EU-FRESHBAKE Project, Final Report, June 2010
Project no.
036302
Project acronym
EU-FRESH BAKE
Project title
Freshly Baked Breads with Improvement of Nutritional Quality and Low Energy Demanding for the
Benefit Of the Consumer and of the Environment
Instrument: Specific Targeted Research Projects
Thematic Priority: 5, Food Quality and Safety
Deliverable Reference
Number: D8.1.6
Title: FINAL REPORT
Period covered: from 1/10/ 2006 to 30/11/ 2009
Date of preparation: 15/02/2010
Start date of project: 1st October 2006
Duration: 38 Months
Project coordinator name:
Project coordinator organisation name:
Professor Alain LE BAIL
ONIRIS (was ENITIAA before)
Rue de la Géraudière BP 82225,
44322 Nantes – France
Tel: +33 + (0)2.51.78.54.73
Fax: +33 + (0)2.51.78.54.67
Email: alain.lebail@oniris-nantes.fr
Revision: version V14- 20 Dec. 2010
BIBLIO: bread 2009 GGP
Page 1 of 68
EU-FRESHBAKE Project, Final Report, June 2010
Project no. 036302 - FP6 – EUROPEAN COMMISION
EU-FRESHBAKE project
“Freshly Baked Breads with Improvement of Nutritional Quality and Low Energy Demanding
for the Benefit Of the Consumer and of the Environment”
Final report
6th Sept 2010
Page 2 of 68
EU-FRESHBAKE Project, Final Report, June 2010
Contents
1
2
3
4
5
6
7
EU-FRESHBAKE PROJECT ....................................................................................................................................... 8
Description of Project Objectives ............................................................................................................................. 8
Contractors Involved ............................................................................................................................................... 8
Coordinator Contact Details..................................................................................................................................... 8
Project Logo and Project Public Website .................................................................................................................. 8
Overview of General Project Objectives.................................................................................................................. 10
1.1
Aims of the Project ....................................................................................................................................... 10
1.2
Pathways of the bake off technologies ............................................................................................................ 10
1.3
The 5 key objectives of EU-FRESHBAKE ....................................................................................................... 11
Project objectives and Project outcomes................................................................................................................. 12
2.1
OBJECTIVE 1: To optimise conventional process pathways in view of environmental concerns. ......................... 12
2.1.1 Part baked bread. ..................................................................................................................................... 12
2.1.2 Frozen dough and pre fermentation treatments ........................................................................................... 16
2.1.3 Impact of the process on Bread aroma and bread quality ............................................................................. 19
2.1.4 Modelling and understanding unit operations in baking ................................................................................ 22
2.1.5 Energy in existing processes. .................................................................................................................... 25
2.2
OBJECTIVE 2: To develop innovative process pathways. ................................................................................ 28
2.2.1
Vacuum baking ................................................................................................................................. 28
2.2.2
Amyloglucosidase : up to 15% energy saving during baking ........................................................... 29
2.3
OBJECTIVE 3: To develop innovative formulations adapted to the innovative processes. ................................... 31
2.3.1
Gluten bread formulation and GI ...................................................................................................... 31
2.3.2 Innovative ferments adapted to bake off technology..................................................................................... 31
2.3.3
Fibres in BOT: impact on the physical characteristics of breads. ..................................................... 33
2.3.4
Fibres in BOT: impact of adding of inulin on the aroma of breads. ................................................. 35
2.3.5
Gluten free formulation (hypoallergenic protein + enriched calcium + fibres) ................................ 35
2.3.6
Gluten free formulation and concepts ............................................................................................... 38
2.3.7
Innovative Organic bread formulation designed with durum wheat flour ........................................ 39
2.3.8
Specific enzymes to improve the nutrition properties and to reduce the energy during baking ....... 41
2.3.9
Gluten free breads enriched with amaranth flour resulted in higher calcium and magnesium and in
an increase of the body mass index in rats ........................................................................................................ 41
2.3.10 Gluten free breads enriched with flaxseed flour ............................................................................... 42
2.4
OBJECTIVE 4: To produce equipments adapted to innovative process that will be developed. ............................ 42
2.4.1
Innovative Infra red Oven : ~ 35% energy saving versus reference oven ........................................ 42
2.5
OBJECTIVE 5: To develop tools that will permit to extend the findings of the project to future formulations and
developments........................................................................................................................................................... 45
2.5.1 Labelling of part baked bread; can we envisage a « reduced GI » nutrition claim ? ......................................... 45
2.5.2
Guide of good practice for the industry ............................................................................................ 47
2.5.3
Transfer of baking concepts and innovative equipment to other products ....................................... 47
IMPACT OF EU-FRESHBAKE ON INDUSTRY AND RESEARCH ........................................................... 52
3.1
Impact of EU-FRESHBAKE on Industry sector....................................................................................... 52
3.2
Impact of EU-FRESHBAKE on Research sector ..................................................................................... 52
3.3
EU-FRESHBAKE Impact vs. Initial objectives ....................................................................................... 53
OUTLOOK OF THE EU-FRESHBAKE PROJECT ........................................................................................ 55
CONCLUSION ................................................................................................................................................. 57
REFERENCES QUOTED IN THIS FINAL REPORT ................................................................................................ 59
REFERENCES PUBLISHED DURING EU-FRESHBAKE PROJECT (June 2010) ...................................................... 62
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EU-FRESHBAKE Project, Final Report, June 2010
List of Tables
Table 1: Contractors list .................................................................................................................................................. 8
Table 1 : Processes of baking applied in FRESH-BAKE PROJECT and the GI values of the products. ................................ 15
Table 2 : Investigated conditions for the refrigeration step applied for Strategy A and B ...................................................... 18
Table 3 : Used recipes for comparison of different dosage of EU-FRESHBAKE AMG ......................................................... 29
Table 4 : Baking programs for the part-baking process..................................................................................................... 30
Table 5 : Measured Lab-values of the baked products .................................................................................................... 30
Table 6 : Physical evaluation of the bread enriched with different legume proteins ............................................................. 36
Table 7 : Nutritional value of the new recipe .................................................................................................................... 37
Table 8 : Comparison of quality parameters of gluten-free reference rolls (obtained by standard technology and with the
application of modified atmosphere packaging) , and products obtained with flaxseed and amaranth (MAP) ......................... 39
Table 9 : Myo-inositol phosphates content in whole wheat flour and bread ......................................................................... 41
Table 10 : Myo-inositol phosphates content in different gluten free breads. ........................................................................ 42
Table 11 : Comparison of selected quality parameters of breads baked with the innovative oven (IR+stone) and a conventional
oven. ........................................................................................................................................................................... 44
Table 12 : Bread labelling regarding the glycaemic index, GI (WHO) ................................................................................. 45
Table 13 : Labelling of white wheat bread regarding GI .................................................................................................... 45
Table 14 : Labelling of innovative white wheat breads designed in step 2 (according to Regulation (EC) 1924/2006) ............. 46
Table 15 : Possible labelling of wholemeal wheat breads from innovative step 3 (according to Regulation (EC) 1924/2006 ) .. 46
Table 16 : Labelling of wholemeal wheat breads from step 3 according to their Nutrition score (NS, Unilever) ...................... 46
Table 17 : Acronyms of the conventional and Bake Off Technology bread making processes - (Published in [39]) ............... 47
Table 18 : World bread market – Market share between Traditional, Industry and in store bakery [43].................................. 49
List of Figures
Table 1: Contractors list .................................................................................................................................................. 8
Figure 1: EU-FRESHBAKE work package structure ........................................................................................................ 9
Figure 2: Process pathways of selected technologies for bread making using Bake Off Technology (BOT). ......................... 10
Figure 3: Picture of a 70 g “buns” used during EU-FRESHBAKE....................................................................................... 12
Figure 4: Volume contraction in percentage of bread baked with different conditions .......................................................... 13
Figure 5 :Example of part baked bread with a crevasse due to the contraction of the crumb after baking. ............................. 13
Figure 6: Time – temperature evolution during baking tests done with a slab of degassed dough ........................................ 14
Figure 7: Young modulus of a degassed bread crumb (whole meal flour) in function of storage time at 10°C. ....................... 14
Figure 8: Time constant “” of equation ( 1 ) in function of the duration (in min) of the baking dwell at 98°C ......................... 14
Figure 9 :Young modulus “E” of equation ( 1 ) in function of the duration (in min) of the baking dwell at 98°C .................... 14
Figure 10 :Glycaemic index of wholemeal bread samples with sourdough addition ............................................................. 16
Figure 11 : Impact of pre fermentation time and freezing temperature on the final bread density [17] ................................... 17
Figure 12 : Evolution of the solubility of CO2 in bread dough ............................................................................................ 17
Figure 13 : Scheme of experimental study on the contraction of prefermented dough during refrigeration ............................. 17
Figure 14 : Evolution of the dough volume after pre-fermentation (80 min at 30°C) followed by a refrigeration at 4°C. ........... 17
Figure 15 : Example of pastries stored at 4 °C for 10 hours (left: A - no pre-proofed / right: B - pre-proofed) ......................... 18
Figure 16 : Average values with 95%-confidence interval for the specific pastry volume depending on strategy and time of
refrigeration ................................................................................................................................................................. 18
Figure 17 : Effect of fungal phytase addition, bread making process and frozen storage on residual InsP6 content in whole
wheat bread. ................................................................................................................................................................ 19
Figure 18 : Correlation plot and bread extracts plot of the quantitative data obtained for the four breads extracts in the two first
dimensions. ................................................................................................................................................................. 21
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EU-FRESHBAKE Project, Final Report, June 2010
Figure 19 : Pareto chart for acrylamide concentration in function of steaming (100 to 300 ml), vault temperature (top T = 170 to
230°C) and of stone temperature (bottom T = 170°C to 230°C) for fully baked breads. ...................................................... 22
Figure 20 : Pareto chart for acrylamide concentration in function of steaming (100 to 300 ml), vault temperature (top T = 170 to
230°C) and of stone temperature (bottom T = 170°C to 230°C) for part baked breads after second baking. ........................ 22
Figure 21 : acrylamide concentration (µg/100 ml of mother solution) in function of steaming (100 to 300 ml) and of stone
temperature bottom T = 170°C to 230°C) for fully baked breads. ...................................................................................... 22
Figure 22 : acrylamide concentration (µg/100 ml of mother solution) in function of steaming (100 to 300 ml) and of stone
temperature (bottom T = 170°C to 230°C) for fully baked breads after second baking. ....................................................... 22
Figure 23 : Experimental and simulated temperature at core (up-left), total mass loss (up-right) and CO2 release during baking
(bottom). Temperatures are simulated at the experimental positions as well as for positions 1mm higher or lower (dotted lines).
................................................................................................................................................................................... 24
Figure 24 : Experimental (MRI) versus simulated profile of local porosity at (left) 3min, (right) 10min of baking. .................... 24
Figure 25 : View of the rolling rack with the empty trays installed. The arrows indicate the direction of the air blown by the fans.
................................................................................................................................................................................... 26
Figure 26 : View of the 4 fans which were blowing the air on the breads installed on the trays. ............................................ 26
Figure 27 : Impact of the set point temperature on the freezing time for -20°C and – 30°C set point temperatures. ............... 26
Figure 28 : Impact of the set point temperature on the energy demand for freezing of bread between 30°C and a given
temperature ................................................................................................................................................................. 26
Figure 29 : Pie chart of the energy demand at -30 °C set point. The basis is the net refrigeration energy. The unexplained
losses have been arbitrarily adjusted at 10% (COP = 0.83). ............................................................................................. 27
Figure 30 : Relative percentage of the freezing ratio (1MJ.kg-1) and of the frozen storage energy (0.268 MJ.kg-1.month-1) in
function of the frozen storage duration. ........................................................................................................................... 27
Figure 31 : Relative percentage of the total energy for frozen part baked bread (3.5 MJ.kg-1 for partial baking, freezing and
final baking according to [33] and of the frozen storage energy (0.268 MJ.kg-1.month-1) in function of the frozen storage
duration. ...................................................................................................................................................................... 27
Figure 32 : Distribution of Energy during shock-freezing depending on different bake-off technologies. A fully loaded shockfreezer was used. ......................................................................................................................................................... 28
Figure 33 : Total height during baking and cross bread section of partial vacuum baked and conventional direct baked breads.
................................................................................................................................................................................... 29
Figure 34 : Picture of the baked products depending on the baking program. ..................................................................... 30
Figure 35 : Results of the measured energy for the products produced with a conventional fermentation system and with the
novel ultrasonic smokescreen – system (MicroTec) ......................................................................................................... 31
Figure 36 : Glycaemic index (%) of fresh and frozen storage wheat rolls enriched with fibres. Data are shown as a mean ±
SEM. Different letters show significantly different values at P< 0.05. ................................................................................. 31
Figure 37 : Influence of sourdough addition (with starter L. fermentum (PL1), L. plantarum (Lp), and L. brevis with S. cerevisiae
var. chevalieri (LV4)) on specific volume of part-baked wholemeal wheat bread ................................................................. 32
Figure 38 : Influence of sourdough addition on crumb firmness of wholemeal part-baked frozen bread ................................ 33
Figure 39 : Effect of fibre enriched formulation and storage conditions of par-baked bread on the crumb hardness of fully baked
breads. ........................................................................................................................................................................ 34
Figure 40 : Evolution of crumb hardness during staling of fibre-enriched breads obtained from conventional bread making (C),
par-baked breads stored at low temperatures (solid symbols) or sub-zero temperatures (open symbols). ............................. 35
Figure 41 : Volume changing at different level addition of pea protein. ............................................................................... 36
Figure 42 : Hardness changing of the crumb in bread enriched with different levels of pea protein ....................................... 36
Figure 43 : Reference recipe (D1.1.3) on the left and new formulation on the right ............................................................. 37
Figure 44 : Qualitative Descriptive Analysis for new formulation and reference bread. An intensity value scale from 0 to 5 was
used, with 0 = the attribute is not perceived and 5 = the attribute is highly perceived .......................................................... 38
Figure 45 : Products obtained with 3 hydrocolloids (left) and 4 hydrocolloids (right) ............................................................ 38
Figure 46 : Effect of different durum wheat flour additions on organic roll volume ............................................................... 40
Figure 47 : Effect of different durum wheat flour additions on organic roll alveolation .......................................................... 40
Figure 48 : Glycemic index (%) of reference organic roll and trial 3 roll (with durum wheat flour). ......................................... 40
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EU-FRESHBAKE Project, Final Report, June 2010
Figure 49 : Young modulus (E) of degazed and baked bread crumb during staling at 10°C in function of the storage duration
(days). ......................................................................................................................................................................... 40
Figure 50 : Enthalpy of melting of amylopectin crystals during staling at 10 °C of degazed bread crumb during in function of the
storage duration (days). ................................................................................................................................................ 40
Figure 51 : LEFT: Picture of the interior of the prototype Infra Red oven developed by ONIRIS. .......................................... 43
Figure 52 : Heat flux in the bread (bottom of the bread – 70g EU-FRESHBAKE loafs) measured with a heat flux sensor. ...... 43
Figure 53 : Pictures of 70 g loafs of organic breads partially baked in different conditions including IR Oven. ........................ 44
Figure 54 : Pictures of “Batard” bread (white flour – lean dough - 400 g loafs) baked in the reference oven and in the Infra Red
oven. Pre heating was done at 230°C. Additional tests are carried out to optimize the processing conditions of the infra red
oven. ........................................................................................................................................................................... 45
Figure 55 : BVP consumption in Europe-27 in 2006 ......................................................................................................... 48
Figure 56 : Artisanal vs. Industrial production in the European market (Europe 27) - 2006................................................... 49
Figure 57 : Retail channels for BVP in 2006 .................................................................................................................... 49
Figure 58 : Advertisement presenting key issues of the “PAIN DE TRADITION FRANCAISE” ............................................. 50
Figure 59 : European market of BVP in 2004 .................................................................................................................. 51
Figure 60 : Craft vs. Industrial production of BVP in 2006 ................................................................................................. 51
Figure 61 : BREAD in 2004 ........................................................................................................................................... 51
Figure 62 : VIENNOISERIE in 2004 ............................................................................................................................... 51
Figure 63 : PATISSERIE in 2004 ................................................................................................................................... 51
Figure 64: BREAD in 2006 ............................................................................................................................................ 51
Figure 65 : VIENNOISERIE in 2006 ............................................................................................................................... 51
Figure 66 : PATISSERIE in 2006 ................................................................................................................................... 51
Figure 67 : BREADS made from frozen BOT Europe-15 market share in 2003 [48] ............................................................ 52
Figure 68 : Evolution of the industrial BVP market between 2006 and 2011. ..................................................................... 55
Figure 69 : Comparison of the contribution of the western European countries (EU-15) vs. New Member States (NMS-12).... 55
Figure 70 : Picture of the “processing” of left over bread returned to a bakery in Germany (ref. provided by pr MEUSER – TU
Berlin). ........................................................................................................................................................................ 56
Figure 71 : Life Cycle Assessment of bread production. Pie chart of main sources of CO2 in the case of a large production unit.
The total CO2 is between 500 and 1000 g CO2 / kg of bread depending on production scheme (time frame 100 years). ....... 56
Figure 72 : Viennoiserie market (2004) ........................................................................................................................... 57
Figure 73 : Patisserie market (2004)............................................................................................................................... 57
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EU-FRESHBAKE Project, Final Report, June 2010
Nomenclature
ALA
alpha-linolenic acid
AS
Antioxidant Status
BOT
Bake Off Technology
BV
Biological Value
BCG
Baked Cereal Goods
CS
Chemical Score
DATEM Diacetyl tartaric acid esters of monoglycerids
DF
Dietary fibres
EAA index
Exogenic Amino Acid index
EEI
Energy Efficiency Index
EFSA
European Food Safety Agency
FBF
Fully Baked Frozen
FB-MAP
Fully Baked Un Frozen (stored in Modified Atmosphere Packaging)
FD
Frozen dough
FFD
Fermented Frozen dough
GI
Glycaemic Index
LP
Lipid profile
NPU
Net protein utilisation
NQI
Nutrition Quality Index
PBF
Partially Baked Bread Frozen
PBUF
Partially Baked Bread Unfrozen (stored at room temperature)
PER
Protein efficiency ratio
QI
Quality Index
TD
True digestibility
UFD
Unfermented Frozen Dough
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EU-FRESHBAKE Project, Final Report, June 2010
EU-FRESHBAKE PROJECT
Description of Project Objectives
EU-FRESHBAKE PROJECT: “Freshly baked breads with improvement of nutritional quality and low energy demanding
for the benefit of the consumer and of the environment”. This project aims at taking benefit of refrigeration to improve the
availability for the consumer of fresh bread with enhanced nutritional and textural quality. It concerns the Bake Off Technology
(BOT), which consists in producing bread from industrial refrigerated or frozen or non frozen bakery goods and to retail them in
downtown baking shops OR to make them available in supermarket for domestic baking. So far, BOT has concentrated its
efforts on production of plain white breads with low nutritional value. The nutritional and organoleptic qualities of bread can be
improved by taking benefit of refrigeration if specific enzymes and ferments and specific process are used. In addition, most
processes and technologies used in the BOT is energy demanding. This project is aiming at improving the industrial practice
versus energy consumption and also in taking benefit of refrigeration to improve the availability for the consumer of fresh bread
with enhanced nutritional and textural quality of bread; applications will concern “gluten” breads, “gluten free” breads and
organic breads. At the same time, it will aim at promoting and helping the ongoing rise of the BOT, which needs to be adapted
to the needs of the consumer for products with improved nutritional quality and health benefit.
Contractors Involved
The twelve partners involved in EU-FRESHBAKE project are shown in the Table 1.
No
1
2
3
4
5
6
7
8
9
10
11
12
Table 1: Contractors list
(coordinator was formerly ENITIAA and is now ONIRIS since January 2010)
Contractor
Country
Steering Committee
ONIRIS (project co-ordinator)
France
Academic
Pr. Dr. Alain LE BAIL
CEMAGREF
France
Research Centre Dr. Tiphaine LUCAS
Krakow University KU
Poland
Academic
Pr. Dr. Marek SIKORA
CSIC-IATA
Spain
Research Centre Pr. Dr. Cristina ROSELL
Zagreb University PBF
Croatia
Academic
Pr. Dr. Duska CURIC
TTZ-EIBT
Germany Research Centre Mr. Thomas PARK
Russian Academy of Science IBCP RAS Russia
Academic
Pr. Dr. Vladimir YURYEV
MIWE
Germany Industry
Mr. Martin PITTROFF
PURACOR
Belgium
Industry-INDUS
Ir. Ingrid VAN HAESENDONCK
BIOFOURNIL
France
Industry-SME
Mme. Maren BONNAND-DUCASSE
BLEZGLUTEN
Poland
Industry-SME
Mr. Mariusz KOCZWARA
SCHAER
Italy
Industry- SME
Dr. Virna CERNE
Coordinator Contact Details
Professor Alain LE BAIL
ONIRIS (was before ENITIAA until Dec. 2009)
Rue de la Géraudière BP 82225, 44322 Nantes – France
Tel: +33 + (0)2.51.78.54.73 - Fax: +33 + (0)2.51.78.54.67
Email: alain.lebail@oniris-nantes.fr
Project Logo and Project Public Website
EU-FRESHBAKE Project: “Freshly baked breads with
improvement of nutritional quality and low energy demanding for
the benefit of the consumer and of the environment”.
http://eu-freshbake.eu/eufreshbake/
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EU-FRESHBAKE Project, Final Report, June 2010
WP1: Material & Methods
(leader: PBF)
SWP1.1: Protocols for process
SWP1.2: Protocols for quality
SWP1.3: Protocols for nutrition
SWP1.4: To do initial consumer survey
WP2: Process Modelling
(leader: CEMAGREF)
SWP2.1: To model mixing
SWP2.2: To model fermentation
SWP2.3: To model refrigeration
SWP2.4: To model baking
WP4: Product Development
(leader: IATA-CSIC)
SWP4.1: Conventional formulations existing
SWP4.2: Conventional formulations improved
SWP4.3: Innovative formulation gluten
SWP4.4: Innovative formulation gluten free
SWP4.5: Innovative formulation organic
WP3: Nutrition
(leader: KU)
SWP3.1: Glycaemic index
SWP3.2: Micronutrients
SWP3.3: Strains & ferments
WP5: Process Development
(leader: TTZ-EIBT)
SWP5.1: Conventional process existing
SWP5.2: Conventional process improved
SWP5.3: Innovative process gluten
SWP5.4: Innovative process gluten free
SWP5.5: Innovative process organic
WP6: Demonstration Equipment & Product
(leader: ONIRIS)
SWP6.1: To design and deliver equipments
SWP6.2: To produce and evaluate gluten breads
SWP6.3: To produce and evaluate gluten free breads
SWP6.4: To produce and evaluate organic breads
SWP6.5: To evaluate products by consumers
WP7: Demonstration Dissemination
(leader: TTZ-EIBT)
SWP7.1: Conference consumers
SWP7.2: Conference industry
SWP7.3: Label design to promote the results
WP8: Management
(leader: ONIRIS)
SWP8.1: Management
SWP8.2: Exchange with other projects
SWP8.3: Financial audit
EU-FRESHBAKE Project: “Freshly baked breads with improvement of
nutritional quality and low energy demanding for the benefit of the consumer
and of the environment”.
http://eu-freshbake.eu/eufreshbake/
Figure 1: EU-FRESHBAKE work package structure
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EU-FRESHBAKE Project, Final Report, June 2010
1 Overview of General Project Objectives
1.1 Aims of the Project
EU-FRESHBAKE concerns industrial frozen and non frozen bakery goods sold in down town hot points (baking stations) or in
supermarkets. Such products are energy demanding, due to the fact that some are baked in a two steps process and are also
frozen. Most of these products are at present partially baked frozen breads. In addition, the industry has mainly focused so far
on plain recipes, with a reduced interest on nutritional quality. This project addresses important strategic objectives for these
products. These are to develop innovative process pathways and formulation to reduce energy consumption with an
improvement of the nutritional quality of the breads. To achieve this goal, specific indexes have been established.
