough temperature (FDT). The ideal temperature range to create an environment for yeast to ferment is between 25°C to 28°C. In most kitchens and bakeries the temperature of the first dough is taken and slight adjustments are made for the following doughs. The temperature is then taken at random times throughout the production and changes are made if needed. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  32 Is should be remember that this process should only be used as a guide as there are so many other factors that can influence and impact on the dough temperature and rate of fermentation. Example: Note: The friction factor is based on 6 minutes of mixing on 2nd speed with a 3°C rise for every minute = 18. All temperatures given in degrees centigrade °C  Required F.D.T 28  Multiplied by 2 56  Subtract flour temp. (22) 34  Subtract friction factor (18) 16 = required water temp. Activity: Below are some examples for which you are to calculate the water temperature to achieve the given required finished dough temperatures (FDT) using the given flour temperatures. The friction factor to be used in this exercise is 18. a) Required F.D.T 27 water temperature _______________ Flour temperature 20 b) Required F.D.T 29 water temperature _______________ Flour temperature 19 c) Required F.D.T 30 water temperature _______________ Flour temperature 21 d) Required F.D.T 30 water temperature _______________ Flour temperature 19 e) Required F.D.T 26 water temperature _______________ Flour temperature 21 “From SUAS. Advanced Bread and Pastry, 1E. © 2009 Delmar Learning, a part of Cengage Learning, Inc. Reproduced by permission. www.cengage.com/permissions” V1 260423 SITHPAT014 Produce yeast-based bakery products  33 Steam “During baking, steam plays a major role in bread development, crust crispness, and colour. After the loaves have been loaded into the oven, hot steam comes in contact with the cooler surface of the bread, and the resulting condensation causes a thin film of water to lightly coat the bread. This makes the surface of the dough more extensible and better able to develop under the gas pressure at the beginning of the bake, leading to a larger volume. (Oven spring) By slowing down the evaporation on the surface of the dough, the coating of the moisture delays crust formation, making the crust thinner and crisper. It also generates a slight dilution of the starch present on the surface of the dough, resulting in a glossy effect after baking. To achieve the greatest benefits from condensation, steam should be injected into the baking chamber before and after the loaves have been loaded. If the injection is late, and the surface of the loaves is allowed to increase in temperature, a skin will form on the loaves before the steam reaches them, automatically lowering the condensation effect and minimising the positive effects of the steam. When rack ovens or convection ovens are used, the baker does not have the option of steaming before loading. However, these ovens are generally well equipped with powerful and efficient steam generators that quickly fill up the baking chamber right after the racks have been introduced. The quantity of the steam should be sufficient to form a light coating of water on the doughs surface. Because different ovens are equipped with steam generators of efficiency, it is very difficult, if not impossible, to give an exact steaming time in seconds. The baker should look at the surface of the loaves, which should be lightly covered with moisture and slightly shiny. Another visual clue is the appearance of steam on the oven door, indicating that the baking chamber has sufficient moisture. If drops of water are running down the surface of the loaves, too much steam has been injected. This can potentially penalise the final product quality, including a crust that is not crispy enough, cuts that do not open sufficiently, and a very shiny surface that looks almost artificial. Steam is only necessary at the beginning of the bake. Once bread starts to bake, it will release some moisture that will have the same effect as the steam.” Steam exists in three forms  Saturated steam: is steam which occurs when water reaches 100°C and evaporates. Steam is at the same temperature as water and is essential for bread making.  