MENDELNET 2016

547 | P a g e

QUALITY PUFF PASTRY PRODUCTS AND THE QUANTITY OF FAT AND DIFFERENT EFFECTS ON LEAF PROCESSING

HANA BACIKOVA, VIERA SOTTNIKOVA, LUDEK HRIVNA, JINDRISKA KUCEROVA

Department of Food technology Mendel University in Brno Zemedelska 1, 613 00 Brno

CZECH REPUBLIC h.bacikova@seznam.cz

Abstract: The aim of this study was to assess the impact of production technology on the technological and sensory value of puff pastry. The effect of recipe innovation has been validated by method of experimental baking and evaluated by objective measurements. We have monitored the influence of the percentage of fat content in the recipe on the number of produced layers. Sensory analysis and objective measurements revealed differences among the various kinds of processing. The recorded values were statistically processed using STATISTICA 8 software. Eighteen trained evaluators have conducted the sensory evaluation. Products that received the best sensory rating and were also the thickest (1.8 mm) were made in a combination of 60% fat for dough rolling and 243 layers in the classic recipe. Products with 60% fat in combination with 729 layers in the improved recipe used the Volumax enzyme product. The highest corpus (2.8 mm) was in the improved recipe with the fourth folding (2187 layers) containing 60% fat. The addition of the enzyme preparation significantly improved the sensory quality and height of the corpus.

Key Words: puff pastry, production technology, baker's attempt, sensory analysis introduction

INTRODUCTION Puff pastry is gaining ever increasing popularity among producers and consumers alike. Over the

last decade, this product line has had the greatest increase in volume of production and consumption of fine bakery products. The main contribution is the automated production on production lines, which facilitates production in very productive and rational manner. An important aspect is the possibility of cooling and freezing of basic laminated dough and finished raw products (Skoupil 2004). In the Czech Republic, the most widespread manufacturing process has three phases (Bláha et al. 2001): (1) treatment of fat and preparation of flour-water dough, (2) wrapping a block of fat with flour-water dough, and (3) folding of dough.

The structure of puff pastry consists of alternating of watery component (flour-water dough) and fat component. This structure must be maintained in the dough and there should be no mixing of layers even after multiple folding and thinning of the original layers. The very low adhesion also contributes to the uniform distribution of layers. The watery component must have a sufficient gluten content, which is flexible, ductile, and easily swelling in order to establish an appropriate ratio between the free water and colloidally bound water that limits the unwanted adhesion to fat (Newberry et al. 1996, Příhoda et al. 2003). The used fat should be characterized by high ductility and therefore its full emulsification is crucial. The fat component must, at a given temperature, have the same consistency as the watery component. This is because a stiffer fat during dough rolling disturbs the dough structure, while a softer fat is being absorbed into the watery component. In both cases, this adversely affects the volume and characteristics of the product (Morren et al. 2015). The specialty of manufacturing laminated dough is folding and rolling of layers with delays for maturing, which takes place in a cold environment. Folding of layers is carried out in a three-fold or four-fold system. The optimal number of layers is 144 while we usually count the fat layers. Today, the prevailing production method is commercial automatic production of laminated dough carried out on modern machinery by using a complex lamination and shock freezing at -30 °C and distributed to customers by freezer trucks (McGill 1975). When baking products from laminated dough, several important physicochemical and chemical processes gradually

MENDELNET 2016

548 | P a g e

take place in accordance with increasing temperature. It starts with gelatinization of starch and protein coagulation, which contributes to making the corpus skeleton. Then, it continues with converting the water from the watery layer to steam, which as an aerating medium contributes to the separation (lamination) of the individual layers of dough. This leads to aerating, increased volume of the products, and to the formation of its fragile structure resulting from regular alternation of horizontally laid layers of dough and fat.

The process is terminated by the formation of yellow dextrins, conducive to the creation of typical flavouring and aromatic substances (Macias 2016). The manufacturing technology was modified several times, but the final product always includes horizontal lamination of layers of fat and dough (Pidmit et al. 2008). The quality of products from laminated dough depends not only on the quality of used raw materials, but also on the production technology of laminated dough (Bláha et al. 2001). Pidmit et al. (2008) suggested an addition of fat during the process for rolling of the laminated dough in the range from 45% to 85%.