 EEI (Energy efficiency Index) will determine the energy consumption of a given process.
 NQI (Nutrition Quality Index) will permit to evaluate changes in specific nutritional parameters.
 QI (Quality Index) will permit to assess the overall organoleptic quality of a given product.
Taking as a reference value the case of a partially baked frozen bread, it will be attempted to develop processes and
formulations that will allow to reduce the energy consumption (expected up to 50%), meanwhile the organoleptic properties will
be preserved (QI constant or improved) and specific parameters related to health benefit will be enhanced (i.e. enhancement
by 25% of the Glycaemic Index).
1.2 Pathways of the bake off technologies
The different pathways of the bake off technologies are summarized in Figure 2 below. EU-FRESHBAKE has focused on part
baked technology and has also covered other technologies.
Dosing
Mixing
First Resting
Dividing/Weighting
Moulding
Second Resting
Rounding
YES
Frozen Dough?
Unfermented
Frozen (UFF)
Freezing
NO
Proofing
YES
PFF?
Prefermented
Frozen (PFF)
Freezing
NO
NO
YES
Par-Baked?
Par-Baking
Frozen?
Cooling
YES
MAP
Par Baked–
Modified
atmosphere
packaging
(PB-MAP)
NO
Cooling
Baking
Freezing
Par Baked
Frozen (PBF)
Frozen?
NO
Fully Baked –MAP
(FB-MAP)
YES
Cooling/Freezing
Fully Baked
Frozen
(FBF)
Figure 2: Process pathways of selected technologies for bread making using Bake Off Technology (BOT).
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EU-FRESHBAKE Project, Final Report, June 2010
1.3 The 5 key objectives of EU-FRESHBAKE
EU-FRESHBAKE has proposed 5 key objectives:
-
OBJECTIVE 1: To optimise conventional process pathways in view of environmental concerns (ETAP). Different
technologies as detailed in Figure 2 are concerned by BOT. The three main technologies are the Un-fermented Frozen
dough (UFD), the Partially Baked Frozen Bread (PBF) and the Partially Baked Unfrozen (PBUF). UFD and PBF
process pathways are presented in Figure 2. Partially baked (PBF and PBUF) products can be prepared rapidly (less than
one hour) and are the emblematic products of the bake off technology; nevertheless, their production is energy demanding
and some quality problems might occur, especially with the crust (flaking, colour …). The unfermented frozen dough
technology (UFD) gives the best quality but at least 3 hours plus a trained personal are needed to deliver a product.
Research is thus needed to improve the energy efficiency of partially baked bread, which is the success story of BOT.
-
OBJECTIVE 2: To develop innovative process pathways. The development of innovative intermediate pathways with
reduced energy consumption improved structure and enhanced nutritional value will be done during the second half
of the project. These processes may play with refrigeration above 0°C and take benefit of the difference between yeast
activity (stopped below ca. 15°C) and specific enzymes activity, which contributes to the aroma, to the textural quality
(activity inhibited below ca. -5°C) and the nutritional quality (availability of micronutrients obtained through the fermentation
process).
-
OBJECTIVE 3: To develop innovative formulations adapted to the innovative processes. The design of innovative
process conditions is muck likely to require the design of adapted formulations. It will be targeted to design specific
formulations for gluten breads, gluten free breads and for organic type breads.
-
OBJECTIVE 4: To produce equipments adapted to innovative process that will be developed. The development of
innovative processing conditions will require the design of specific equipments adapted to the new technology. The basic
equipments needed to produce bread are a mixer, a fermentation cabinet and an oven. A chiller and a freezer must be
considered in the case of frozen products. Some of these equipments may be improved to optimize the energy efficiency
index on one hand and on the other hand to adapt existing equipment or to develop new equipments adapted to the
innovative process pathways that will be tackled. One may think for example to specific oven (i.e. using microwave),
specific fermentation cabinet adapted to prolonged fermentation at moderate temperature, specific chiller or freezers…
The mixing step will not be investigated in this project.
-
OBJECTIVE 5: To develop tools that will permit to extend the findings of the project to future formulations and
developments. The project will work on a bread formulation. Nevertheless, the indexes that will be developed (EEI, QI,
NQI) will be adaptable to other cases and other type of bakery products. Communication on the results of the project is
planned at the end of the project. Two targets are concerned, namely the baking industry and the consumers. In a more
general matter, this project concerns refrigeration applied to bakery products to extend the shelf life and to increase the
convenience of these products. Some of the results may be transferred to some products of the food industry such as
pizza, pie … for which wheat dough is used and baked.
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EU-FRESHBAKE Project, Final Report, June 2010
2 Project objectives and Project outcomes
.
EU-FRESHBAKE has considered a model “portion bread”
of 70 g (mass of dough) with the shape of a “bun”. Most of
the investigation have been obtained with this type of
bread which is representative of the products retailed
within the bake off technology. The loaf as shown in
Figure 3 had no “cut” on the upper surface to prevent any
artefact on the final bread volume. Indeed, the depth of the
cut can have a big impact on the oven rise and on the final
bread volume. Instead, 5 holes were made on the loaf with
a needle to provide an exhaust to the moisture and CO2
which is vaporized in the bread at the beginning of baking.
EU-FRESHBAKE has mainly focused on part baked bread
and on frozen dough technologies.
Figure 3: Picture of a 70 g “buns” used during EUFRESHBAKE.
Most results have been obtained with this type of bread.
There was no cut on surface to avoid any artefact on the
volume (opening of the loaf during baking and therefore
bread volume depends on the depth of the cut)
2.1 OBJECTIVE 1: To optimise conventional process pathways in view of environmental
concerns.
2.1.1 Part baked bread.
The concept of partial baking remains very vague in terms of defining the threshold between a partial baking and a full baking.
The colour of the crust is the most obvious criteria. However, even this parameter is not easy to define and can be affected by
the duration of the fermentation, by the recipe, by the steaming conditions …. During baking, the temperature of the crumb
rises up to around 98 °C, which represents the equilibrium temperature and which is limited by the boiling temperature of
water. Beside, the surface temperature of the bread may rise much higher. Depending on the degree of dehydration of the
surface of the bread, the temperature of the surface of the bread will pass the 100°C threshold. The degree of baking has
several impacts on different parameters; this has been investigated during EU-FRESHBAKE. The main results are as follow.
 Impact of the degree of baking on the crumb contraction.
The impact of the degree of baking of part baked bread has been investigated by Fadhel BEN-AISSA (PhD at ONIRIS).
Results are gathered in an article published in the Journal of Cereal Sciences [1]. Partial baking has been studied with portion
bread of 70 g. It has been observed that the shorter the baking, the higher was the contraction of the bread during the chilling
phase after baking. The volume of the breads has been measured with a touch less technique (laser volumeter) just after
baking (hot bread) and after the chilling down to room temperature. The contraction of the bread during chilling and even
freezing has been observed by several authors [2-7] and has been identified as one of main reason to explain crust flaking in
the case of frozen part baked bread. The contraction of the bread also addresses some issue in terms of outlook of the bread
which in turn can be a draw back for the consumer (in particular for part baked bread stored at room temperature and
presented in transparent packaging – see Figure 5).
Page 12 of 68
EU-FRESHBAKE Project, Final Report, June 2010
Bread Rolls
30.00
Contraction after Baking (%)
25.00
20.00
15.00
10.00
5.00
0.00
75°C
85°C
95°C
98°C, 5min
98°C, 10min, full
baking
Baking rate
Figure 4: Volume contraction in percentage of bread
baked with different conditions
(from ref. [1]. 75 °C, 85°C and 95°C means that the
bread has been transferred to refrigeration once this
temperature has been reached in the bread during
baking.
Figure 5 :Example of part baked bread
with a crevasse due to the contraction of
the crumb after baking.
This bread was stored at room
temperature with modified atmosphere
packaging.
 Impact of the degree of baking on staling.
Staling is a complex phenomenon in which multiple mechanisms operate[8]. The macromolecules contained in starch are
gelatinized during baking. Amylose, a linear biopolymer is leached outside the starch granules resulting in a gel like structure
which acts as a cement in the crumb matrix. During storage, the “retrogradation” (re crystallisation) of amylopectin occurs, and
because water molecules are incorporated into the crystallites of amylopectin. Therefore, the distribution of water is shifted
from gluten and amylose gel toward the starch/amylopectin crystallites, thereby affecting the mechanical properties of the
gluten network and finally the overall texture of bread. The role of additives may be to change the nature of starch protein
molecules, to function as plasticizers, and/or to retard the redistribution of water between components. The melting of
amylopectin crystals is related to the staling phenomena [9] even though the firming of the crumb is indirectly linked to it.
Results [10, 11]obtained within the EU-FRESHBAKE project showed that (i) PBF breads had a rather slower kinetic of staling
in comparison with conventional breads. In [11], a miniaturized oven was used to mimic the kinetic of baking observed on loafs
of 70 g baked in a real oven. The samples that were obtained were slabs of 3 mm thick (degassed crumb). In these
experiments, the texture of the degassed crumb was measured by compression tests. These tests gave a value called the
Young modulus which represents “hardness” of the material (in the elastic domain); the higher the young modulus, the more
resistant is the material to deformation. The evolution of the Young modulus during staling was modelled using a first order
kinetic model as presented in equation ( 1 ) where E(t) is the Young modulus in function of time t, and E0 and E are the
Young modulus at the beginning and at the end of the staling. The time is “t” and the time constant “” appearing in the
exponential function is a characteristic time (same unit as t). The amount of retrogradated amylopectin (re crystallized) has
been measured with a calorimeter (between e.g. 40°C and 60°C).
t 



E(t)  E  (E0  E ).e 
( 1)
Bread baked in an oven at 180°C, 200°C and 220°C underwent heating rates of 7.8°C/min, 9.8°C/min and 13 °C/min
respectively. These heating rates were reproduced in the miniaturized baking oven. Results [11] showed that a faster heating
rate resulted in a faster kinetic of staling, meanwhile the texture of the crumb at the end of staling was not significantly affected.
However, the difference was not very important. Other results (unpublished) obtained during the MSc trainee of Soumya
AGRANE at ONIRIS with the same miniaturized baking system and with organic bread formulation (whole meal flour) are
presented in Figure 6 and Figure 8. It showed that a longer baking plateau at 98°C (baking temperature of the crumb) resulted
in a harder crumb at the end of staling. The evolution of the kinetic parameter (“” in equation ( 1 )) and of the final Young
modulus (E in equation ( 1 )) are presented in Figure 8 and in Figure 9 respectively. Both values increased with increasing
Page 13 of 68
EU-FRESHBAKE Project, Final Report, June 2010
duration of the baking. However, the value of was minimally affected (~ + 10% indicating a slower staling for longer baking)
whereas the texture of the crumb (Young modulus) was significantly affected (+30% from 0 to 8 minutes baking plateau at
98°C).
Evolution du module de
de Young
Young (E)
(E) de
de la
la plaque
plaque de
de mie
mie dégazée
dégazéeprécuites
précuiteslors
lorsdu
du
vieillissement à 10°C
10°C (programme4)
(programme4)
16 min
12 min
8 min
4 min
T (°C)
98°C
CH
en MPa
YOUNG MODULUS OF ETHE
DEGAZED CRUMB (MPa)
As a
G
N
LI
IL
90°C
40
P3
in
P2
m
P1
P4
30°C
10 min
4,500
4,000
P4: 98°C – 8 min
3,500
P3: 98°C – 4 min
3,000
P2: 98°C – 0 min
2,500
P1: 90°C – 0 min
2,000
1,500
1,000
0,500
0,000
0
1
2
3
4
5
6
7
8
9
10
11
Jours
de stockage
à 10°C
10°C
après
après
précuisson
précuisson
STORAGE
TIME
AT 10°C
AFTER
PARTIAL
BAKING
TIME ( min)
Figure 7: Young modulus of a degassed bread crumb
(whole meal flour) in function of storage time at 10°C.
The baking was done according to the evolution shown in
Figure 6.
MSc AGRANE-ONIRIS 2009
Submitted J Cereal Sciences 2010
YOUNG MODULUS (MPa)
.
Figure 6: Time – temperature evolution during baking
tests done with a slab of degassed dough
(miniaturised system to mimic bread baking).
MSc AGRANE-ONIRIS 2009
Submitted J Cereal Sciences 2010
4.2
4.1
4
3.9
3.8
3.7
3.6
3.5
3.4
3.3
3.2
3.1
3
2.9
2.8
y = 0.1171x + 2.9668
R2 = 0.974
0
2
4
6
8
10
PLATEAU DURATION AT 98°C (min)
Figure 8: Time constant “” of equation ( 1 ) in function of the
duration (in min) of the baking dwell at 98°C
(from results of Figure 7 obtained with organic bread).
MSc AGRANE-ONIRIS 2009
Submitted J Cereal Sciences 2010
Figure 9 :Young modulus “E” of equation ( 1 ) in function of
the duration (in min) of the baking dwell at 98°C
(from results of Figure 7 obtained with organic bread).
MSc AGRANE-ONIRIS 2009
Submitted J Cereal Sciences 2010
conclusion, it seems that the longer the baking (temperature plateau at around 98°C), the harder will be the crumb at the end
of the staling phenomena. This observation is supported by the fact in the case of a longer baking time, a larger amount of
amylose is leached outside the starch granules resulting in a more resistant crumb (mechanical point of view). The SEM
pictures presented in [11] show that for prolonged baking the starch granules change in form and it seems also that more
material is leached outside the ghosts of the starch granules. Further study are carried out (follow up of EU-FRESHBAKE) to
assess if the difference can be explained (i) by a lower amount of crust for part baked bread resulting in a lower amount of
water transferred from the crumb to the crust during storage (moisture re equilibration resulting in a more pronounced
dehydration of the crumb for conventional bread) or (ii) by a difference in the degree of baking of starch (difference in starch
swelling). Results obtained in baking the dough without crust seem to indicate that the longer the baking, the slower the staling
rate (see [12]).
 Impact of the degree of baking on the Glycaemic Index.
One of the major finding of EU-FRESHBAKE regarding nutrition was to find out that partially baked breads had a lower GI than
conventionally baked breads. GI was measured in vivo with healthy volunteers by partner KU and by partner PBF. The
reduced GI has been observed first with a standard formulation and has been published in an article [13].
In EU-FRESH BAKE PROJECT different processes of baking have been used and their influence on glycaemic index
was investigated. They were fully baked and non frozen (FBNF or DIRECT), partially baked and frozen conventional (PBF
conv.), partially baked and frozen improved (PBF imp.), fully baked and frozen (FBF), unfermented frozen dough (UFD) and
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EU-FRESHBAKE Project, Final Report, June 2010
partially fermented and frozen (PFF). The differences in baking parameters among applied processes are presented in table
the below.
The significant reduction in GI in comparison to control bread (conventionally baked) have been observed when the
appropriate processes (partially baked and frozen- PBF) together with the particular additives (ingredients) were used. The
additives were different depending on flour used for baking. Namely, fibres and sourdough powder were used for white flour
rolls, while fresh sourdough and whey proteins for whole meal flour rolls baking. The obtained GI were low (below 55 %) for all
above mentioned rolls.
Table 1 : Processes of baking applied in FRESH-BAKE PROJECT and the GI values of the products.
Values with the same (*) number, come from the same study.
The BLACK and RED marked values are the results obtained by the partner KU and PBF respectively.
FBNF or
PBF conventional
PBF improved
FBF
UFD
DIRECT
PFF
MIXING [min]
SHAPING
PROOFING
9 min.
+
30oC
9 min.
+
30oC/105 min.
9 min
+
30oC/85 min.
9 min.
+
30oC
9 min.
+
-
BAKING
230oC/
20 min
190oC/3 min and
165oC/14 min.
230oC/
20 min
-
+
-
+
30 min
190-200oC/30’’
and 180170oC/16’30’’
+
35 min.
10 min.
+
28oC/50-65
min.
-
+
30 min.
30 min.
35 min.
-
+
+
+
+
+
-
+
+
+
+
+
-
230oC/12 min
210-220oC/
8 min
-
35oC/60min
230oC/
20 min
160oC/4min.
180oC/11 min.
190-200oC/16
min.
COOLING
FREEZING
(-30oC)
STORAGE
(-18oC)
DEFROSTIN
G
PROOFING
BAKING
GI ± SEM
* 83.03 ± 6
** 73.68 ± 1
***86.78 ± 11
----
* 60.66 ± 6
** 61.81 ± 9
*** 67.03 ± 5
****67.29 ± 6
---** 55.47 ± 8
*** 67.20 ± 3
----
* 73.00 ± 9
------****73.78 ± 7
* 73.28 ± 6
------****66.83 ± 8
---** 59.47 ± 9
-------
The calculated glycaemic index (GI) (mean ± SEM) ranged from 55.47 ± 8 for PBF improved to 86.78 ± 11 for FBNF. The
FBNF has been tested three times and each time had high glycaemic index, above 70 %. The application of freezing treatment
to wheat rolls resulted in lower glycaemic indices. Namely, the PBF conventional that has been examined four time always had
the medium GI value (55 % < GI < 69 %). The PBF improved in which the baking time and temperature has been modified in
comparison to PBF conventional has been tested twice and the GI value was medium as well (55 % < GI < 69 %). The fully
baked and frozen rolls (FBF) have been tested twice and in both cases the glycaemic index was regarded as high (> 70 %).
The unfermented frozen rolls (UFD) have been tested twice but the glycaemic index was not classified to the same group each
time. Namely, in the first case, the GI was high (> 70%),(according to KU Partner) while in the second trial, it was medium
value according to Zagreb University Partner (55 % < GI < 69 %). The PFF process involved freezing treatment after partial
fermentation. This process resulted in GI of medium value.
The influence of sourdough addition on glycaemic index was investigated by Partner PBF for white and wholemeal part-baked
wheat bread. In white breads sourdough prepared with commercial starter LV4 containing Lactobacillus brevis and
Saccharomyces cerevisiae var. chevalieri or with LV4 in combination with pure culture Lactobacillus sanfranciscensis was
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EU-FRESHBAKE Project, Final Report, June 2010
added at 10 % (bread dough basis). The glycaemic response was studied in vivo on ten healthy volunteers. The results
showed that the part-baked frozen breads made from white wheat flour with sourdough prepared with investigated starters did
not have significantly different GI value from control bread made without sourdough addition (p<0.05). The GI of all these
breads was high (>70%). Wholemeal wheat part-baked frozen breads were prepared with 10, 15 or 20 % of sourdough made
with commercially available starter with Lactobacillus fermentum without/with enzyme phytase (PL1/PL3), Lactobacillus brevis
and Saccharomyces chevalieri (LV4), and pure culture Lactobacillus plantarum. The control wholemeal bread made without
sourdough exhibited high glycaemic response (GI >70 %), and sourdough addition (10% and 15%) decreased the GI value of
part-baked wholemeal breads from high to moderate (56-69) or even low (PL3 sourdough 20%) (see Figure 10). L. plantarum
sourdough containing dominantly lactic acid had less pronounced decreasing effect on bread GI than sourdough containing
additionally acetic acid (LV4, PL1 and PL3). The optimal sourdough dosage for reducing GI value of bread needs to be further
investigated. The paper entitled “Effect of sourdough starter on glycaemic index of part-baked frozen whole wheat bread” with
some of the results was submitted to scientific journal Food Research International in November 30 th 2009.
90
80
75
70
70
56
GI (%)
60
59
68
65
50
71
60
56
56
46
50
40
30
20
10
0
STD
PL1
10%
PL1
15%
PL1
20%
LV4
10%
LV4
15%
LV4
20%
L.plant L.plant L.plant
10%
15%
20%
PL3
10%
PL3
20%
Figure 10 :Glycaemic index of wholemeal bread samples with sourdough addition
mean values ±SEM - (data from partner PBF)
The conclusion about the GI tests done during EU-FRESHBAKE is that the most considerable reduction in glycaemic
response (up to 22 %) has been noticed for partially baked and frozen rolls, both conventional and improved (PBF), in which
the freezing treatment was applied after partial baking. The conventional process of baking under conditions of high
temperature and moderate water content leads to gelatinization of starch granules [9, 14, 15] and results in a rapidly digestible
product with high GI. However, cooling of gelatinized starch leads to its retrogradation, and result in the formation of starch
complexes, called resistant starch (RS), which are insoluble and resistant to gastrointestinal enzymes, thus giving low GI
values when consumed [13]. The refrigeration as such may thus be proposed as a first explanation about the reduction of GI.
Another explanation about the reduction of the GI lies in that SEM pictures showed that in the case of partially baked bread,
the swelling of the starch granule was less important than for conventional baking. The better preservation of the starch
granules in the case of a short baking (partial baking) may be a second explanation about the reduction of the GI. Adding of
sourdough to partially baked and frozen bread resulted in a very significant reduction of the GI (see later).
2.1.2 Frozen dough and pre fermentation treatments
 Impact of the degree of pre fermentation on the volume of prefermented frozen dough
The impact of the degree of pre fermentation on the final volume of dough of prefermented frozen dough has been investigated
by ONIRIS [16, 17]. Refrigeration was applied after 1h, 1.5h and 2 h before freezing of the dough sticks. After frozen storage,
the dough pieces were thawed and fermentation was completed to reach a total of 2 h fermentation (including before and after
freezing). Rapid and slow freezing were compared corresponding to freezing at -20°C and -40°C respectively. Results showed
that a faster freezing was preferable; indeed, it prevents the collapse of the fragile fermented dough by solidifying the outer part
Page 16 of 68
EU-FRESHBAKE Project, Final Report, June 2010
before low temperature reaches the centre of the dough piece. Beside, it was preferable to limit the degree of prefermentation
to the minimal level (in our conditions) to obtain the largest bread volume after baking (lower bread density - see Figure 11.
Figure 11 : Impact of pre fermentation time and freezing
temperature on the final bread density [17]
Figure 12 : Evolution of the solubility of CO2 in bread dough
(PhD of F. Ben Aissa – ONIRIS) [18]
In addition, an experimental work has been carried out by Fadhel Ben-Aissa (PhD student at ONIRIS) on the determination of
the solubility of CO2 in dough in function of the temperature. Results presented in [18] showed that the solubility of CO2 in
bread dough increases for lower temperature. Therefore, during refrigeration of the dough, the gaseous CO2 which governs
the expansion of the gas cells embedded in the dough will be trapped by the liquid phase of the dough. This will yield in a
reduction of the total pressure in the gas cell in combination with the contraction of the gas due to the reduction in temperature
(perfect gas law). In addition, the condensation of the moisture contained in the gas cell may contribute to the reduction of the
pressure in the gas cell, resulting in a collapse of the dough when refrigerated. Collaboration with partner PBF (visit of PhD
student D. Gabric in 2007 and 2008 for a total of 4 months) permitted to do some experiments and to develop mathematical
models to better understand the collapse of a pre fermented dough during refrigeration. An example is provided in Figure 16
(scheme of experimental set up) and in Figure 17 (comparison between model and experiment). A good agreement has been
observed between model and experiments; as a first result, it appeared that the temperature as such had a much higher
impact that the increase of the solubility of CO2 in the dough on the dough collapse during refrigeration.
T(t)
Dough 70g
Temperature (°C)
35
6
30
5
25
4
20
3
15
2
10
1
5
0
0
50
100
150
200
Température (°C)
1V/cm
DOUGH
VOLUME
Volume de pâte (m3)
7
Displacement
transducer
Mesure
TEMPERATURE (°C)
Modèle
TEMPERATURE
EXPERIMENTAL
MODEL
0
250
TIME (min)
Tem ps (m in)
Figure 13 : Scheme of experimental study on the
contraction of prefermented dough during refrigeration
(collaboration between 2 PhDs of ONIRIS and PBF –
paper in preparation).
Figure 14 : Evolution of the dough volume after pre-fermentation (80
min at 30°C) followed by a refrigeration at 4°C.
