2011-04 30 Continuous Biscuit Doughs

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by encapsulating the flour particles, which is specifi-

cally exploited to achieve the required plastic dough

structures.

b. he additional presence of rather large amounts of sugar

(in different states) further delays dough development

(by up to 30 min in batch mixing processes).

3. For the majority of hard biscuit doughs, dough temperaturesaround 40 °C are associated with considerable effects on

swelling and dissolution processes during dough develop-

ment, as well as with the possible triggering of chemically

induced leavening effects (raising agent).

Recipe demarcation of hard biscuit groups

Biscuits, especially hard biscuits, are long-life baked goods;

a distinction is usually made between biscuits and crackers.

SEIBEL [1991] distinguishes between the following groups

of hard biscuit doughs: butter biscuits, Albert biscuits and

cake biscuits. he essential recipe characteristics that dis-

tinguish between these hard biscuit representatives are the

proportions of fat and sugar, involving a decrease in the

proportion of fat from 20 % through 14 % to 10 %, while the

proportion of sugar increases from 22 % through 25 % to 28 %.

Alternatively, the proportion of water remains unchanged at

around 20 %. At least with regard to butter biscuits, this shift

in the ingredients leads to a completely different dough

structure development.

A butter biscuit dough containing 20 % butter, 22 % sugar

and around 20 % water behaves like a short pastry in dough

preparation. In this respect it differs completely from the

hard biscuit types in the Albert or cake biscuit group,

both of which have a dough temperature around 40 °C. Con-

sequently a distinction between cold and warm dough with

regard to the target dough temperature is mandatory fortechnological reasons and is more sensible than the distinction

between soft and hard biscuit dough often encountered in

the specialist literature.

The basic technical-technological concept of the

“butter biscuit” type of hard biscuit (cold dough)

However, due to the distinctly lower fat content compared to

a classical short pastry (e.g. 1-1-2 with 5 % water – for short

pastry piecrusts [Kaiser, 2011]), the dough pasting properties

play a particular role, especially when implementing con-

tinuous dough preparation using Zeppelin Reimelt’s CODOS®

continuous mixing system. Without a suitable adaptation of

the tool design, the raw materials are insufficiently pulled

into the mixing tools. Congestion occurs in the intake region,

which can only be compensated by raising the mixer rotation

speed. However, the input of mixer energy is of only secondary

importance for this dough type. Consequently it was necessary

to make a technical change to the tools that were suitable for

the dough system to avoid the congestion.

R E S E A R C H 3 1

B A K I N G + B I S C U I T I S S U E 0 4 2 0 1 1


http://slidepdf.com/reader/full/2011-04-30-continuous-biscuit-doughs 3/4B A K I N G + B I S C U I T I S S U E 0 4 2 0 1 1

Marie biscuit++ figure 2

R E S E A R C H3 2

Since many industrial applications for butter biscuits (cold

dough) contain sugar in the form of powdered sugar, which

is also often ground in the bakery’s own sugar mills and

thus frequently also needs to be processed at temperatures

> 40 °C, adherence to the dough temperature is a serious

problem.

his problem can be exacerbated if liquid sugar (e.g. glucose)is processed. he temperature of the glucose needs to be ad-

justed to approx. 35 °C to enable it to be metered in. he

thermal physical potential of the remaining bulk water (dis-

pensed as ice water) together with the temperature-con-

trolled butter, in conjunction with the mixing system’s

trough wall cooling, must then be sufficient to guarantee the

required temperature with an adequate mixing intensity.

Te usual form in which the raising agent is added as a solution

represents another problem. Part of the bulk water is used

for this purpose. For example six, or better still seven parts

of water are needed to dissolve one part of ammonium hy-

drogen carbonate in water, which reduces the available “cooling

potential” of the remaining bulk water. A suitable process

technology solution to dispense a homogeneous dispersion

of the raising agent in the CODOS® system was developed

for this purpose.

Achieving a uniform (i.e. gravimetrically controlled) dis-

pensing of plasticised, cooled butter is technically challeng-

ing but urgently necessary.

Based on the achieved thermal management of the raw ma-

terials’ batches to be dispensed and the design of the CODOS®

system’s mixing tools specifically adapted to the dough, a

technical-technological process concept (figure 1 on page 34)for butter biscuit dough (cold dough) was developed by the

IGV GmbH Company, Bergholz-Rehbrücke, Germany, and

technically implemented by the Zeppelin Reimelt GmbH

Company. he concept enables this typical market represent-

ative of hard biscuits to be manufactured industrially using

the CODOS system.

First of all the technical-technological concept was trialled

on the IGV pilot plant. Subsequent full-scale tests using

Zeppelin Reimelt’s test plant allowed the laboratory testresults to be confirmed on an industrial scale.

he production test was operated at plant throughputs of up

to 2.5 t of dough per hour.

The prospects for the continuous manufacture of hard

biscuits of the “warm dough” type, e.g. the Marie biscuit

Due to the even smaller proportion of water and fat in hard

biscuit dough of the “warm dough” type, the 1st phase of

mixing (dough pasting) plays an even more important role.

In addition to the special design of the mixing tools in the

intake area, dough pasting is achieved by a targeted thermal

process management of raw materials’ batches with a selected

composition. A distinct partial acceleration of the dough

pasting process is achieved by targeting prior temperature

adjustment (in this case warming) batches of raw materials

specifically matched to the respective recipe. In addition to

the prior temperature adjustment of the raw materials’

batches, this process can be further assisted by specific tem-

perature control of the mixer trough, as figure 2 shows.

Both the dough physics data (measured with a exture Ana-

lyser) and the fracture data (also measured with a exture

Analyser) of the biscuits manufactured were very largely

comparable as a result of implementing this concept.Te key strategy when implementing hard biscuit applications

(type: warm dough) to a continuous production method

Dough production takes place in a temperature controlled laboratory spiral mixer with a trough volume of 10 l. The target dough temperature should be 42.5 °C.

mixer untempered/without targeted tempering

mixing time: 20:52 min; dough temperature 42.5 °C

mixer tempered: 45 °C /batches tempere d

mixing time: 5:20 min; dough temperature: 42.5 °C

stress-strain

dough profile

stress-strain

dough profile

biscuit

break test

© I G

V

force (g) force (g) force (g)

biscuit

break test

force (g)

length (mm) length (mm) length (mm) length (mm)

2011-04 30 Continuous Biscuit Doughs

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