Wet steam is steam and water mixed, due to particle condensation of saturated steam by cooling. If steam is not used correctly it can cause blemishes, marks or grey streaks on the crust of the bread.  Super-heated steam, also known as dry steam, is steam in the absence of water so that its temperature is raised to a point above that, corresponding to its pressure. Effects of steam in bread making  Imparts a glaze on the surface of the bread, which enhances the appearance of the product.  To ensure an even symmetrical oven-spring, by keeping the surface of the dough in pliable conditions, allowing it to expand without tearing.  Prevents excessive evaporation of moisture from the dough piece, which results in weight loss.  Produces a turbulence which assists in even heat distribution.  Modifies heat at entry to the oven when steam is applied.  Pressure may be too high if super-heated steam is used, which could result in loss of final shape and cracked products. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  34 Amount of steam can vary, depending on:  Formulae and ingredients: Formulas with high fat content must not be steamed, as they could run flat (lidded Hamburger Buns). The higher the rate of rye flour in a formula, the more moisture is required to achieve crust colour gloss and symmetry.  Desired crust characteristic: Steam is vital to obtain typical crust characteristics of French and Vienna Breads. Steam supplies moisture to the dough surface, this hot condensed moisture gelatinises the starch and converts it to dextrin which, when dry, results in a crispy crust and high gross. To achieve a gloss on baked goods, some products are water or starch washed and others may be egg washed to achieve a very high gloss. The application of these washes is prior to baking. Temperature of the oven General rule is:  With hot oven temperature increase steam  Colder oven temperature decrease steam Proof of dough pieces  Little proof – increased steam  Full proof – decrease steam  Too much proof – no Steam Ovens  Ovens are in general different, so is the steam input and the capacity of the retention of the steam  Bread in general produces its own steam, some ovens are designed in a way that no steam is required, as the moisture comes from the product Correct steaming conditions’ are essential:  Ovens with low steam levels or no steam could bake products which have leathery crust characteristics, pale crust colour and no gloss as well as poor oven spring. It is also possible that the crust can separate from the crumb.  Excessive use of steam causes blistering of the crust and could result in flat products. V1 260423 SITHPAT014 Produce yeast-based bakery products  35 Example Workflow plan Name: Date: Production Expected yield = 1.680 Required yield = 21.000 New flour weight = 12.500 Ingredients Bakers % 1kg dough New dough Bakers Flour 100 1.000 12.500 Salt 2 0.020 0.250 Bread Improver 1 0.010 0.125 Oil 2 0.020 0.250 Yeast Compressed 3 0.030 0.375 Water +/− 60 0.600 7.500 Expected yield = 1.680 Total dough = 21.000 Production 0 minute 2nd speed = 2 units × 0.800kg – Sandwich loaf 2 minute 2nd speed = 2 units × 0.800kg – Sandwich loaf 6 minute 2nd speed = 2 units × 0.800kg – Sandwich loaf One unit at 1.400 – Dinner rolls Remaining dough divided into 0.450 and produce Baguette, Vienna and Cobbs 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  36 list of ingredients ___________________________________________________________________________ Baker’s flour Salt Bread Improver Oil Compressed Yeast (fresh) Water Flour for dusting Spray oil or greasing compound for bread tins and trays list of equipment Bowls for weighing up Scales Spiral bread mixers or planetary mixer with dough hook Plastic scraper Metal scraper Digital thermometer Plastic for covering the dough Lame or sharp knife for scoring the dough 680gr bread tins Baking trays Proover Oven Cooling wires Baking trolley Cooling baskets and trolley V1 260423 SITHPAT014 Produce yeast-based bakery products  37 Example Work Schedule Times 1. Wash hands 2. Weight up all ingredients and double check against recipe 3. Place all dry ingredients into mixer 4. Add water, reserving a small amount to adjust consistency later on 5. Turn mixer on to low speed and mix for a minimum of 5 minutes to form the dough and gluten 6. Check consistency of dough and add water if needed 7. Turn mixer onto high speed 8. Mix the dough for the required time to achieve the desired level of gluten development. 