Comparison of experiment (PhD D. Gabric-PBF)
and model (F. Ben Aissa – ONIRIS)
 Impact of low temperature on dough formation and fermentation ability
The impact of refrigeration during fermentation on the crumb structure was investigated by partner BILB-EIBT with the
reference and improved gluten formulation. The objective was here to assess if the action of enzymes during a refrigeration
step could led to an improvement of the quality of the bread. In a first trial series basically two strategies were investigated with
the conventional process. Strategy A was with no pre-proofing and strategy B was with a pre-proofing step. In a second trial
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EU-FRESHBAKE Project, Final Report, June 2010
series the conventional and part baked process were additionally investigated applying also strategy A and B in each process.
For the step of refrigeration the influencing effects “time” and “temperature” were varied according to a design of experiments
(see Table 2).
Table 2 : Investigated conditions for the refrigeration step applied for Strategy A and B
In strategy A the refrigeration step was carried out directly after dividing and moulding of the dough pieces (before
fermentation) whereas in strategy B, the refrigeration step was applied after pre-proofing of the dough pieces. The expansion
ratio was checked. In order to obtain always the same volume of dough pieces before the baking step the fermentation was
controlled with the volume factor 4.0 for the conventional process and 3.6 for the part baking process. After the baking process
and cooling the products at room temperature the volume, crumb firmness and the porosity were analysed according the EUFRESHBAKE protocols. It was found that the products from strategy B with the pre-proofing step showed a significant higher
pastry volume as illustrated in Figure 15 & Figure 16. Comparing the conventional and part baked process higher volumes
were achieved with the conventional process. But this could be expected because of the higher volume factor of 4.0. The use
of a pre-proofing step did not influence the pastry volume significantly in the second trial series (see Figure 15 & Figure 16).
Porosity depends on the pastry volume and is the denser and more even the smaller the pastry volume is. Products with bigger
volume showed a more open and uneven porosity. The temperature did not show significant influences on the products.
Figure 15 : Example of pastries stored at 4 °C for 10
hours (left: A - no pre-proofed / right: B - pre-proofed)
Figure 16 : Average values with 95%-confidence interval for the
specific pastry volume depending on strategy and time of refrigeration
 Freezing of wholemeal dough improves minerals availability [19]
Partner CSIC-IATA has investigated the interest of fungal phytase to improve the nutrition quality of whole meal wheat flour.
Key results are gathered in the paper [19] (“Wholemeal wheat bread: a comparison of different breadmaking processes and
fungal phytase”). Despite the beneficial effect of consuming whole wheat bread, public’s acceptance of this product is limited
due to its lower volume, coarser texture and faster staling compared to refined wheat bread. Therefore, some technological
efforts are needed in the performance of whole wheat breads to meet consumer’s needs and demands. Concerning bakery
products, freezing dough, partially baked or fully baked bread become in many cases necessary to face the present demands
[20]. Numerous studies have been focussed on the sensory and technological quality of refined wheat loaves obtained from
frozen dough or partially baked breads and those revealed that breads with qualities close to the ones obtained from
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EU-FRESHBAKE Project, Final Report, June 2010
conventional breadmaking process are obtained. Nevertheless, scarce information exists about the impact of those
breadmaking processes on whole wheat breads loaves, where studies have been addressed to the improvement of formulation
for counteracting the negative effects of the bran particle size on the breadmaking performance and bread quality.
EU-FRESHBAKE has investigated the effect of different breadmaking processes (conventional, frozen dough, frozen partially
baked bread) and the effect of the storage period on the technological quality of the fresh wholemeal wheat breads. In addition,
the impact of the exogenous fungal phytase on the phytate content was also determined. Results showed that breadmaking
technology significantly affected the quality parameters of wholemeal breads (specific volume, moisture content, crumb and
crust colour, crumb texture profile analysis and crust flaking) and frozen storage affected in different extent the quality of the
loaves obtained from partially baked breads and those obtained from frozen dough, particularly crust flaking.
Breadmaking process and the addition of fungal phytase significantly (P<0.05) affected the phytates hydrolysis during frozen
storage (Figure 17). Initially, the InsP6 amount showed a slight increase during frozen storage compared to the samples
without storage, which was significant (P<0.05) in the case of PB samples. Presumably, the effect of freezing and frozen
storage on dough microstructure could favor both the substrate liberation and the accessibility of the fungal phytase to the
phytate compounds, as has been observed at dough level [21], being the overall result an increase in the level of InsP6. A
reverse tendency was observed with longer storage, the InsP6 amount significantly (P<0.05) decreased, thus enzymes were
not inactivated. On the other hand, in frozen systems although the low temperatures decrease reactions rate, the increment of
solute concentration in the unfrozen phase could increase the rates. Another factor that may be involved is a possible catalytic
effect of ice crystals, greater proton mobility in ice than in water, a favourable substrate catalyst orientation caused by freezing
or a greater dielectric constant for water than ice. Regarding the type of process, in general the InsP6 level was significantly
(P<0.05) higher in breads from PB samples than those from FD samples (Figure 17). Partial baking could induce partial
inactivation of the fungal phytases, whereas in FD samples the enzyme might remain active during the storage. Therefore,
although phytase did not induce a significant effect on bread specific volume and crust flaking, significantly softer crumbs were
obtained in breads from FD containing phytase.
7
InsP 6, µ mol/ g d.m.
6
5
4
3
2
3
1
2
1
0
FD -
FD +
PB -
PB +
0
Time (months)
Figure 17 : Effect of fungal phytase addition, bread making process and frozen storage on residual InsP6 content in whole wheat bread.
Breads containing phytase (+) or in the absence of phytase (-). FD: frozen dough, PB: partially baked [19, 21]
Therefore, freezing and frozen storage of wholemeal bread in the presence of fungal phytase decreased significantly the
phytate content, independently of the bread making process followed, thus the combination of both variables could be a good
approach to increase the mineral bioavailability in whole wheat breads.
2.1.3 Impact of the process on Bread aroma and bread quality
 Evaluation of the quality of bread: a quality index
The expression of bread quality index (QI) was based on technological characteristics in order to enable objective evaluation of
breads produced by different processes. QI was determined using the instrumental methods for evaluation of crumb firmness,
bread specific volume, shape (height/diameter) and sensory test for flavour evaluation of bread produced by different recipe
(gluten bread, gluten-free bread and organic bread) and processes (UFD, PBF, FBF) in comparison to bread prepared
following the reference recipe and process (conventional). The obtained results of each bread property were normalized by
linear transformation according to [22, 23]:
Page 19 of 68
EU-FRESHBAKE Project, Final Report, June 2010
zi 
x i  x min
x ma x  x min
if xmax = xopt
zi 
x max  x i
x ma x  x min
if xmin = xopt
and
The quality index of bread sample (QI) is calculated as a sum of normalized variable (zi) multiplied by the factor of significance
for the attribute (0.3 for specific volume; 0.1 for shape, 0.3 for crumb firmness and 0.3 for bread flavour), relatively to the
reference (conventionally produced) sample:
QI 
0.3  z
Vs
 0.1  z Sh  0.3  z Fc  0.3  z Bf sample
(0.3  zVs  0.1  z Sh  0.3  z Fc  0.3  z Bf ) reference
where
zVs is normalized value for bread specific volume;
zSh – normalized bread shape (height/diameter);
zFc – normalized crumb firmness and
zBf- bread flavour.
The paper entitled „Design of a quality index for the objective evaluation of bread quality: Application to wheat breads using
selected bake off technology for bread making“ was published in Food Research International, 41 (2008) 714–719.
 Impact of selected baking process on bread aroma
The PhD thesis of Pauline POINOT, who has been engaged by ONIRIS within EU-FRESHBAKE has been defended in
October 2009. The focus was on the impact of selected baking processes on the aroma of bread. Most of the results presented
below are detailed in references [24, 25].
To analyse the impact of the process stages on bread flavour, an extraction method has been optimised. Among the
techniques which could be applied to identify the compounds responsible for the bread flavour, Solid-Phase MicroExtraction
(SPME) is a particularly useful method compared with others which are more tedious or more expensive. It is sensitive,
selective and compatible with low detection limits. Placed in the sample headspace, SPME is a non-destructive and noninvasive method to evaluate volatile and semi volatile compounds. The optimisation of Head Space-SPME (HS-SPME) for the
bread volatile compounds extraction was carried out to produce breads odorant extracts representative to the corresponding
food. Several HS-SPME conditions were then tested (fibre type, extraction time and extraction temperature), in order to obtain
extracts as close as possible to the bread odour perceived by the human nose. Among the tested conditions, a 75 µm
CAR/PDMS fibre, associated with an extraction time of 30 min and an extraction temperature of 35°C permitted to obtain
breads odorant extracts representative to the bread odour. These conditions were then applied to analyse breads obtained
under different bread making processes. The impact of the partially baked process was then analysed by comparing the
aromatic profiles of conventional (or fully baked) breads and part-baked breads. As well, adding a freezing stage in the process
of the conventional and part-baked bread was studied, by comparing the volatiles released from frozen and non frozen breads.
The aromatic profile of frozen dough breads was also studied and compared to the one of the conventional bread.
Breads were formulated according to reference recipes and baking procedures from EU-FRESHBAKE (wheat flour - type 55 –
French standard). Bread makings were realised four times. The identification and the quantification of volatile compounds
trapped were then carried out and a PCA was performed on the mean quantity of volatile compounds identified for each bread
making (Figure 18).
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3-Furfural
8
2,5-Dimethylpyrazine
Maltol
1-Octen-3-ol
2-Methylbutanal
6
2-Acetylfuran
1-Propanol
2-Ethyl-6-methylpyrazine
2,3-Butanedione
Dihydro-2-methyl-3(2H)-furanone
Butyric acid
Hexanal
2-Pentylfuran
3-Methylbutanal
2-Ethyl-3-methylpyrazine
Hexanoic acid
Pyrrole 2,3-Pentanedione
Pyrazine
1-Methylpyrrole
2-Methylpropanal
Furfuryl alcohol
Isovaleric acid
2-Methylpyrazine
2-Methylfuran
2-Ethyl-5-methylpyrazine
Isobutyric acid
2,3-Dimethylpyrazine
2,3-Butanediol
Hydroxyacetone
2-Ethylpyrazine
Acetic acid
2-Methyl-1-butanol
Ethanol
2-Methyl-1-propanol
1-Hexanol
3-Methyl-1-butanol
1-Pentanol
4
Fully baked frozen
bread
Propionic acid
PC 2 - 12.0%
PC 2 - 12.0%
Benzaldehyde
Partially-baked
bread process
5-Methyl-2-furfural
2
Partially baked
frozen bread
0
-2
Partially baked
bread
Fully baked bread
-4
2-Butanone
Furfural
Phenylethyl alcohol
Ethyl acetate
Fully baked bread
process
-6
-8
-8
-6
-4
-2
0
2
4
6
8
PC 1 - 78.2%
3-Hydroxy-2-butanone
PC 1 - 78.2%
Figure 18 : Correlation plot and bread extracts plot of the quantitative data obtained for the four breads extracts in the two first dimensions.
A total of 46 volatile compounds were identified. The quantities of these volatiles varied between the different bread-makings.
Indeed, it could be seen that the HS-SPME conditions applied discriminated fully baked breads (frozen or not) from partially
baked breads (frozen or not). As shown of the bread extracts plot, fully baked bread and fully baked frozen bread are opposed
to partially baked and partially baked frozen breads on the first dimension. The volatile extracts of the two first breads were
characterised by higher quantity of Maillard compounds. Partially baked breads (frozen or not) extracts were characterised by
lower amounts of these compounds, whereas they contained more alcoholic compounds issued from the fermentation and/or
the lipid oxidation. Compared to the results obtained from a discriminative sensory analysis, it was demonstrated that these
analytical differences had an impact on breads odorant perceptions. Indeed, the odours of fully baked breads were perceived
differently from the ones of partially baked breads.
In order to determine the impact of the freezing stage on fully baked bread and partially baked bread aroma, an ANOVA was
performed on the volatile compounds quantities in fully baked bread compared to fully baked frozen bread, as well as in
partially baked bread compared to partially baked frozen bread (data not shown). These results revealed that adding a freezing
stage in these two bread making processes did not have a significant effect at a confidence level of 5% on bread volatile
compounds released. Indeed, extracts obtained from fully baked bread and fully baked frozen bread had a similar volatile
compounds composition. Extracts obtained from partially baked breads were also characterised by a close composition.
The flavour of frozen dough bread was also compared to the one of the conventional bread. Results reveal that neither its
odorant perception, nor its volatile composition differed from the one of the conventional bread. More results can be obtained in
the PhD manuscript of Pauline POINOT (in French – reference [26]) and in the papers published by P. Poinot.
 Impact baking process on acrylamide
The impact of baking process on selected neoformed compounds has been investigated by ONIRIS. The objective was
to assess if bake off technologies have an impact on neoformed compounds. Pr Keramat (IUT-Iran) as visiting professor in
2008 at ONIRIS carried out an experimental design in collaboration with T Dessev (post doc – Univ. Food technology –
Plovdiv) ) to determine the amount of acrylamide in bread crust. Conventional bread baking and partial baking processes have
been compared.
The amount of acrylamide formed during different conditions of baking was measured in bread crust. In parallel to fresh baked
bread project, 29 samples are prepared according to an experimental design. The variation factors are three different
temperatures (170, 200 and 230oC) of the bottom and the top of the oven and three amounts of steaming (100, 200 and 300
ml). Along with these factors, six breads are collected after the crumb temperature is reached to 98oC and baked for five
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minutes. Three of those are kept at 4oC for a week and then baked under the same conditions for fifteen minutes. The other
three are analyzed as partial baked breads. The full baked breads are baked for twenty minutes after the temperature of the
crumb reaches to 98oC. The whole crust is separated and dried at room temperature by the oven with air circulation over night.
After that, the dried crusts are finely grounded and stored at -21oC. Acrylamide measurement was with a GC. The
concentration is given in µg per ml of mother solution.
Standardized Pareto Chart for concentration
C:steaming
Standardized Pareto Chart for concentration
C:steaming
+
-
B:top T
+
-
A:bottom T
AB
AB
AC
AC
BC
BC
A:bottom T
B:top T
0
2
4
6
8
0
Standardized effect
Figure 19 : Pareto chart for acrylamide concentration in
function of steaming (100 to 300 ml), vault temperature (top
T = 170 to 230°C) and of stone temperature (bottom T =
170°C to 230°C) for fully baked breads.
8
top T=0.0
0.6
-0.20.2
-1-0.6
concentration
concentration
steaming
6
Estimated Response Surface
top T=0.0
0.6 0.2 -0.2
-0.6 -1
4
Figure 20 : Pareto chart for acrylamide concentration in
function of steaming (100 to 300 ml), vault temperature (top
T = 170 to 230°C) and of stone temperature (bottom T =
170°C to 230°C) for part baked breads after second baking.
Estimated Response Surface
330
310
290
270
250
230
210
1
2
Standardized effect
1
340
300
260
220
180
1401
bottom T
0.6 0.2
-0.2 -0.6
steaming
Figure 21 : acrylamide concentration (µg/100 ml of mother
solution) in function of steaming (100 to 300 ml) and of
stone temperature bottom T = 170°C to 230°C) for fully
baked breads.
-1 -1 -0.6 -0.2
1
0.2 0.6
bottom T
Figure 22 : acrylamide concentration (µg/100 ml of mother
solution) in function of steaming (100 to 300 ml) and of
stone temperature (bottom T = 170°C to 230°C) for fully
baked breads after second baking.
One can see in Figure 19 and Figure 21 for fully baked bread (conventional), and in Figure 20 and Figure 22 for part baked
bread (after second baking) that :
- The amount of acrylamide is slightly lower for part baked bread in particular for low steaming. This can be explained by the
fact that for high steaming, the expansion of the bread is more pronounced during baking resulting in a more insulating loaf
(heat transfer) and therefore in a higher rise in temperature of the crust. However, this hypothesis is in opposition with the
results proposed by [27] who did baking with injection of steam at different moment during baking. This resulted in a lower
amount of acrylamide.
- In our results, the vault (top) temperature has more influence on acrylamide formation for fully baked bread whereas for part
baked bread it is the stone temperature which has more influence. This can be explained by the fact that for part baked bread,
a shorter baking is done (first baking). Since the baking is divided in two steps (part baking and final baking), the crust is
exposed to a different treatment than for direct baking.
More on acrylamide in baking is available in the final HEATOX project report and in [28]. Globally, it seems that part baked
bread is contains less acrylamide (or eventually a similar amount) than similar bread baked directly.
2.1.4 Modelling and understanding unit operations in baking
 Modelling of dough and bread freezing
Modelling of dough and bread freezing has been carried out during the PhD of F BEN AISSA at ONIRIS. The models have
been developed to better understand the impact of refrigeration on the quality of bread in particular for bread freezing. Indeed,
during freezing, bread crumb contracts exposing the crust to strains which may result in crust flaking. Coefficient of thermal
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EU-FRESHBAKE Project, Final Report, June 2010
contraction of the crumb has been determined experimentally with a dilatometer. A good agreement has been observed
between model and experiments. Results have been presented in the PhD of F Ben Aissa defended in December 2009 in
Nantes. [29].
 Modelling of dough expansion and contraction during low temperature excursions
During the PhD of Fadhel Ben Aissa ([29] – done at ONIRIS), a model has been developed to describe the expansion and
contraction of a dough during fermentation and contraction. This work has been done in collaboration with partner PBF from
the University of Zagreb (visits of D. Gabric in 2007 and 2008). Different hypothesis have been considered: the initial cell
distribution was uniform in diameter and the temperature in the dough piece was supposed to be uniform. A refined modelling
has been developed regarding the equilibrium of the gas cell in the dough. In the case of prefermented dough exposed to
refrigeration, during refrigeration the gas cells are exposed to a pressure drop resulting in a collapse of the fragile structure.
The pressure drop is caused by the reduction of the partial pressure of air (perfect gas law), by the condensation of moisture
and by the increase of the solubility of CO2 in the dough. Results (comparison between model and experiments ) are
presented in Figure 13 & Figure 14 as shown before.
 Modelling of dough baking
The mathematical modelling of dough baking takes into account heat and mass transports combined with volume changes of
the matrix (development of a gas fraction); partner CEMAGREF has worked with the objective of better understanding the
bottlenecks linked to baking under low pressure or baking of prefermented dough. Compared to the literature, improvements
have been proposed so to take into account the balance between the increase of pressure in bubbles (at the global porosity
scale considered here) and the mechanical resistance of the dough film surrounding the bubble. Different transport
mechanisms were also considered, particularly the evapo-condensation-diffusion mechanism that is suggested by numerous
authors to be responsible for the fast increase of temperature and moisture content at core during baking.
The model is available in a 1D (sheet with moving boundary at the top only) and 2D (cylindrical with moving boundary at the
half top surface) geometries. The model was validated for a large number of variables, as temperature and water content
profiles, overall water and CO2 losses. Overall and local expansion of dough was dynamically monitored by MRI and compared
to simulation. Lastly, it should be emphasized that confrontations between models of baking and experiment are not very
numerous in the literature and still rarely at such scales (profile of several points) or on a large range (number of variables) as
those proposed in this study. The experimental trends were appropriately reproduced, providing a satisfactory qualitative
validation of the model. Considering the validation on local and overall scales, there was no invalidation of the mechanisms as
they were proposed and formalized in the model, even if some discrepancies were observed for local porosities and water
content at the surface layers for the longest baking times. It should be emphasized here that some results may require a more
thorough analysis of the underlying mechanisms and that such analysis should be validated against a larger data base with
other experimental conditions.
Analysis of local expansion monitored by MRI established that not all regions in the bread loaf expanded to the same extent
and at the same rate, and some of them were subject to late compression, generating porosity heterogeneities between the
core and the surfaces. The inflation of bubbles was successfully simulated at the beginning of baking and at core for prolonged
baking. Squeezing of crumb beneath the top surface was initiated but the model failed into reproducing the same intensity of
squeezing as observed by MRI at the end of baking. Squeezing of crumb above the bottom surface was not reproduced at all –
conversely it was the area of the highest expansion.
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180
0.10
160
experimental
simulated
0.09
Water content (kg water)
Temperature (°C)
140
120
100
80
60
0.08
0.07
0.06
40
0.05
20
0
0
5
10
15
Time (min)
20
25
5
10
30
15
20
25
30
Time (min)
0.0012
0.0010
MCO2 (kg)
0.0008
0.0006
0.0004
experimental
0.0002
simulated
0.0000
0
5
10
15
20
25
30
time (min)
Figure 23 : Experimental and simulated temperature at core (up-left), total mass loss (up-right) and CO2 release during baking (bottom).
Temperatures are simulated at the experimental positions as well as for positions 1mm higher or lower (dotted lines).
On the one hand, the mechanical dynamics in the surface layers of dough did offer a resistance to crumb expansion, as
expected; this was evidenced by the early cessation of the oven-rise compared to bubble inflation at core and the squeezing of
crumb beneath the top surface. First hypothesis to explain the discrepancy reported above was hence that the viscosity was
not high enough especially at the very surface, that the model of viscosity fitted on a couple of data set failed in reproducing
adequately the mechanical behaviour of extreme heat moisture pathways encountered in the surface layers and that more
pathways should be reproduced in the DMTA oven and added to the data basis before the fitting of the model of viscosity.
On the other hand, the balance between pressure forces in the crumb and viscous forces in the surface layers was highlighted.
Pressure forces are driven by the rate of gas formation, the rate of gas escape and the stiffening of dough films. The
parameters governing these mechanisms will be undoubtedly fine-tuned together with the dependency of mechanical
properties on water content and a preliminary sensitive study to these parameters will be required upstream.
0.05
0.05
initial porosity
experimental
simulated
0.03
0.03
0.02
0.02
0.01
0
0.50
-0.01
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0.95
experimental
initial porosity
simulated
0.04
Height (m)
Height (m)
0.04
1.00
0.01
0
0.50
-0.01
-0.02
-0.02
-0.03
-0.03
-0.04
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
-0.04
Porosity
Porosity
Figure 24 : Experimental (MRI) versus simulated profile of local porosity at (left) 3min, (right) 10min of baking.
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EU-FRESHBAKE Project, Final Report, June 2010
2.1.5 Energy in existing processes.
 Control of final temperature during freezing process to save energy
Controlling the final freezing temperature of the product can result in energy saving between 30 and more than 50% depending
on the conditions. Bread freezing is challenging for several reasons. At first it is a poorly conductive material resulting in a long
freezing even though the enthalpy change per kg of product to consider for the freezing is relatively lower than for other foods
such as meat for example. Second, when frozen, it occupies a large storage volume due to its low density. There are also
some quality issues such as flaking off of the crust. Bread quality can be significantly affected by the freezing rate. However, it
seems that even though the freezing should not be too long to prevent excessive moisture loss, a very fast freezing rate may
yield in crust flaking problems due to the thermo-mechanical problem linked to crust flaking as presented by [3, 5]. Indeed, the
contraction of the crumb during freezing exposes the outer layer of the bread (namely the frozen crust) to contraction strain.
EU-FRESHBAKE has investigated the impact of processing conditions on energy demand during freezing. Results have been
obtained with a small scale freezer (1.5 m3 - 9 kg/m3) and a larger freezer (5 m3 - 8 kg/m3). The detailed results obtained in
the small scale freezer have been published in [30-32]; the results obtained with the large freezer have not been published yet.
Equipments that have been used in this work used electrical energy. The commercial brands of the equipments are not
provided for confidentiality reasons. Bread dough was made using a simple bread recipe. The recipe was for 100 g flour, 58 g
water (CONV) or 52 g water (PBF), 5 g yeast (CONV) or 2 g yeast (PBF) (Michard SAS - Theix, France), 2 g salt (Esco,
Levallois-Perret, France S.A.) and 1 g improver (PURATOS – Groot-Bijgaarden - Belgium). The breads were partially baked in
a preheated oven at 190°C. The set point was then adjusted at 175°C during the baking which lasted 17 minutes in total.
Freezing was done in a air blast freezer (internal volume 1.5 m3) equipped with 4 fans of 300 Watts each. The freezer was set
so that the fans were in operation during the whole freezing process even if the compression unit was turned off by the
regulation system.
