Chapter 3 The Baking Process and Dough Mixing

Introduction CHAPTER 3 This chapter includes: • An overview for the baking process •

The Baking Process CHAPTER 3 • Traditional Method - Basic steps never - Pre-shaping changed over centuries - Resting time - Preferment - Shaping - Mixing - Final Proof - First fermentation - Oven Loading - Dividing - Scoring - Unloading the Oven © 2009 Cengage Learning. All Rights Reserved.

The Baking Process CHAPTER • The proper transformation of basic ingredients into bread • Succession of 12 steps • Handling of each step greatly affects on the quality of final product © 2009 Cengage Learning. All Rights Reserved. 3

The Baking Process: Traditional Method CHAPTER 3 • Preferment - Before mixing of the final dough - Improvement of the final product - A portion of dough is allowed to ferment - Different preferments provide different characteristics © 2009 Cengage Learning. All Rights Reserved.

The Baking Process: Traditional Method CHAPTER 3 • Mixing - All the ingredients are

The Baking Process: Traditional Method • First Fermentation - A dough is allowed to ferment as a large mass - Increase dough strength (mass effect) - Develop flavor © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

The Baking Process: Traditional Method CHAPTER 3 • Dividing – desired weight For Manual Dividing: – Caution must be paid not to damage the dough – Try to cut a dough in one piece For Mechanical Dividing: – Choice of equipment is critical © 2009 Cengage Learning. All Rights Reserved.

The Baking Process: Traditional Method • Pre-Shaping CHAPTER 3 – By hand or by machine – Loose ball for boules and batards, cylinders for baguettes – Adjustment on the dough strength – Important to assess the dough characteristics – Form smooth skin on outside to promote proper and better shaping © 2009 Cengage Learning. All Rights Reserved.

The Baking Process: Traditional Method CHAPTER • Resting Time (or Intermediate Proof) – The dough is relaxed between pre-shaping and shaping – Continue producing gas – The dough pieces should always be protected from drying out © 2009 Cengage Learning. All Rights Reserved. 3

The Baking Process: Traditional Method CHAPTER 3 • Shaping - Forming into the final shape By Hand: - The characteristics of the dough must be carefully examined - Adjustment by the strength of the dough By Machine: - Choose equipment with minimum pressure and stress on the dough © 2009 Cengage Learning. All Rights Reserved.

The Baking Process: Traditional Method CHAPTER 3 • Final Proof – Gas accumulates and creates internal pressure – The balance of gluten strength and gas pressure creates volume and crumb structure – The dough should be protected from drying out – Use of rack cover, linen and proofs box © 2009 Cengage Learning. All Rights Reserved.

The Baking Process: Traditional Method • Oven Loading By hand: – Use of an oven peel or loader – Minimize damage during transferring the dough By Machine (for a larger production): – Automatic loading system – Even spacing for an even heat distribution © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

The Baking Process: Traditional Method CHAPTER 3 • Scoring – an incision on the skin of the dough – Direct impact one volume and final appearance of the bread © 2009 Cengage Learning. All Rights Reserved.

The Baking Process: Traditional Method • Unloading the Oven – With an oven peel

The Baking Process: Traditional Method CHAPTER 3 • Cooling – The bread goes through a series of transformation after baking and during cooling – The quality of the bread can be severely compromised © 2009 Cengage Learning. All Rights Reserved.