9. After mixing, check the final dough temperature (FDT) 10. Transfer the dough to a floured bench and cover with plastic 11. Allow the dough to bulk proof for the required time. 12. Clean the mixer 13. Prepare all baking tins and trays 14. After bulk proof, divide and scale the dough as required 15. Pre-shape the dough as required (round) 16. Cover the dough and rest for 20 minutes (intermediate proof) 17. Turn on prover and ovens - set temperatures and humidity 18. Shape the dough into the final shape and place into tins or onto baking trays a. 800gr sandwich loaf – 680 bread tins b. 350gr cobbs and Vienna’s – baking trays c. Dinner rolls – baking trays 19. Place the dough into the prover (final proof) 20. Clean, wash and sanitise benches and any utensils 21. After final proof, score the Cobbs and Viennas 22. Place lids onto bread tins 23. Place dough into the oven and apply steam 24. Set baking timer 25. Check all fridge’s and freezers for perishable items 26. After baking remove the bread from the tins or baking trays and place into cooking baskets 27. Clean and maintain kitchen 28. Product evaluation 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  38 Final checklist  Check to make sure that the recipe been calculated correctly  Do I have all the required ingredients?  Do I have all the required equipment and is it in a safe working order?  Is the workflow achievable? Provide a brief description of the expected product characteristics which should include appearance, colour, consistency, crumb structure, moister content, shape, taste and texture. Also include any relevant historical or cultural. Example: Baguette The baguette has a sweet, thin splintery crust that is golden foxy red/ brown in colour. The shape is long and slightly oval. The tender moist crumb is milky white in colour and has a sweet, mild fermented flavour. The baguette is considered a staple and symbol of France with French bakers widely using a Poolish to increase the complexity of flavour. V1 260423 SITHPAT014 Produce yeast-based bakery products  39 Session 1 White Dough Cobbs and Vienna loaves 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  40 Activity: White bread Ingredients Bakers % 1kg dough New dough Bakers Flour 100 1.000 12.500 Salt 2 0.020 0.250 Bread Improver 1 0.010 0.125 Oil 2 0.020 0.250 Yeast Compressed 3 0.030 0.375 Water +/− 60 0.600 7.500 Expected yield = 1.680 Total dough = 21.000 Production 0 minute 2nd speed = 2 units × 0.800kg – Sandwich loaf 2 minute 2nd speed = 2 units × 0.800kg – Sandwich loaf 6 minute 2nd speed = 2 units × 0.800kg – Sandwich loaf Remaining dough divided into 0.450 Cobbs and Vienna loaves V1 260423 SITHPAT014 Produce yeast-based bakery products  41 Process final dough Mix Improved mix – medium consistency Final Dough Temperature (FDT) 26° – 27°C First fermentation (bulk proof) 30 minutes Divide 0.450kg Pre-shape Boule (Ball) Resting time 20 – 30 minutes Final shape Vienna & Boule (Cobb) Final proof 45 minutes – 1 hour Scoring As directed Steam 2 seconds Baking – deck oven 18 – 25 minutes at 230°C approximately For information on factors that influence gluten formation and peak development refer to pages: 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  42 Dough that is about 50% developed Dough that is fully developed Notice that there is no veining. V1 260423 SITHPAT014 Produce yeast-based bakery products  43 Session 2 Wholemeal, honey, sultana and oat bread Focaccia 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  44 Introduction Wholemeal flour Wholemeal flour is made when the Bran of the wheat grain is added back to the Endosperm after milling leaving out the wheat germ. This type of wholemeal flour is the most commonly use in the bakery industry as it is easier to use and has a longer shelf life then 100% Stone-ground wholemeal. 