BAKERY PRODUCTS SCIENCE AND TECHNOLOGY BAKERY

Preface to the Second EditionBakery products, especially bread, have a longhistory and they form an important part of thediets of humans around the globe. Bakery products are not only popular in traditional markets such as Europe, but they are also gainingpopularity in emerging markets. For example,Euromonitor International recently reportedthat China’s market for industrial baked goodswas valued at US 25.4bn for 2013, up fromUS 19.6bn in 2012.Meanwhile, today’s consumers are increasingly conscious of health issues, so producinghigh-quality bakery products presents both achallenge and an opportunity. While there is nodispute that bakery products contain a highamount of carbohydrate and some may also contain gluten and high levels of fat and sugar, theycan also be a source of wholesome food and balanced nutrients. Producing new types of bakeryproducts or reformulating existing ones to increasetheir nutritional value or raise their nutritionalprofile is likely to remain a trend for the foreseeable future.Since the publication of the first edition of thisbook in early 2006, progress in the science andtechnology of baking and bakery products hasdone much to address these and other challenges.Therefore, the second edition provides a timelyupdate and expansion to the previous edition.The book consists of 42 chapters that are groupedinto 7 parts:1. Introduction to baking and bakery products;2. Characterization and properties of importanttypes of flours for bakery products, includingthose from wheat, rye, rice, barley, maize, sorghum, millet, and other grains;3. Major baking ingredients such as water, yeastand other leavening agents, ascorbic acid andother redox agents, sugar and sweeteners,lipids, egg, dairy ingredients, enzymes, andother functional additives;4. Science and technology of bakery productionwith dedicated chapters on mixing and doughmaking, fermentation, baking, and packaging.Also included are shelf-life prediction, process optimization and control, and sensoryand nutritional attributes of bakery products.Specific issues such as rheology, browning,and functional bakery products are alsocovered;5. Manufacturing of a variety of bread productsincluding yeast bread, sourdough, frozendough, par-baked bread, and steamed bread,as well as their quality control issues;6. Other selected bakery products such as cakes,biscuits, pastries, pretzels, bakery products fromunconventional flours, and dietetic bakeryproducts; and7. An overview of specialty bakery productsfrom around the world as well as an in-depthanalysis of bakery products from selectedcountries including China, Italy, Mexico, andTurkey.Despite every intention to provide a compre hensive reference book on baking science and technology, we appreciate that it is not possibleto claim that this book represents completecoverage. Nevertheless, we hope it serves as anessential reference on the latest knowledge andtechnologies for professionals in the baking industry, academia and government bodies, as well asfor undergraduate and postgraduate students in

viiiPREFACE TO THE SECOND EDITIONtheir study and research related to baking andbakery products.We thank the contributors, all respected professionals from industry, government, and academia, for sharing their experience and expertisein their particular fields. The 65 authors are from21 countries and have a diversity of expertise andbackground that cover the whole spectrum of thescience, technology, and engineering of bakingand bakery products.We also express our sincere thanks to thefive associate editors who are domain expertsfrom five countries, for their dedication to producing a book of the highest quality possible,and the editorial and production teams atWiley Blackwell for their efforts, advice, andprofessionalism.We truly wish that you enjoy the book and findits contents informative and beneficial to yourwork, research, or study.Weibiao Zhou and Y.H. Hui

