Source: KANSAS STATE UNIV submitted to NRP
UNDERSTANDING AND OVERCOMING QUALITY CONSTRAINTS IN FROZEN DOUGH PROCESSING
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
Reporting Frequency
Annual
Accession No.
0231058
Grant No.
(N/A)
Cumulative Award Amt.
(N/A)
Proposal No.
(N/A)
Multistate No.
(N/A)
Project Start Date
Oct 1, 2012
Project End Date
Sep 30, 2017
Grant Year
(N/A)
Program Code
[(N/A)]- (N/A)
Recipient Organization
KANSAS STATE UNIV
(N/A)
MANHATTAN,KS 66506
Performing Department
Grain Science And Industry
Non Technical Summary
Producing yeast-leavened products using frozen dough technology has a number of manufacturing and economic advantages. However, the quality of the resulting product doesn?t come up to that of its fresh dough counterpart. The problem is partially remedied by the inclusion of potassium bromate as a dough improver. Health concerns about the use of potassium bromate have limited its use and will restrict further in the future. One promising replacement for bromate is the combination of the enzyme xylanase and ascorbic acid. Understanding how and why this replacer works would allow the creation and use of more (and more effective) improvers fro frozen doughs. This research seeks to gain that understanding and develop those replacers.
Animal Health Component
50%
Research Effort Categories
Basic
50%
Applied
50%
Developmental
(N/A)
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
50115402020100%
Goals / Objectives
To overcome constraints/limitations in the processing and product quality of products made using frozen dough technology. To understand why and how the potassium bromate replacer combination of xylanase/ascorbate improves the quality of frozen dough products. To understand how that improving effect is modified or mitigated by processing and formulation variables. To use the understanding gained from the first 2 objectives to create new, more effective (or more broadly effective) dough improvers and processes for the frozen dough industry. Increase in fundamental knowledge and understanding of dough behavior, chemistry and product quality. New, more effective dough improver formulations for industrial applications (Intellectual property possibilities).
Project Methods
Laboratory experimentation on frozen dough systems, systematically varying specific process, formula and dough improver parameters. Results/effects will be assessed at three levels: fundamental rheological properties (via Small Angle Oscillatory rheometry), change in dough microstructure (via x-ray microtomography) and change in final product quality (via analytical bread baking).

Progress 10/01/12 to 09/30/17

Outputs
Target Audience:Academic (university and governmental) colleagues, industrial researchers, product development scientists and nutrition scientists, cereal millers and processors Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?Thirteen students were graduated, completed their degrees. Seven PHD's and six MS. How have the results been disseminated to communities of interest?Conference presentations, journal articles, invited presentations. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? The research projects in this program identify difficulties, limitations or constraints in the manufacture of high quality baked products, primarily; HW products produced from frozen dough systems, when appropriate, determines their underlying cause or mechanism and discovers appropriate science-based solutions to those constraints. The constraints are related primarily to the replacement of the oxidizing improver, potassium bromate. Consequently, the discoveries/new knowledge resulting from the research may involve outputs relating to one or more of those aspects of baking science/cereal science. Specific outputs from this research include publications in scholarly journals (e.g. Cereal Chemistry), broader coverage technical journals (e.g. Cereal Foods World), presentations at technical conferences (e.g. American Association of Cereal Chemists), new analytical or testing methods or invited presentations. Outcomes/Impacts This research provides individuals and organizations who create new processed cereal grains, produce cereal based foods, the equipment used to process them and, particularly, the ingredients that go into them with the means or knowledge to make the of higher quality, etc. By overcoming constraints to higher quality, better nutrition etc, the results of this program will directly and positively affect not only the processors of cereal grains and cereal products but also (and ultimately) the , better nutrition etc, the results of this program will directly and positively affect not only the processors of cereal grains and cereal products but also (and ultimately) theconsumers of those examples.

Publications


    Progress 10/01/15 to 09/30/16

    Outputs
    Target Audience:Academic (university and governmental) colleagues, industrial researchers, product development scientists and nutritionscientists, cereal millers and processors Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?Three students were graduated, completed their degrees. Two PHD and one MS. Two students were in progress, two MS. How have the results been disseminated to communities of interest?Conference presentations, journal articles, invited presentations. What do you plan to do during the next reporting period to accomplish the goals?Continuing to pursue major research objectives in this area.

