FUNCTION OF INGREDIENTS IN BISCUIT PRODUCTION

M.R . Sundar

Senior Consultant

V MARS

360◦ Bakery Solution Provider

Bangalore

MAJOR INGREDIENTS IN BISCUIT PRODUCTION

Ingredients used in cookie and cracker production may be classified loosely as:

Sugars & SyrupsSugars & Syrups

FlourFlour

FatFat

MINOR INGREDIENTS IN BISCUIT PRODUCTION

WaterWater

Milk & Milk ProductsMilk & Milk Products

StarchesStarches EmulsifiersEmulsifiers

Chemical leavenersChemical leaveners

Minor Ingredients Contd….

YeastYeast SaltSalt Dough conditionersDough conditioners Fruits and nutsFruits and nuts ChocolateChocolate EnzymesEnzymes FlavorsFlavors ColorsColors

WHEAT FLOUR Function: basically a structure builder or binder that

provides the basic framework in a biscuit Principle ingredient of biscuits is wheat flour Typically untreated soft wheat milled from red and

white varieties Cookie/pastry flour protein content 7.0% to 9.5% Cracker flour protein content 9.0% to 10.5% In cracker doughs In cookie doughs The most important properties of biscuit flour

– Protein content/quality– Gluten percentage– Water absorption

WHEAT FLOUR CONTINUED

Three most common tests which serve as a guide to perform- ance characteristics of a flour

– Farinograph– Extensograph– Alveograph– Bake test (probably the most meaningful)

Once a good cookie formula has been developed, then any obvious variability in appearance such as too much spread, too little spread, etc. can normally be attributed to varying flour quality, assuming there has been no mistakes in weighing ingredients and baking times and temperatures are correct

Options available to control the spread of a cookie with flour The most important aspect of flour is that good communica -tion

between the baker and miller is a must

Functions of sugars and syrups

Browning (except for sucrose) Sweetness and flavour Impacts biscuit spread Impacts texture of product Provides fuel for yeast Can be a source of moisture Improves shelf life Improves body of creams

Sugars and syrups

Sucrose Dextrose Maltose Invert Syrup Brown sugar Corn syrup (glucose syrup) HFCS Honey

WATER Not really a minor ingredient but taken for granted Function: used as a processing aid to control biscuit

dough consistency and temperature as well as an ingredient that influences finished product characteristics

Areas of concern - quantity, quality and changing quality Usage level varies by product (expensive ingredient in

biscuit production: what you put in you have to bake out)

MILK & MILK PRODUCTS

Function: contribute taste/flavor, nutritive attributes, and improvements of internal and external biscuit characteristics

Liquid milk rarely used in production

Powdered whole milk, nonfat milk, and whey most commonly used

Usage level varies from 0% to 10% based on flour weight

STARCHES Unmodified starches Function: Weakening of the flour due to its diluting

effect on the gluten in the flour, may also have a tenderizing effect on the finished product

Usage level 0% to 20.0% based on flour weight Modified starches Function: imparts a variety of desirable

characteristics to the finished product, i.e. moisture retention, textural modification (crispness/hardness), volume, etc.

Usage level 0% to 3.0% based on flour weight

What is Yeast ?

Fungus kingdom Saccharomyces cerevisiae

– Used in fermentation processes Bakery strains

– Approximately 15-20– Differ in adaptability– Available in different forms

Compressed (fresh) yeastDried yeast: ADY & IDY

Yeast

Action influenced by time, temperature, pH, and water availability

Yeast is Saccharomyces CerevisaeEnzymes come from living thingsYeast provides leavening in Crackers

Checks on Yeast

Temperature– Fresh yeast under 7C– Dry yeast under 24C

Gassing Activity– Depends on instrument

and process– Varies from supplier to

supplier

Color & pH– Poor indicators of yeast

performance

Yeast Fermentation

Produces CO2– Rapid in initial stages– Levels off in about 6 hours

Affects rheology and product appearance– Lowers dough density

Affects texture– Provides nucleus for puff between

laminationsProvides flavor

SALT Function: contribute flavor and enhance

other flavors Used in and on doughs In cookies: usage level varies from 0% to

1.25% based on flour weight In crackers: usage level varies from 0% to

1.50% based on flour weight On crackers: usage level varies from 0% to

3.0% based on product weight

Leavening - Defined

Leavening is defined as a “raising” action that aerates doughs or batters during mixing and baking so that the finished products are greater in volume than the raw ingredients, and have superior flavor and eating characteristics compared to the same ingredients baked without leavening.