ContributorsVictoria Kristina AnaningsihFood Technology Department,Soegijapranata Catholic University,Central Java, IndonesiaInês CastroCastro,Pinto & Costa, Lda,Maia, PortugalLidia Ballester-TomásDepartment of Biotechnology,Instituto de Agroquímica y Tecnologíade Alimentos,Consejo Superior de Investigaciones Científicas,Paterna, SpainStanley P. CauvainBakeTran,Witney, Oxford, UKLuis A. Bello-PerezCentro de Desarrollo de Productos Bióticos delInstituto Politécnico Nacional,Yautepec, Morelos, MéxicoFrancesco BonomiDepartment of Food, Environmental andNutritional Sciences (DeFENS),Università degli Studi di Milano,Milan, ItalyGabriella BottegaDepartment of Food, Environmental andNutritional Sciences (DeFENS), Università degliStudi di Milano,Milan, ItalyAna Isabel BourbonCentre of Biological Engineering,Universidade do Minho,Braga, PortugalMiguel Ângelo CerqueiraCentre of Biological Engineering,Universidade do Minho,Braga, PortugalSelena ChanChristchurch Polytechnic Institute of Technology,Christchurch, New ZealandXiao Dong ChenDepartment of Chemical and Biochemical Engineering,College of Chemistry and Chemical Engineering,Xiamen University,Xiamen, ChinaPeter Chung ChiehDepartment of Chemistry,University of Waterloo,Waterloo,Ontario, CanadaNyuk Ling ChinDepartment of Process and Food Engineering,Faculty of Engineering,Universiti Putra Malaysia,Serdang, Selangor, Malaysia

xContributorsConcha CollarFood Science Department,Instituto de Agroquímica y Tecnología de Alimentos,Consejo Superior de Investigaciones Científicas,Paterna, SpainFrank D. ConfortiDepartment of Human Nutrition, Foods, and Exercise,Virginia Tech,Blacksburg, Virginia, USAI. De LeynFaculty of Bioscience Engineering,Department of Applied Biosciences,Ghent University,Ghent, BelgiumPasquale FerrantiDipartimento di Scienza degli Alimenti,Università di Napoli “Federico II”,Portici, ItalyPamela C. Flores-SilvaCentro de Desarrollo de Productos Bióticos delInstituto Politécnico Nacional, Yautepec,Morelos, MéxicoVirginia GiannouLaboratory of Food Chemistry and Technology,School of Chemical Engineering,National Technical University of Athens,Athens, GreeceAvi GoldsteinDepartment of Food Science,University of Guelph,Guelph, Ontario, CanadaManuel GómezCollege of Agricultural Engineering,University of Valladolid,Palencia, SpainNoël HaegensClasso Foods, Vrasene, BelgiumRaija-Liisa HeiniöVTT Technical Research Centre of Finland,Food Biotechnology/Flavour Design,FinlandM. S. HemalathaDepartment of Biochemistry and Nutrition,CSIR–Central Food Technological ResearchInstitute, Mysore, IndiaSidi HuangGrain Growers Limited,North Ryde, New South Wales,AustraliaY. H. HuiScience Technology System,West Sacramento,California, USAGözde İnanAbant Izzet Baysal University,Faculty of Arts and Sciences,Department of Biology,Bolu, TurkeyKati KatinaUniversity of Helsinki, FinlandHyunsook KimDepartment of Physiology,College of Veterinary Medicine,Konkuk University,South KoreaVassilios KiosseoglouLaboratory of Food Chemistry and Technology,School of Chemistry,Aristotle University of Thessaloniki,Thessaloniki, GreeceDimitra LebesiLaboratory of Food Chemistry and Technology,School of Chemical Engineering,National Technical University of Athens,Athens, Greece