    Impacts
    What was accomplished under these goals? The research projects in this program identify difficulties, limitations or constraints in the manufacture of high quality baked products, primarily; HW products produced from frozen dough systems, when appropriate, determines their underlying cause or mechanism and discovers appropriate science-based solutions to those constraints. The constraints are related primarily to the replacement of the oxidizing improver, potassium bromate. Consequently, the discoveries/new knowledge resulting from the research may involve outputs relating to one or more of those aspects of baking science/cereal science. Specific outputs from this research include publications in scholarly journals (e.g. Cereal Chemistry), broader coverage technical journals (e.g. Cereal Foods World), presentations at technical conferences (e.g. American Association of Cereal Chemists), new analytical or testing methods or invited presentations. Outcomes/Impacts This research provides individuals and organizations who create new processed cereal grains, produce cereal based foods, the equipment used to process them and, particularly, the ingredients that go into them with the means or knowledge to make the of higher quality, etc. By overcoming constraints to higher quality, better nutrition etc, the results of this program will directly and positively affect not only the processors of cereal grains and cereal products but also (and ultimately) the , better nutrition etc, the results of this program will directly and positively affect not only the processors of cereal grains and cereal products but also (and ultimately) theconsumers of those examples.

    Publications


      Progress 10/01/14 to 09/30/15

      Outputs
      Target Audience:Academic (university and governmental) colleagues, industrial researchers, product development scientists and nutrition scientists, cereal millers and processors. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?Three students were graduated, completed their degrees. One PHD and two MS. Three students were in progress, two PHD and one MS. How have the results been disseminated to communities of interest?Conference presentations, journal articles, invited presentations. What do you plan to do during the next reporting period to accomplish the goals?Continuing to pursue major research objectives in this area.

      Impacts
      What was accomplished under these goals? The research projects in this program identify difficulties, limitations or constraints in the manufacture of high quality baked products, primarily; HW products produced from frozen dough systems, when appropriate, determines their underlying cause or mechanism and discovers appropriate science-based solutions to those constraints. The constraints are related primarily to the replacement of the oxidizing improver, potassium bromate. Consequently, the discoveries/new knowledge resulting from the research may involve outputs relating to one or more of those aspects of baking science/cereal science. Specific outputs from this research include publications in scholarly journals (e.g. Cereal Chemistry), broader coverage technical journals (e.g. Cereal Foods World), presentations at technical conferences (e.g. American Association of Cereal Chemists), new analytical or testing methods or invited presentations. Outcomes/Impacts This research provides individuals and organizations who create new processed cereal grains, produce cereal based foods, the equipment used to process them and, particularly, the ingredients that go into them with the means or knowledge to make the of higher quality, etc. By overcoming constraints to higher quality, better nutrition etc, the results of this program will directly and positively affect not only the processors of cereal grains and cereal products but also (and ultimately) the , better nutrition etc, the results of this program will directly and positively affect not only the processors of cereal grains and cereal products but also (and ultimately) theconsumers of those examples.

      Publications


        Progress 10/01/13 to 09/30/14

        Outputs
        Target Audience: Academic (university and governmental) colleagues, industrial researchers, product development scientists and nutrition scientists, cereal millers and processors. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest? Nothing Reported What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