MATERIALS AND METHODS The topic of this study was the influence of production technology, amount of used fat and different recipes in dough preparation on the quality of puff pastry. The experimental work, namely the preparation of laminated dough as well as its baking and evaluation were carried out in the technological and chemical laboratory of Mendel University. The Ireks-Enzyma Company has provided all the necessary ingredients and equipment. The laminated dough was prepared according to the classic recipe (see Table 1) and according to the recipe supplied by the Ireks-Enzyma Company (hereinafter referred to as “improved” recipe) (see Table 2). The Volumax additive with its enzyme component contributes to the improvement. The weight of the testing dough was given by used recipe (see Table 1 and 2).

Table 1 Classic recipe Table 2 Improved recipe Material Amount

Fine flour T 530 100% Egg melange 6.7% Cooking salt 0.8%

Vinegar 1.7% Water 41.7%

Fat 40 and 60%

For the preparation of the watery part of dough, we have used fine light wheat flour T530 of good quality, suitable for the preparation of laminated dough, as seen in the Table 3 summary.

Table 3 Basic quality parameters for flour for laminated dough

As fat, we have used the ductile Zich-Platte margarine, which has a suitable composition, and

meets the manufacturing requirements in a wide range of temperatures. Its exceptional quality allows even fat dosage reduction while maintaining product quality (Skoupil 2004). A trimmed fat layer was wrapped with flour-water dough to form an envelope (see Figure 1) and rolled to a thickness of 8 mm.

Material Amount Fine flour T 530 100%

Volumax 1.4% Cooking salt 1.2%

Sugar 2.9% Gluten 1.6% Water 50%

Fat 40 and 60%

Moistness [%] 14.2 Wet gluten in dry matter [%] 34.8

Gluten index 95 Falling number [s] 349 P/L(alveograph) 80/118 Zeleny test [ml] 51

W (alveograph) [Jx10-4] 278 Flour valence at [14 %] 60.3

MENDELNET 2016

549 | P a g e

The resulting semi-product was folded three times, which, after standing in an environment of about 10°C was repeated several times according to the methodology in 10 minute intervals. For rolling, we have used a Compass dough sheeter of the Rondo Doge Company. The flour-water dough layer under the fat prism and above it must be equally thick, so that the dough during the next folding and rolling would not tear (Příhoda et al. 2003, Morren et al. 2015).

Figure 1 Method of fat wrapping with flour-water dough layer, the so-called envelope

To assess the influence of the proportion of fat and number of folds on the quality of the final

product, we have made dough with 40% and 60% fat on the proportion of flour. Each dough was folded always three times (total 7 times), thereby achieving 81, 243, 729, and 2187 layers. After the final rolling to a thickness of 2 mm, we have cut the tested slab using a cutter to form a square 100 x100 mm. To stabilize the height of the baked product and to refine its assessment, before baking we have pierced the top layer of dough with a roller docker to prevent blistering, and put a load at the centre of the product with 10 g of poppy seed filling. After treatment, the sheets with products were placed in a hot air oven MIWE Aeromat that due to the heating principle permits to reduce the temperature and baking time. Laminated dough was baked at 200 °C for 10 minutes.

Evaluation of finished products was carried out after cooling and always after two hours. We have measured the height of samples in the centre of the product with a caliper and expressed it in millimetres. For the sensory evaluation, we have selected samples with fat content of 40% and 60% and the number of 4, 5, 6, and 7 folds, which corresponds to 81, 243, 729, and 2187 layers. All samples underwent sensory evaluation using several parameters. They included crust colour, height and shape, lamination, fragility, mouthfeel and overall impression using an ordinal sensory scale, where 1 was the best quality while 5 was the least acceptable sample (Renzetti et al. 2016, Dukic et al. 2009). Eighteen trained evaluators conducted the evaluation.

RESULTS AND DISCUSSION The results of measuring the product height with a different fat content ratio and number of folds

have demonstrated that in the classic recipe, as evident from Figure 2, the maximum was achieved by the second folding (234 layers), for the products containing 60% fat it was also the double folding, where the product height was by 0.5 mm higher. Wickramarachchi et al. (2015) reported quadruple folding for the classic recipe to be optimal.

