Patent Application
20120003353
The present invention relates to a packaged dry mix bread product and a method of making bread from the mix without conventional bread dough development.
In the practice of making bread and bread like items, flour is mixed with water and other ingredients including leavener, such as yeast, to form a dough. The leavener, preferably yeast, provides carbon dioxide to expand the dough and produce a cell structure in the cooked dough. Typically, the dough is mixed to peak development to form what most bread consumers consider desirable bread attributes, such as texture and appearance. After mixing, the dough is allowed to rise, after which the dough is cooked to set the structure of the dough to form the finished bread. Typically, the rising dough is punched down and allowed to rise again. This is well known in the art of bread making. Many different types of bread and bread like products are made this way, both commercially and at home. Such breads are typically made using wheat flour that contains gluten, a protein that forms the gas retention properties of the developed dough. These methods require mechanical mixing to develop the dough.
Another method has come about recently and that is the so called Artisan bread process. It too requires mechanical mixing to form the dough. A book entitled My Bread by Jim Lahey (copyright 2009 and published by W. W. Norton & Company, Inc. of New York, N.Y.) discusses the making of Artisan bread. Rather than mix the dough to full development, the mixed dough is allowed to rise for a long period of time say, for example, 24 hours before baking. The final cooked product is like the bread products produced using the “mix to full development” process. This process is sometimes referred to as a “no knead” method, but still requires handling by the preparer. Dough prepared by this method is also very high in moisture content.
Both these methods require the use of a mechanical mixer and containers to hold the dough during mixing and development. These processes require cleanup of the mixing device and the containers.
The present invention allows for the production of bread like items without the required mechanical mixing. It was surprisingly discovered that bread like products can be easily made and produce a high quality cooked item without mechanical mixing of the dough, and that a dough can be formed by simply shaking the bread ingredients together in a container followed by an extended fermentation step. As seen in
While it is known that batters can be easily formed by shaking or mechanical mixing, there are two attributes which differentiate a batter from a dough. First, a batter has a much higher water content, and hence fluidity, than a dough and hence permits intimate and uniform mixing of the ingredients. This facilitates the uniform hydration of the flour in a batter by shaking and hence the formation of a flowable viscous liquid, commonly known as a batter. Second, batters do not rely on development of the gluten in the batter to achieve the desired baked product. In fact, the aim is to avoid development of a gluten matrix. Batters, when cooked produce a crumb structure.
A dough is a plastically deformable solid and was not considered formable without mechanical agitation with a mixing device to obtain sufficient and uniform hydration of the flour and alignment of the gluten molecules (e.g. dough development) throughout the dough mass to permit bread making. Hand kneading has also been used as a form of mechanical mixing with a mixing device, the hands.
The present invention involves the provision of a method of making a bread like food item. The method includes adding a predetermined amount of water to flour containing gluten, such as a wheat flour or a blend of flours including gluten. The water is added in an amount in the range of between about 55% and about 95% by weight of flour (as is) making the total water in the mix, including the water in the ingredients (flour typically has about 12% moisture) present in the range of between about 75% and about 125% by weight of dry flour. The flour and added water are in a closable container. The container can be a rigid container or a flexible container such as a bag made of a flexible film. After adding the water to the flour, the container is at least substantially closed. The flour and water are mixed by shaking the container sufficiently to form an agglomeration of the water, flour and other ingredients. The initial agglomeration is allowed to ferment and quiescently develop to form dough from the action of yeast, a leavener, for a period of time of at least about 8 hours. The fermented dough can be handled, which will decrease its volume, and then either cooked (e.g., baked) directly or allowed to rise for a short period of time (e.g., 30-45 minutes) after which it is then cooked (e.g., baked).
The invention also involves a product for making a bread like product. The product can include a sealed package that contains flour with gluten and yeast leavener. A sealable container is provided with the product. The sealable container has a volume potential of at least about 200% in excess of the volume of the dry mix (e.g., flour, salt and yeast) in the sealed package and water to be added.
The package 2 contains flour 8 (
As shown, the container 9 can be in the form of a closable flexible bag. The container 9 may include a mechanical closure device 11 such as those found on resealable plastic bags that have slide locks or those that have a rib that fits into a corresponding groove. An adhesive closure may also be used.