The set point temperature was either –20 °C or –30 °C. The breads were installed on aluminum trays in a rolling rack. Breads
made from 13 kg of dough were used for each freezing experiment. Two set point temperatures were used, -20 °C and -30 °C
for case 1 and 2 respectively. The breads were installed on aluminum trays into the rolling rack were equilibrated at 30 °C in a
fermentation cabinet before freezing. The temperature of the bread placed on the trays was measured during freezing and was
averaged from the temperature of three breads located at the upper middle and bottom locations of the trays installed in the
rolling rack. The temperatures of the trays and of the rack were logged and used for the energy balance. An energy counter
was used to measure the energy consumption. The energy counter had a 2 Wh or 7.2 kJ resolution (VM14 96 - Carlo Gavazzi,
Lainate, Italy). The specific electrical energy demanded was calculated from the mass of dough. The water resulting of frosting
was removed from the evaporator heat exchanger with compressed air before each test. The freezer was equilibrated for 30
min at the selected set point temperature prior to freezing. The energy was measured until an average temperature of – 14.8
°C was reached by the breads. This temperature corresponds to the temperature for which 80 % of the freezable water is
frozen. The temperature was determined from an enthalpy function that had been established assuming a crust – crumb ratio
of 0.2. The total mass of the bread was measured before and after baking or freezing. More details are available in [33].
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Figure 25 : View of the rolling rack with the empty trays installed.
The arrows indicate the direction of the air blown by the fans.
Figure 26 : View of the 4 fans which were blowing the air on
the breads installed on the trays.
RESULTS - Impact of the set point temperature on energy demand
The impact of the set point temperature on the energy demand is quoted in Figure 27. It is clear that the lower is temperature,
the lower is the specific energy needed to freeze the bread. The final temperature of the bread has also a big impact. The
criterion proposed by the IIR to determine if a product can be considered as frozen is, either that 80% of the freezable water is
effectively frozen or that the temperature of the product is -12°C [34]. In our case, the criteria to consider was the “80% of
freezable water frozen”, which correspond to around -15°C [33].
The values that were observed in this small freezing unit are not fully representatives of the values that would be obtained on a
large freezer (values should rather be around 0.5 MJ.kg-1). However, the values that we measured correspond to the realistic
case of a freezing operation in a medium scale blast air freezer. Other results obtained with a larger freezer which was
equipped with the same power for the fans (5 m3 internal volume and 3 fans of 400 Watts each) showed that values of the
energy demand were around 0.5 MJ.kg-1. Other experiments have been done with a reduced power of the fan (not shown).
However, such equipment represents what can be found on the market and used by SMEs.
FREEZING
TIME (min)
SPECIFIC ENERGY (MJ/kg)
4.0
240
220
-20°C
200
180
160
-30°C
140
120
100
80
60
40
-30
-25
-20
3.5
-20°C
3.0
-30°C
2.5
2.0
1.5
1.0
-15
-30
BREAD TEMPERATURE (°C)
-25
-20
-15
BREAD TEMPERATURE (°C)
Figure 27 : Impact of the set point temperature on the freezing time for 20°C and – 30°C set point temperatures.
Figure 28 : Impact of the set point temperature on the energy demand for
freezing of bread between 30°C and a given temperature
The pie chart presented in Figure 29 has been obtained by considering some unexplained losses at a 10% level. This
adjustment has been done to accommodate uncontrolled losses linked for example to door opening, heaters installed around
the gasket of the door to prevent sticking, etc…. The coefficient of performance (COP) was adjusted to reach this 10% level;
the COP was 0.83. Once can see that the fans demand around 42% of the available refrigeration energy, which is a lot. The
energy demanded by the fans, could be reduced by reducing the fan speed. This has been done in other experiments.
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-30°C
Unexpl. Losses;
10.0%
Energy of product;
21%
Energy of fan;
42%
Energy of support;
13%
Energy of walls;
14%
Figure 29 : Pie chart of the energy demand at -30 °C set point. The basis is the net refrigeration energy. The
unexplained losses have been arbitrarily adjusted at 10% (COP = 0.83).
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
% OF TOTAL ENERGY
(PROCESS + STORAGE)
% OF ENERGY FOR FREEZING
AND FROZEN STORAGE
The data related to frozen storage energy are scarce and depend a lot on selected conditions such as volume of the cell, set
point temperature, occupation ratio, ventilation, …. Data provided by a report available from [35] have been used. as a first
approach. The energy for frozen storage was evaluated as (mean value) 75 kWh.m -3 storage per year or 270 MJ.m-3.Yr-1. The
occupancy ratio of cardboards in the frozen storage was evaluated to be 0.7 m 3.m-3 storage. The occupancy ratio of breads in
a cardboard was determined experimentally and was 120 kg.m-3. The effective occupancy ratio was therefore 84 kg.m-3 of
storage. This results in energy for the frozen storage of 270 MJ.m-3 storage or 22.5 MJ.m-3 storage for one year or again for
one month 0.268 MJ.kg-1.month-1. Considering a freezing energy of 1 MJ.kg-1 of bread, the evolution of the relative energy
corresponding to the process and to the storage respectively is shown in Figure 30. After 3 months of frozen storage, the
energy taken for freezing the bread was almost equal to the energy spent during the frozen storage. This indicates that even
though a lot of efforts are done to reduce the energy demand during the freezing process, the energy demanded during the
frozen storage can become much higher. Therefore, the frozen storage should not be too long if possible. A more realistic
overview of the energy stake linked to frozen storage is shown in Figure 31. In this case, the energy considered for the bread
encompasses the energy for partial baking, freezing and final baking (making a total of 3.5 MJ.kg -1). After 3 months storage,
the frozen storage energy represents around 20 % of the cumulated energy.
FREEZING PROCESS
FROZEN STORAGE
0
0.5
1
1.5
2
2.5
% PROCESS
% STORAGE
0
3
0.5
1
1.5
2
2.5
3
STORAGE DURATION (MONTHS)
STORAGE DURATION (MONTHS)
Figure 30 : Relative percentage of the freezing ratio
(1MJ.kg-1) and of the frozen storage energy (0.268 MJ.kg1.month-1) in function of the frozen storage duration.
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Figure 31 : Relative percentage of the total energy for frozen part
baked bread (3.5 MJ.kg-1 for partial baking, freezing and final baking
according to [33] and of the frozen storage energy (0.268 MJ.kg1.month-1) in function of the frozen storage duration.
Another set of results has been obtained by partner TTZ using larger equipments. Different bake-off technologies were
investigated in terms of their energy consumption during the freezing step. Bake-off technologies which contain the freezing
step are the fully baked frozen process (FBF), the part baked frozen process (PBF), the unfermented frozen process (UFD)
and the pre-fermented frozen process (PFF). To measure and compare the energy needed for each bake-off technology there
were produced as much products as needed to have a full occupied freezer. That means for each trial 18 baking trays were
filled with 30 pieces of dough or baked/par-baked products. The energy for freezing was determined by controlling the core
temperature inside the product which should reach around -18 °C. Additionally the energy for cool down the freezer at an
operating temperature of -30 °C and for cooling the equipment such as the baking trays and rolling carrier as well as the
energy needed for running the fans have been determined and partly theoretical calculated for setting up an energy balance
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calculation. The unexplained energy losses are the difference between the theoretical calculated energy and the practical
measured energy consumption. Most energy was needed for cooling down the freezer to its operating temperature of -30 °C.
The energy for freezing the dough or baked product was between 16 and 19 %. For running the fans between 11 and 17 % of
the energy was needed. In this study between 2 and 7 % of the measured energy was declared to unexplained losses.
Figure 32 : Distribution of Energy during shock-freezing depending on different bake-off technologies. A fully loaded shock-freezer was used.
2.2 OBJECTIVE 2: To develop innovative process pathways.
2.2.1 Vacuum baking
Moderate vacuum (-20kPa) during baking favoured oven rise (28% compared to 18-20% in commercial oven) with lower
temperature (90°C compared to 230°C). Given the operating temperature of the air in the oven, the crust was still white (no
brightness) and thin, making this technology applicable to part-baked bread only. Water loss was also reduced (18% down to
8%). Due to lower operating temperature and lower load for the initial oven heating and then for temperature regulation, up to
50% of energy might be saved still relative to the conventional part-baked bread technology. The concept and the set-up of the
process under concern were carried out on the lab scale and would merit confirmation on pilot scale.
Effect of different parameters on oven-rise was tested, such as: proofing time, pressure lowering, steam injection and flour
crop. Proofing time was the most sensitive parameter. A short proofing duration produced an increase in oven-rise from 28%
(at 45 min proofing) to 50% (at 30 min proofing). This would undoubtedly lead to higher potential reduction of energy
consumption, although this point was not further investigated. Conversely, a proofing duration of 60 min combined to a vacuum
baking at -20 kPa yielded oven-rise of the same order as the one obtained at atmospheric pressure in the vacuum laboratory
oven.
Ultimately the crumb texture was also coarser, with medium to large bubbles quite uniformly distributed (see deliverable
D5.19); some dense areas might also appear at the bottom. Monitoring with Magnetic resonance Imaging combined to
variations of different process parameters provided a better understanding of bubble growth under partial vacuum baking and
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further control (see deliverable D5.23). In no case did the lowering of pressure (within the first few minutes of baking) produce
heterogeneities in crumb texture. Dense areas in crumb at the bottom were shown to disappear by controlling the temperature
increase at the plate. In fact, the formation of a dry skin at the dough surface, especially near the bottom, controlled the overall
expansion and the extent of densification in crumb. Steam injection was not helpful in the present conditions, although it would
merit further investigation before final conclusion. Large bubbles reported above were observed when overall expansion was
maximised. Although it would merit further analysis and investigation, it was understood that these bubbles appeared where
the stresses were the highest in the roll, the dough being too highly stretched in this region.
65
Height (mm)
60
55
Self-supporting
structure
50
45
Commercial oven
Vacuum oven
40
0 1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031
Time (min)
Figure 33 : Total height during baking and cross bread section of partial vacuum baked and conventional direct baked breads.
Pictures on the right: LEFT = vacuum baking, RIGHT = conventional baking.
2.2.2 Amyloglucosidase : up to 15% energy saving during baking
During EU-FRESHBAKE, partner TTZ-EIBT has investigated the impact of Amyloglucosidase (AMG) on crust colouration and
by the way on baking duration. The enzyme has been provided by partner PURACOR. The effect of 300 ppm and 600 ppm
EU-FRESHBAKE-AMG (related on flour) on the browning behaviour were analysed and compared to a reference without EUFRESHBAKE AMG (see Table 3). AMG does decompose the starch to glucose which promotes the work of yeast and
therefore the browning reaction. The part-baking process was used for this analysis. For the pre-baking step the conditions
were the same in all trials with and without EU-FRESHBAKE AMG. In the final baking step the products were baked with the
same temperature conditions but in the cases with the addition of EU-FRESHBAKE AMG the baking program was shortened
from 12 min. down to 10 and 8 min. in step 1 (see Table 4). The effect of EU-FRESHBAKE AMG was determined by
comparing the degree of browning using the Lab-colour space as reference.
Results of baking trials with the use of EU-FRESHBAKE AMG and the reduced baking time (in step 2 of the project) showed
that under this condition the dosage of 600 ppm EU-FRESHBAKE AMG did lead to a comparable colour with the reference
product. The product with the addition of 600 ppm EU-FRESHBAKE AMG was baked with a four minutes shorter final baking
program and this means an energy reduction of around 30 %.
Table 3 : Used recipes for comparison of different dosage of EU-FRESHBAKE AMG
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Table 4 : Baking programs for the part-baking process.
The second baking step was reduced from a baking time of 12 min. down to 10 and 8 min.
 Mist Fermentation – Energy saving during baking (energy saving 17%)
Partner TTZ-EIBT has investigated the interest of pre fermentation on the final quality of bread made with frozen dough; this is
called the pre-fermented frozen dough process (PFF). A conventional working fermentation chamber in which the steam is
produced by vaporising was used as reference process. Using this reference system the baking time for the products was
about 31 min. In a second trial the PFF dough pieces were fermented in a novel fermentation chamber with the ultrasonic
smokescreen system and the products were baked with the same baking program but different baking times with 31 min., 29
min., 27 min. and 25 min. After the baking process the browning of the products were compared using the Lab-colour space
system. Considering the conditions in this study the colour of the products fermented with the ultrasonic smokescreen system
and baked with 27 minutes showed nearly the same colour as those products coming from the conventional fermentation
system baked with 31 minutes (see Figure 34). The ΔE (colour difference) was the smallest meaning it is most comparable
with the reference product. The 4 minutes shorter baking program in this case means an energy reduction of around 17 % (see
Figure 35).
Table 5 : Measured Lab-values of the baked products
Figure 34 : Picture of the baked products depending on the baking program.
The two upper lines of bread have been obtained with pre fermented frozen dough using Ultrasonic smokescreen fermentation,
and the two products at the bottom have been obtained with conventional fermentation cabinet.
From left to right, the baking time was 31, 29, 27 and 25 min. Based on the crust colour, a baking time of 27 min for PFF +
Ultrasonic smokescreen was similar to a conventional process with 35 min baking time.
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EU-FRESHBAKE Project, Final Report, June 2010
Figure 35 : Results of the measured energy for the products produced with a conventional fermentation system and with the novel
ultrasonic smokescreen – system (MicroTec)
2.3 OBJECTIVE 3: To develop innovative formulations adapted to the innovative processes.
2.3.1 Gluten bread formulation and GI
Added fibres combined to partial baking induces higher reduction of GI, with the subsequent nutritional impact. The addition of
fibres together with freezing treatment significantly reduced the glycaemic index of wheat rolls (P<0.05). This effect has not
been seen when fibres or freezing treatment were used separately.
Figure 36 : Glycaemic index (%) of fresh and frozen storage wheat rolls enriched with fibres. Data are shown as a mean ± SEM. Different
letters show significantly different values at P< 0.05.
Partner PURATOS has contributed to the formulation of bread, in particular in proposing selected fibres and sourdough. The
effect of addition of different sourdoughs, respectively at different concentrations, to the recipe of PBF rolls has been evaluated
and a dry wheat sourdough that allows adding a sufficient amount of organic acid, in order to positively influence the GI of the
final product and obtain PBF rolls with good sensorial properties after final baking, has been selected. Addition of the dry
wheat sourdough to the recipe of PBF rolls allows obtaining a final baked product with a low GI, < 55.
2.3.2 Innovative ferments adapted to bake off technology.
Ferments have been tested and selected by partner PBF according to both nutritional and quality effect on the fresh product.
The work has been carried out within the PhD preparation of Domagoj GABRIC. Initially, the potential of sourdough addition in
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EU-FRESHBAKE Project, Final Report, June 2010
part-baked frozen wholemeal wheat bread for overcoming volume and crumb texture impairment was evaluated. The
sourdough was prepared with wholemeal wheat flour (ash content 1.7 %), tap water (100% on flour), and starter in
fermentation cabinet at 30°C, 15 to 18 h, until pH 4 was reached, depending on the used starter. For sourdough fermentation
two commercially available starters Pallazo PL1 (Blessing Biotech GmbH, Germany) containing Lactobacillus fermentum, and
Saf Levain LV4 (Lesaffre, France) Lactobacillus brevis with S. cerevisiae var. chevalieri, and pure cultures Lactobacillus
plantarum (DSM2601) and Lactobacillus sanfranciscensis DSM20451 (DSMZ GmbH, Germany) were used. Sourdough was
added in bread dough at three levels: 10 %, 15 %, and 20 %. The sourdough starter and dosage did not significantly influence
the maximum relative volume expansion ratio () of dough during proofing, while the proofing time (t inifinity) was shorter when
sourdough was added. Sourdough addition prolonged time when bread dough started to rise but the maximum specific growth
rate of dough was increased, depending on the sourdough dosage. As reported in literature, the drop in pH associated with
organic acids production causes an increase in the proteases and amylases activity of the flour, thus leading to an increased
concentration of free sugars and weakening of gluten structure. Since gluten is partially degraded, dough capabality of keeping
developed CO2 is reduced in comparison to yeast dough.
For baking test, bread dough was proofed according to determined t infinity and breads were produced according to the
established EU-FRESHBAKE part-baked frozen protocol. After final baking and 1 hour cooling at room temperature, quality
parameters of bread samples were determined. The positive influence of LV4 and L.plantarum sourdough addition up to 15 %
on bread specific volume and crumb firmness was determined (Figure 37 & Figure 38) while bread shape has remained almost
the same. PL1 sourdough did not affect bread quality parameters while L. sanfranciscensis sourdough addition in experimental
conditions had negative effect. However, higher sourdough dosage (20 %) had detrimental effect on bread volume and crumb
texture decreased specific volume in comparison to control bread, caused by weakening of the gluten network. All bread
samples had improved flavour with sourdough addition. Overall, the highest bread quality in terms of specific volume, shape,
crumb texture and flavour was achieved with addition 15 % of LV4 and L. plantarum sourdough. During sourdough
fermentation, lactic acid bacteria metabolites, mainly organic acids, exopolysaccharides (EPS) and/or enzymes which have
been shown to have a positive effect on the texture and staling of bread (Arendt, Ryan and Dal Bello, 2007). An original paper
entitled „Influence of sourdough addition on dough proofing and quality of wholemeal partially baked frozen wheat bread” was subimitted
to Journal of Food Process Engineering.
3,8
3,6
3,6
Specific volume,cm-3g
Specific volume,cm-3g
3,4
3,2
3,0
2,8
2,6
2,4
3,4
3,2
3,0
2,8
2,6
2,4
2,2
0
10
15
Sourdough addition,%
20
Mean
Mean±SE
Mean±SD
Outliers
Extremes
2,2
PL1
Lp
LV4
Starter used
Yeast
Mean
Mean±SE
Mean±SD
Outliers
Extremes
Figure 37 : Influence of sourdough addition (with starter L. fermentum (PL1), L. plantarum (Lp), and L. brevis with S. cerevisiae var.
chevalieri (LV4)) on specific volume of part-baked wholemeal wheat bread
Page 32 of 68
320
320
300
300
280
280
260
260
Firmness,g
Firmness,g
EU-FRESHBAKE Project, Final Report, June 2010
240
220
200
240
220
200
180
180
160
160
140
PL1
Lp
LV4
Starter used
Yeast
Mean
Mean±SE
Mean±SD
Outliers
Extremes
140
0
10
15
20
Sourdough addition,%
Mean
Mean±SE
Mean±SD
Outliers
Extremes
Figure 38 : Influence of sourdough addition on crumb firmness of wholemeal part-baked frozen bread
2.3.3 Fibres in BOT: impact on the physical characteristics of breads.
Partner CSIC IATA has investigated the interest of fibres addition on the physical characteristics of bread. Results are
gathered in reference [36] (Impact of fibres on physical characteristics of fresh and staled bake off bread – 2010). Bread quality
has long been the target of cereal technologist, looking for ingredients and improvers that provide better volume and improved
sensory characteristics. Nowadays, consumer expectations include the term healthy, being necessary to meet the binomial
healthy-pleasant when innovative formulations are foreseen. Considerable scientific research has confirmed the beneficial role
of the dietary fibre in the reduction of chronic ailments such as cardiovascular disease, certain forms of cancer and
constipation. Those statements have raised consumer awareness about the healthy role of dietary fibre intake, gaining
popularity fibre enriched cereal based products. In conventional breadmaking, fibre replacement of flour disrupt the starch–
gluten matrix and restrict and force gas cells to expand in a particular dimension affecting dough viscoelastic behaviour and
constraining dough machinability and gassing power. The fibre source and the type and degree of processing are the main
factors influencing functional properties. In the last decades bake off or interrupted technologies (BOT) are becoming a
common practice for the big bakeries, but despite the increasing awareness about increasing the fibres intake in bread making
products, there is scarce literature about their impact on the bread technological quality obtained from BOT technologies.
In the frame of the EU-FRESHBAKE project, the technological functionality of different fibres (high methylated ester pectin,
resistant starch, insoluble-soluble fibre blend) was tested in partially baked breads stored either under sub-zero or low
temperatures, in order to assess their possible role as bread making ingredients in bake off technologies (BOT). Fibrecontaining formulations affected bread specific volume and crumb hardness, and those characteristics were also dependent on
both the breadmaking process (conventional or BOT) and the storage conditions of the par-baked bread (low or sub-zero
temperatures). Formulation had great impact on the crumb hardness of bread obtained by conventional bread making process
(Figure), namely resistant starch and fibre blend that resulted in a significant increase of the crumb hardness. The fibre blends
had a marked effect on crumb hardness yielding a coarse crumb structure; similar effect, although in lesser extent was
observed in the presence of resistant starch. The same tendency was observed with BOT technologies, again fibre blend gave
the highest hardness followed by resistant starch. The presence of pectin did not modify the crumb hardness, and that effect
was independent of the breadmaking process. Storage of par-baked bread led to a steady increase of the crumb hardness, but
the slope of the enhancement was strongly dependent on the formulation and storage temperature. In general, storage at low
temperatures gave fully baked breads with harder crumbs than their counterpart stored at sub-zero temperatures.
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EU-FRESHBAKE Project, Final Report, June 2010
1400
1400
Conv
Conv
0 days
0 months
3 days
1200
1200
7 days
1 months
2 months
10 days
3 months
1000
Hardness (g)
Hardness (g)
1000
800
600
600
400
400
200
200
0
0
control
RS
pectin
fibers blend
Formulation
1
800
control
RS
pectin
fibers blend
Formulation
Figure 39 : Effect of fibre enriched formulation and storage conditions of par-baked bread on the crumb hardness of fully baked breads.
Left: partially baked bread stored up to 10 days at low temperatures, Right: partially baked bread stored up to three months at sub-zero
temperatures. Conv: conventional bread making; RS: resistant starch.
The storage of par-baked breads at low temperatures accelerates crumb hardening during staling; this effect was greatly
dependent on the duration of the storage and was magnified for breads containing fibre blend, whereas was minimized in the
samples containing pectin. Storage of par-baked breads at low temperatures accelerates crumb hardening during staling, and
that effect was greatly dependent on the duration of the storage. Moreover, those storage conditions had negative impact on
the breads containing fibre blend. Breads from partially baked frozen showed slow crumb hardness increase and that
enhancement was independent on the time of storage. Control samples and bread containing pectin obtained from PBF had
the same hardening trend than their counterparts obtained by conventional bread making, thus the BOT process did not affect
the crumb hardening. In addition, pectin was the polymer that kept softer crumbs during longer period, and also reduced crumb
hardness differences among breads stored for different periods at low or sub-zero temperatures (Figure 39).
Obtained breads can be labelled as source of fibres (fibre content ≥ 3) or high in fibres (fibre content ≥ 6). Adding of inulin
resulted in a faster crust colouration. Overall results indicated that storage conditions of the partially baked breads had also
great incidence on specific formulations like those containing fibre blend, which were not strong enough to keep crumb
structure. The supplementation with pectin or resistant starch resulted in breads from PBF, keeping their specific volume and
crumb texture during sub-zero temperature storage. Low temperatures are a recommended alternative for extending the shelflife of partially baked bread due to their lower energy input, but, although it has reduced impact on the specific volume, crumb
hardness and staling of fully baked breads were progressively accelerated along storage.
Therefore, formulations should be carefully checked with the specific bread making process to be followed, and in the case of
BOT processes, even the storage conditions of the partially baked bread play a fundamental role on the technological quality of
fresh breads and their behaviour during staling.