For the improved recipe in products containing 40% fat, the maximum height at the fourth folding was 2.4 mm. When using 60% fat, the achieved maximum height was 2.9 mm, as seen in Figure 3. Often, the fat is rolled into the flour-water dough layer thus undermining the aerating effect while the height of the product is reduced.

The number of folds depends on the quality of flour, baker’s skills and the type of product. The dough made from flour with strong gluten can tolerate a larger number of folds and requires a longer period of maturing between repeated rolling. For dough with weaker gluten the effect is opposite (Moran et al. 2015).

Laminated dough made according to the improved recipe exhibits more stable values. McGill (1975) carried out measurements at 75% fat to flour and English method of wrapping. The form of the curve was the same as in our work. The highest increase of the product was at the level of fourth repetition of folding. As indicated by Newberry et al. (1996), it is likely that the area of this maximum will depend on the perfection and uniformity of rolling and folding, in order to avoid harming the integrity of the layers.

MENDELNET 2016

550 | P a g e

Shaped corpuses are brushed with egg yolks diluted by milk before baking. Through brushing, products receive better colour and the escape of vapour during baking through the surface is slower (Haegens 2014, Simovic et al. 2015). According to the results of our observation, brushing has no demonstrable effect on the height of the product.

Figure 2 Dependence of the height of the product on the amount of fat in the classic recipe

Figure 3 Dependence of the height of the product on the amount of fat in the improved recipe

The resulting sensory protocol was compiled from scoring average values of a given parameter

from eighteen trained evaluators who assessed the intensity of sensory perception using an ordinal scale (1 – best quality, 5 – least acceptable sample). We have evaluated recipes with ratio of fat 40% and 60% for rolling. Each recipe in combination had 81, 243, 729 or 2187 layers in the dough.

Samples were sorted in descending order according to the proportion of fat in two rows and four columns with rising tendency of layers from left to right. The colour intensity represents the intensity of sensory perception in so arranged samples (see Tables 4 and 5). The more intense the colour, the better is the positive sensory evaluation of the sample. In our observation of the classic recipe, the best sensory evaluation received the variant with 60% fat at 234 layers. The improved recipe achieved the best sensory evaluation at 60% fat content and 729 layers.

Table 4 Diagram of intensity of overall sensory perception for the classic recipe

81 243 729 2187 40% 60%

Legend: the darkest color - the best sensory quality (graded 1), the lightest color - the worst sensory value (graded 5)

Table 5 Diagram of intensity of overall sensory perception for the improved recipe

81 243 729 2187 40% 60%

Legend: the darkest color - the best sensory quality (graded 1), the lightest color - the worst sensory value (graded 5)

0,5

1,0

1,5

2,0

2,5

3,0

81 243 729 2 187

Hei

ght [

cm]

Number of layers

Classic recipe

40 % fat60 % fat

0,5

1,0

1,5

2,0

2,5

3,0

81 243 729 2187

Hei

ght [

cm]

Number of layers

Improved recipe

40 % fat60 % fat

MENDELNET 2016

551 | P a g e

Figure 4 illustrates an output of data processing in Statistica 8 software as a projection of the variables on the factor plane. The degree of dependence of individual variables is evaluated here according to the size of the angle between them. The smaller the angle, the stronger is their dependency. Concurrently, the cosine of the angle indicates the approximate value of the correlation coefficient. If the arrows are horizontal and point in the same direction than it means that the variables are dependent on each other positively. If the arrows are horizontal but point in the opposite direction than it means that the variables are dependent on each other negatively. If the arrows are perpendicular to each other, variables can be considered independent. The length of an arrow indicates the variability of the measured data.

Figure 4 Projection of the variables on the factor plane

In Figure 4, we can see that the recipe closely positively correlates with smell and fragility as well as dependence of the height on fat content in the classic recipe. Fragility and flavour have a strong correlation with the recipe and the dependency of the height of the baked corpus depends on the amount of the used fat. Smell in the improved recipe is perpendicular to the number of folds, which means that the variables are independent of each other. The greatest variability of measured values (the longest arrow) was recorded in the smell.