The Dough Mixing Process • Mixing – the first mandatory step to producing bread • Dough consistency and gluten development are determined during mixing © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Four Critical Steps of Dough Mixing CHAPTER 3 • Scaling – Precise scaling of

Four Critical Steps of Dough Mixing • Water Temperature – Controls the final dough temperature, which is directly related to the rate of fermentation – Desirable Dough Temperature for most dough: 74°-77°F – Factors: Temperatures of the room, flour, preferment and the friction from mixer – Friction of mixer varies by the type of mixer, the shape of the hook, quantity of the dough etc © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Four Critical Steps of Dough Mixing • Water Temperature • Calculation to determine water temperature Room°F + Flour°F + Preferment°F+ Friction°F=X DDT(75°F) x 4 = 300°F Water °F = (300 – X) °F © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Four Critical Steps of Dough Mixing • Ensuring Clean Equipment – Make sure the mixer bowl and hook are clean – Old dough scrap will not dissolve in the next dough © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Four Critical Steps of Dough Mixing CHAPTER • Adding Ingredients to the Mixing Bowl – Add the flour first, then water – Flour based on 100% • For mixer without reverse option: – Add the half of the water first, then flour, and then the rest of the water until the desired consistency is achieved © 2009 Cengage Learning. All Rights Reserved. 3

Ingredient Incorporation: Autolyse • Special Considerations for Autolyse CHAPTER 3 – When using instant dry yeast, add it one minute before the autolyse is over to properly hydrate the yeast cell – Liquid preferments must be incorporated before autolyse – Stiff preferments must be incorporated after autolyse © 2009 Cengage Learning. All Rights Reserved.

Ingredient Incorporation CHAPTER • During mixing on 1 st speed; • The ingredients are incorporated as well as the preferments • A baker must pay a close attention to see if additional water is necessary © 2009 Cengage Learning. All Rights Reserved. 3

Ingredient Incorporation CHAPTER 3 • Autolyse – Resting the flour and water for a minimum of 15 -20 minutes – Salt, yeast and preferment are added after an autolyse – Better hydration of the flour = better gluten structure – Protease degrades some gluten bonds = better extensibility and machine ability © 2009 Cengage Learning. All Rights Reserved.

Dough Development • After all ingredients are incorporated, the dough is continuingly mixed to achieve a desired degree of dough development • Can be done in first or second speed © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Dough Development • Dough Temperature CHAPTER 3 – Confirm the dough temperature right after mixing – The first fermentation time varies depending on the dough temperature – Do not continue mixing when the dough temperature is too cold – over development of the dough – Over-mixed dough creates excess extensibility and lack of elasticity © 2009 Cengage Learning. All Rights Reserved.

Dough Development CHAPTER • Physical Changes During the Formation of Dough – Hydrates the flour components, primarily starch and protein – Starch: native starch and damaged starch – Protein: Glutenin (provides elasticity) and Gliadin (provides extensibility) – Glutenin and Gliadin form chains of proteins, called Gluten © 2009 Cengage Learning. All Rights Reserved. 3

Dough Development • Physical Changes During the Formation of Dough • As the dough hook continues mixing, it organizes the cell structure by stretching and folding – The longer the mixing, the finer the crumb – Rheological change – less extensibility, more elasticity © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Dough Development: Physical Changes During the Formation of Dough • Protein Hydration and Mixing Time in First Speed CHAPTER 3 – Protein hydrates at slower rate than starch – For a larger batch of dough, 5 to 6 minutes of mixing on 1 st speed is necessary © 2009 Cengage Learning. All Rights Reserved.

Dough Development CHAPTER 3 • Chemical Changes During the Formation of the Dough – When water is introduced into the mix, Fermentation Activity and Enzyme Activity start – The wetter the dough, the faster the fermentation rate becomes – adjust yeast amount depending on the hydration © 2009 Cengage Learning. All Rights Reserved.

Dough Development: Chemical Changes During the Formation of the Dough • Oxidation of the Dough CHAPTER 3 – Caused by oxygen naturally incorporated into dough during mixing – Positive affects: Strengthen gluten bonds – Creates micro cells – gas produced by yeast accumulates in the cells – “Alveoles” or the cell structure of the crumb © 2009 Cengage Learning. All Rights Reserved.