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EU-FRESHBAKE Project, Final Report, June 2010
0 3
CControl
4500
7
10
0*
1*
2*
3*
b
4000
3500
3500
3000
3000
2500
2000
1500
500
0
0
0
72
60
48
36
0*
1*
2*
3*
1500
500
24
10
2000
1000
12
7
2500
1000
0
0 3
CControl
4500
4000
Hardness (g)
Hardness (g)
a
12
24
72
60
48
36
Time (h)
Time (h)
1
0 3
CControl
4500
7
10
0*
1*
2*
3*
d
4000
3500
3500
3000
2500
2000
1500
0 3
CControl
4500
4000
Hardness (g)
Hardness (g)
c
7
10
0*
1*
2*
3*
3000
2500
2000
1500
1000
1000
500
500
0
0
0
12
24
36
48
60
72
0
12
24
36
48
60
72
Time (h)
Time (h)
2
Figure 40 : Evolution of crumb hardness during staling of fibre-enriched breads obtained from conventional bread making (C), par-baked
breads stored at low temperatures (solid symbols) or sub-zero temperatures (open symbols).
a: control (without fibres), b: resistant starch, c: pectin, d: fibre blend. Legend is referred to the days of storage at low temperatures or the
months of storage at sub-zero temperatures.
2.3.4 Fibres in BOT: impact of adding of inulin on the aroma of breads.
The impact of fibres on the aroma of breads has been investigated at ONIRIS during the PhD of Pauline POINOT [26]. Key
results have been presented in references [37, 38]. Structurally different fibres have been tested with special emphasis on the
interaction with the bread making process. Fibres tested gave some stability to the product quality when BOT technology
including frozen storage was used.
Breads that can be labelled as source of fibres (fibre content ≥ 3) or high in fibres (fibre content ≥ 6) are obtained. The adding
of inulin resulted in a faster crust colouration, which in turn can become an advantage to reduce the baking time. The impact of
inulin on the formation and release of white bread volatiles has also been studied. For that, an innovative on-line baking
extraction device was designed to enable the extraction of volatiles released during different time intervals of the same baking.
Physico-chemical properties of breads were also followed throughout their baking. It was demonstrated that inulin accelerated
bread baking and, more particularly, bread crust formation and the Maillard reaction. This led to breads with a similar overall
quality to that of non-enriched breads, but baked for a shorter time. Adding inulin to white breads could thus have several
advantages. First, inulin-enriched breads possess an increased nutritional quality, combined with organoleptic properties
similar to conventional white bread, which is better accepted by consumers. Secondly, adding inulin to breads could have a
positive environmental impact, as such breads could be baked for a shorter time to achieve acceptable organoleptic qualities.
2.3.5 Gluten free formulation (hypoallergenic protein + enriched calcium + fibres)
Partner Dr SCHAER is a company specialized in gluten free bakery products. It has been mainly in charge of developing
specific formulation adapted to its market. A new formulation developed during the EU-FRESHBAKE project, provides
nutritional and sensory improvements:
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EU-FRESHBAKE Project, Final Report, June 2010
-
It contains hypoallergenic protein (rice protein), it is a source of Calcium (15% RDA, 120 mg/100g of bread) and it is
high in fibre (6g /100g of bread);
Compared to reference gluten free formulation it shows a crumb and crust colour improvements, less off odour and a
more typical taste.
Gluten free bread is poor in protein compared to ordinary bread. Furthermore bread, both gluten free and ordinary bread,
contains a low content of Lysine. Legumes are rich in this essential amino acids (FAO, 1981 and Iqbal et al, 2006). For this
reason, at the beginning of the project, legumes addition (pea protein, chickpea flour, bean flour and fava bean flour) was
evaluated. It was decided to not consider soybean, because it is one of eight most common allergens.
Two levels of proteins were tested: 3.8 and 4.8g/100g of bread. The effect of the two level additions was studied on pea protein
and the lower level was selected for all proteins in order to get a compromise between nutritional value and physical quality of
bread. In fact the addition of protein in the formulation resulted in a bread with lower volume (from 2.11 to 1.76 cm3/g, see
Figure 41) and a harder crumb (173.5 g at level 0, 197.7 g at level 1 (3.8g/100bread) and 355.4 g at level 2 (4.8g/100g bread)
at1 hour, see Figure 42).
Volume of the bread
Hardness of the bread at different level of
pea protein
y = -0,1744x + 2,2945
R2 = 0,995
2,50
hardness (g)
Volume (cm3/g)
2,00
1,50
1,00
0,50
0,00
0
1
2
800,0
600,0
400,0
200,0
0,0
0
% pea protein on the recipe
Figure 41 : Volume changing at different level addition of pea
protein.
Data with different letter are statistically different with P<0.05
(Fisher's least significant difference procedure)
1 hour
1 day
1800,0
1600,0
1400,0
1200,0
1000,0
1
%pea protein on the recipe
2
Figure 42 : Hardness changing of the crumb in bread enriched with
different levels of pea protein
The addition of chickpea and bean flour resulted in bread with the higher volume and higher softness both at 1 hour and at 1
day. The cells of the crumb were the smallest and their number on cm2 was the highest (see Table 6). Chickpea flour was
rejected because the bread showed a too strong legume aroma and a too crumbly texture. Bean flour was preferred for its
positive sensory and technological characteristics.
Table 6 : Physical evaluation of the bread enriched with different legume proteins
(cm3/g)
Volume
shape (d/h)
Moisture Content (%)
Hardness 1h (g)
Hardness 1day (g)
Crumb cell analysis:
Porosity
n°cell/cm2
Area
PEA
average
1.96 a
1.73 a
44.2 a
198 a
729 a
0.23 a
12.99 a
1.04 a
ds
0.11
0.09
1.1
68
213
FAVA
BEAN
average
2.09 b
1.99 c
43.5 ab
257 b
859 b
ds
0.11
0.17
1.1
66
167
CHICKPEA
average
2.33 c
1.87 b
43.0 bc
134 c
523 c
ds
0.06
0.08
0.7
21
60
BEAN
average
2.36 c
2.13 d
42.6 c
152 c
633 d
ds
0.06
0.17
1.5
29
162
0.03
0.86
0.06
0.24 a
13.26 a
0.94 b
0.02
1.02
0.06
0.22 a
14.19 b
0.87 c
0.03
1.26
0.08
0.24 a
14.35 b
0.92 bc
0.03
1.07
0.07
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Unfortunately there were some problems with the bean flour quality: it was found not constant for gluten content and
technological characteristics. For this reason bean flour was replaced by rice protein: an hypoallergenic ingredient which
received a good sensory score.
Individuals with celiac disease has been identified as having a higher daily calcium requirement than the general population:
for this reason calcium citrate was added to the formulation
The final formulation included also some fibres (pectins and inulin) in order to have 6 g of it in 100 g of bread (high fibre
product). Fibre fortification is important both for conventional wheat bread and gluten free bread for its nutritional value, ranging
from good gastrointestinal health benefits to resistance to cancer and hearth disease.
In Table 7 are summarized the nutritional values. From a sensory point of view, the new formulation showed a less yellow
crumb, a more brown crust, less off aroma and a strong bread taste (see
Figure 43 & Figure 44).
Figure 43 : Reference recipe (D1.1.3) on the left and new formulation on the right
Table 7 : Nutritional value of the new recipe
Analysis
Energy value
Energy value
Proteins (Nx 6,25)
Fat
Saturated fatty acid
Unsaturated fatty acid
Carbohydrates
Fructose
Glucose
Sucrose
Lactose
Maltose
Unsoluble Fibre
Soluble Fibre
Inuline and fructose polymers
Ash content
Chloride (NaCl)
Sodium (Na)
Calcium (Ca)
Value
233
985
4.6
3.6
0.59
2.85
45.5
0.63
0.25
4.2
3.0
2.0
1.17
0.65
345
126
Standard Deviation
0.2
0.5
2.3
0.06
0.03
0.6
0.7
0.4
0.11
0.03
7
2
Page 37 of 68
Unit
kcal/100g
kJ/100g
g/100g
g/100g
g/100g
g/100g
g/100g
g/100g
g/100g
g/100g
g/100g
g/100g
g/100g
g/100g
mg/100g
mg/100g
EU-FRESHBAKE Project, Final Report, June 2010
D 4.8.47
bread aroma
5,00
off flavour
reference
staling odour
4,00
3,00
bread taste
2,00
off aroma
1,00
0,00
intensity of the yellow
colour of the crumb
juiciness
intensity of the brown
colour of the crust
crumblyness
softness
Figure 44 : Qualitative Descriptive Analysis for new formulation and reference bread. An intensity value scale from 0 to 5 was used, with 0
= the attribute is not perceived and 5 = the attribute is highly perceived
2.3.6 Gluten free formulation and concepts
During EU-FRESHBAKE, Partner BEZGLUTEN which is a Polish company specialized in gluten free bakery products has
developed different formulation with the objective of obtaining a crispy roll with improved quality. In order to improve rheological
properties of the dough guar gum was partially replaced with galactomannan with larger molecules and hot water solubilitylocust bean gum. The replacement resulted in better machinability of gluten-free dough, and helped to divide and shape the
rolls. It also significantly diminished hardness during 3 days of storage.
The application of innovative gluten-free formulation slightly improved quality of the obtained rolls. At the same time the
application of partial baking combined with modified atmosphere packaging allowed to reduce energy consumption at the
production plant, although total energy for bread preparation would probably be increased, depending on the equipment used
for final baking.
Figure 45 : Products obtained with 3 hydrocolloids (left) and 4 hydrocolloids (right)
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EU-FRESHBAKE Project, Final Report, June 2010
Modified recipe for gluten-free bread was used as a basis for rolls with improved nutritional quality. The replacement of starch
and corn flour with amaranth flour caused some deterioration of dough machinability, which was the reason to shorten the
fermentation time. The use of amaranth flour had significant impact on volume and texture of gluten-free rolls. The obtained
products were however highly acceptable, taking into account their taste and aroma. Taking into account chemical composition
of the obtained products, they were significantly improved in nutritionally important components.
Quality parameters of flaxseed enriched rolls were lower than standard, although they displayed good smell and taste. Slightly
better results were obtained, when the rolls were baked on laboratory scale, which could be due to differences in fermentation,
and baking. Because of important nutrients present in flaxseed enriched rolls, they could still be an interesting option for the
consumers of gluten-free products.
The results of performed consumer survey indicated, that overall acceptability of gluten-free rolls among non-celiac consumers
is quite low. However they also showed that the addition of flaxseed didn't negatively affect quality of the product, and such
products could be an interesting offer for existing market, especially when nutritional benefits of its use are demonstrated. It
seems that celiac people could be much more interested in a possibility of baking the product at home, as they are often
accustomed to do so.
Table 8 : Comparison of quality parameters of gluten-free reference rolls (obtained by standard technology and with the application of modified
atmosphere packaging) , and products obtained with flaxseed and amaranth (MAP)
Quality parameter
REFERENCE
Reference-MAP
Amaranth
Flaxseed
Specific volume
[cm3/g]
4.07
4.17
3.35
2.17
Shape
0.62
0.65
0.54
0.5
Firmness [N]
6.18
14.53
19.73
25
6
6
7
7
Flavour
NORMALIZED
Specific volume
0.61
0.63
0.43
0.14
Shape
0.61
0.68
0.4
0.31
Firmness
0.77
0.46
0
0
Flavour
0.37
0.37
0.68
0.68
Total score
0.74
0.68
0.52
0.41
100.00%
91.32%
67.29%
59.91%
%
2.3.7 Innovative Organic bread formulation designed with durum wheat flour
Partner BIOFOURNIL is a French SME bakery, which is specialized in organic breads. A new formulation was tested in order
to improve nutritional characteristics of organic wheat bread and glycaemic index (GI) in particular. The mix of durum wheat
flour and soft wheat flour is traditional in east of Europe and can provide interesting structure combined with different nutritional
profiles. Several durum wheat flour additions to dough and several water additions were tested in order to choose the optimal
one in terms of dough handling and product development. Trial n°3 (see Figure 46 & Figure 47) gives the best compromise
between bread volume, alveolation score and dough handling (stickiness). In terms of GI, trial n°3 was compared to reference
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100
7
90
6
80
Glycemic Index (%)
180
160
140
120
100
80
60
40
20
0
Alveolation (score)
Bread Volume (cm3)
recipe. With the same process (part-baked packed under protective atmosphere) trial n°3 gives a significantly lower GI than
the reference recipe (Figure 48).
5
4
3
2
1
2
54,57
60
50
40
30
20
10
0
1
71,9
70
3
1
2
0
3
reference
Trials
Trials
Figure 46 : Effect of different durum wheat
flour additions on organic roll volume
Figure 47 : Effect of different durum
wheat flour additions on organic roll
alveolation
trial 3
Figure 48 : Glycemic index (%) of
reference organic roll and trial 3 roll (with
durum wheat flour).
Data are shown as a mean  SEM.
Based on this result, breads made with recipe n°3 (trial 3) could be considered as low-GI (< 55) products. Besides, Protein
Efficiency Ratio and calcium concentration were significantly higher in rats fed with breads n°3.
This new formulation gives interesting results concerning nutritional quality improvement of our organic products.
In parallel, a study on the impact of durum wheat on crumb texture has been carried out in collaboration between ONIRIS and
BIOFOURNIL (2009). During this study, a protocol similar to the one presented before to assess the impact of the degree of
baking on staling has been used (Figure 6, Figure 7, Figure 8 & Figure 9). Samples have been prepared as degassed bread
dough and have been baked in the miniaturized baking system developed at ONIRIS. The baking was done with baking at 6.8
°C/min followed by a plateau of 8 min at 98°C. One can see on Figure 49 that the bread made with the durum wheat flour had a much
softer crumb than the reference bread made with organic formulation. In Figure 50, one can see that the amount of amylopectin (and the
related energy of melting of crystals during staling) was much lower for the bread made with durum wheat. This could explain the fact that
the durum wheat bread is much softer than the reference bread. Sensory analysis has been carried out during the demonstration phase at
the end of the project comparing these two breads. The consumers were able to detect that the crumb was softer and were interested by
this new product. Questionnaire has been proposed during the sensory tests which has been carried out and showed that the fact that the
bread was baked with less energy should no have any impact on the price of the bread. Beside, consumers were keen to pay more if the
bread had a lower GI, which was the case for the durum wheat bread. The research activity carried out by BIOFOURNIL has thus been
successful in terms of innovation, resulting in both a softer crumb and a lower GI.
1,600
4,500
1,400
4,000
1,200
3,500
1,000
E en MPa
E en MPa
3,000
2,500
2,000
0,800
points expérimentaux P4 BD
modèle P4 BD
points expérimentaux P4 référence
modèle P4 référence
0,600
points expérimentaux P4 BD
1,500
0,400
modèle P4 BD
1,000
points expérimentaux P4 référence
0,500
0,200
modèle P4 référence
0,000
0,000
0
1
2
3
4
5
6
7
8
9
10
0
11
1
2
3
4
5
6
7
8
9
10
11
Jours de stockage à 10°C après précuisson
Jours de stockage à 10°C après précuisson
Figure 49 : Young modulus (E) of degazed and baked bread crumb
during staling at 10°C in function of the storage duration (days).
The upper plot (purple) is the reference recipe (organic bread). The
lower plot (blue) is the bread made with a mix of wheat flour
(whole meal) and of durum wheat flour.
Figure 50 : Enthalpy of melting of amylopectin crystals during
staling at 10 °C of degazed bread crumb during in
function of the storage duration (days).
The upper plot (purple) is the reference recipe (organic bread).
The lower plot (blue) is the bread made with a mix of
wheat flour (whole meal) and of durum wheat flour.
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2.3.8 Specific enzymes to improve the nutrition properties and to reduce the
energy during baking
The effect of wholemeal formulation containing xylanases on the phytate content of the resulting fresh wholemeal wheat
breads is presented in this deliverable. Wholemeal breads containing xylanases showed lower content of InsP6, InsP5 InsP4
than the reference bread, although differences were not always statistically significant. The addition of xylanases in the
formulation of wholemeal bread modifies the myo-inositol phosphate profile of the resulting fresh bread and that effect was
dependent on the type of xylanase used as technological aid. The hydrolytic activity of xylanases on the polymeric compounds
might favour the accessibility of the endogenous phytase to its substrate, obtaining different myo-inositol phosphate profile in
the fresh breads.
Table 9 : Myo-inositol phosphates content in whole wheat flour and bread
Samples
Whole wheat flour
No Xylanase bread
Xylanase bread 1
Xylanase bread 2
Myo-inositol phosphates
InsP6
InsP5
8.57b
0.61a
6.18a
1.14c
5.73a
1.09c
4.90a
0.86b
moles/ g (d.m.)
InsP4
0.11a
0.55c
0.45b
0.46bc
InsP3
0.02a
0.76b
0.61b
0.72b
Mean±SD, at least n=2, n.d.: no detectable, d.m.: dry matter
Values followed by the same letter in the same column are not significantly different at 95% confidence level.
Partner PURATOS has contributed to the study of PBF process. Part Baked Frozen process has been identified as beneficial
for the GI of the final baked product. In order to further improve the nutritional quality of the rolls whole wheat flour has been
used. BOT-products offer great convenience to both the bakers and the consumers. In the process of stimulating the whole
grain consumption it is importance to link the advantages of BOT products and the health benefits of whole grain bakery
products together and to develop whole grain BOT products with high quality.
Baked products prepared with whole wheat flour tend to have a lower specific volume due to the dilution of the gluten by the
fibre fraction and the physical effect of the particles on the gas-cell stability. Xylanases are added in order to improve both the
quality and the nutritional properties of the baked product, due to respectively their positive effect on the visco-elastic
properties of the dough and the amount of soluble fiber in the dough and the final baked product.
Partner PBF has investigated the impact of amyloglucosidase addition in partially baked frozen bread – step 3 (recipe with
pectin): Total phenol content increased by the amyloglucosidase addition and antioxidative activity was in positive correlation
with total phenol content. Sterol content, in lipid fraction as well as in sample, also increased with the amount of
amyloglucosidase added.
2.3.9 Gluten free breads enriched with amaranth flour resulted in higher calcium
and magnesium and in an increase of the body mass index in rats
Rolls supplemented with amaranth flour were considerably richer in protein, fat, dietary fibre, and minerals, in comparison to
standard products. The animals fed with the rolls enriched with amaranth were characterised by significantly higher gain of
body mass as compared to control group. The level of total cholesterol, its LDL and HDL fractions, and triglycerides in serum
was the same for rats fed with standard and amaranth enriched rolls, irrespectively of the applied baking method. Significant
increase of Ca and Mg in serum of rats fed with amaranth enriched rolls, as compared to control group, was observed
irrespective of the baking method. In livers of rats fed with amaranth enriched rolls a significant increase in the levels of K, P,
Mg, Zn, Cu and Mn, as compared to control group, was observed. Supplementation of rolls with amaranth flour positively
influenced the concentration of P, Mg, and Cu in bones of rats fed with these rolls, irrespective of the baking method.
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2.3.10
Gluten free breads enriched with flaxseed flour
The supplementation of rolls with flaxseed meal caused an increase in the level of total protein, non-soluble dietary fibre, and
ash as compared to the control rolls. The products displayed higher concentrations of copper, iron, calcium, magnesium,
potassium and manganese. The level of fat, soluble dietary fibre fraction and total dietary fibre were significantly higher
(p<0.05) in rolls supplemented with flaxseed as compared to rolls supplemented by amaranth flour. Significantly higher level of
unsaturated fatty acids was determined in rolls enriched with flaxseed compared to amaranth and control rolls. The most
pronounced change was observed in the content of ALA. The content of all measured amino acids in rolls supplemented by
flaxseed was found to be higher as compared to control and products supplemented with amaranth.
The content of phytates in different gluten free breads containing amaranth or linseed flour was studied by partner CSIC-IATA.
Amaranth and linseed flour contained high amount of myo-inositol hexakisphosphate (InsP6), but only residual amounts were
present in the gluten free breads containing those flours, which resulted from their dilution in the recipe and also some
hydrolysis happened during the breadmaking process.
Table 10 : Myo-inositol phosphates content in different gluten free breads.
Samples
Whole amaranth flour
Whole linseed flour
Reference bread
Amaranth bread
Linseed bread
Myo-inositol phosphates moles/ g bread (d.m.)
InsP6
InsP5
InsP4
31.57c
1.79c
0.91b
27.28b
3.59d
0.26a
n.d.
0.04a
n.d.
1.38a (4%)
0.67b (37%)
0.36a (39%)
1.84a (7%)
0.35ab (10%)
0.06a (23%)
InsP3
n.d.
n.d.
0.28c
0.17b
0.04a
Mean±SD, n=2, n.d.: no detectable, d.m. dry matter
Values followed by the same letter in the same column are not significantly different at 95% confidence level.
Data between brackets describe the relative residual amount.
2.4 OBJECTIVE 4: To produce equipments adapted to innovative process that will be
developed.
2.4.1 Innovative Infra red Oven : ~ 35% energy saving versus reference oven
ONIRIS has developed an innovative baking oven during the Post Doc stay of Tzvetelin DESSEV from University of Food
Technology of Plovdiv (October 2008 - October 2009). Bread baking requires a large quantity of energy - roughly 2 to 5
Mjoules / kg that is 2 to 3 times higher than the energy required for the same mass of a food product in the form of canned
food for example. Furthermore food habits are changing in the world : we see in most European countries a decreasing
consumption of bakery products at home while the consumption of bakery products outside home increases significantly.
The invention which has been developped during the EU-FRESHBAKE project has been patented by the CNRS in July 2009.
The invention concerns a baking oven for the baking of dough made of cereal flour, in particular a fermented dough, which
includes a sole in refractory material and thermally insulated surrounding walls. The main characteristics of the invention lies
in that the heating means consist exclusively in IR radiation lamps located in the top of the cavity of the oven and directed in
the direction of the sole. No other heating means are required. Baking can be done as usual in a two steps process
(preheating followed by baking).
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Figure 51 : LEFT: Picture of the interior of the prototype Infra Red oven developed by ONIRIS.
One can see the infra red bulbs. RIGHT: prototype of the control unit designed and constructed in full at ONIRIS for the oven.
Comparison of energy consumption and bread quality have been performed on two similar commercial ovens (0.25 m 3 – 1
m² internal surface); one oven has been modifed according to the invention whereas the second one was used as a control.
Tests have been done with the EU-FRESHBAKE Part Baked improved recipe and protocols (for the energy measurments
and validation of the concept + patent filling), with organic breads (demonstration phase – sept. – oct. 2009) and with other
recipes at follow (contact with industrial partners after the end of the project). Results concerning energy show (
Figure 52) that pre-heating lasts respectively 9 and 40 min. The energy consumption was respectively 2,450 and 5,000 Wh
for the preheating phase and 680 and 1,340 Wh per kg of dough during the baking phase. This energy does not take into
account the energy for steam preparation (pre heating of the steam box), which was the same for both ovens.
Figure 52 : Heat flux in the bread (bottom of the bread – 70g EU-FRESHBAKE loafs) measured with a heat flux sensor.
In both cases, a similar evolution of the heat flux was observed, showing that the infra red oven concept can bake bread in conditions
similar to the reference oven.
Selected quality attributes of bread (moisture content, hardness, pores size, colour, taste...) were not affected by this baking
technology in comparison with the control oven. The specific energy used by the innovative oven according to the invention
was between 35 and 40 % lower than that used by the standard oven during pre heating step whereas the duration of this
step was reduced by around 70 % (up to 77%). Globally, the energy consumption was reduced by 35 % for a complete
baking cycle (preheating plus baking not including the steaming).
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Table 11 : Comparison of selected quality parameters of breads baked with the innovative oven (IR+stone) and a conventional oven.
EU-FRESHBAKE “Part Baked Improved” protocol and recipe has been use for these tests.
Parameters
Baking system
IR + Stone baking
Control baking
Preheating: time (min)/energy (Wh)
7/370
17/380
Baking: time (min)/energy (Wh)
NB : The energy to maintain the steaming
system ready is not taken in account. The
corresponding value is taken for the
reheating phase.
Maximum crust temperature (°C)
16/280
12/320
111
107
Bread : Specific volume, (ml/g)
2.9
2.8
Bread : Crumb hardness, (N)
1.8
1.7
crust/crumb ratio (on dry basis)
0.92
0.91
Water loss during baking, (%)
6.7
7
The benefits of the invention are:
 Rapid preheating of the oven; low energy consumption; easy to implement, no modification of baking process, bread
quality equivalent to conventionnal oven; concept can be installed in existing oven.