100% Stone-ground wholemeal – This flour is made using 100% of the wheat grain and contains the germ. In comparison to white flour products, mainly white bread, the fermentation requirements for whole wheat breads are less, due to the weaker nature inherent in whole wheat flour. Doughs made from whole-wheat flour will show less resistance to pull. Because of the dilution of the gluten due to the high bran content, the gluten protein must be developed to the maximum gas retention potential through fermentation. Whole-wheat dough lack tolerance to over fermentation. To increase this tolerance, the baker can lower dough temperature, and the fermentation time may be increased. Comparing whole-wheat dough to white dough, in general, the mixing requirements are less due mainly to the bran diluting the percentage of gluten-forming proteins along with the cutting action exhibited upon the gluten during the mixing process. The mixing requirements are not only less, but also less tolerant and have very little recovery from over mixing. In order to improve mixing tolerance, the addition of dough conditioners and the use of cooler dough temperatures should be incorporated into the process V1 260423 SITHPAT014 Produce yeast-based bakery products  45 Activity: Wholemeal, honey and sultana Ingredients Bakers % 1kg dough New dough Bakers Flour 10 0.100 Wholemeal Flour 90 0.900 Salt 1.5 0.015 Bread Improver 1 0.010 Gluten 3 0.030 Honey 7 0.070 Oil 2 0.020 Yeast 3.5 0.035 Water +/- 60 0.600 Sultanas 20 0.200 Walnuts 8 0.080 Expected yield = 2.060 Total dough = Production (required yield) 16 x 0.550 = _______ Plus 5% _____ x 0.05 = 0.440 _____ + 0.440 = 9.240 9.240 ÷ 2.055 = _____ _____ x ingredient % = new ingredient weight 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  46 Process final dough Mix Improved mix – medium consistency Final Dough Temperature (FDT) 26° – 27°C First fermentation (bulk proof) 30 minutes Divide 0.550kg Pre-shape Boule (Ball) Resting time 20 – 30 minutes Vienna, rolled in oats and place into small 0.450kg Final shape bread tins Final proof 45 minutes – 1 hour Scoring N/A Steam 2 seconds Baking – deck oven 20 – 25 minutes at 200°C – 210°C approximately * Remember: when adding fruit or nuts to dough to add them at the end of the mixing process and on low speed, this is to ensure that the fruit and nuts are not destroyed. V1 260423 SITHPAT014 Produce yeast-based bakery products  47 Activity: Focaccia Final dough Ingredients Bakers % 1kg dough New dough 1 Bakers Flour 100 Salt 2 Oil 5 Fresh Yeast 3.5 Water 60 For brushing on top before baking Garlic - - To taste Olive oil - - To taste Rosemary - - To taste Production 2 x 1.800kg = 3.600 3.600 ÷ ________ = Process final dough Mix Improved Final Dough Temperature (FDT) 26° – 27°C First fermentation (bulk proof) 1 hour Divide N/A Pre-shape Round Resting time 15 minutes Final shape Rolled out to fit into a baking tray Final proof 1 to 1.5 hours Topping Garlic oil and rosemary Steam N/A Baking – deck oven 210°C for 20 minutes 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  48 Method 1. Process the dough to fill a baking tray. 2. Top with garlic oil and rosemary 3. After baking allow to cool 4. Cut slab into small squares of about 10cm 5. Cut in ½ through the middle and fill with roasted pumpkin spread, rocket, feta cheese and salt. 6. Wrap in paper ready to be served. Activity: Roast pumpkin spread Ingredients Quantity Butternut pumpkin 1 medium Garlic 4 cloves Oil As required Salt To taste Cumin seeds To taste Method 1. Cut pumpkin into cubes and roast with garlic until soft 2. Puree pumpkin with garlic and season to taste with salt and cumin 3. Use oil to adjust the consistency. *Note – this product could easily be adapted to suit someone that is following a vegetarian or vegan diet through ingredient selection. V1 260423 SITHPAT014 Produce yeast-based bakery products  49 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  50 Session 3 New York style rye and caraway seed Bagels V1 260423 SITHPAT014 Produce yeast-based bakery products  51 Introduction Rye bread was comparatively unknown in Australia prior to the 1950s when, due to the influx of migrants from European countries in particular, demand for this product increased. Historically, rye is the principal bread grain of Northern Germany, Russia and the Scandinavian countries. It is also widely used in Poland and several of the Balkan countries. In these regions, rye breads have traditionally been made with rye flours, to which have been added little or no white wheat flour. Such bread is often called ‘black bread.’ For some years there has been a tendency, in the so-called light ryes to replace the rye flour with a high percentage of wheat flour, resulting in a very mild or lack of definite rye flavour. Rye bread containing a high percentage of rye flour has a pronounced flavour, which is liked by some; it is enjoyed occasionally by many and objected to by others. Production of rye breads In the production of rye bread, it is extremely important that a complete understanding of the effect of the various rye flour grades on the finished loaf be known, before an acceptable rye bread can be made. Rye flour contains protein but not of the gluten forming type. It will not make a well-risen loaf unless mixed with a good proportion of wheat flour to supply the gluten to give it gas-retaining properties. The principal proteins of wheat are gliadin and glutenin, which together make up from 85%- 88% of the total protein. Gliadin and glutenin combine when wheat flour is kneaded with water to form gluten. It is further conditioned and made elastic by the process of fermentation. Rye flour contains gliadin but not enough glutenin to form sufficient gluten and its gas retaining properties are practically nil. Rye breads can be produced in the normal bakery environment. Perhaps the most important thing to remember is that just having the recipe will not guarantee a good result. The greatest emphasis is on the processing. Rye flour characteristics  Rye is a cereal grain with good protein content, but very little gluten. Rye flour has distinctly different characteristics from wheat flour.  Contains very little gluten forming proteins – possible 0.5%  Rye flour deteriorates very rapidly – short storage time  Fermentation of rye flour is faster, total time is less than for wheat flour  Salt can be used in higher quantities for products – 2% or more  Rye is intolerant to mixing – tends to get sticky  Absorption is slightly higher than wheat flour  Rye flour is usually purchased by brand name or sample (not protein level’) 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  52 Pentosans 8% (Gum) stickiness of dough. Pentosans can absorb and hold fifteen times their weight in water. This characteristic accounts for the stickiness associated with rye doughs. Pentosans form complexes with proteins, hence reduce their gluten forming capacity, Example: add 2% rye gums (pentosans) to wheat flour, Gluten cannot be washed out. Pentosans take water from flour proteins. General types of rye flour Light rye flour It is milled from near the centre of the rye berry. It is light in colour and represents the patent flour from the rye grind. It is used for the production of white rye bread and can be used in greater percentages than other rye flours without diminishing loaf volume. Medium rye flour It is milled from near the outer edge of the rye berry. It contains the white and dark rye mill streams and represents the dark rye mill streams and represents the straight flour. It is used for the production of medium dark or medium rye bread. It has more pronounced flavour than white rye flour but cannot be used in a high percentage without diminishing, loaf volume. Dark rye flour It is made by removing part of the white rye flour from the straight and contains more finely ground bran than medium rye flour. It represents the clear flour streams of the rye grind. It possesses an excellent true rye flavour and is used for old-fashioned dark rye breads. It contains a higher percentage of fibrous material than white rye flour, consequently the gas retaining properties of the dough is lower than in white rye flour doughs. Rye meal This is the entire ground rye kernel with nothing removed. The only difference being granulation (coarse, medium, fine). It is used for the production of various types of pumpernickel bread. Special white rye, special medium rye, medium dark rye, extra dark rye, special extra dark rye, rye chop and rye flakes are made by millers. Rye blends, a uniform blend of various types and clear flour ready mixed are offered to the bakers and patissiers by millers. The advantages of these blended flours are a saving of