The package 2 can also contain a predetermined amount of water in a sealed container 30. It has been found that the amount of water added to the flour 8 can be an important factor. This can be due to the fact that people have trouble accurately measuring water using typical household measuring cups because of their large cross sectional area, the difficulty in holding them level and the fact that many are not accurately calibrated or manufactured. The ability to judge the amount of water when there is a meniscus is also limited. A measuring device for water may also be provided that has a small transverse cross sectional area, much like a graduated cylinder that would make measuring a proper amount of water easier and more accurate if water is not included in the package 1. The container 30 can serve this function in subsequent uses and need not be provided in additional kits. If water is provided in the kit, it is provided in an amount in the range of between about 55% and about 95%, preferably in the range of between about 65% and about 85%, and most preferably in the range of between about 70% and about 80% by weight of flour as the flour exists in the package. This water amount is based on the flour having a 12% moisture content. The total water in the mixed water and flour would be in the range of between about 75% and about 125%, preferably in the range of between about 85% and about 110%, and most preferably in the range of between about 95% and about 105% by weight of dry flour. As known to one skilled in the art, the optimal amount of water in dough is a function of several factors, including the type of bread being made, the moisture content of the flour and the absorption value of the flour. These amounts of water are also the same as those to be provided and added by the preparer.
The water may optionally come from a liquid food which contains a high percentage of water. Examples include milk (skim, 1% fat, 2% fat or whole milk), cream, beer and fruit juices. When these items are used, their percentage in the formula is adjusted to reflect the percentage of water in each item. For example, skim milk contains approximately 10% of non-water components. Thus, if the formula called for 100 grams of water, approximately 111 grams of skim milk would be used in its place.
Alternates to container 9 are shown in
The flour 8 may be any suitable flour and contains gluten. The flour may be a blend of different cereal grain flours and preferably contains wheat flour, which can be white flour, whole wheat, or a blend of the two. Other flours contain gluten, e.g., rye, and barley. The total gluten content is in the range of between about 8% and about 14% by weight of flour on a dry weight basis. Gluten is a protein that helps form the gas holding ability of the formed dough that allows the dough to rise from the production of carbon dioxide by the leavener. The flour present in the package for a loaf type bread is in the range of between about 100 gr. and about 600 gr., preferably in the range of between about 200 gr. and about 500 gr., and most preferably in the range of between about 300 gr. and about 400 gr. on a dry weight basis.
Any suitable yeast leavener can be used. Enough yeast should be provided to allow the initial agglomeration to double in volume during the fermentation and quiescent development as described below. Different yeasts will have different carbon dioxide producing capacities. A preferred yeast is dry yeast such as Saccharomyces cerevisiae. Yeast (e.g., active dry yeast), is present in the range of between about 0.1% and about 6% by weight of flour on a dry weight basis. If the agglomeration does not contain a significant amount of sugar, the most desired range of dry yeast is between about 0.1% and about 1% by weight of flour on a dry weight basis. Preferably, the yeast is packaged separately and in a moisture and air resistant package 15. However, the yeast may be premixed with the flour 8 and stored with the flour in the container 9.
Other ingredients may be included and can be provided in a separate package, or if dry, in the flour like the yeast described above. One such ingredient might be a flavor provider such as dry bacterial cultures of selected strains of lactic acid; bacteria can be added to produce a sour dough type of product.
Hydrocolloid may be added, such as a mixture of xanthan and guar gum. The amount of water can exceed the above described amount to accommodate the gum. This can increase chewiness to make a Ciabatta type of bread with a chewy texture. One example was using 1.0% (total agglomeration content basis) of this gum mixture, and 50% formula added water. This is 100 grams water per 100 grams of flour (as is) and 127 grams of total water per 100 grams of flour (dry basis). At this level of water, dough is relatively sloppy if no gum is included. With the gum, it is a nice dough and baked to a very nice final product.
Other ingredients may be included such as flavorings, salt, sugar, butter, oil, food particulates such as dried fruit and dough conditioners. They may be premixed with the flour or can be provided in separate packages (not shown).
The above described packaged food product is adapted for sale at retail outlets such as grocery stores. It is provided for the household production of bread like items such as artisan bread. The produced agglomeration may also be divided to produce smaller items such as demi-loaves or dinner rolls. The dough may also be flattened and shaped after fermentation and before cooking to use as a very high quality pizza crust.