        Impacts
        What was accomplished under these goals? The research projects in this program identify difficulties, limitations or constraints in the manufacture of high quality baked products, primarily; HW products produced from frozen dough systems, when appropriate, determines their underlying cause or mechanism and discovers appropriate science-based solutions to those constraints. The constraints are related primarily to the replacement of the oxidizing improver, potassium bromate. Consequently, the discoveries/new knowledge resulting from the research may involve outputs relating to one or more of those aspects of baking science/cereal science. Specific outputs from this research include publications in scholarly journals (e.g. Cereal Chemistry), broader coverage technical journals (e.g. Cereal Foods World), presentations at technical conferences (e.g. American Association of Cereal Chemists), new analytical or testing methods or invited presentations. Outcomes/Impacts This research provides individuals and organizations who create new processed cereal grains, produce cereal based foods, the equipment used to process them and, particularly, the ingredients that go into them with the means or knowledge to make the of higher quality, etc. By overcoming constraints to higher quality, better nutrition etc, the results of this program will directly and positively affect not only the processors of cereal grains and cereal products but also (and ultimately) the consumers of those examples. Examples from research completed or substantially completed in 2013 follow. Wheat varieties whose doughs change relatively little with increases or decreases in dough moisture (i.e. absorption tolerant) would have a distinct economic advantage in some domestic and many foreign markets. Still, the phenomenon is not well understood. If the biochemical and, subsequently, the genetic bases for absorption tolerance were understood, it should be possible to create wheat varieties of both good bread baking quality and high absorption tolerance. Research by Gabriela Rattin identified wheat varieties/growth locations that produced higher absorption tolerance. Studies of the underlying bases of tolerance have shown a strong positive correlation between higher tolerance and one particular group of the gliadin storage protein fraction. Research conducted by Elyse Buckley (Becky Miller) is extending that work to a different population of wheats (PNW) and new employing more sophisticated protein analytical tools. Syrups (carbohydrate hydrolysates) are valuable and functional ingredients in a wide range of cereal foods from breakfast bars to granola to a range of healthy snacks. However, the use of refined carbohydrates (primarily cereal starches) as the starting materials to create these syrups leaves behind other valuable/nutritious compounds present in cereals. Functional syrups, created from whole grains would contain not only higher protein content but also the entire range of bioactive molecules known to be present in the bran and germ. The results could be a new, 'value added' product for both producers and consumers. Jill Lutz' masters research, conducted at the Research and Development labs of General Mills, established processing parameters for the creation of a number of syrups from whole grain amaranth as well as initiating the functional characterization of these materials, both in and of themselves and as ingredients in cereal products. At least 2 of the processing schemes produced materials with significant potential to replace all or part of the refined carbohydrate in the model cereal foods tested.

        Publications

        • Type: Conference Papers and Presentations Status: Published Year Published: 2014 Citation: Lutz, J., Hansen, L, and J. Faubion. Whole Grain Amaranth Syrups: Process and Properties. 2014 AACCI Meeting. POSTER Cropper, S., Lape, A., Dogan, H. and Faubion, J. Evaluation of Polar and Nonpolar Lipids effects on Air Cell Structure and Distribution in Bread. 2014 IFT Meeting. POSTER


        Progress 10/01/12 to 09/30/13

        Outputs
        Target Audience: Academic (university and governmental) colleagues, industrial researchers, product development scientists and nutrition scientists, cereal millers and processors. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest? Nothing Reported What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

        Impacts
        What was accomplished under these goals? To facilitate the creation and/or manufacture of the highest quality cereal-based food products by identifying, understanding and discovering science-based solutions to constraints in their processing, formulation, chemistry or ingredients. 2. To advance the science underlying those solutions and the disciplines of cereal chemistry and baking science. Outputs The research projects in this program identify difficulties, limitations or constraints in the manufacture of high quality baked products, primarily, HW products produced from frozen dough systems, when appropriate, determines their underlying cause or mechanism and discovers appropriate science-based solutions to those constraints. The constraints are related primarily to the replacement of the oxidizing improver, potassium bromate. Consequently, the discoveries/new knowledge resulting from the research may involve outputs relating to one or more of those aspects of baking science/cereal science. Specific outputs from this research include publications in scholarly journals (e.g. Cereal Chemistry), broader coverage technical journals (e.g. Cereal Foods World), presentations at technical conferences (e.g. American Association of Cereal Chemists), new analytical or testing methods or invited presentations. Outcomes/Impacts This research provides individuals and organizations who create new processed cereal grains, produce cereal based foods, the equipment used to process them and, particularly, the ingredients that go into them with the means or knowledge to make the of higher quality, etc. By overcoming constraints to higher quality, better nutrition etc, the results of this program will directly and positively affect not only the processors of cereal grains and cereal products but also (and ultimately) the consumers of those examples. Examples from research completed or substantially completed in 2013 follow. Frozen doughs have a number of production advantages for intermediate scale, point of sale (e.g. supermarket) bakeries. A major hurdle to the production of high quality frozen doughs is the loss of dough processing quality over frozen storage time. Building on previously conducted research which alleviated most of the problem, by the incorporation of specific combinations of enzymes and oxidants other than potassium bromate, Reona Oshikiri determined that, if the breadmaking process is optimized, that the combination of Ascorbic Acid and an endoxylanase can completely replace (produce results equivalent to) potassium bromate. The testable hypothesis he developed to explain the mechanism by which enzyme/oxidants improve frozen dough storage tolerance has been tested rheologically and shows that the bromate replacer’s effects are manifest during dough proofing and before baking.. This information is and will be impactful because, the model/mechanism can be used to isolate and quantitate the relative contribution of each component of the replacer,optimizing its composition for a range of frozen dough products and processes.

        Publications