Line breakdowns can spell disaster for a sensitive wheat-mix dough. Here’s how to extend your time window for repairs.
Every industrial baker has experienced it. The dough is mixed and in the middle of proofing when the production line grinds to a halt. The line operators have got just five minutes to locate and resolve the problem.
If they fail, the dough will go over its maximum proofing time, causing it to collapse and the final bread to be unfit for sale. Wheat-mix recipes containing rye flour are particularly sensitive to variations in proofing time – becoming unfortunate, expensive waste.
Line breakdowns are a fact of life in industrial bakeries, with dough stickiness, mechanical glitches and various other factors playing a role. But, while it is hard to rule out all the breakdowns, there is something you can do to prevent your dough from flopping.
You need to buy more time for trouble-shooting.
In our bakery labs here at DuPont, we’ve been looking into a way to help you do that in wheat-mix bread with rye or wholemeal. We believe we have found it in a synergistic combination of hexose oxidase (HOX) and cellulase.
While cellulase benefits dough stickiness and crumb softness, HOX is known for its ability to improve dough proofing stability by catalysing the production of hydrogen peroxide. The substrates for this reaction are glucose and cellobiose, both abundantly present in rye and wholemeal wheat flour. Hydrogen peroxide builds cross-links in the structure-giving arabinoxylan in the flour. It is this that produces a firmer, more stable dough.
Until now, though, oxidases have been considered unsuitable for rye-containing recipes, as their firming effect has a negative impact on crumb softness. This is where our tests of HOX and cellulase in combination have produced interesting results.
Ten more minutes
What we have found is that proofing stability is further enhanced when the enzymes are used together – extending the time window for line repairs by a critical 10 minutes to 15 minutes in all. The surprise is that this extra stability is obtained at no expense to crumb softness. In fact, the soft, fresh feel of the bread is considerably enhanced.
Another important gain is easier processing, brought about by reduced stickiness of the dough – again our tests have revealed a significant improvement than when cellulase is used alone. Not only does this eliminate one of the main factors responsible for line problems, it turns up your production capacity by an extra notch.
Securing fewer breakdowns and more time to resolve them when they happen, the HOX-cellulase synergy is rich with potential for cutting costs, improving bread quality and increasing sales. That’s worth a closer investigation.
We used POWERBake® 9000 and SureBake® 900 from the DuPont™ Danisco® range for our trials.