Salt and fat reduc1on in puff pastry Emanuele Zannini University College Cork Ireland FINAL PLEASURE Conference on SALT -‐ SUGAR & LIPIDS Reduc:on in Foods 5th December 2014 Brussels, Belgium A European Project supported within the Seventh Framework Program for Research and Technological Development Puff Pastry – differenLaLon, definiLon Laminated dough “Puff Pastry” no yeast, no leavening agents sweet or savoury filled a light, flaky pastry made of a laminated dough containing several layers of fat “Danish Pastry” (wienerbrød) yeast leavened Croissant, Plunder Sausage rolls, Pastete, Turnovers University College Cork, Emanuele Zannini 1 December 2014 2 Fat in puff pastry Puff Pastry dough with layers of dough and margarine/fat Dough Margarine/Fat http://www.palsgaard.com Puff pastry margarine, Palsgaard Technical Paper, October 2011 Puff Pastry dough during baking process Ø Plays key role in puff pastry Ø SeparaLon of dough layers during laminaLon process Ø Important for mouthfeel, taste, structure of final product http://www.palsgaard.com Puff pastry margarine, Palsgaard Technical Paper, October 2011 University College Cork, Emanuele Zannini 1 December 2014 3 Fat reducLon 2 ways of fat reduc1on Fat replacement Fat reduc1on ParLally or total Ø Fat subsLtutes e.g. “Olestra“ Ø Fat mimeLcs e.g. inulin, carrageen, hydrocolloids Ø Change only technological parameters : 1. Number of layers based on CH 2. Final dough thickness “Reduced in FAT” (RegulaLon (EC) No. 1924/2006) Ø minus 30% fat compared to similar product Ø To comply with limit values fat level was reduced by up to 40% University College Cork, Emanuele Zannini 1 December 2014 4 Salt in puff pastry Salt Ø Important for dough structure (gluten strengthening) Ø Acts as preservaLve (water acLvity) Ø Overall flavour and salt percepLon Salt reduc1on Regula1on (EC) No. 1924/2006 normal salt content g salt/ salt [g] in 1500 g 100 g product dough * Na [g] x 2.54) (x 0.8) 20.38 -‐ 25% compared to similar product 15.25 reduced in sodium/salt ≤ g/100g final product max. g/100g final product 0.12 0.3048 0.244 5.43 low sodium/salt 0.04 0.1016 0.081 1.80 very low sodium/salt 0.005 0.0127 0.010 0.22 sodium-‐free/salt-‐free ~ 20%) * 0.8 factor from unccoked to cooked PP dough (bake loss Na (sodium) NaCl (Salt) Ø AddiLonally: InvesLgaLon of double (1.8%) and four 1mes (3.6%) the amount of salt University College Cork, Emanuele Zannini 1 December 2014 5 Puff pastry producLon Basic recipe Weigh in ingredients Ingredients weight [g] % Flour 970.2 43.3 Water Lemon juice Dough total 494.8 14.6 1500 22.1 0.7 67.0 Salt 20.4 Roll-‐in fat 740 Mix (5 min) Rest (20 min RT) 0.9 33.0 Roll down to 2.50 mm http://www.rondo-online.com Folds: 2 double + 2 single turns, in between dough rest for 30 (90) min Double turn = 4 fat layers Single turn = 3 fat layers Cut out samples 10 x 10 cm University College Cork, Emanuele Zannini Wrapp fat into dough Pastry rest over night at 4°C Bake at 210°C for 12 min 1 December 2014 6 Physicochemical Analysis -‐ Methods VolScan Ø Volume and the external structure of PP Texture Analyser (TA) adached with 2 different probes: Extended Craf Knife (ECK) + Mul1ple Puncture Probe (MPP) Ø Firmness of PP ECK 100 Force-‐Lme curve of PP force [N] 90 80 70 60 50 40 30 20 10 0 0 1 2 3 4 5 6 7 8 time [s] C-‐Cell image analysis system Texture Analyser + Kieffer Rig Ø Resistance of dough Ø Internal structure of PP products (No. of cells, slice brightness) http://128.121.92.221/media/Pictures-Used/kieffercropped.jpg University College Cork, Emanuele Zannini 1 December 2014 7 RSM – experimental procedure 54 puff pastry doughs with various fat contents, number of layers and final thicknesses Analysis Proper1es Volume, lif VolScan Texture Analyser C-‐Cell Sensory eyes Texture, structure, „bite“ mouth, hands Internal structure eyes, mouth Response Surface Methodology (RSM) Threshold values/set scopes Op1mum parameters University College Cork, Emanuele Zannini 1 December 2014 8 Microbiological analysis Ø Shelf life test: 4 weeks at 4°C and 5 weeks at -‐18°C Test Total bacterial Lac1c acid count (TBC) bacteria (LAB) Yeasts Agar Plate count agar MRS agar Yeast agar Addi1ves Cyclohexamide and Vitamins Cyclohexamide Chloramphenicol and Erythromycin Technique Spread plate Spread plate Spread plate 30°C 37°C 25°C 2 days 2 days 5 days Aerobic Anaerobic Aerobic Incuba1on temperature Incuba1on period Incuba1on condi1on University College Cork, Emanuele Zannini 1 December 2014 9 Results – Fat reducLon Results FAT REDUCTION in Puff Pastry University College Cork, Emanuele Zannini 1 December 2014 10 Results – Fat reducLon (RSM) Op1mum parameters for fat reduced (40%) puff pastry Full fat PP (old) – Control Design-Expert® Software Desirability 1 Desirability plots (RSM) à highest plateus represent opLmal parameters 0 