ContributorsKim LittleCampden BRI, Chipping Campden,Gloucestershire, UKN. N. MisraSchool of Food Science and Environmental Health,Dublin Institute of Technology, Dublin, IrelandShao Quan LiuFood Science and Technology Programme,c/o Department of Chemistry,National University of Singapore,SingaporeBonastre Oliete MayorgaRegional Centre of Animal Selection andReproduction, Valdepeñas, SpainTiphaine LucasIRSTEA Food Process Engineering Research Unit,Rennes Cedex,FranceMara LucisanoDepartment of Food, Environmental and NutritionalSciences (DeFENS), Università degli Studi di Milano,Milan, ItalyGianfranco MamoneIstituto di Scienze dell’ Alimentazione – CNR,Avellino, ItalyAlejandro MarangoniDepartment of Food Science,University of Guelph, Guelph, Ontario,CanadaManuela MariottiDepartment of Food, Enviromental and NutritionalSciences (DeFENS), Università degli Studi di MilanoMilan, ItalyAlessandra MartiDepartment of Food, Environmental and NutritionalSciences (DeFENS), Università degli Studi di Milano,Milan, ItalyPeter J. MartinSchool of Chemical Engineering and AnalyticalScience, The University of Manchester,Manchester, UKxiPerla Osorio-DiazCentro de Desarrollo de Productos Bióticos delInstituto Politécnico Nacional,Yautepec, Morelos, MexicoM. A. PaganiDepartment of Food, Environmental and NutritionalSciences (DeFENS),Università degli Studi di Milano,Milan, ItalyAdamantini ParaskevopoulouLaboratory of Food Chemistry and Technology,School of Chemistry,Aristotle University of Thessaloniki,Thessaloniki, GreeceDaniel PintoCastro, Pinto & Costa, Lda,Maia, PortugalKaisa PoutanenVTT Technical Research Centre of Finland,FinlandU. J. S. Prasada RaoDepartment of Biochemistry and Nutrition,CSIR–Central Food Technological ResearchInstitute,Mysore, IndiaJosé Antonio PrietoDepartment of Biotechnology,Instituto de Agroquímica y Tecnología de Alimentos,Consejo Superior de Investigaciones Científicas,Paterna, Spain

xiiContributorsEmmanuel PurlisCentro de Investigación y Desarrollo en Criotecnologíade Alimentos (CIDCA – CONICET La Plata),Facultad de Ciencias Exactas, UNLP, La Plata,ArgentinaFrancisca Rández-GilDepartment of Biotechnology, Instituto deAgroquímica y Tecnología de Alimentos,Consejo Superior de Investigaciones Científicas,Paterna, SpainC. M. RosellFood Science Department, Instituto de Agroquímicay Tecnología de Alimentos,Consejo Superior de Investigaciones Científicas,Paterna, SpainSarabjit S. SahiCampden BRI, Chipping Campden,Gloucestershire, UKMaria E. Sanchez-PardoEscuela Nacional de Ciencias Biológicas delInstituto Politécnico Nacional, México, D.F.Koushik SeetharamanDepartment of Food Science,University of Guelph, Guelph,Ontario, CanadaJ. D. SelmanFossatello Group, Carnforth, Lancashire, UKN. TherdthaiDepartment of Product Development,Faculty of Agro-Industry, Kasetsart University,Bangkok, ThailandBrijesh K. TiwariDepartment of Food Biosciences, Teagasc FoodResearch Centre, Dublin, IrelandGary TuckerCampden BRI, Chipping Campden,Gloucestershire, UKConstantina TziaLaboratory of Food Chemistry and Technology,School of Chemical Engineering,National Technical University of Athens,Athens, GreeceRubi G. Utrilla-CoelloCentro de Desarrollo de Productos Bióticos delInstituto Politécnico Nacional,Yautepec, Morelos, MéxicoAntonio VicenteCentre of Biological Engineering,Universidade do Minho,Braga, PortugalWallace H. YokoyamaUSDA, ARS, Western Regional Research Center,Albany, California, USASeyhun YurdugülAbant Izzet Baysal University, Faculty of Artsand Sciences,Department of Biology,Bolu, TurkeyLu ZhangDepartment of Chemical and Biochemical Engineering,College of Chemistry and Chemical Engineering,Xiamen University,Xiamen, ChinaWeibiao ZhouFood Science and Technology Programme,c/o Department of Chemistry,National University of Singapore, Singapore