Dough Development: Chemical Changes During the Formation of the Dough • Oxidation of the dough – Negative affects: Damage on Carotenoid pigments = whiter crumb, blander flavor – Salt slows down chemical reaction in dough © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Dough Development • Incorporation of Secondary Ingredients into a Dough System – Examples of

Dough Development: Incorporation of Secondary Ingredients into a Dough System • Incorporation of Fat CHAPTER 3 – 2 to 4% of solid fat can be incorporated with the flour at the beginning of the mixing – 5 to 15% of solid fat can be added when the dough is halfway trough development – more than 15% of fat should be incorporated when the gluten is almost fully developed – The fat lubricate the gluten and prevent from bonding easily © 2009 Cengage Learning. All Rights Reserved.

Dough Development: Incorporation of Secondary Ingredients into a Dough System CHAPTER • Incorporation of Fat – Liquid fats can be incorporated at the beginning of the mixing – Larger quantity can be incorporated after the gluten is fully developed © 2009 Cengage Learning. All Rights Reserved. 3

Dough Development: Incorporation of Secondary Ingredients into a Dough System • Incorporation of Sugar – Up to 12% of sugar can be incorporated the beginning of the mixing. – Higher % of sugar is incorporated in several steps – Hydroscopic characteristic © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Dough Development: Incorporation of Secondary Ingredients into a Dough System • Incorporation of Eggs – Should be incorporated at the beginning of the mixing – Major part of hydration – At least 10% of water in addition to the egg is necessary to hydrate flour properly © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Dough Development: Incorporation of Secondary Ingredients into a Dough System • Incorporation of Dry Ingredients – Malt and milk powder can be incorporated at the beginning of the mixing © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Dough Development: Incorporation of Secondary Ingredients into a Dough System • Incorporation of Solid Ingredients like Nuts, Dry Fruits, Chocolate Chips and More – Nuts, seeds and fruits must be incorporated at the end of the mixing – Incorporate on 1 st speed – Gentle incorporation will reduce damage to the gluten structure © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Dough Development • Mixing Process Conclusion – Following each step of mixing with precision and close attention results in a consistent production © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Mixing Techniques • Three main mixing techniques – Short mix – Intensive mix – Improved mix • Quality of bread depending on different gluten development © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Mixing Techniques CHAPTER 3 • Short Mix – Popular technique before mechanical mixers became available – Hand mixed dough: Not sufficient gluten development – Long fermentation with folds © 2009 Cengage Learning. All Rights Reserved.

Mixing Techniques • Intensive Mix – Mechanical mixers with two speeds enabled intensive development of gluten – Shorter fermentation time – Tight crumb with large volume – Oxidation of the dough leads to lack of flavor © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Mixing Techniques • Improved Mix – – Shorter mixing time than intensive mix Gluten is not fully developed Limits the oxidation of the dough Enable to produce higher quality of bread with a larger quantity © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Short Mix Description • Similar to hand-mixed dough • Under-developed gluten requires a long fermentation time and two to four folds • Low percentage of yeast • Gassy and soft dough © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Short Mix Description CHAPTER • Short Mix Effects of Bread Characteristics – Very creamy crumb color due to no oxidation during mixing – Long fermentation time enhances flavor and shelf life of the final product © 2009 Cengage Learning. All Rights Reserved. 3

Intensive Mix Description • The ingredients are mixed on first speed to an incorporation • It is then mixed on second speed to a full development of gluten • Great machine ability • Stiff and fluffy dough • Short first fermentation time © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Intensive Mix Description • Intensive Mix Effects on Bread Characteristics – Oxidation of the dough creates a very white crumb color – Tight cell structure – Large volume on the final product – Lack of shelf life and flavor © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Improved Mix Description • Compromise between the short mix and the intensive mix • Ingredients are incorporated in first speed and then mixed to half development of gluten in second speed • Medium-soft consistency of dough • Sufficient dough for hand-shaping or a semimechanized process © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Improved Mix Description CHAPTER • Improved Mix Effects on Bread Characteristics – Creamy color and open crumb – Flavorful product with a good shelf life – Volume is between that of short mix and intensive mix © 2009 Cengage Learning. All Rights Reserved. 3