0.8 Actual Factor A: Fat reduction = 0.00 0.6 D e sira b ility Full fat PP (improved) X1 = C: Final thickness X2 = B: Fat layers 0.4 0.2 0 50.00 87.50 3.50 125.00 2.88 Design-Expert® Software 2.25 162.50 1.63 Desirability 1 1.00 C: Final thickness B: Fat layers 200.00 0 0.8 Actual Factor A: Fat reduction = 40.00 0.6 D e sira b ility Fat reduced (40%) PP X1 = C: Final thickness X2 = B: Fat layers 0.4 0.2 0 50.00 87.50 3.50 125.00 2.88 2.25 162.50 1.63 C: Final thickness University College Cork, Emanuele Zannini 1.00 B: Fat layers 200.00 1 December 2014 11 Sensory of fat reduced PP (n = 60) -‐ Results 1.0 0.8 Modified Flash Profile Sensory Analysis Improved PP control Principal Component 2 0.6 0.4 Appearance 0.2 Saltiness Acceptance Firmness Off-flavour Crispiness 0.0 Moisture Fatness Layers Volume Mouthfeel/Texture Flavour -0.2 PP control Ø No significant correla1ons to fatness Colour -0.4 -0.6 Ø Fat reduc1on of PP by 40% was successful! Fat reduced PP -0.8 -1.0 -1.0 -0.8 -0.6 Ø Consumer accepted improved PP control and fat reduced ( 4 0 % ) P P ( p o s i L v e l y correlated) -0.4 -0.2 0.0 0.2 0.4 0.6 0.8 1.0 Principal Component 1 ANOVA-‐parLal least squares regression (APLSR) correlaLon loadings plot for puff pastry (PP) samples. ▲ = samples, ♦ = sensory adributes (cursive style: hedonic adributes, not cursive: intensity adributes) Sample PP control Liking of Flavour Overall Acceptability Fatness -‐0.0195 * -‐0.0103 ** 0.4047 ns Improved PP control Fat reduced PP 0.1247 ns 0.1246 ns -‐0.4934 ns University College Cork, Emanuele Zannini 0.0292 * 0.0128 * -‐0.3588 ns 1 December 2014 12 Results – Salt reducLon Results SALT REDUCTION in Puff Pastry University College Cork, Emanuele Zannini 1 December 2014 13 Salt reducLon (Dough) -‐ Kieffer extensibility rig Force [N] Distance to rupture [mm] Higher force à dough is more resistant Lower extensibility à dough can be stretched less Ø No significant differences in force and distance for all salt reduced doughs (40, 60 min) Ø Higher salt content showed significant higher resistance to rupture (all rest periods) Ø No technical limita1ons for salt reduced doughs University College Cork, Emanuele Zannini 1 December 2014 14 Salt reducLon (PP) – Results physicochemical Analysis Salt reduc1on in full fat PP (compared to control) Ø No significant differences in total firmness and specific volume (salt red. PP) Ø “No salt” PP showed decrease in volume and increased firmness Ø Lif decreased and firmness increased with increasing salt level (2x and 4x salt) Salt reduc1on in fat reduced (40%) PP (compared to control) PP full fat, 30% salt reduced Ø Salt reduc1on (30%) is possible without significantly affecLng total firmness Ø But: lower specific volume and lower maximum lif Ø “No salt” and “very low salt” PP (full fat/fat red.) are poor in taste PP 40% fat reduced, 30% salt reduced University College Cork, Emanuele Zannini 1 December 2014 15 Sensory of salt (30%) + fat reduced (40%) PP (n = 56) Ø No significant differences for all aqributes Ø No significant recogni1on of reduced salt content Ø Consumer à no significantly higher salt percep1on for PP with salt located in roll-‐in fat Ø Posi1ve correla1on to overall acceptability for salt reduced doughs Ø Salt reduc1on by 30% in fat red. PP was successful University College Cork, Emanuele Zannini 1 December 2014 16 Microbiological analysis -‐ Results Ø pH à Slight acidity by addiLon of citric acid from lemon juice Ø Water ac1vity (aW): high à Products tend to be highly perishable Ø Dough with added alcohol à significantly reduced bacterial numbers each week Ø Frozen dough complied the required alarm values à in the range of week 0 Ø Very few Lactic acid bacteria (LAB) were detected occasionally Ø Yeast levels indicator for good manufacturing practises Ø Alcohol addition adequately reduced yeast growth University College Cork, Emanuele Zannini 1 December 2014 17 Conclusion Ø Successful fat reduc1on in model PP by 40% Ø Sensory study showed high acceptance towards fat reduced PP Ø Salt reduc1on (30%) in PP is possible without major deviaLons to control Ø Salt and fat reduced PP were overall accepted by consumer panel Ø Puff pastry dough is a highly perishable product Ø Salt reducLon has low impact on microbiologically shelf life Ø Ethanol and freezing are effecLve methods for extending the shelf life Ø Bacteria may adversely affect the physicochemical proper1es of the puff pastry University College Cork, Emanuele Zannini 1 December 2014 18 Credits Thanks to ... University College Cork Prof Elke Arendt Christoph Silow Inken Rethwisch Jamie O’Connor Susann Fellendorf and you! Funding This work was funded by the PLeASURe Project of the European Union. University College Cork, Emanuele Zannini 1 December 2014 19
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