time, labour, storage space and assured uniform results. Note: Absorption is greater in rye dough than corresponding grades of wheat flour. The darker the rye flours the higher the absorption. V1 260423 SITHPAT014 Produce yeast-based bakery products  53 Mixing rye doughs The purpose of mixing dough is to obtain a uniform distribution of all ingredients and to form and develop the gluten in the dough. Generally speaking, Rye doughs will produce best results when they are mixed at low speed, although many rye doughs containing the lighter Rye in smaller percentages are being very successfully mixed at high-speed. Care should be taken to prevent over mixing any rye dough as this will result in very sticky dough and a small loaf volume. Heavy, high percentage rye flour doughs should always be mixed at comparatively, slow speed. Rye flours are easily broken down by over mixing. However, sufficient mechanical development must be given to the dough to condition the wheat flour portion for good cell structure and loaf volume. Bakers in some instances may use a combination of slow and high speed mixing suited to their particular rye bread formula and shop conditions. Under mixed or over mixed rye doughs will produce a loaf of poor quality and this too should be avoided. Fermentation/dough temperatures Best results are obtained in rye doughs by setting them at lower temperatures (24ºC - 26ºC) and allowing them to ferment for a longer period of time. Dark rye flour matures faster than medium rye flour and medium rye flour matures faster than white rye flour. Adjustments should he made for ingredients or conditions which affect the rate of fermentation in the rye dough. Shape of rye breads Traditionally, rye breads have been hearth or sole-baked, and loaf shapes are varied, the most popular being round/cob shape, or cigar/torpedo shape. Careful proofing and baking is absolutely necessary, for good loaf shape and volume, regardless of how well the loaf has been moulded. It is possible to bake rye breads in conventional pans or tins, and this is now quite common, particularly with the light varieties 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  54 Activity: New York style rye and caraway seed Ingredients Bakers % 1kg dough New dough Bakers Flour 60 0.600 Rye Flour 40 0.400 Salt 2 0.020 Yeast 3 0.030 Water +/- 70 0.700 Caraway seed 1 0.010 Expected yield = 1.760 Total dough = Production (required yield) 16 x 0.600 = ______ Plus 5% ______ ÷ 1.760 = ______ V1 260423 SITHPAT014 Produce yeast-based bakery products  55 Process final dough Mix Improved mix – medium consistency Final Dough Temperature (FDT) 26° – 27°C First fermentation (bulk proof) 30 minutes Divide 0.600kg Pre-shape Boule (Ball) Resting time 20 minutes Final shape Vienna or Boule Final proof 1 hour NOT IN PROVER Scoring As pictured Steam 2 seconds Baking – deck oven 20 – 25 minutes at 200°C – 210°C approximately 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  56 Activity: Poached bagels Ingredients Bakers % 1kg dough New dough Bakers Flour 100 1.000 Caster sugar 7.5 0.075 Salt 1.4 0.014 Gluten 1.4 0.014 Milk Powder 5 0.050 Fresh Yeast 2 0.020 Oil 5.8 0.058 Water +/- 57.8 0.578 Expected yield = 1.809 Total dough = Production (required yield) 1 x 2.400 = _______________ ______________ ÷ 1.809 = ______________ V1 260423 SITHPAT014 Produce yeast-based bakery products  57 Process final dough Mix Improved mix – medium consistency Final Dough Temperature (FDT) 26° – 27°C First fermentation (bulk proof) 10 minutes Divide 0.100kg Pre-shape round Resting time 10 minutes Roll out each round into an even long length and wrap around Final shape 4 fingers with the ends underneath and roll on the bench to join. Final proof 30 minutes Bring a large pot of water to the boil and reduce to a simmer. Place each bagel into the water for 20 Poaching seconds each side. Remove from the water and place onto baking trays. Sprinkle with seeds Steam 2 seconds Baking – deck oven 18 – 20 minutes at 200°C – 210°C approximately 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  58 Session 4 Baguette Round rolls V1 260423 SITHPAT014 Produce yeast-based bakery products  59 Activity: Baguettes Baguettes are generally associated with France; they are long thin, crispy bread made from lean dough. In France there are laws that determine what a Baguette should be. A baguette will be 5 – 6cm in diameter and a length of approximately 65cm. It should produce from flour, salt, water and yeast. The scoring of a Baguette should be done in a way to produce what are known as “ears”. This is the rising of the cut. To achieve this, the lame or blade should be held almost flat as to cut under the crust and not too deep in to the crumb. There should be 5 to 6 cuts along the centre line of the Baguette. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  60 1kg Ingredients Bakers % Per student 2 x student dough Bakers Flour 100 1.000 Salt 2 0.020 Bread Improver 1 0.010 Oil 2 0.020 Yeast Compressed 3.5 0.035 Water +/− 60 0.600 Expected yield = 1.685 Total dough = Production per student: (double production if working in pairs) 2 x 450gr Baguette 9 x 80gr round bread rolls (6 no seed 3 with seeds) Include an extra 5% for wastage. 2 x 0.450 = ____________ 9 x 0.080 = ____________ Plus 5% waste = ____________ Required yield =_____________ ______÷ 1.685=_____________ = new flour weight V1 260423 SITHPAT014 Produce yeast-based bakery products  61 Method  Preheat ovens to 220°C to 230°C and turn on prover.  Correctly weigh all ingredients.  Prepare mixing equipment.  Combine dry ingredients and add to mixer.  Add most of the water to dry ingredients reserving a small amount.  Mix on 1st speed for 5 minutes to hydrate ingredients and form the gluten.  Mix on 2nd speed 6-8 minutes or until the gluten is 90% developed – use the window test to check.  Allow the dough to rest for 15 minutes (bulk proof).  Divide the dough into the required weights and pre-shape.  Allow to rest for approximately 10 minutes to allow the gluten to relax before shaping.  Prepare baking trays.  Shape Baguettes and rolls, place onto prepared baking trays and place into the prover.  Allow the Baguettes and Rolls to prove at 80-85% humidity and 30-35°C until ready (approximately 45 min- 1 hour).  Bake Baguettes at 230°C for 18 – 25 minutes.  Bake Rolls at 230°C for 15-18 minutes.  Apply steam as soon as the oven has been loaded and door is closed.  Bake product until ready.  After baking cool baguettes.  When cool, cut and fill Baguettes as directed with Ham, cheese and rocket. Note:  The final proving time may vary depending on level of gluten development, ingredients used, final dough temperature (FDT), amount of yeast, water temperature, shaping and size of loaf.  Score Baguette just before placing into the oven for baking.  Bake time and temperature for products may vary depending on oven type. 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  62 Session 5 Assessment V1 260423 SITHPAT014 Produce yeast-based bakery products  63 Assessment Each student will need to produce and present the following items:  2 Baguette, 1 baguette cut in 1/2 filled with Ham, cheese and rocket paste  9 round bread rolls 6 plan and 3 with sesame seed Baguette and rolls Ingredients Bakers % 1kg dough New dough Bakers Flour 100 1.000 Salt 2 0.020 Bread Improver 1 0.010 Oil 2 0.020 Yeast Compressed 3.5 0.035 Water +/− 60 0.600 Expected yield = 1.685 Total dough = 2 Baguettes @ 450gr each 9 Bread Rolls @ 80gr each Plus 5% One baguette will need to be cut in half to about 15cm long. Fill cut baguette with Ham, cheese and Rocket. NOTE - (Students only need to fill one 15cm long baguette) 26423-V1 250423 SITHPAT014 Produce yeast-based bakery products  64 Session 6 Hot Cross Buns V1 260423 SITHPAT014 Produce yeast-based bakery products  65 Activity: Hot cross buns Hot cross buns are a sweet bun that is spiced and fill with dried fruits such as currants, raisins and sultanas. Historically it was made in many Christian countries and was eaten during Lent. It is believed that bun/cake that had a cross on top first appeared as part of a pagan spring festival that worshiped the goddess Eovfstre. The cross was part of an offering to the goddess. Final dough Ingredients Bakers % 1kg dough New dough Bakers Flour 100 Salt 1.5 Yeast Fresh 6 Bread Improver 1 Butter 8 Sugar 10 Water 55 Currants 2 Sultanas 45 Mixed Peel 5 Spice 0.5 Cinnamon 0.5 Total Production: 24 hot cross buns per student 1 x 3.000 = 2.400 plus 5% 2.400 x 5% =_____ ______ ÷ _____ = _______ 26423-V1 250423