 Already implemented on an industrial oven.
 Concept applicable to domestic oven
Figure 53 : Pictures of 70 g loafs of organic breads partially baked in different conditions including IR Oven.
Using Infra Red oven (IR) and conventional reference oven (REF): 210°C – 14 min, 220°C – 14 min and 240°C – 14 min. Lower set
point temperature seem sufficient for IR oven whereas a higher ste point temperature seems necessary to obtain the same bread
volume with REF oven.
Further tests have been carried out with plain white breads (“batard” loaf, 400 g). Pictures of the bread are shown in figure
below. The baking condition was direct baking at 230°C. The upper surfaces of the bread were quite similar. However, the
bottom of the breads were a bit burned in the infra red oven due to its higher level of energy stored in the stone. Tests are
still going on to adjust the optimal operating conditions for the infra red oven which seems to be very promissing and well
adapated to the production of part baked bread (SMEs), of part baked breads and fully baked breads in craft bakeries (rapid
pre heating) and in baking stations for bake off technology.
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INFRA RED
OVEN
REF.
Figure 54 : Pictures of “Batard” bread (white flour – lean dough - 400 g loafs) baked in the reference oven and in the Infra Red oven. Pre
heating was done at 230°C. Additional tests are carried out to optimize the processing conditions of the infra red oven.
2.5 OBJECTIVE 5: To develop tools that will permit to extend the findings of the project to
future formulations and developments.
2.5.1
Labelling of part baked bread; can we envisage a « reduced GI » nutrition claim ?
The enhanced nutritional quality of bread can be labelled in different ways indicating defined substances which should be reduced in the
diet, such as salt, saturated fats, sugar, or increased desirable parameter such as dietary fibre or protein. Labelling for each of 3 “groups”:
wheat bread, gluten-free bread, and organic bread, can be done according to Regulation (EC) 1924/2006 (Nutrition claims. Health claims),
traffic light, Guideline Daily Amount (GDA), nutritive score (NS), or according to their glycaemic index.
Permission or legislation to label the GI of foods is not yet completely solved regarding standardised methodology, way to express the GI
on products, and claims of benefits of low-GI values. Nevertheless, according EFSA’s Modus Operandi for Article 13 (3) Health Claims of
Regulation (EC) 1924/2006 from 22nd December 2008, based on a previously food industry claims list (CIAA/ERNA7EHPM list October
2008) breads with GI < 55 % could have claim “Low GI carbohydrates sustain steady blood sugar levels”. In the same time, high content
of salt make nutritional profile of bread not good. Even if EFSA did not deliver nutritional profile for food with health claims, it is up to a
producer to make final decision according the regulation at time when product supposes to be launched on the market.
Table 12 : Bread labelling regarding the glycaemic index, GI (WHO)
Glycaemic index, GI
Low
Moderate
High
GI (%)
<55
56-69
>70
Label
“Low GI”
“Moderate GI”
“High GI”
Some bread reaching criteria to be label as “Low GI” also have “general function” health. Possible labelling of some wheat breads
developed during FreshBake project is shown bellow.
Table 13 : Labelling of white wheat bread regarding GI
(*Value obtained in several studies)
Bread making process
GI value*
Label
Conventional
81.33
“High GI”
Part-baked frozen
63.17
“Moderate GI”
Part-fermented frozen
59.47
“Moderate GI”
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Table 14 : Labelling of innovative white wheat breads designed in step 2 (according to Regulation (EC) 1924/2006)
STEP 2 (1.8%NaCl)
Fibre blend
10% Resistant Starch
PFFI (2%gluten)
1071(253)
1095(258)
1081(255)
Protein (g/100g)
6.96
6.93
8.24
Carbohydrate (g/100g)
51.03
53.06
53.43
Lipid (g/100g)
Fibre (g/100g)
0.53
8.23
0.95
4.91
0.12
3.55
Sodium (g/100g)
0.500
0.501
0.488
Energy kJ (kcal) /100g
Labelled as
“High fibre”
“Source of fibre”
“Bread with added oat fibre and inulin” “Bread with added resistant starch”
GI value
70.54
“Moderate”
73.68
“Moderate”
“Source of protein”
64.77
“Moderate”
Table 15 : Possible labelling of wholemeal wheat breads from innovative step 3 (according to Regulation (EC) 1924/2006 )
STEP 3 (1.5%NaCl)
StdCON
StdPBF
Energy kJ (kcal)
974 (243)
961(240)
Protein (g/100g)
7.74 SP
7.85
7.84
7.95
8.94
Carbohydrate (g/100g)
45.33
44.38
45.36
44.83
43.11
of which sugars (g/100g)
4.05
3.86
3.95
3.63
3.66
Fat (g/100g)
1.58
1.52
1.47
1.38
1.39
of which saturates g/100g)
0.32
0.38
0.27
0.25
0.29
Fibre (g/100g)
8.44
8.86
7.79
7.95
7.63
1.2
„High fibre“
„Source of
protein“
54.5 %
„Low GI“
1.2
„High fibre“
„Source of
protein“
43.8%
„Low GI“
Salt (g/100g)
Possible label
Labelling according GI value
CONsourdough PBFsourdough PBFsourdough
(15%)
(15%)
+whey
963 (242)
958 (239)
944 (236)
1.2
1.3
1.2
„High fibre“ „High fibre“
„High fibre“
„Source of
„Source of
„Source of
protein“
protein“
protein“
73.6%
59.1%
58.9 %
„High GI“ „Moderate GI“ „Moderate GI“
Most of the designed breads reached criteria for nutrition claim such as “Source of fibre” and “Source of protein”. Some of the breads
produced according to innovative formulations reached criteria for claims ”High fibre” or “Naturally/Natural source of fibre”. (wholemeal
bread) and/or “Low GI”, but no bread reached criteria “Reduced sodium/salt content” or “Reduced available carbohydrate content”.
Table 16 : Labelling of wholemeal wheat breads from step 3 according to their Nutrition score (NS, Unilever)
STEP3 (1.5%NaCl)
StdCON
StdPBF
Trans (%kJ)
CONsourdough PBFsourdough PBFsourdough
(15%)
(15%)
+whey
Category 1 Category 1 Category 1
Category 1
Category 1
SFA (%kJ)
Category 1 Category 1
Category 1
Category 1
Category 1
SFA (% total fats)
Category 1 Category 1
Category 1
Category 1
Category 1
Sodium (mg/kcal)
Category 3 Category 3
Category 3
Category 3
Category 3
Sugars, total (%kJ)
Category 1 Category 1
Category 1
Category 1
Category 1
Sugar, added (g/100g)
Category 1 Category 1
Category 1
Category 1
Category 1
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According to NS values all samples were ranked at Category 3 due to too high sodium level. Neither one can not have front-of- pack logo
„My choice“
To lower sodium level in bread is one of the major international nutritional strategy and it would drastically change
nutritional level of these breads.
If traffic light labelling is applied for labelling than: a) “green light” (low) would be obtained mostly for content of fat, saturates and sugars,
and b) “orange light” (medium) for salt/sodium.
Organic bread can be label as “organic” (organic logo) and bread without gluten as “gluten-free”, using the established logo on national
level. Some bread samples may have “general function” health claims, because of fibre content and low GI.
Since some bread were produced by new fermentation process and low energy consumption it would be possible to communicate/label it:
“This bread has been designed using long fermentation and low energy consumption and has improved nutritional quality”.
Reference: Colić-Barić, I., Sučić, M., Novotni, D., Neđeral, S., Ćurić, D. (2008) Can we measure the real nutritional quality of bread
through nutrient density methods? Proceedings of the 2008 Joint Central European Congress, Vol 2: 439-447. 4th Central European
Congress and 6th Croatian Congress of Food Technologists, Biotechnologists and Nutritionists, Cavtat, Croatia.
2.5.2 Guide of good practice for the industry
A guide of good practice has been designed and delivered during EU-FRESHBAKE. This guide of good practice, which was
initially expected by month 24 has been delivered finally at the end of the project to gather as much information as possible on
the subject. Indeed, EU-FRESHBAKE project has generated a lot of new data and information on the theme of the Bake Off
Technology. The guide is approximately 50 pages long and pools data from EU-FRESHBAKE and from the existing literatures.
Details are provided on energy consumptions and on recommendation are provided to reduce energy without forgetting about
the quality of the product.
2.5.3 Transfer of baking concepts and innovative equipment to other products
The EU-FRESHBAKE project (FP6-project 036302) concerns the domain of industrial baking. In particular, it focuses on the
Bake Off Technology (BOT), which allows the retail of freshly baked breads made from industrial frozen (and non frozen)
products. Several technologies are concerned as presented in
.
Table 17 : Acronyms of the conventional and Bake Off Technology bread making processes - (Published in [39])
NAME
Fully Baked Unfrozen or
Conventional
Fully Baked Frozen
Partially Baked
Un-Frozen
Partially Baked
Frozen
ACRONYM
FB-U
Unfermented
Frozen Dough
U-FD
Fermented
Frozen Dough
F-FD
FB-F
PB-UF
PB-F
Brief description of the process
Main steps are Mixing – Rest – Dividing – Shaping – Fermentation – Baking Refrigeration
The bread is obtained from FB-U process and is frozen
The bread is obtained from FB-U except that baking is stopped before crust
colouration. Bread is cooled and is stored in packaging at to room temperature
The bread is obtained from FB-U except that baking is stopped before crust
colouration. Bread is cooled and is frozen in packaging at freezing conditions (i.e; 20°C)
Dough is prepared as for FB-U; the rest period is shortened and care is taken to
prevent excessive fermentation before freezing, which is done as soon as possible
after shaping.
A slow freezing is usually recommended.
Dough is prepared as for FB-U; the fermentation is started and is stopped before full
development.
The fermented dough is then frozen.
A quite rapid freezing is usually recommended.
Baking is most of the times done in one process
(frozen – ready to bake) or after thawing
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The BOT, which represents an alternative to conventional “scratch” conventional baking is growing at a much faster rate than
any other. If the total bread consumption per capita is more or less constant, it appears that the market share of BOT is
growing at a very high rate (more of less around 10%/year). Beside, such technology is much more energy demanding than
conventional bread making.
THE EUROPEAN BREAD MARKET: Different classifications of the European bread market can be tackled to assess the
impact of the EU-FRESHBAKE project on the European bread market. Few data are available on the web. Among which the
GIRAFOOD prospects relates some highly relevant data [40, 41]. Selected data are available freely on the web (year 2004 and
year 2006).
BREAD, VIENNOISERIE and PATISSERIE CONSUMPTION IN EUROPE
The total BVP European-27 market represented 38,7 million tons in 2006. Within this market, Bread represents 32.1
million tons (82.9%) of total BVP whereas Patisserie and viennoiseries make 3.3 million tons each (8.5% each). It is
considered that bread consumption in western Europe is stable [42], although it varies greatly for each country.
French, Germans, Austrians eat about 80kg per person per year. The consumption is even higher (above 100 kg) for most
eastern European countries. UK, Ireland, Netherland … are at the bottom of the list with an annual consumption of around
50 kg. Bread consumption is not likely to grow dramatically since bread is eaten in nearly every household and it is
unrealistic to expect bread to make any major inroads into other sectors [42].
Figure 55 : BVP consumption in Europe-27 in 2006
Total market 38,7 million tons in 2006
Source GIRAFOOD - [40]
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INDUSTRY vs. ARTISANAL
GIRA-FOOD [40] proposes the following differentiation between Industry and Artisanal production:
 Artisanal production means artisanal scratch baking at the point of sale, using flour or pre-mixes
 The product is directly sold to the consumer
 This is mainly to be found at bakers' shops and in-store baking units in hypermarkets (but can also be found in
restaurants for patisserie)
 Industrial production encompasses several technologies:
 Prepacked long-life – branded products
 Prepacked part-baked or frozen – branded products
 Fresh finished products, to be resold fresh at the point of sale
 Bake-off: frozen (or refrigerated) products, to be cooked at the point of sales in bake-off stations and sold fresh
The ratio between Artisanal and industrial bread production is roughly of 50-50 (world scale as well as
European scale) considering “in store” bakery as “industry”. [43]
Table 18 : World bread market – Market share between Traditional, Industry and in store bakery [43]
World Market
Traditionnal baker
Industry
In Store Bakery
2006
112 Billion US$
53%
35%
12%
Figure 56 : Artisanal vs. Industrial production in the
European market (Europe 27) - 2006
Source GIRAFOOD - [40]
http://www.girafood.com/
2009
118 Billion US $
49%
40%
11%
Figure 57 : Retail channels for BVP in 2006
European market (Europe 27) - 2006
Source GIRAFOOD - [40]
http://www.girafood.com/
Attention should be drawn on the fact that in such a comparison, “industry” production may include fresh product (packed in
Map for example), whereas “artisanal” may include all the technologies as detailed in
. For example, the “Slow Baking“ concept has been initiated in Germany. A “Slow Baking “ certificate can be obtained from
IGV of Berlin/Bergholz Rehbrücke (Institut für Getreideverarbeitung Gmbh). The slow baking concept is to produce bread
using conventional and traditional concepts, formulations and unit operations. Nevertheless, the “Slow Baking” considers
freezing as an acceptable process (http://www.slowbaking.de/). On the other hand, the “Décret Balladur” French law text [44]
describes several restrictions concerning the labelling of “French bread type” regarding the formulation but also the process.
Among these restrictions, a baker that claims the production of “conventional” type of bread it is not allowed to use the freezing
process.
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Figure 58 : Advertisement presenting key issues of the “PAIN DE TRADITION FRANCAISE”
This kind of product is described in the French law text related to bakery. [44] . It indicates “Pas de SURGELATION = no freezing”
Source of the image : http://www.boulangerie.org/qualite/tradition.htm
There is thus a confused situation in Europe regarding the concept of conventional / artisanal and industrial baking. Moreover,
many “traditional bakers” use frozen industrial products (i.e. frozen non fermented puffing pastries such as croissants – it is
admitted that over 70% of the croissant eaten in France are industrial products!) even though the major part of their production
is made “from scratch”. The above mentioned focus concerns freezing. The same difficulties may arise with the baking
process as such. Indeed, innovative technologies such as microwave baking may be considered. This confusing situation
resulted in unfair publication presented in the media on the EU-FRESHBAKE project such as reference [45] published in
BACK-BUSINESS journal. It opposes the baking industry against traditional bakers, whereas obviously, both are merging with
mutual interest in terms of economy-business, convenience, and even quality.
EUROPEAN MARKET OF BREAD vs. Viennoiserie and Patisserie
- 72% of BVP products are fresh product (vs. long life and part- baked – frozen (Figure 59)
- Scandinavian countries and Germany are largest consumers of part baked products (Figure 59)
- Bread represents 17 million tons (86% BVP) in 2004 – EU-15 [46] and 32.1 million tons (83% BVP) in 2006 – EU-27 [40]
 Bread represents over 83% of the whole sale tonnage of BVP products.
 FRESH BREAD represents 73% of the EU-27 tonnage of bread production (data of 2006 [40]). Frozen – part baked
bread .. represent only 2% of the total EU-27 tonnage.
 Part baked bread represents ca 60 to 70% (of the 20% of industrial frozen breads (from Figure 61and Figure 67
– Europe 15- year 2003-2004), but…
 Part baked bread (most of the time frozen) is growing at a much higher rate than any other bakery product.
Between 2001 and 2004, it rises by 29.6% in France for bakery installed in supermarket (35% of part baked vs. 65% of
production on site) reference [47].
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Figure 59 : European market of BVP in 2004
Fresh vs. Long life and part baked products –
country by country
Source GIRAFOOD - [41]
http://www.girafood.com/
Figure 60 : Craft vs. Industrial production of BVP in 2006
Europe 27 - European market – country by country –
Source GIRAFOOD - [40]
http://www.girafood.com/
Figure 61 : BREAD in 2004
Europe 15 - European market –
GIRAFOOD - [46]
http://www.girafood.com/
Figure 62 : VIENNOISERIE in 2004
Europe 15 - European market –
GIRAFOOD - [46]
http://www.girafood.com/
Figure 63 : PATISSERIE in 2004
Europe 15 - European market –
GIRAFOOD - [46]
http://www.girafood.com/
Figure 64: BREAD in 2006
Europe 27 - European market –
GIRAFOOD - [40]
http://www.girafood.com/
Figure 65 : VIENNOISERIE in 2006
Europe 27 - European market –
GIRAFOOD - [40]
http://www.girafood.com/
Figure 66 : PATISSERIE in 2006
Europe 27 - European market
GIRAFOOD - [40]
http://www.girafood.com/
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FULLY BAKED FROZEN
5%
FROZEN DOUGH
32%
3
FROZEN PART BAKED
63%
Figure 67 : BREADS made from frozen BOT Europe-15 market share in 2003 [48]
IMPACT OF EU-FRESHBAKE ON INDUSTRY AND RESEARCH
3.1 Impact of EU-FRESHBAKE on Industry sector
Thanks to the substantial communication efforts carried out during EU-FRESHBAKE, the bake off technology domain has been
informed about several issues regarding the bake off technology: energy, quality and nutrition.
-
-
Data have been gathered also on the energy demand for bake off technologies. Different communication events have
been organized during the project (dissemination event during the IBA Fair in Düsseldorf in Oct 2009) and after the project
(oral communication at IPA Fair in Paris in Oct 2010).
Around 20 articles and brief notes have been published in professional journals of different countries (France, Poland,
Spain, Croatia, Germany, etc…).
Thanks to the guide of good practice, it is expected that the baking industry will have a better advice to reduce the energy
demand in baking and in freezing of bread.
An Innovative low energy baking oven has been designed and patented by ONIRIS. CEMAGREF is also working on the
concept of low pressure baking. Technology transfer and implementation of these technologies in the baking industry is
expected. Licensing is researched by ONIRIS at the moment with industry partners.
Beside, it should be stressed out that the contribution to the growth rate of the baking sector expected in the
Figure 68 will mainly come from the western European countries (EU-15) for the bake off, whereas as the NMS (New Member
States – NMS-12) will impact mainly the market of prepacked bread with long shelf life as shown in
Figure 68.
3.2 Impact of EU-FRESHBAKE on Research sector
EU-FRESHBAKE has contributed to different important aspects related to the bake off technology. 37 Peer reviewed articles
have been published in scientific journals, 7 articles in national journals and over 20 articles in professional journals. Significant
step forward have been done in particular on :
- Nutrition: The results obtained on the impact of the processing conditions and on the formulation on the glycaemic index
are new in the field. The significant lowering of the GI for frozen part baked bread plus a synergistic effect of sourdough
technology has been demonstrated. The increased action of phytase enzyme in the case of frozen dough is a new result in
the field.
-
Food Science: The indicators (nutrition quality indexes) designed during EU-FRESHBAKE to assess the nutrition quality of
the product and also the Quality Index can be considered as innovative. They have been published in a peer reviewed
paper. These concepts can be useful for future research projects being on bread or other food products. Other aspects
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related to the quality of bakery products in general and the interaction with the processing are original results: better
overview of the partial baking process, investigation on prefermented frozen dough technology, investigations on new
strains for dough fermentation including mixing of different strains etc …
-
Processing issue: The evaluation of the energy for baking process remains a very challenging issue. This has been clearly
highlighted in several papers published by ONIRIS within EU-FRESHBAKE. EU-FRESHBAKE has contributed to a better
understanding of the energy consumption in Baking ovens. These data are of ultimate importance for the oven
manufacturers to design new equipments with low energy demand; in particular, the insulation, the control of heal losses
through the chimney, the control of the steam injection, … are very important.
3.3 EU-FRESHBAKE Impact vs. Initial objectives
EU-FRESHBAKE was organized around 5 key objectives. The short paragraph below summarizes the impact of EUFRESHBAKE versus its initial objectives.
- OBJECTIVE 1: To optimise conventional process pathways in view of environmental concerns (ETAP).
Visible impacts :
Un-fermented Frozen dough (UFD): ranking of energy demand for this process vs. other processes. Recommendation on the
final freezing temperature (-12°C) to reduce energy demand.
Partially Baked Frozen Bread (PBF):ranking of energy demand for this process vs. other processes. Recommendation on the
final freezing temperature (-15°C) to reduce energy demand. Better knowledge on the impact of the baking conditions on
aroma of bread and staling rate. Identification of a reduced acrylamide content in the case of part baked frozen bread in
comparison to conventional bread making.
Partially Baked Unfrozen (PBUF): demonstration thanks to the technology of BIOFOURNIL that PBUF can be kept for very
long time in MAP (up to 3 months and more). This is due to specific sourdough technology. Identification of the impact of the
degree of baking on the contraction of the crumb during storage.
Energy efficiency of partially baked bread: identification of the main targets to save energy in particular the control of the
amount of steaming.
- OBJECTIVE 2: To develop innovative process pathways.
Visible impacts :
- Prefermented frozen technology has been investigated. Even though it is not a new technology, there is still a lot to do
to better understand this technology. MRI analysis done by CEMAGREF showed the apparition of internal cavities in the
loaf; they resulted from the collapse of the fermented loafs in the case of excessive fermentation.
- Low pressure baking, which has been developed by Cemagref offers a new track to the concept of baking. It is rather
adapted to part baked technology and offers a huge potential in terms of product structure as well as energy savings.
- Innovative process pathways have been identified by TTZ regarding the use of specific enzymes (Amyloglucosidase)
and of specific time temperature histories during the process of fermentation. Higher quality and faster baking were
obtained resulting in energy savings (upt o 15%) and in breads with a sweet taste.
-
OBJECTIVE 3: To develop innovative formulations adapted to the innovative processes.
Visible impacts :
- Each industrial partner has developed innovative recipes during this project. This concerns in particular recipe and
processes adapted to frozen part baked technology. Surprisingly, the customers of the industrial partners were waiting for
these technologies which are more energy demanding because of the refrigeration and frozen storage phase. Beside,
frozen part baked offers more flexibility in terms of the final baking of the product, less packaging (in comparison to
modified atmosphere packaging) and a better shelf life (risk of mold).
-
BIOFOURNIL has developed recipes made of a mix of durum wheat and soft wheat for its whole meal bread. This solution alloxed a
better nutrition quality (higher protein content) and interesting organoleptic properties.
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-
BEZGLUTEN has developed solutions to improve the machinability of gluten-free dough. Guar gum was partially replaced with
galactomannan with larger molecules and hot water solubility- locust bean gum. These solutions helped to divide and shape the rolls.
It also significantly diminished hardness during 3 days of storage.
-
Dr SCHAER has continued working on BOT technology. Information and suggestions from EU-FRESHBAKE project has
-
Specific enzymes have been used for the processing of dough including refrigeration during fermentation. AMG
(Amyloglucosidase) have been used to facilitate the release of sugar and finally to facilitate the fermentation and the
baking (rapid baking thanks to a faster coloration of the crust during baking.
-
OBJECTIVE 4: To produce equipments adapted to innovative process
been implemented to improve the current freezing process (during 2010) and to develop a new partbaked frozen product
(launch in 2011) in order to save energy and improve the quality of the final product.
Visible impacts :
- ONIRIS has developed a low energy baking oven based on infrared technology.
- MIWE has implemented and tested solutions to reduce the energy for refrigeration equipments. The development of
innovative processing conditions will require the design of specific equipments adapted to the new technology. The basic
equipments needed to produce bread are a mixer, a fermentation cabinet and an oven. A chiller and a freezer must be
considered in the case of frozen products. Some of these equipments may be improved to optimize the energy efficiency
index on one hand and on the other hand to adapt existing equipment or to develop new equipments adapted to the
innovative process pathways that will be tackled. One may think for example to specific oven (i.e. using microwave),
specific fermentation cabinet adapted to prolonged fermentation at moderate temperature, specific chillers or freezers…
The mixing step will not be investigated in this project.
-
OBJECTIVE 5: To develop tools that will permit to extend the findings of the project to future formulations and
developments.