Improved Mix Description: Improved Mix Effects on Bread Characteristics • Visual Comparison of the

Improved Mix Description: Improved Mix Effects on Bread Characteristics • Double Hydration CHAPTER 3 – Growing popularity of “super” hydrated dough created this technique – Water incorporation in two phases – Enough water is incorporated to create a mediumsoft consistency of dough – When the dough reaches 2/3 of its full development, the rest of water is added in stages – Very soft dough with sufficient strength for machine ability © 2009 Cengage Learning. All Rights Reserved.

How to Calculate Mixing Time • Based on the revolution of the dough hook • Short mix – 600 revolutions in first speed • Improved mix – 1000 revolutions in second speed • Intensive mix – 1600 revolutions in second speed © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

How to Calculate Mixing Time • Mixing time of the dough = Total Revolutions Required / RPM (RPM=Revolutions per Minute) • RPM varies with the brand of mixer © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

How to Calculate Mixing Time • Factors Affecting Mix Time – – – Type and design of mixer Batch size Characteristics of the flour Dough hydration Incorporation of additional ingredients © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

How to Calculate Mixing Time: Factors Affecting Mix Time CHAPTER • Type and Design of Mixer – – Motor speed Shape of the hook Mixer design Different type of mixer requires different mixing time © 2009 Cengage Learning. All Rights Reserved. 3

How to Calculate Mixing Time: Factors Affecting Mix Time CHAPTER 3 • Batch Size

How to Calculate Mixing Time: Factors Affecting Mix Time • Flour Characteristics – Stronger flour may require longer mixing time – Flour with lower quality and quantity of protein (example: Rye flour) requires more gentle mixing; longer mixing in first speed and shorter in second speed © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

How to Calculate Mixing Time: Factors Affecting Mix Time • Dough Hydration – Stiffer

How to Calculate Mixing Time: Factors Affecting Mix Time • Incorporation of Extra Ingredients – Seeds, fruits and nuts must be added after gluten development has been completed – Incorporation should be done in first speed © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

How to Calculate Mixing Time • Comparison of the Main Mixing Techniques © 2009

How to Calculate Mixing Time • Comparison of Mixing Processes and Effects on the

Developing Your Own Process CHAPTER 3 • Balance of mixing and fermentation • Understand that mixing and fermentation works together – if the mixing is changed, so as the fermentation time © 2009 Cengage Learning. All Rights Reserved.

Developing Your Own Process • Which Method to Use? Factors: – Desired characteristics of the final product – Schedule / Time limitation – Equipment issues (batch size, type of mixer, etc. ) – Understand outcomes of each mixing method and fermentation time © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3

Developing Your Own Process CHAPTER • Mixing and Training – The bake who is in charge of mixing should see the final products of his mixing shift – In a large product, standardizing the mixing procedure is important to maintain a good consistency © 2009 Cengage Learning. All Rights Reserved. 3

What Can Go Wrong and How to Fix It CHAPTER 3 • Scaling – Incorrect scaling of water or flour: should be noticeable within the first few minutes – Salt and yeast: may not be noticed until the first fermentation or the baking process is completed – Always double check the measurements before mixing © 2009 Cengage Learning. All Rights Reserved.

What Can Go Wrong and How to Fix It CHAPTER • Ingredient Incorporation – Salt or yeast can be dissolved in a small quantity of water and added to the dough when forgotten, only when the dough has just finished mixing © 2009 Cengage Learning. All Rights Reserved. 3

What Can Go Wrong and How to Fix It • Dough Development – Under-

Conclusion of Mixing and Mixing Techniques • When mixing is done carefully, the following steps will be easy • Be accurate and careful when scaling, incorporating ingredients and during mixing • A good understanding of mixing and fermentation helps to troubleshoot © 2009 Cengage Learning. All Rights Reserved. CHAPTER 3