It was surprisingly found that by simply shaking the flour with the added water in at least a substantially closed container that an initial agglomeration could be produced, which, following an extended fermentation and development step, would make a high quality baked product. The container may be completely closed. However, the agglomeration immediately after formation, had an appearance as seen in
The flour, leavener and other ingredients that are to be part of the dough are placed in a mixing container adapted to be shaken, such as the container 9, 21, 25 or 40. The water is then added to the container and the container is closed, at least substantially, to prevent loss of ingredients. The ingredients are mixed at room temperature preferably above about 65° F. (18° C.). The order of ingredient addition to the container for mixing is not important. The dry ingredients may be first added and shaken to obtain mixing thereof prior to water addition if desired. The flour, salt, yeast and other dry ingredients may already be preblended and contained in the container 9, 21, 25 or 40 depending on the particular execution of the product 1 and its package 2. The container 9 may be a water impermeable flexible bag, a rigid utensil with a receptacle and lid, which can be a form of package 2 if desired. The flour, water and other ingredients are then shaken until a doughy mass is formed. The agglomeration is then allowed to ferment and quiescently develop without any further mixing. Fermentation and quiescent development can occur in the container 9 or in another location or receptacle as desired. It is preferred that the doughy mass be handled during the fermentation and development at least once in a manner to reduce its volume and then allowed to again rise prior to cooking. Transferring the dough from a fermentation device to a cooking device is a preferred method of accomplishing this.
The fermentation and development are allowed to continue at room temperature until the flour is more uniformly hydrated, the gluten structure is developed, and the flavor typical of artisan bread has been produced. Alternately, if the doughy mass is to be divided to make a plurality of individual items, the agglomeration can be divided prior to fermentation and development. The fermentation is preferably allowed to occur for a time period of at least about 8 hours and more preferably for at least about 24 hours until fermentation and quiescent development is considered complete. It is preferred that the fermented dough has a volume of at least about 1.5 and more preferably at least about 2 times its original formed volume prior to its being cooked. The dough is then transferred to a baking surface or device. This transfer or handling may reduce the dough volume, and the dough after transfer may be allowed to set for a while to permit secondary rising of the dough for approximately 30 minutes for additional increase in specific volume. The dough may be cooked with or without the secondary rise step, i.e. without any appreciable additional rising or fermentation prior to starting the cooking; the cooking is started substantially immediately with some rising occurring during the cooking. A preferred method of cooking is by baking. As is known to one skilled in the art, there is a general relationship of the specific volume of dough (measured as cc's/gram) and the final baked specific volume. Thus, allowing the dough to increase in specific volume just prior to baking results in a final baked product with a larger specific volume. Depending on the texture desired in the product, this may or may not be desirable. The dough can then be cooked as desired, for example, at a temperature above about 350° F. (117° C.) and more preferably above about 400° F. (204° C.) for a time until done as is known in the art. Prior to cooking, flavorants may be applied to the exterior of the dough as can be liquid washes, such as an egg wash. It is preferred to handle the doughy mass as little as is practicable after formation of the agglomeration and before cooking.
The formula for the bread was as follows:
A dry mix was prepared which contained the flour, salt and yeast. This dry mix was placed in a screw cap high density polyethylene container which was approximately 16 cm in height and 12 cm in diameter. The water was then added to the container and the cap screwed onto the container. The container was then shaken for 15 seconds. The cap was slightly loosened and the container was held at 20° C. for 24 hours. After the 24 hours of fermentation and quiescent development, the dough was transferred from the container to a non-stick baking tray. Twenty grams of olive oil and 1 gram of dried oregano was applied to the surface of the dough. The dough was then baked in a consumer oven at 220° C. for 30 minutes. The baked product was very high quality artisan style bread.
The formula for the bread was as follows:
A dry mix was prepared which contained the flours, sugar, salt and yeast. This dry mix was placed in a screw cap high density polyethylene container which was approximately 16 cm in height and 12 cm in diameter. The water was then added to the container and the cap screwed onto the container. The container was then shaken for 15 seconds. The cap was slightly loosened and the container was held at 20° C. for 24 hours. After the 24 hours of fermentation and quiescent development, the dough was transferred from the container to a non-stick baking tray. It was then allowed to rise for approximately 30 minutes. Five grams of whole wheat flour was applied to the surface of the dough. The dough was then baked in a consumer oven at 220° C. for 30 minutes. The baked product was very high quality rustic artisan style whole wheat bread.
The formula for the bread was as follows:
A dry mix was prepared which contained the flour, powdered butter, sugar, salt and yeast. This dry mix was placed in a screw cap high density polyethylene container which was approximately 16 cm in height and 12 cm in diameter. The water was then added to the container and the cap screwed onto the container. The container was then shaken for 15 seconds. The cap was slightly loosened and the container was held at 20° C. for hours. After the 20 hours of fermentation and quiescent development, the dough was transferred from the container to a non-stick loaf style baking pan. It was then allowed to rise for approximately 30 minutes. Five grams of whole wheat flour was applied to the surface of the dough. The dough was then baked in a consumer oven at 220° C. for 30 minutes. The baked product was very high quality loaf of white bread.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