Visible impacts :
- The project will work on a bread formulation. Nevertheless, the indexes that will be developed (EEI, QI, NQI) will be
adaptable to other cases and other type of bakery products. Communication on the results of the project is planned at the
end of the project. Two targets are concerned, namely the baking industry and the consumers. In a more general matter,
this project concerns refrigeration applied to bakery products to extend the shelf life and to increase the convenience of
these products. Some of the results may be transferred to some products of the food industry such as pizza, pie … for
which wheat dough is used and baked.
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4
OUTLOOK OF THE EU-FRESHBAKE PROJECT
A trend in terms of evolution of the technology and of the market is proposed by [40]. It concerns globally the BVP, but one
should keep in mind that bread makes over 83% of the total BVP tonnage. Between 2006 and 2011, Prepacked Part baked,
part baked frozen and Bake Off technologies will grow significantly whereas other productions will be reduced (Fresh finished)
or will grow slowly. There is thus an important issue to optimise the industrial practice for part baked technology.
Figure 68 : Evolution of the industrial BVP market between 2006 and 2011.
Prepacked Part baked, part baked frozen and Bake Off technologies will grow significantly whereas other productions
will be reduced (Fresh finished) or will grow slowly (Prepacked long – life). - Europe-27 [40]
Beside, it should be stressed out that the contribution to the growth rate expected in the
Figure 68 will mainly come from the western European countries (EU-15) for the bake off, whereas as the NMS (New Member
States – NMS-12) will impact mainly the market of prepacked bread with long shelf life as shown in
Figure 68.
Figure 69 : Comparison of the contribution of the western European countries (EU-15) vs. New Member States (NMS-12).
Western European countries (EU-15) is rather growing towards bake off, whereas as the NMS (New Member States – NMS-12)
will impact mainly the market of pre packed bread with long shelflife. - Europe-27 [40]
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The main outcomes of the EU-FRESBAKE project that could impact the existing bread production in Europe are therefore of
different types. Part baked and BOT are much likely to impact the EU-15 whereas general results on energy and
baking and maybe innovative equipments may rather impact the NMS-12. Details aspects of the potential impact are listed
at follow.
The BOT permits to prepare the bread on demand each hour depending on the sales in a shop. Even though the energy
demand for part baked frozen bread is roughly 2.2 times larger than for conventional baking (EU-FRESHBAKE), one should
also take into account that the amount of left over bread coming from the bake off technology is much lower than for
conventional bread making. The Bake off technology also permits to prepare bread at home on demand, with a broader choice
of products and with the possibility to have specialties such as gluten free products for a member of a family for example. In
some countries such as Germany, there is a policy which makes obligatory the return of left over bread to the bakery (see
Figure 70). The life cycle assessment of bread production has been evaluated by [49] in 1999. The results obtained for a large
baking company (30,800 Tons/year) are presented in Figure 71 showing that the processing makes 37% and the transport
22%. It would be a non sense to transport bread back to its production place considering the so high energy demand and high
CO2 impact associated to this product
GERMANY : UNSOLD BREAD MUST BE RETURNED TO BAKERY
-ANIMAL FEED ? : DIFFICULT (SAFETY ISSUE)
-METHANE PRODUCTION (FERMENTATION) ? : LIFE CYCLE ??
Caterpillar at work on
the bread mountain !!!
From TU Berlin – Pr MEUSER + Adapted from a presentation of Dr. S. Reimelt
TUB-GV 1807/09
Figure 70 : Picture of the “processing” of left over bread returned to a bakery in Germany (ref. provided by pr MEUSER – TU Berlin).
A Caterpillar is at work on the top of the bread mountain.
PROCESS
37%
TRANSPORT
22%
AGRICULTURE
41%
CO2 – BREAD
Total : 0.95 kg CO2 / kg
SIK (1999)
Figure 71 : Life Cycle Assessment of bread production. Pie chart of main sources of CO2 in the case of a large production unit. The total
CO2 is between 500 and 1000 g CO2 / kg of bread depending on production scheme (time frame 100 years).
(bread factory concerned here = 30,800 Tons of bread per year – 950 gCO2/kg bread - more details in reference [49]).
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EXTENDING THE FINDINGS and OUTCOMES TO OTHER PRODUCTS
Thinking to other goods prepared from a wheat flour dough, Viennoiserie, Patisserie and Biscuits (high lipid content) come to
the surface. These products represent a relatively small market share in comparison to bread (14% for viennoiserie, patisserie
vs. bread in 2004 – Europe 15 - [41] and 17% in 2006 for Europe-27). This makes that the impact will however be small even
though not negligible.
VIENNOISERIE INDUSTRY
Viennoiserie such as puffing pastry, croissant are baked at lower temperature (ca. 170 °C) than bread (ca. 200 to 230 °C). The
baking temperature of viennoiserie is close to that of part baked bread. Therefore innovative baking processes and equipments
that will be developed during EU-FRESHBAKE may be adopted by the viennoiserie and maybe patisserie industry.
Figure 72 : Viennoiserie market (2004)
Scratch vs. BOT
(EU-15 market) - GIRAFOOD - [41]
http://www.girafood.com/
Figure 73 : Patisserie market (2004)
Scratch vs. BOT
(EU-15 market) - GIRAFOOD - [41]
http://www.girafood.com/
PIZZA INDUSTRY
Pizza has become a universal and international food. Pizza baking requires high temperature baking, which may not be
achieved by the baking equipments under development within the EU-FRESHBAKE project. When produced by the industry,
pizza it is rather PARTIALLY BAKED and then frozen. Indeed, the frozen pizza must not be fully baked to undergo a final
baking before consumption.
Partially baked pizza may accommodate with mild balking temperature (adapted to partial baking conditions) and may
therefore be concerned by the EU-FRESHBAKE innovations especially the innovative baking equipments.
BAKING SUPPORTS (BAKING TRAYS, BAKING MOULD)
Almost all the bake off technology products are baked on baking supports coated with either silicone or perfluorinated coatings.
The regulation regarding food contact material is not harmonized within Europe regarding silicon, which addresses an issue
regarding the risk of transfer of contaminants during baking and eventually second baking. In addition the protocols and food
simulants used in the protocols for food contact materials are not fully adapted to the case of baking. The most temperature
resistance food stimulant if olive oil, which obviously is not adapted to the temperature level which is reached during baking.
Research is thus needed to developed protocols adapted to the case of baking (temperature level) and also to assess the
ageing of a baking support undergoing multiple baking cycles.
5 CONCLUSION
The EU-FRESHBAKE project has covered several aspects :
- equipments
- formulation
- application to gluten breads
- application to gluten free breads
- application to organic breads
- labelling
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The outcomes in terms of equipments will concern:
- Innovative baking equipment with low energy demand (two tracks with reduction by 30 to 50%)
- Innovative refrigeration equipment: tracks showed savings by 5 to 15% on equipment and savings by up to 50% and
more by controlling the final freezing temperature and the fan power.
The outcomes in terms of formulations will concern mainly the combined impact of formulation and process on selected
quality attributes. Some results concern:
- The positive impact of freezing on the activity of phytase and by the way on the availability of minerals in bread.
- The positive effect of part baked formulation (fibres) and of freezing on GI (under investigation)
- Selected applications have been developed with the industrial partners of the project. PURATOS for gluten breads,
SCHAER and BEZGLUTEN for gluten free breads and BIOFOURNIL for organic bread.
The outcomes in terms of labelling are likely to concern:
- Labels promoting good baking practice resulting in a reduced energy demand
- Labels promoting a lower GI.
The EU-FRESHBAKE GUIDE OF GOOD PRACTICE :
EU-FRESHBAKE has prepared and edited a guide of good practice concerning the bake off technology. It covers several
results from EU-FRESHBAKE and also results and data from the existing literature. This document is in English.
The dissemination of results :
Toward the baking industry: A conference has been organized at the IBA fair in October 2009 to transfer key results of the
project to the European bread industry and equipments manufacturers.
Toward the scientific communities and the European consumers: A conference has been organized as pre-conference of the
Flour-Bread congress held in Opatija – Croatia on 20th Oct. 2009.
Toward SME’s : EU-FRESHBAKE is also involved in the CSA “AGRIFOOD RESULTS”, which aims at disseminating results
of projects toward SME (April 2009 – April 2011) .
Powerpoint presentations presented during these events and are available for free download on the website of the project.
~
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http://www.frperc.bris.ac.uk/defraenergy/storage.html 2008(FRPERC, University of Bristol).
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Poinot, P., G. Arvisenet, J. Grua-Priol, C. Fillonneau, A. Le-Bail, and C. Prost, Influence of inulin on
bread: kinetics and physico-chemical indicators of the formation of volatile compounds during baking.
Food Chemistry, 2010. 119(4): p. 1474-1484.
Poinot, P., J. Grua-Priol, G. Arvisenet, C. Fillonneau, A. Le-Bail, and C. Prost, Influence of inulin and
phytase on the aromatic properties of white and whole breads. Sciences des Aliments, 2010. submitted.
LeBail, A., N. Hamdami, V. Jury, J.Y. Monteau, A. Davenel, T. Lucas, and P. Ribotta, Examining crust
problems resulting from processing conditions with respect to freezing. New Food Magazine - Russell
Publishing Ltd, 2006. Vol. 3: p. 10-14.
GIRAFOOD, The GIRA European PVP & PVP Companies. Panorama 2006-2011 - Mini market report
(Dec 2007). http://www.girafood.com/data/en/minimarket/europeanfresh.asp, 2007.
GIRAFOOD, Frozen BVP Market Wetsern Europe - Update 2004 and Prospect 2010- A Mini Market
Report 2008.
BAKERS-FEDERATION-EUROPE, European Bread Market.
http://www.bakersfederation.org.uk/europe.aspx, 2008.
Anonymous, Le marché du pain : retour vers le futur. Filière Gourmande, 2008. Mars-Avril 2008 p. 1415.
Balladur, E., A. E., P. Mehaignnerie, and J. Puech, Décret no 93-1074 du 13 septembre 1993 pris pour
l'application de la loi du 1er août 1905 en ce qui concerne certaines catégories de pains Journal Officiel
de la Rébublique Française, 1993. NOR : ECOC9300130D.
Anonymous, EU-Project Freshbake forscht für die TK-Bäckerei. BACK-BUSINESS, 2007. 27 July 2007
p. 27-28.
GIRAFOOD, Frozen BVP Market Wetsern Europe - Update 2004 and Prospect 2010- A Mini Market
Report - January 2006. http://www.girafood.com/data/en/minimarket/europeanfresh.asp, 2006.
Darmon, J., Les ménages dépenses plus de 400 € par an en BVP fraîche. Filière Gourmande, 2006.
Décembre 2006 - Janvier 2007.
Aubry, J.F., Le monde du surgelé, 2003(Octobre 2003): p. 16-28.
Andersson, K. and T. Ohlsson, Life cycle assessment of bread produced on different scales. International
Journal of Life Cycle Assessment, 1999. 4(1): p. 25-40.
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7 REFERENCES PUBLISHED DURING EU-FRESHBAKE PROJECT (June 2010)
ONIRIS
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
ONIRIS
CEMAGREF
KU
IATA
PBF
RAS
International
Journal
26
9
3
5
6
3
National
journal
7
0
2
1
1
0
International
congress
22
5
8
5
4
3
National
congress
7
0
9
0
0
0
Total
62
14
22
11
11
6
TOTAL
37
7
40
14
98
International Journal
P. Poinot, J. Grua-Priol, G. Arvisenet, C. Rannou, M. Semenou, A. Le Bail, C. Prost. (2007). Optimisation of HS-SPME to Study
Representativeness of Partially Baked Bread Odorant Extracts. Food Research International, 40, 1170–1184
A. Le-Bail, R. Zuniga, C. Prost, J.L. Lambert, T. Lucas, M. Sikora, C. M. Rosell, D. Curic, T. Park, V. Kiseleva, M. Pitroff, I.
VanHaesendonck, M. Bonnand-Ducasse, M. Koczwara, V. Cerne. (2008). Energy, nutrition and quality of breads; an overview of
what is going on within the European project “EU-Freshbake”. New Food Magazine, 2008, 4, pp 60-64.
P. Poinot, G. Arvisenet, J. Grua-Priol, D. Colas, C. Fillonneau, A. Le Bail, C. Prost. (2008). Influence of formulation and process
on the aromatic profile and physical characteristics of bread. Journal of Cereal Science, 48, 686–697
J.L. Lambert, A. Le-Bail, R. Zúñiga, I. Van-Haesendonck, E. Van-Zeveren, C. Petit, M.C. Rosell, C. Collar, D. Curic, I. Colic-Baric,
M. Sikora, R. Ziobro. (2009). The attitudes of European consumers toward innovation in bread; interest of the consumers toward
selected quality attributes. Journal of Sensory Studies, 24 (2), 204-219.
Mezaize, S.; Chevallier, S.; Le Bail, A.; de Lamballerie, M. (2009). Optimization of gluten-free formulation for French style breads.
Journal of Food Science, 74(3), 140-146.
P. Poinot, G. Arvisenet, J. Grua-Priol, C. Fillonneau and C. Prost. (2009). Use of an artificial mouth to study bread aroma. Food
Research International, 42(5-6), 717-726.
A. Le-Bail, K. Boumali, V. Jury, F. Ben-Aissa, R. Zuniga. (2009). Impact of the baking kinetics on staling rate and mechanical
properties of bread crumb and degassed bread crumb. Journal of Cereal Science, 50, 235–240.
R. Zúñiga, A. Le-Bail. (2009). Assessment of thermal conductivity as a function of porosity in bread dough during proving. Food
and Bioproducts Processing, 87(1), 17-22.
Le-Bail,A., (2009), , « Frozen Bake off – From strength to strength “, EUROPEAN BAKER, May-June 2009, n° 104, p 22-24
Le-Bail, (2010), « Frozen Bake off – Good and easy “, EUROPEAN BAKER, Jan-Feb 2010, n° 108, p 14-17
A. Le-Bail, C. Nicolitch and C. Vuillod. (2010). Fermented Frozen Dough: Impact of Pre-fermentation Time and of Freezing Rate
for a Pre-fermented Frozen Dough on Final Volume of the Bread. Food and Bioprocess Technology. 2010. 3( 2): p. 197-203
P. Poinot, G. Arvisenet, J. Grua-Priol, C. Fillonneau, A. Le-Bail, C. Prost. (2010). Influence of inulin on bread: Kinetics and
physico-chemical indicators of the formation of volatile compounds during baking. Food Chemistry, 2010. 119(4): p. 1474-1484.
A. Le-Bail, T. Dessev, V. Jury, R. Zuniga, T. Park, M. Pitroff. (2010). Energy demand for selected bread making processes.
Conventional versus Part Baked frozen technologies. Journal of Food Engineering 2010, 96 : p. 510-519
F. Ben-Aissa, .J.-Y. Monteau, A. Perronnet, G. Roelens, A. Le-Bail. (2010) Impact of the baking degree on the volume change of
bread and bread crumb during cooling, chilling and Freezing. Journal of Cereal Sciences, doi:10.1016/j.jcs.2009.10.006
Le-Bail, A., Dessev, T., Jury, V., Park, T., Zuniga, R., (2010). Bread freezing and storage. Impact of process condition on energy
demand. In I.I.R (Ed.), 1st IIIR Conference on sustainability and the cold chain. International Institute of refrigeration,
Cambridge, UK, p. Paper 239 (6 pages). ISBN 978-2-913149-75-5
S. Chevallier, R. Zúñiga, A. Le-Bail. Assessment of bread dough expansion during fermentation. Food and Bioprocess
Technology (DOI 10.1007/s11947-009-0319-3).
G. Leray, B. Oliete, S. Mezaize, S. Chevallier, M. de Lamballerie (2010). Effect of freezing and frozen storage conditions on
rheological properties of different formulas of wheat and gluten-free dough. Journal of Food Engineering (Submitted).
J. Keramat, A. Le-Bail, C. Prost, N. Soltanizadeh (2010), “Acrylamide in Foods: Chemistry and Analysis A Review”, submitted to
Food and Bioprocess Technology: An International Journal (submitted)
P. Poinot, J. Grua-Priol, G. Arvisenet, C. Fillonneau, A. Le-Bail, and C. Prost (2010), Influence of inulin and phytase on the
aromatic properties of white and whole breads. Sciences des Aliments. (submitted)
P. Poinot, G. Arvisenet, J. Grua-Priol, D. Colas, A. Le Bail, C. Prost, (2010), “Physical Analysis and Volatile Extracts
Characterisation of Five Different Commercial Breads”. “Journal of Cereal Science” (submitted)
P. Poinot, J. Grua-Priol, G. Arvisenet, C. Fillonneau, A. Le-Bail and C. Prost, (2010), Odorant and Physical Properties of White
and Whole Breads: Combined Effects of Inulin and Phytase, “Journal of the Science of Food and Agriculture” (submitted)
T. Dessev, V. Jury, A. Le-Bail (2010), Absorptivity of bread dough in the case of short infra red. Journal of Food engineering
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5
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7
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3
4
5
6
7
8
9
10
11
12
(Submitted)
T. Dessev, A. Le-Bail, J. Keramat, V. Lalanne, C. Prost, and V. Jury, (2010), Influence of baking conditions on bread
characteristics and on acrylamide concentration, Manuscript in preparation to be submitted to Journal of Food Engineering.
A. Le-Bail, G. Leray, A. Perronnet, G. Roelens, (2010)Impact of the chilling conditions on the kinetics of staling of bread.
Submitted to Journal of Cereal Sciences YJCRS-S-10-00213 on 27 May 2010
A. Le-Bail, T. Dessev, D. Leray, T. Lucas, S. Mariani, G. Mottollese & V. Jury, (2010), Influence of the amount of steaming during
baking on the kinetic of heating and on selected quality attributes of crispy rolls. Submitted to Journal of Food Engineering ref
JFOODENG-D-10-00767 (1st July 2010).
A. Le-Bail, S. Agrane, (2010) Impact of the duration of the baking of part baked bread on staling. Submitted to Journal of
Cereal Sciences on 25 June 2010 - ref. YJCRS-S-10-00213
National Journal
P. Poinot, G. Arvisenet, J. Grua-Priol, C. Fillonneau, S. Mezaize, M. De Lamballerie, A. Le-Bail and C. Prost. (2009). Advances in
the understanding of the chemical reactions responsible for bread flavour quality. Czech Journal of Food Sciences, 27-Special
Issue, pp 54-57.
A. Le-Bail, T. Dessev, S. Cherrier, V. Jury, R. Zuniga (2009). Congélation des produits de boulangerie ; enjeux énergétiques et
qualitatifs. Revue générale du froid. Novembre 2009. p 55-59
A. Le-Bail. (2009) Énergie et Nutrition: l’étude EU-Freshbake. Filière Pain Gourmand, n°5, Août/September 2009.
A. Le-Bail. (2009). Projet EU-FRESHBAKE ; pour une meilleur maîtrise des procédés de cuisson différée. Pains-ServicesGateaux, juin 2009, pp. 20-22.
A. Le-Bail, (2010), Professional journal – France : « Énergie : Le CNRS développe un four à infrarouge ‘intelligent’ »
Environnement magazine (www.environnement-magazine.fr), Lundi 18 janvier 2010 - N° 42, page 5
A. Le-Bail, (2010), Professional journal – France : «Eau et maitrise de l’énergie, les lauréats des PTIE 2009 : Boulangerie, un gain
énergétique de 35 à 40% »: Environnement et techniques, N° 293, Janv. Fev. 2010, p 56-57,
A. Le-Bail , T. Dessev, V. Jury, R. Zuniga, T. Lucas, T. Park, A. Weissenberger, (2010), Enjeux d’énergie pour les procédés de
cuisson et de congélation des pains, In press in “Journal des Industries des Céréales”
International Congress
A. Le-Bail (2007): "Trends and technologys for the baking market Europe - Background for the EU-Freshbake Projekt and the
bake off technology", Back 2007, 2007 Produzent oder Händler – Wie wird das Bäckerei-Unternehmen von morgen
aussehen? 19-20 june 2007, Wiesbaden, Germany (ORAL).
Le-Bail, A., C. Nicolitch, and C. Vuillod (2007) Prefermented frozen dough. Impact of prefermentation on baking performance. in
C&E Spring Meeting - Consumer Driven Cereal Innovation: Where Science Meets Industry. 2007. Montpellier, FRANCE:
AACC International (ORAL).
A. Le-Bail, G. Arvisenet, F. Ben-Aissa, S. Chevallier, J. Grua-Priol, V. Jury, M. De Lamballerie, J-Y. Monteau, S. Mezaize, P.
Poinot, C. Prost. Food refrigeration and baking-challenges and needs for the future. 4th central European congress on food
and 6th Croatian congress of food technologists, biotechnologists, and nutritionists, 15 - 17 May 2008 , Cavtat, Croatia.
(ORAL – INVITED LECTURE)
F. Ben Aissa, Q. T. Pham, J-Y. Monteau, A. Le Bail. Stresses and Cracking in Freezing Part-Baked Bread: A Numerical Model.
(2008), IV International Symposium on Applications of Modelling as an Innovative Technology in the Agri-Food-Chain:
Model-IT, ISHS, Madrid, Spain, 2008 (ORAL+PAPER)
A. Le Bail, F. Ben-Aissa, S. Deobald, J.Y. Monteau. The mechanical properties of baked crumb - from the baked degased crumb
to the cellular solid. 13th ICC Cereal and Bread Congress, June 15-18, 2008, Madrid, Spain (ORAL)
S. Mezaize, S. Chevallier, A. Le Bail, M. de Lamballerie. Optimisation of gluten-free formulations for french-style breads. 13th ICC
Cereal and Bread Congress, June 15-18, 2008, Madrid, Spain (ORAL)
S. Chevallier, R. Zúñiga, A. Le Bail. Assessment of bread dough expansion during fermentation; a benchmark approach. 13th ICC
Cereal and Bread Congress, June 15-18, 2008, Madrid, Spain (POSTER)
P. Poinot, G. Arvisenet, J. Grua-Priol, C. Fillonneau, A. Le Bail, C. Prost. Effect of freezing and partial baking on breads aromatic
profile and physical properties. 13th ICC Cereal and Bread Congress, June 15-18, 2008, Madrid, Spain (ORAL)
A. Le-Bail, R. Zúñiga, T. Lucas, T. Park, M. Pitroff. Bread baking and industrial practice; toward a better practice and innovative
processes. AACC International Annual Meeting. Honolulu, USA, 21-24 September 2008 (POSTER).
F. Ben-Aissa, Alain Le Bail and J.Y. Monteau. Assessment of crumb hardness using a model of cellular solid; a mechanical
approach of crumb staling. AACC International Annual Meeting. Honolulu, USA, 21-24 September 2008 (ORAL).
A. Le-Bail. The EU-Freshbake european project: innovation in bread making. EFFoST Congress: First European Food
Congress : 4- 9 November 2008, Ljubljana, Slovenia (ORAL).
A. Le-Bail, R. Zúñiga, T. Lucas, M. Sikora, C. M. Rosell, D. Curic, T. Park, V. Kiseleva, M. Pitroff, I. VanHaesendonck, M.
Bonnand-Ducasse, M. Koczwara, V. Cerne. Bread making technology for the industry: Challenges and needs for the future. An
overview through the European project “EU-FRESHBAKE”. 6th International Food Convention IFCON-2008 "Newer
challenges in Food Science and Technology". Mysore, INDIA, 15-19 December 2008 (ORAL – KEYNOTE LECTURE).
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14
15
16
17
18
29
20
21
22
V. Jury, R. Zuniga, A. Le Bail (2008): "The EU-FRESHBAKE Project (FP6):
Emerging technologies in the baking industry. A case study of the part
baked bread." ISEKI/HEALTHGRAIN Workshop - Trends in cereal science and technology - Industrial applications,
Thessaloniki, Greece (ORAL).
V. Jury, A. Pinson, J. Launay, A. Le-Bail. Impact of refrigeration conditions on Energy consumption, energy efficiency index and
Co2 impact of frozen part baked bread. Congress of chemical engineering - Montreal - Aug 2009 (ORAL).