Leavening Systems

Can be achieved by– Non-traditional leavening agents

Air Steam

– Leavening agents Bio-chemical, such as yeast Chemical, such as baking powder

Gas can be produced during mixing, following mixing, or during baking

Leavening by Air

Minor source of leaveningProvides nucleation for other leavening

systems Incorporated during creaming step

– Shortening: Solid, liquid, vs. oil– Sugar particle size: It depends– Creaming time: More is not always better– Temperature of cream: Affects shortening – Mixing speed: Quantity of air incorporated

Leavening by Steam

Mainly in crackersGenerated during bakingTiming of steam generation: If

delayed, it could lead to checkingControl of oven humidity using

dampers is critical

Leavening agents:Chemical Leaveners

Chemical Leaveners Most convenient means of obtaining desired cell

structure in cookies and crackersCarbon dioxide is produced much faster by

chemical reaction than by yeast fermentation.Some decompose in heat and release carbon

dioxide, such as ABCOther types use acid-base chemical reactions to

produce carbon dioxide, such as baking powder

ABC LeaveningIn heat, ABC decomposes into ammonia,

water and carbon dioxideIt has little effect on pHThe ammonia smell could be a problem in

products above 4% moistureAs ABC is increased in a formula, biscuit

diameter increases whereas its height stays the same. Thus, the spread ratio increases.

Sodium Bicarbonate Leavening Also referred to as Soda It is the work horse of most chemical leavening

systems Has a significant impact on pH and taste Sole alkaline source that reacts with the acid in any

bakery ingredient:– Difficult to achieve uniform gassing using natural acids in

flour, invert sugars, molasses, etc.– Desired gassing can be achieved through standard acid

salts such as MCP, SALP, SAPP, etc.

Chemical Leavening Acids

Any acid leavening agent will release carbon dioxide from soda in the presence of water

Value of leavening agent depends on:– Strength of acid or neutralizing value

(NV)– Rate of release of carbon dioxide

NV of Leavening Acids

Neutralizing Value (NV) is the weight in pounds of baking soda required to completely neutralize 100 pounds of acid

Leavening Acid NV Rate of ReactionTartaric Acid 116 Very rapidCream of Tartar 45 RapidMonocalcium Phosphate Monohydrate 80 IntermediateSodium Acid Pyrophosphate 72 SlowSodium Aluminum Phosphate 100 Very slowSodium Aluminum Sulphate 100 Very slow

Baking Powder

Combination of soda, leavening acid, and filler (usually starch)

Can be fast acting (containing fast reacting acid salts), slow acting (containing slow acting acid salts), or double acting (containing both)

Functions of Leavening

Grain and texture: Tighter grain leads to harder texture

Spread: Increases as leavening increases; Impacts quality, packaging

Surface cracks: Controlled late release of carbon dioxide

Color and Flavour: Depends on product pH

FRUITS AND NUTS Considerable variety of flavor,

appearance and texture can be achieved in biscuits by the use of fruits and nuts

Raisins, coconut and a wide variety of nuts most commonly used

Usage level? (expensive)

CHOCOLATE, CHOCOLATE PRODUCTS AND COCOA

Chocolate, chocolate products and cocoa find a wide range of application in adding value to biscuit products

Good idea to refrigerate chocolate chips before adding to cookie doughs, this will help reduce smearing of chips through the dough

Flavours in foods

A major factor in the successful sale of food productsImpart aroma and taste to food productsMakes the food attractive and palatable.Have no food value.

Our Senses

Nose MouthAroma + Taste = FlavourMany sweet acid salt bitter

FLAVOURANTS/ FLAVOUR RAW MATERIALS

BASE/SUPPORT/SOLVENT=

FLAVOUR/FLAVOURING

WHAT IS A FLAVOUR

??

