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The Baking Process and Dough Mixing (The Baking Process: Traditional…
The Baking Process and Dough Mixing
The Baking Process
• The proper transformation of basic ingredients into bread
• Succession of 12 steps
• Traditional Method
Pre-shaping
Resting time
Dividing
Shaping
First fermentation
Final Proof
Mixing
Oven Loading
Preferment
Scoring
Basic steps never changed over centuries
Unloading the Oven
• Handling of each step greatly affects on the quality of final product
The Baking Process:
Traditional Method
• Mixing
All the ingredients are combined to form a dough
Effects on the quality of final product
• First Fermentation
Increase dough strength (mass effect)
Develop flavor
A dough is allowed to ferment as a large mass
• Preferment
Improvement of the final product
A portion of dough is allowed to ferment
Before mixing of the final dough
Different preferments provide different characteristics
• Dividing
desired weight
Manual Dividing
– Caution must be paid not to damage the dough
– Try to cut a dough in one piece
Mechanical Dividing
– Choice of equipment is critical
Pre-Shaping
– Loose ball for boules and batards, cylinders for baguettes
– Adjustment on the dough strength
– By hand or by machine
– Important to assess the dough characteristics
– Form smooth skin on outside to promote proper and better shaping
Resting Time (or Intermediate Proof)
– Continue producing gas
– The dough pieces should always be protected from drying out
– The dough is relaxed between pre-shaping and shaping
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
• Final Proof
– The balance of gluten strength and gas pressure creates volume and crumb structure
– The dough should be protected from drying out
– Gas accumulates and creates internal pressure
– Use of rack cover, linen and proofs box
• 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
– Scoring
– an incision on the skin of the dough
– Direct impact one volume and final appearance of the bread
– Unloading the Oven
– With an oven peel or a loader
– Avoid damaging the crust of the bread
– Cooling
– The bread goes through a series of transformation after baking and during cooling
– The quality of the bread can be severely compromised
The Dough Mixing Process
– The bread goes through a series of transformation after baking and during cooling
– The quality of the bread can be severely compromised
Four Critical Steps of Dough Mixing
• Water Temperature
– Desirable Dough Temperature for most dough:
74°-77°F
– Factors: Temperatures of the room, flour, preferment and the friction from mixer
– Controls the final dough temperature, which is directly related to the rate of fermentation
– Friction of mixer varies by the type of mixer, the shape of the hook, quantity of the dough etc
• 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
• Scaling
– Precise scaling of ingredients is very important
• Ensuring Clean Equipment
– Make sure the mixer bowl and hook are clean
– Old dough scrap will not dissolve in the next dough
• 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
Ingredient Incorporation
Autolyse
• Special Considerations for Autolyse
– Liquid preferments must be incorporated before autolyse
– Stiff preferments must be incorporated after autolyse
– When using instant dry yeast, add it one minute before the autolyse is over to properly hydrate the yeast cell
• During mixing on 1st speed
• The ingredients are incorporated as well as the preferments
• A baker must pay a close attention to see if additional water is necessary
• Autolyse
• Salt, yeast and preferment are added after an autolyse
• Better hydration of the flour = better gluten structure
• Resting the flour and water for a minimum of 15-20 minutes
• Protease degrades some gluten bonds = better extensibility and machine ability
Dough Development
• Can be done in first or second speed
• Dough Temperature
• 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
• After all ingredients are incorporated, the dough is continuingly mixed to achieve a desired degree of dough development
• Physical Changes During the Formation of Dough
• Starch: native starch and damaged starch
• Protein: Glutenin (provides elasticity) and Gliadin (provides extensibility)
• Hydrates the flour components, primarily starch and protein
• Glutenin and Gliadin form chains of proteins, called Gluten
• 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
• 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
• Incorporation of Secondary Ingredients into a Dough System
• Examples of primary ingredients
• Mixing Process Conclusion
• Following each step of mixing with precision and close attention results in a consistent production
Dough Development: Physical Changes During the Formation of Dough
• Protein Hydration and Mixing Time in First Speed
– Protein hydrates at slower rate than starch
– For a larger batch of dough, 5 to 6 minutes of mixing on 1st speed is necessary
Dough Development: Chemical Changes During the Formation of the Dough
• Oxidation of the Dough
– Creates micro cells
gas produced by yeast accumulates in the cells
– “Alveoles” or the cell structure of the crumb
– Positive affects: Strengthen gluten bonds
– Negative affects
Damage on Carotenoid pigments = whiter crumb, blander flavor
– Caused by oxygen naturally incorporated into dough during mixing
alt slows down chemical reaction in dough
Dough Development:
Incorporation of Secondary Ingredients into a Dough System
• 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
– The fat lubricate the gluten and prevent from bonding easily
– more than 15% of fat should be incorporated when the gluten is almost fully developed
– 5 to 15% of solid fat can be added when the dough is halfway trough development
– 2 to 4% of solid fat can be incorporated with the flour at the beginning of the mixing
• Incorporation of Sugar
– Higher % of sugar is incorporated in several steps
– Hydroscopic characteristic
– Up to 12% of sugar can be incorporated the beginning of the mixing.