Le-Bail A., Ben-Aissa F., Gabric D., Curic D., Monteau J-Y. Behaviour of prefermented dough during refrigeration; impact of CO2
solubility on gas cell equilibrium. AACC International Annual Meeting - American Association of Cereal chemistry - 13-16
September 2009, Baltimore USA (ORAL)
S. Mezaize, S. Chevallier, C. Guyon, A. Le Bail and M. de Lamballerie. Gluten-free frozen dough: influence of freezing on proteins,
dough properties and bread quality. AACC International Annual Meeting - American Association of Cereal chemistry - 13-16
September 2009, Baltimore USA (POSTER)
G. Leray, B. Oliete, S. Mezaize, S. Chevallier, M. de Lamballerie, A. Le Bail. Effect of dietary fibres on rheological properties of
frozen wheat dough. EFFoST Conference - New Challenges in Food Preservation – Processing, Safety, Sustainibility. 11-13
November 2009, Budapest, Hungary (POSTER).
V. Jury, A. Le-Bail (2008): "Trends and technologies for the baking market
in Europe." Back 2008, Wiesbaden, Germany (ORAL).
Poinot, P., J. Grua-Priol, C. Rannou, C. Fillonneau, S. Mezaize, M. De-Lamballerie, A. Le-Bail, G. Arvisenet, and C. Prost. (2009),
Advances in the understanding of the chemical reactions responsible for bread flavour quality. in Chemical Reactions in Foods
VI. 2009. Praha, République Tchèque (ORAL).
Le-Bail, A., Ben-Aissa, F., Gabric, D., Curic, D. & Monteau, J.Y., (2009), Behaviour of prefermented dough during refrigeration;
impact of CO2 solubility on gas cell equilibrium, Congress AACC – Baltimore – USA 13-16 Sept. 2009 (ORAL)
A. Le-Bail, K. Boumali, S. Agrane, V. Jury, F. Ben-Aissa, R. Zuniga, (2009), Impact of the baking kinetics and baking duration on
the staling rate; a new approach using degassed crumb. Proceedings 5th International Congress “Flour-Bread’09” and the
7th Croatian Congress of Cereal Technologists “Brasno-Kruh ‘9” in Opatija, Croatia 21-23 October ISBN, in press 2009.
(ORAL)
A. Le-Bail, T. Dessev, V. Jury, T. Park & R. Zuniga. Bread freezing and storage. Impact of process condition on energy demand.
Ist IIR (International Institute of refrigeration) Conference on Sustainability and the Cold Chain, Cambridge, 29th, 30th
and 31st March 2010. (ORAL)
#
1
National Congress
J.L. Lambert, A. Le-Bail, R. Zúñiga, I. Van-Haesendonck, E. Van-Zeveren, C. Petit, M.C. Rosell, C. Collar, D. Curic, I. Colic-Baric,
M. Sikora, R. Ziobro. Attitudes des consommateurs européens vis à vis des innovations en boulangerie. Une étude portant sur les
procédés de cuisson différée faite au sein du projet européen EU-FRESHBAKE. 59es Journées Techniques des Industries
Céréalières, 24 et 25 Octobre 2008, Paris, France.
2
G. Diller, A. Le Bail, S. Chevallier, D. Queveau, R. Zuniga, L. Guihard, C. Couedel, F. Ben-Aissa, J.Y. Monteau. Propriete
mecanique d’une mie de pain; de la mie degazee a la mie alveolee. 59es Journées Techniques des Industries Céréalières, 24
et 25 Octobre 2008, Paris, France.
3
A. Le-Bail, R. Zuniga, T.Lucas, T. Park, M. Pitroff. Enjeux énergétiques de la cuisson et de la congélation des pains. Etude de cas
liés aux procédés industriels dans le cas du projet européen EU-FRESHBAKE. Société Française de Thermique, Efficacité
énergétique - Vannes, 26 - 29 mai 2009.
4
J-Y. Monteau , S. Bahloul, F. Ben Aïssa, A. Le Bail. Solubility and carbon dioxide production in bread dough during proving. XIIème
Congrès de la Société Française de Génie des Procédés, 14-16 October, Marseille, France 2009.
5
A. Le-Bail. Bread making technology for the industry: Challenges and needs for the future. An overview through the European
project “EU-FRESHBAKE”. Conférence - séminaire à l'Université McGill el 17 sept 2009.
6
A. Le-Bail, technologies de cuisson du pain, aspects énergie, qualité et propriétés nutritionnelles. Congélation et enjeux d’énergie
et de qualité, (2009), Conférence invitée au CRDA – St Hyacinthe-Québec-CANADA, 26 Nov. 2009
7
Le-Bail, Energie, Backen und Brotqualität An overview through the European project “EU-FRESHBAKE” , Invited lecture at the
GDL annual meeting, Bremerhaven – GERMANY, – 23-24 Juin 2009
8
Le-Bail, A., 2010 - Formation Inter-entreprises WELIENCE – 3 presentation to a panel of Industry « Pains précuits surgelés »,
« Pâtes crues congelées » et « Pâte préfermentées congelées », Dijon, 23 avril 2010
ONIRIS= 26(IJ) + 7(NJ) + 22(IC) + 7(NC) = 62
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CEMAGREF
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8
9
International Journal
Vanin, F.M., Lucas, T., Trystram, G., 2009. Crust formation and its role during bread baking. Trends in Food Science &
Technology 20(8), 333-343.
Grenier, D., Le Ray, D., Lucas, T. Combined local pressure-temperature measurements during bread making: insights into the
crust properties and the alveolar structure of crumb, Journal of Cereal Science (2009). in press (doi:10.1016/j.jcs.2009.09.009)
Lucas, T., Grenier, D., Bornert, M., Challois, S., Quellec, S., Bubble growth and collapse in pre-fermented dough during freezing,
thawing and final proving, Food Research International (2009) in press (doi:10.1016/j.foodres.2010.01.014).
Lucas, T., Davenel, A., Cambert, M., Le-Bail, A. & Mariette, F. “Assessment of NMR relaxation times and ice fraction in frozen
raw dough”, “Journal of Agricultural and Food Chemistry” (In Press)
Grenier, D., Le Ray, D., Lucas, T. Local pressure measurement during proving of bread dough sticks: contribution of surface
tension and dough weight to pressure of the gas in bubbles Journal of Cereal Science (2010). Under second reviewing stage.
Vanin, F.M., Grenier, D., Doursat, C., Flick, D., Trystram, G., Lucas, T. Water loss and crust formation during bread baking. II.
Technological insights from a sensitivity analysis. Journal of Food Engineering (2010). Submitted.
Grenier, D., Vanin, F.M., Lucas, T., Doursat, C., Lucas, T., Flick, D., Trystram, G., Density setting and expansion during bread
baking: Technological teachings from simulations, Journal of Food Engineering (2010). Waiting for submition.
Grenier, D., Le Ray, D., Lucas, T. Bread baking at low vacuum and temperature (2010). In redaction.
Vanin, F.M., Doursat, C.; Grenier, D.; Flick, D.; Trystram, G.; Lucas, T. Two dimensional mathematical model of bread baking:
experimental validation and insights into the crust role in the oven-rise. In redaction.
#
National Journal
#
1
International Congress
Grenier, D., Vanin, F.M., Lucas, T., Doursat, C., Flick, D., Trystram, G., Multiphysics During Bread Baking: Numerical Modelling
and Technological Teachings from Simulations. in: P. Barreiro, M.L.A.T.M. Hertog, F.J. Arranz, B. Diezma, and E.C. Correa, (Eds.),
IV International Symposium on Applications of Modelling as an Innovative Technology in the Agri-Food-Chain: Model-IT,
ISHS, Madrid, Spain, 2008, pp. 147-154.
Vanin, F.M., Lucas, T., Grenier, D., Doursat, C., Flick, D., Trystram, G. A study of the crust setting and its effect on heat and mass
transport and expansion during bread baking. In: 13th ICC Cereal and Bread Congress, Madrid (Spain) 2008, prime of better
innovation study (by KRAFT).
Vanin, F.M., Lucas, T., Trystram, G., Grenier, D., Doursat, C., Flick, D. Crust setting during bread baking as studied by a baking
model. In: 1st International Symposium Crispy Cracks 'Creating and retaining the crispiness of food', Wageningen (PaysBas) 2008 (oral communication);
Vanin, F.M., Lucas, T., Grenier, D., Doursat, C., Flick, D., Trystram, G. A study of the crust setting and its effect on heat and mass
transport and expansion during bread baking. In: 10 International Congress of Engineering and Food, Valparaiso (Chile), 2008.
Vanin, F.M, Lucas, T, Doursat, C, Flick, D, Trystram, G. Crust formation and 2D modeling of heat and mass transfer and expansion
during bread baking. In: 6th European Young Cereal Scientists and Technologists Workshop, Montpellier (France) 2007. (oral
presentation)
2
3
4
5
#
National Congress
CEMAGREF= 9(IJ) + 0(NJ) + 5(IC) + 0(NC) = 14
KU
#
1
2
3
International Journal
Sikora M., Kowalski S., Krystyjan M., Ziobro R., Wrona P., Curic D., LeBail A., Starch gelatinization as measured by rheological
properties of the dough. Journal of Food Engineering 2010, 96, (4), 505-509.
Borczak B., E.Sikora, M.Sikora, D.Curic, I.van Haesendonck, Sourdough and freezing treatment as a tool for low GI wheat bread.
Food Chemistry (under preparation).
Borczak B., E.Sikora, M.Sikora, C.Rosell, C.Collar. Impact of oat fiber and inuline addition to partially baked and frozen wheat
bread on glycemic response in human volunteers. Journal of Cereal Science (under preparation).
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8
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6
7
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9
National Journal
B. Borczak, P. M. Pisulewski, M. Sikora, J. Krawontka, Comparison of glycemic responses to frozen and non-frozen wheat rolls in
human volunteers - a short report. Polish Journal of Food and Nutrition Sciences, 2008, 58, nr 3, 373-376.
Gambuś H., Gambuś F., Wrona P., Pastuszka D., Ziobro R., Nowotna A., Kopeć A., Sikora M., Supplementation of gluten-free rolls
with amaranth and flaxseed increases the concentration of calcium and phosphorus in the bones of rats. Polish Journal of Food
and Nutrition Sciences, 2009, 59, 349-355.
Professional journal – Poland : M. Sikora, Osiągnięcia i dalsze zamierzenia projektu EU Freshbake. Przegląd Piekarski i
Cukierniczy 2009, nr 6, 14.
International Congress
R. Ziobro, H. Gambuś, M.Sikora, P. Gaura, A. Samiec, Comparison of different methods for the measurement of gluten free dough
consistency. XV International Starch Convention, Moscow, 2007, s. 95.
M. Sikora, S. Kowalski, M. Krystyjan, D. Curic, A. LeBail, R. Ziobro, Study on starch gelatinization of the dough during processing.
13th ICC Cereal and Bread Congress, June 15-18, 2008, Madrid, Spain, 102.
Borczak B., Sikora M., Pisulewski P.M., Gambuś H., Impact of different methods of dough fermentation on glycemic index of wheat
rolls in humans. 13th ICC Cereal and Bread Congress, June 15-18, 2008, Madrid, Spain, 274.
P.Wrona, H. Gambuś, M. Krystyjan, R. Ziobro, D. Pastuszka, M.Sikora, D. Gumul, Rheological properties of gluten-free dough, as
influenced by the use of hydrocolloids and supplements. 36-th International Conference of Slovak Society of Chemical
Engineering, May, 25-29, 2009, Tatranske Matliare, Slovakia, 334.
Borczak B., P. M. Pisulewski, M. Sikora, I. Van Haesendonck. The impact of two freezing processes of wheat rolls on glycemic
index in human volunteers. XVII International Starch Convention, 16-18 June 2009 Moscow.
Sikora M., P.M. Pisulewski, I. Van Haesendonck, B. Borczak. Glycemic index of bread: impact of process and formulation. 5th
International Congress “Flour-Bread” 21-23 October, Opatija, Croatia.
Kopeć A., Borczak B., Pysz M., Sikora M., Pisulewski P.M., Rosell C.M., Collar C., 2009. The effect of bread enriched with
sourdough on the level of some mineral components in rats. 5th International Congress & 7th Croatian Congress of Cereal
Technologists "Flour-Bread '09, Opatija, Croatia.
Pysz M., Kopeć A., Borczak B., Sikora M., Pisulewski P.M., Rosell C.M., Collar C., 2009. Biological value of proteins bread
traditionally baked or partially baked and frozen supplemented with sourdough and dietary fiber. 5th International Congress & 7th
Croatian Congress of Cereal Technologists "Flour-Bread, Opatija, Croatia.
National Congress
R. Ziobro, H. Gambuś, M. Sikora, P. Gaura, A. Samiec, Porównanie metod badania konsystencji ciasta bezglutenowego. XXXVIII
Sesja Naukowa KNoŻ PAN, Żywność a jakość życia. Olsztyn 20-21 września 2007, s. 170.
H. Gambuś, P. Gaura, Pastuszka D., F. Gambuś, R. Ziobro, A. Nowotna, M. Sikora, Wpływ mieszanki hydrokoloidów i użytych
suplementów na jakość i proces starzenia się bułeczek bezglutenoych. XXXVIII Sesja Naukowa KNoŻ PAN, Żywność a jakość
życia. Olsztyn 20-21 września 2007, s. 201.
Sikora M., EU-Freshbake – europejski projekt dotyczący optymalizacji technologii odroczonego wypieku pieczywa. Przegląd
Piekarski i Cukierniczy, 2008, nr 7, 24-27.
M. Sikora, Osiągnięcia i dalsze zamierzenia projektu EU Freshbake. Przegląd Piekarski i Cukierniczy 2009, nr 6, 14.
Borczak B., P. M. Pisulewski, R. B. Kostogrys, M. Sikora. Glucose level in rats serum fed with wheat bread that underwent different
technological processes before baking. III PhD Students Conference, 21 March 2009, Kraków, Poland.
Borczak B., P.M.Pisulewski, M.Sikora, C.M.Rosell. Impact of wheat bread enrichment with resistant starch on glycemic index. XVI
Scientific Session of Polish Food Technologist Association, 21-22 May 2009, Gdynia, Poland.
Pysz M., Kopeć A., Borczak B., Sikora M., Pisulewski P.M., Rosell C.M., Collar C., 2009. Wpływ dodatku błonnik pokarmowego do
pieczywa pszennego na wartość biologiczną białka. Mat. Konf. Naukowej Żywność wzbogacona i nutraceutyki, Kraków 18-19
czerwca, 68.
Kopeć A., Borczak B., Pysz M., Sikora M., Pisulewski P.M., Rosell C.M., Collar C., 2009. Wpływ chleba wzbogacanego błonnikiem
pokarmowym na profil lipidowy oraz zawartość wybranych składników mineralnych w organizmie szczurów doświadczalnych. Mat.
Konf. Naukowej Żywność wzbogacona i nutraceutyki, Kraków 18-19 czerwca, 100.
Borczak B., Pisulewski P., Sikora M., Krawontka J., Perronnet A., Roelens, G ., Chevallier S., Boumali K. et Le Bail A.. Impact du
procede de cuisson sur l’indice glycemique d’un pain de type français. 59es Journées Techniques des Industries Céréalières,
24 et 25 Octobre 2008, Paris, France.
KU=3(IJ) + 2(NJ) + 8(IC) + 9(NC) = 22
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IATA
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2
3
4
International Journal & Book chapters
Rosell CM., Collar, C. “Effect of temperature and consistency on wheat dough performance.” International Journal of Food
Science and Technology. 2009. 44, 493-502.
Rosell CM., Santos E, Sanz-Penella JM., Haros M. “Wholemeal wheat bread: a comparison of different breadmaking processes
and fungal phytase.” Journal of Cereal Science. 2009. 50, 272-277.
Rosell CM., Santos E.
“Impact of fibers on physical characteristics of fresh and staled bake off bread.” Journal of Food Engineering. 2010. 98, 273-281.
“Trends in breadmaking: Low and subzero temperatures”. Rosell CM., In: Innovation in Food Engineering: New
Techniques and Products. Ed M.L. Passos, C.L. Ribeiro. 2009. Taylor and Francis, CRC Press. p 59-79.
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1
National Journal
Professional journal – Spain: “Encuentran mejoras nutricionales en el pan precocido”, Molinería y Panadería, page 24 – July
2009
#
1
International Congress
Sanz Penella, J.M., Rosell, C.M., Haros, M. Effect of fungal phytase addition, fermentation and freezing on the phytate degradation
of whole wheat dough. In Cereals-The future challenges. ICC Conference Proceedings. 2007.
Rosell, C.M., Haros, M. Impact of cyclodextrin glycoxyltransferase and fatty acids on wheat flour thermomechanical behaviour.
Congress on Cereals – their products and processing. 2008, Debrecen, Hungary. ISBN: 978-963-9732-38-4
Rosell, C.M., Santos E., Sanz Penella JM., Haros M, Collar C. Phytate profile in different fiber containing partially baked frozen
breads. Congress on Cereals – their products and processing. 2008, Debrecen, Hungary. ISBN: 978-963-9732-38-4.
E.Santos, C.M. Rosell, C. Collar Plural characterisation of dietary fibres from different sources in breadmaking applications. 13rd
ICC Cereal and Bread Congress. Madrid. Spain. 2008.
“Breadmaking technology meeting consumer drivers for healthy breads”. Rosell, C.M. Proceedings 5th International
Congress “Flour-Bread’09” and the 7th Croatian Congress of Cereal Technologists “Brasno-Kruh ‘9” in Opatija, Croatia
21-23 October ISBN, in press 2009.
2
3
4
5
IATA= 5(IJ) + 1(NJ) + 5(IC) + 0(NC) = 11
PBF
#
1
2
3
4
5
6
#
1
#
International Journal
Ćurić, D., Novotni, D., Škevin D., Rosell, C.M., Collar, C., Le Bail, A., Colić-Barić, I., Gabrić, D. (2008) Design of quality index for
the objective evaluation of bread quality: Application to wheat breads using selected bake off technology for bread making. Food
Research International, 41, 714-719.
Galić K., Ćurić D., Gabrić D. (2009) Shelf-life of Packaged Bakery Goods - A Review. Critical Reviews in Food Science and
Nutrition, 49, 405-426.
Novotni, D., Ćurić, D., Galić, K., Škevin, D., Neđeral, S., Kraljić, K., Gabrić, D., Ježek, D. Influence of frozen storage and packaging
on oxidative stability and texture of bread produced by different processes – sent to LWT and waiting for final decision.
Gabrić, D., Ben Aissa, F., Le Bail, A., Monteau, J.Y., Novotni, D., Ćurić, D. Chilling and freezing of prefermented dough: Part 1.
Experimental results – Submitted Sept 2010.
Gabrić, D., Ćurić, D., Novotni, D., Rosell, C.M., Galić, K., Petrović, M., Ivanec-Šipušić, Đ. Influence of sourdough addition on dough
proofing and quality of wholemeal partially baked frozen wheat bread– submitted to „Journal of Food Process
Engineering“
Novotni, D., Curic D, Bituh, M., Colic Baric I., Skevin, D., Cukelj, N. „Glycemic index and phenolics of partially-baked frozen bread
with sourdough“ in International Journal of Food Sciences and Nutrition, 2010; Online: 1–8 (doi:10.3109/09637486.2010.506432)
National Journal
Professional journal – Croatia : “FP6 Projekt - Kratki naziv projekta « EU-FRESH BAKE ». Naziv projekta - Proizvodnja svjezih
pekarskih proizvoda povecane prehrambene vrijednosti uz ustedu energije, a na zadovoljstvo potrosaca i okolisa - Vrsta projekta:
Ciljani istrazivaiki projekt (STRP) Prioritet: 5, Kvaliteta i sigurnost hrane” , in HRVATSKI CASOPIS ZA PREHRAMBENU TE
HNOLOGIJU, BIOTEHNOLOGIJU I NUTRICIONIZAM – CROATIAN JOURNAL OF FOOD TECHNOLOGY,BIOTECHNOLOGY
AND NUTRITION –Vol.1., Page 48 - 2009
International Congress
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4
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Ćurić D., Novotni D., Gabrić D., Polenghi O., Cerne V., Sikora M. Influence of proofing and baking time on selected properties of
gluten-free bread. Proceedings of the 2008 Joint Central European Congress (Ed. D. Ćurić), Vol 1: 311-319. 4th Central
European Congress on Food- 6th Croatian Congress of Food Technologists, Biotechnologists and Nutritionists, 15-17 May 2008,
Croatia.
Colić Barić I., Sučić M., Novotni D., Neđeral Nakić S., Ćurić D. Can we measure the real nutritional quality of bread through nutrient
density methods. Proceedings of the 2008 Joint Central European Congress (Ed. D. Ćurić), Vol 1: 375-382. 4th Central European
Congress on Food - 6th Croatian Congress of Food Technologists, Biotechnologists and Nutritionists, 15-17 May 2008, Croatia.
Ćurić, D., Novotni, D., Gabrić, D., Žikić, A., Bauman, I. Dough fermentation modeling. 3rd International Congress FLOUR –
BREAD ´07, 6th Croatian Congress of Cereal Technologists, 24-27 October 2007, Croatia.
Ćurić D., Gabrić D., Novotni D., Čukelj N., Krička T. Dough fermentation optimization by application of modified Gompertz equation.
IUFOST Congress, 19-23 October 2008, China.
National Congress
PBF= 6(IJ) + 1(NJ) + 4(IC) + 0(NC) = 11
RAS
#
1
International Journal
T.A. Misharina, V.I. Kiseleva, M.B. Terenina, N.I. Krikunova, I.B. Medvedeva " Release of volatile compounds from the bread” In:
“Kinetics and Thermodynamics for Chemistry and Biochemistry” Eds. by M. Pearce, G.E. Zaikov, G. Kirshenbaum. Nova Science
Publishers, New York, 2009, pp. 169-180
2
V.I. Kiseleva, A. Le Bail, A. I. Sergeev, S. S. Kozlov, V.P. Yuryev “Investigations of heat-induced transitions in model (starchwater, starch-gluten-water) and real dough systems” , submitted on LWT- Food science and technology
V.I. Kiseleva, W. Błaszczak, J.Fornal, S. S. Kozlov, A. I. Sergeev, V. P. Yuryev “Cryotexturing of dough and bread structure”,
submitted on LWT- Food science and technology
L. A. Wasserman, V. G. Vasil’ev, M. V. Motyakin, W. Blaszchak, J. Fornal, L. G. Damshkaln, V. I. Lozinsky, V. P. Yuryev. (2009).
Influence of Gluten and Gum Additives and Cryogenic Treatment on Some Properties and Morphology of Wheat Starch Complex
Gels. Starch/Stärke 61, 377–388.
N. K. Genkina, V. P. Yuryev , Synergistic and Antogonistic Effects in Viscosity of Polysaccharide Blends , ch.13, pp. 147-160 in "
Starch Science and Technology" (Eds.: V.P. Yuryev, P. Tomasik, A. Blennow, L. Wasserman , G.E. Zaikov ) 2008, Nova
Science Publishers, NY.
3
4
5
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National Journal
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International Congress
N.K. Genkina, V.P. Yuryev "Synergic and antagonistic effects on viscosity of polysaccharides blends". In Conference book XV
International starch convention Moscow-Cracow, Moscow, 2007, June 19-21
Valentina I. Kiseleva, Grigoriy V. Kotelnikov, Alain Le Bail, Andrey I. Sergeev, Sergey S. Kozlov , Vladimir P. Yuryev Investigation
of DSC, MTDSC and 1H NMR transitions in wheat flour dough during heating. XV International starch convention Moscow-Cracow,
Moscow, 2007, June 19-21, Abstarct book, p.53
V.I. Kiseleva, W. Blaszczak, J. Fornal, V.P.Yuryev Effect of freezing on the properties of dough and bread quality. XVI International
starch convention Cracow-Moscow, Cracow, 2008, June 16-20. abstract book, p.33
2
3
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National Congress
RAS= 3(IJ) + 0(NJ) + 3(IC) + 0(NC) = 6
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