Classification of flavour ingredients

Natural

Nature identical

Artificial

Orange oil,lemon oil

Vanillin, ethyl butyrate

Ethyl vanillin, methyl coumarin.

Is the essential oil , oleoresin, essence OR extractive , protein hydrolysate which contains the flavoring constituent, derived from spice , fruits,herbs etc.,

Is the essential oil , oleoresin, essence OR extractive , protein hydrolysate which contains the flavoring constituent, derived from spice , fruits,herbs etc.,

Molecules available in nature which are synthesised and made chemically identical

Molecules available in nature which are synthesised and made chemically identical

Flavour that are made than don't meet the defining the above.

Flavour that are made than don't meet the defining the above.

Physical classification of flavours

Liquid water soluble oil soluble

emulsionsPowder dispersed

encapsulatedPaste

FLAVOUR M ATRIX

COLOURSFood Does not taste ‘as it should’ when it is not coloured ‘right’

Colour is Associated with Every aspect of our Lives.

Colour -Plays an Integral role - in our Behavioral decisions.-in conditioning our Choice.

-Plays an Important role-in Taste threshold,-in flavour Identification--in food Preference-in Pleasantness and Food Choice

Role of Colours

Colour influences the taste of Food. Vision interacts with taste and odour. Colour can affect the perception of foods and drinks. People learn and become familiar with specific

combinations of colours and tastes. These learned associations may alter our perceptions

and create expectations about how a food should smell and taste

Flavour can be influenced by the way food or drink looks, smells and feels .

Role of colour in Foods

Visual attribute , makes the product attractive and appetising

Plays a greater role in the success or failure of a food product.

Natural colours /Approved Synthetic colours /Caramel colour .

Natural ColoursEXAMPLES OF

NATURALOCCURRENCE

COLOUR PIGMENT EC No

AnnattoCarrotsOrangesPrawns

Red PeppersSaffron

TomatoesPalm Fruit

YellowOrange

Red

Carotenoids: 

Mixed CarotenesE 160a ( i )

beta-CaroteneE 160a ( ii )

Bixin/Norbixin E 160b Capsanthin/Capsorubin E 160c

Lycopene E 160dApocarotenal E 160e

Apocarotenal ( Ethyl Ester)

E 160fLutein E 161b

Canthaxanthin E 161g       

Turmeric Yellow Curcumin E 100       

Eggs, Milk , Yeast Yellow Riboflavin E 101       

Carbonised Vegetable Material Black Carbon Black E 153 

 

   

Melanoidins (Caramel) Brown MelanoidinsE 150a-d       

Synthetic Colours

Synthetic Food Colours, also known as Artificial Food Colours, are manufactured chemically and are the most commonly used dyes in the food.

• Primary Colours

• Blended Colours

• Lake Food Colours

Synthetic ColoursPrimary Food ColoursThese colours are also known as food colors,colourings, food dyes, food additives, food lakes & food blends worldwide.

 Product/Colour Shade C.I.No. F.D. & C.No E.No.

 QUINOLINE YELLOW 47005 - E 104

  Di sodium salt of disulfonates of 2-(2quinolyl) - 1, 3 indandione.)

 TARTRAZINE 19140 Yellow 5 E 102

  ( Tri sodium salt of 5-hydroxy (1-p-sulphophenyl 4- ( p-sulphophenylazo) pyrazol -3- carboxylicacid

 SUNSET YELLOW FCF 15985 Yellow 6 E 110

  ( Di sodium salt of disulfonates of 2-(2quinolyl) - 1, 3 indandione.)

 ERYTHROSINE 45430 Red 3 E 127

  ( Di sodium salt of disulfonates of 2-(2quinolyl) - 1, 3 indandione.)

 PONCEAU 4R 16255 - E 124

  ( Di sodium salt of disulfonates of 2-(2quinolyl) - 1, 3 indandione.)

 ALLURA RED 16035 Red 40 E 129

  ( Di sodium salt of disulfonates of 2-(2quinolyl) - 1, 3 indandione.)