Part 1Introduction

1Introduction to Bakingand Bakery ProductsWeibiao Zhou1, N. Therdthai2, and Y. H. Hui3Food Science and Technology Programme, c/o Department of Chemistry,National University of Singapore, Singapore2Department of Product Development, Faculty of Agro-Industry,Kasetsart University, Bangkok, Thailand3Science Technology System, West Sacramento, California, USA1Introduction 4Flours 4Wheat flour 4Wheat flour chemistry 4Rye flour 6Rice flour 6Barley, corn, sorghum, and othercereal grains 6Baking ingredients 6Water 6Yeast 7Chemical leavening agents 7Ascorbic acid and redox agents 7Sugar and sweeteners 7Fats and fat replacers 8Eggs 8Dairy ingredients 8Enzymes 8Other functional additives 9Baking science and technology 9Mixing, dough making and doughmake-up 9Fermentation and proofing 9Baking 9Packaging and shelf-life prediction 10Process optimization and control 10Sensory attributes 10Nutritional attributes 10Browning 10Functional bakery products 11Rheology and bread and otherbakery products 11Bread 11Bread manufacture 11Quality control 12Sourdough 12Frozen dough and par-baked bread 12Steamed bread 13Traditional and specialty products 13Cakes 13Bakery Products Science and Technology, Second Edition. Edited by W. Zhou, Y. H. Hui, I. De Leyn,M. A. Pagani, C. M. Rosell, J. D. Selman, and N. Therdthai. 2014 John Wiley & Sons, Ltd. Published 2014 by John Wiley & Sons, Ltd.

4CH 1Introduction to Baking and Bakery ProductsBiscuits 13Pastries 14Pretzels 14Bakery products of unconventionalflours 14Dietetic bakery products 15Examples of world bakery products 15IntroductionBakery products, particularly bread, have a longhistory of development. Evidence from the mostrecent archaeological discovery indicates thatbaking practice may have started as early as 23 000 years ago (i.e. 21,000 BC) during thePaleolithic Period (Piperno and others 2004). Atthat time, people discovered wheat and learnt tomix wheat grain meal with water and bake it onstones heated by fire. This gave birth to the firstflat bread made by humans. During the periodof 2600–3000 BC, yeast was used by ancientEgyptians to make fermented bread. Due to thehigh cost of milling, whole wheat and whole grainbread was generally consumed. White bread wasalso available, but limited only to groups of richpeople. Since the 1900s, white bread has becomecommon for everyone. Today, bakery productsrange in complexity from consisting of the simpleingredients of a plain pastry to the numerous components that make up a cake. The evolving ofbakery products from the original plain and simpleforms to the modern varieties with specific attributes and functionalities using sophisticated manufacturing technologies has been going hand-in-handwith the progress in many related fields of scienceand technology. For today’s professionals, keepingabreast of the advanced knowledge in bakeryproducts’ science and technology is critical to continuously improve the productivity of currentpractice, identify the most important areas to directlimited research and development resources, andlaunch new competitive products into the market,as well as to predict future trends in the industry.This chapter highlights the topics covered inthis book using selected material from eachWorld specialties 15Bakery Products in China 15Italian bakery products 15Mexican bakery products 16Bakery products in Turkey 16References 16chapter. Table 1.1 serves as a frame of referencefor the discipline.FloursWheat flourWheat is the most versatile cereal due to thecapacity of its storage proteins to interact anddevelop the gluten network, which forms thebasic framework of many bakery products.Because there is a deep crease in the kernel, flouris extracted by a sequence of breaking, sieving,and size-reducing processes, known as the millingprocess. This process makes it possible to contemporaneously separate the bran and germregions and to break the endosperm cells into avery fine product, suitable for rapid hydrationand gluten development. Milling yield and flourrefinement are closely related both to the millingconditions and the variety of wheat used. Thelatter highly influences the technological per formance of the flour (measured by severalinstrument tests) and bread characteristics. Aswell as refined flours, increasing attention isbeing given to whole wheat flours that includethe bran and germ fractions, which are presentlyconsidered to be by-products despite their richness in several bioactive compounds.Wheat flour chemistryThe biochemistry of the main components ofwheat flour (proteins, carbohydrates, and lipids)are presented and discussed with a focus on thoseproperties relevant to the baking industry. Aswell as considering the composition and s tructure

