Baking & Snack - July 2010 - 61

FROZEN DOUGH / PARBAKED

training people to do it properly day in and day out." This
is especially true for the high end of the crusty bread and
roll category.
Going from a raw frozen to a parbaked format also
may require some changes in mixing and makeup. In
fact, Mr. Rosenberg said, many parbaked breads and
rolls need more weight than fresh-baked items to offset
the moisture loss when the product is baked a second
time. An indirect-fired tunnel oven can provide bakeries with better ability to control moisture in the crust.
A separate steam chamber in conjunction with moisture
evacuation capability in multiple zones can be adjusted
to produce baked foods ranging from sandwich rolls to
crusty artisan breads.
"Baking a crusty bread and roll requires an oven with
a good steaming environment to maintain moisture in
the baking environment," he said. "Direct-fired ovens
have a tendency to superheat steam and dry out the
crust, which may be beneficial for some products, but for
crusty parbaked products, indirect-fired ovens are the
more accepted technology."
After the initial baking process, internal temperatures
for parbaked products should be between 165°F for lean

Cleanliness by Design
Because frozen dough products are shipped in a raw state, there are no
"kill steps" to eliminate pathogens and bacteria until they're baked off
in the in-store bakery or by a food service operator. That's why sanitary
design has become more prevalent in the baking industry. Specifically,
many baking companies have adopted the "10 Principles of Equipment
Design for Low-moisture Foods," which was modeled after the American Meat Institute's sanitary guidelines and created by the Grocery
Manufacturers Association (GMA) Sanitary Design Working Group (See
"Avoiding Accidents" on Page 14).
In response to this movement, Rondo, Inc. recently completed a
redesign of its sheeting lines so they can be cleaned more easily with
high-pressure water and approved food-safe chemicals, said Jerry Murphy, president of Rondo, Inc. North America, Moonachie, NJ. The newly
designed production lines will be featured at this year's International
Baking Industry Exposition.
"From our standpoint, we went all the way back to the drawing
board," Mr. Murphy said.
The company eliminated flat surfaces as well as nooks, crannies and
other surfaces where pathogens, ingredients and other materials can
gather. In the past, engineers simply used covers to protect switches,
wires, gears, ball bearings and other essential parts. Today, that doesn't
suffice, Mr. Murphy said, because the new standards require bakers to
completely disassemble production lines during the deep-cleaning
process. Easy access is the rule of
the day to streamline sanitation
and preventive maintenance.
▶ Sanitary design has become an important
issue for frozen dough manufacturers.
RONDO INC. NORTH AMERICA

BAKING & SNACK / July 2010

formulas and 185°F for rich ones, noted Tim Sieloff, coordinator of baking training service at AIB International,
Manhattan, KS. "You want to make sure that you get full
starch gelatinization, which will give you rigidity and
structure and provide volume retention," he said.
Mr. Sieloff pointed out that bakers also can provide moisture retention by adjusting the amount of sugar and fats in a
formula or by adding gums or pregelatinized starches.
RIGHT TO OVEN. During the past few years, freezerto-oven (FTO) products have become popular because
they provide the convenience of raw frozen dough
without the end-user having to proof the product. In
many cases, however, the FTO process is limited to unbaked croissants, Danish and other laminated products,
Mr. Sieloff said.
"After proofing and freezing, you denature the yeast proteins so you have little or no yeast function," he noted. "Freezing has a damaging effect to that yeast cell structure, but what
you have is lamination, and that [folding of the dough] provides the oven spring or oven kick in the product."
To make FTO and other frozen products, many producers rely on a low-stress makeup process that doesn't
tear up the dough structure or require extended relaxation periods for the dough to come together again, according to Eric Riggle, vice-president, Rademaker USA,
Hudson, OH.
The company's initial foray into this technology, its
LSS, or low-stress sheeting, system, came out about 12
years ago and features two hexagonal rollers set above two
smooth base rollers. The hexagon rollers massage and feed
the dough to create an undamaged sheet instead of chewing it up like many dough extruders, Mr. Riggle said.
Rademaker updated this system with the X Pack, which
relies on a series of eight rollers. The X Pack is used predominately for making bread. Two large-diameter rolls
initially act as a sheeting roller and guide the dough between two sets of large-radius grooved rollers. These two
sets of rollers not only rotate but also move in a peristaltic
way that guides the dough to the final set of rollers that
establishes the final sheet's thickness. Unlike the LSS, the X
Pack provides a continuous mass to the system and doesn't
require overhead chunking into the hopper.
At Europain this spring, Rademaker rolled out its newest
low-stress system, which features a double chunking system
along with side and top tamping rollers to create a continuous sheet of dough. The first chunker provides larger, dough
chunks that are about 1 m long, and a subsequent chunker
adds another lighter meter-long piece to create a continuous dough sheet. The new production line, which will be
featured at IBIE 2010 in Las Vegas, NV, this fall, doesn't use
any oil to create the sheet and is designed for sticky artisan
doughs or those products with long preferments that may
create processing problems, Mr. Riggle said.

Baking & Snack - July 2010

Table of Contents for the Digital Edition of Baking & Snack - July 2010