CONCLUSIONS According to past experience, we could expect that, due to the influence of different amounts of

fat on rolling and due sheeting technology, there will be change in the character of the dough. The addition of fat above 60% and removing of fat for rolling below the threshold of 40% has caused structural damage of lamination, even a loss of the typical character of the laminated dough. In practice, the optimal number of layers in laminated dough is 144. This work has shown that the products are sensorically acceptable in the range between 81 and 729 layers. However, it is necessary to draw attention to the fact that all assessments have been carried out in laboratory conditions with the utmost care. We can therefore assume that in the operating conditions, results may be different.

Sensory properties, evaluated by the customer, were evaluated by a complex evaluation of pastries using the method of sensory analysis. The best sensory evaluation of products in classic recipes, have been made in the combination of 60% fat for rolling and 243 layers. The improved recipe received the best sensory evaluation with 60% of fat content in combination with 729 layers. The addition of the enzyme preparation significantly improved the sensory quality and height of the layered corpus.

REFERENCES Bláha, L., Kadlec, F., Conková, V. 2001. Cukrářská výroba I: pro 1. ročník učebního oboru: Cukrář, Cukrářka. Praha: Informatorium.

Classic recipe

active variable additional variable

-1,0 -0,5 0,0 0,5 1,0

Faktor 1 : 51,29%

-1,0

-0,5

0,0

0,5

1,0

Fak

tor 2

: 33

,90%

fat 40% height

fat 60% heightflavor

fragilitysmell

*number of layers

Improved recipe

active variableadditional variable

-1,0 -0,5 0,0 0,5 1,0

Faktor 1 : 74,79%

-1,0

-0,5

0,0

0,5

1,0

Fak

tor 2

: 18

,38%

fat 40% heightfat 60% height

flavorfragility

smell

*number of layers

MENDELNET 2016

552 | P a g e

Dukic, G., Sesar, M., Sesar, I. 2009. Analysis of consumer attitudes toward puffed pastry. In Processing of the 5th international kongres flour-bread 2009 and Croation Congress on Cereal Technologies, pp. 157–164. Haegens, N. 2014. Bakery Products Science and Technology. 2nd ed., University of California. McGill, E. A. 1975. Puff pastry production. Bakers Digest, Oxford, UK: Blackwell Publishing Ltd. Macias, B., Marangoni, A., G. 2016. Physicochemical and Rheological Characterization of Roll-in Shortenings. Journal of the American Oil Chemists Society, 93(4): 575–585. Morren, S., Van Dyck, T., Mathijs, F. 2015. Applicability of the food texture puff device for rheological characterization of viscous food products. Journal of Texture Studies, 46(2): 94–104. Newberry, M. P., Morgenstern, M. R., Ross, M. 1996. Dough relaxation during and after puff pastry processing, Cereals. In Proceedings of 46th International Congress Australian Cereal Chemistry Conference, Sydney, pp. 311–314. Pidmit, K., Therdthai, N., Jangchug, K. 2008. Effects of fat replacers on the physical, chemical and sensory characteristics of puff pastry. Journal of Natural Science, 42(4): 739–746. Příhoda, J., Humpolíková, P., Novotná, D. 2003. Základy pekárenské technologie. Pekař a cukrář s.r.o. 1. vyd., Praha. Renzetti, S., de Harder, R., Jurgens, A. 2016. Puff pastry with low saturated fat contents: The role of fat and dough physical interactions in the development of a layered structure. Journal of Food Engineering, 170(4): 24–32. Skoupil, J. 2004. Technologické vady korpusů z listových těst. Ročenka pekaře a cukráře. Pelhřimov: Nová tiskárna. Simovic, D., Soronja, P., Biljana, Z. 2014. Effect of low-trans margarine on physicochemical and sensory properties of puff pastry. International Journal of Food Science and Technology, 44(6): 1235–1244. Wickramarachchi, K. S., Sissons, M. J., Cauvain, P. 2015. Puff pastry and trends in fat reduction: An update. International Journal of Food Science and Technology, 50(5): 1065–1075.