Table 1.1 Baking science and technology: a composite pictureaMaterials of Baking ProductsIngredients from wheatWheat flour millingOther wheat productsIngredients from other grainsRyeRiceBarleySorghumCornOatMilletSoyYeast and chemical leaveningYeastChemical leavening agentsAcidsBaking powderAscorbic acid and redox agentsFats and oilsFat and oil processingTypes of fat and oilButterMargarineShorteningVegetable oilsFat’s role in bakery productsYeast-raised productsLaminated productsCakesCookies and crackersDough fatFilling fatSpray oilCoating fatSweetenersNutritive sweetenersSucrose (regular refined sugars)Invert sugarFondantBrown sugarMolassesFructoseStarch hydrolysatesHoneyMalt syrupAlternative sweetenersSugar alcoholsHigh intensity sweetenersNutritional profilesBrowningFunctional productsRheologySome of the listings in this table are inspired by Lai and Lin (2006).aDairy productsFresh liquid milkCreamFermented milk productsEvaporated and condensed milkWhey productsCheeseEggsFruits and nutsFruitsNutsChocolate and cocoaSalt, spices, and flavoringsSaltSpicesFlavoringWaterProduction of Bread and Yeast-LeavenedBakery FoodsTypes of yeast productsLean dough productsRich dough productsRolled-in yeast dough productsSpecial dough productsSteps in yeast dough productionTypes of dough-making processesStraight dough methodSponge-and-dough methodChorleywood bread processSourdoughsProduction of soft wheat productsCrackersCookiesCommercially made cookiesHandmade cookiesDough mixing methodsTypes and make up methodsCakesTypes of cakesCake formula balancingMethods of mixingBakingPastriesShelf-life and Packaging of Bakery ProductsThe mechanism of stalingAnti-staling additivesPackaging technologiesAdditional TopicsSensory profilesQuality controlComputer technology, optimization and automationWorld specialty products

6CH 1Introduction to Baking and Bakery Productsof each of the major macromolecules in flour,particular attention is paid to the interactionsamong the various flour components and totheir modification in the various phases ofbaking-related processes. The role of water transfer issues is also considered, along with itsmodulation by flour components or by addedingredients.Rye flourRye (Secale cereale L.) is a traditional rawmaterial for baking in northern and easternEurope. The flavor and structure of rye breadare quite different from those of wheat bread,and vary depending on flour type, other rawmaterials and ingredients, dough making process, baking conditions, and time, as well asthe size and shape of the bread. Generally consumed as whole grain products, rye offers agood source of dietary fiber, phenolic compounds, vitamins, trace elements, and minerals.Rye bread has also been shown to have beneficial physiological effects, especially for glucosemetabolism and satiation. Expanding researchdata strengthen the position of rye grain as animportant raw material for healthy foods, andthe potential for developing novel products isgrowing with the knowledge about its transformations during milling and baking processes.Barley, corn, sorghum, and othercereal grainsDeveloping countries with diets based oncoarse grains continue to derive 70–80% oftotal food calories from maize, sorghum, and/or millet. In developed countries, the conceptof using South American, African, and Asiantraditional non-wheat cereals and ethnic grainsas a template for wheat, wheat-free, and gluten-free based foods, matches the interest inwesternized countries for exotic foods withtheir previously unappreciated extra nutritional value. Chapter 6 gives an update on thetraditional and new uses in baking of majorcoarse grains worldwide. Special emphasis isplaced on the challenges and opportunities ofusing maize, barley, oat, sorghum, and millet incomposite breads. The evolution of the production, consumption, share of calories, and categories of use of individual coarse grains isrevised, and the diversity of ethnicl goods andbakery products from coarse grains across thecontinents is presented. An overview of theadvances in coarse grain-based baked goodsbased on scientific and technological progressand on their health-promoting effects isprovided.Baking ingredientsRice flourWaterRice is one of the most consumed cereals, mainlyas milled rice. However, several different valueadded rice products have been developedprompted by the unique nutritive properties ofthis grain. Among all the processed rice-basedproducts that are being launched, bakery products have received special attention. Nowadays,more people are attracted to wheat-free foodsbecause of health concerns or to avoid wheat inthe diet. The chapter on rice gives a brief description of rice production and re

and other leavening agents, ascorbic acid and other redox agents, sugar and sweeteners, lipids, egg, dairy ingredients, enzymes, and other functional additives; 4. Science and technology of bakery production with dedicated chapters on mixing and dough making, fermentation, baking, and packaging.