• Incorporation of Eggs
– Major part of hydration
– At least 10% of water in addition to the egg is necessary to hydrate flour properly
– Should be incorporated at the beginning of the mixing
• Incorporation of Dry Ingredients
– Malt and milk powder can be incorporated at the beginning of the mixing
• Incorporation of Solid Ingredients like Nuts, Dry Fruits, Chocolate Chips and More
– Incorporate on 1st speed
– Gentle incorporation will reduce damage to the gluten structure
– Nuts, seeds and fruits must be incorporated at the end of the mixing
Mixing Techniques
• Three main mixing techniques
– Intensive mix
– Improved mix
– Short mix
• Intensive Mix
– Shorter fermentation time
– Tight crumb with large volume
– Mechanical mixers with two speeds enabled intensive development of gluten
– Oxidation of the dough leads to lack of flavor
• Quality of bread depending on different gluten development
• Short Mix
– Popular technique before mechanical mixers became available
– Hand mixed dough: Not sufficient gluten development
– Long fermentation with folds
• Improved Mix
– Gluten is not fully developed
– Limits the oxidation of the dough
– Shorter mixing time than intensive mix
– Enable to produce higher quality of bread with a larger quantity
Short Mix Description
• Under-developed gluten requires a long fermentation time and two to four folds
• Low percentage of yeast
• Similar to hand-mixed dough
• Gassy and soft dough
• 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
Intensive Mix Description
• Great machine ability
• Stiff and fluffy dough
• It is then mixed on second speed to a full development of gluten
• Short first fermentation time
• The ingredients are mixed on first speed to an incorporation
• 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
Improved Mix Description
• Medium-soft consistency of dough
• Sufficient dough for hand-shaping or a semi-mechanized process
• Ingredients are incorporated in first speed and then mixed to half development of gluten in second speed
• 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
• Compromise between the short mix and the intensive mix
Improved Mix Description: Improved Mix Effects on Bread Characteristics
• Visual Comparison of the Three main Mixing Techniques
• Double Hydration
• Water incorporation in two phases
• Enough water is incorporated to create a medium-soft consistency of dough
• Growing popularity of “super” hydrated dough created this technique
• 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
How to Calculate Mixing Time
• Intensive mix – 1600 revolutions in second speed
• Mixing time of the dough =
Total Revolutions Required / RPM
(RPM=Revolutions per Minute)
• Improved mix – 1000 revolutions in second speed
• RPM varies with the brand of mixer
• Short mix – 600 revolutions in first speed
• Factors Affecting Mix Time
• Characteristics of the flour
• Dough hydration
• Batch size
• Incorporation of additional ingredients
• Type and design of mixer
• Based on the revolution of the dough hook
• Comparison of the Main Mixing Techniques
• Comparison of Mixing Processes and Effects on the Final Products
How to Calculate Mixing Time: Factors Affecting Mix Time
• Batch Size
– Smaller batches mix faster than larger batches
• 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
• Type and Design of Mixer
– Mixer design
– Different type of mixer requires different mixing time
– Shape of the hook
– Motor speed
• Dough Hydration
– Stiffer dough (lower hydration) requires longer mixing 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
Developing Your Own Process
• Understand that mixing and fermentation works together – if the mixing is changed, so as the fermentation time
• Which Method to Use?
Factors
– Schedule / Time limitation
– Equipment issues (batch size, type of mixer, etc.)
– Desired characteristics of the final product
– Understand outcomes of each mixing method and fermentation time
• Balance of mixing and fermentation
– 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
What Can Go Wrong and How to Fix It
• 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
• 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
What Can Go Wrong and How to Fix It
• Dough Development
– Under- or Over- mixing of dough can affect on the first fermentation time
Conclusion of Mixing and Mixing Techniques
• Be accurate and careful when scaling, incorporating ingredients and during mixing
• A good understanding of mixing and fermentation helps to troubleshoot
• When mixing is done carefully, the following steps will be easy