WO1996011577A1 - Pre-moulded, filled or topped dough systems - Google Patents

Abstract

Unbaked or pre-baked dough products such as pizzas or short-crust doughs have improved microwave properties when the products are provided with a moisture barrier layer. Therefore, the pre-moulded dough comprises: 25-65 % flour, 0-40 % fat, 0-5 % salt, 0-7 % leavener, 0-35 % of a flour encapsulated in oil or fat, 10-50 % water, while a barrier layer is present comprising less than 5 wt. % of water and oil and a water binder in a ratio of (90:10) to (20:80), which barrier layer represents 0.1-35 wt. % of the weight of the dough layer.

Description

PRE-MOULDED. FILLED OR TOPPED DOUGH SYSTEMS

Dough systems that are provided with a moist topping or filling, such as pizzas, or pastries, such as Quiche Lorraine, are well known. As the topping or filling is moist, a problem arises during baking and microwaving of the product. It was found that during baking and storage the moisture present in the topping or filling material migrates to the dough layers of the product, thereby reducing the crispness of the product after microwaving and making it soggy.

The above-mentioned problem can be derived from the prior art, e.g. from US 4,283,424. In this US patent, a solution is presented whereby a frozen pizza is made with improved microwavable properties, which product includes a crust comprising a first and a second crust element. The first crust element is a baked cracker-type dough material having a water content of less than 5%, while the second element comprises a baked bread dough-type crust having a moisture content of 20-40%. The cracker dough absorbs excess moisture present in the oven that is liberated during microwave cooking of the product. The pizza topping is added to the second crust after baking of the crust. The above solution therefore requires the use of a cracker dough, which will adversely affect the taste performance of the pizza. It will further be ineffective against moisture migration from the topping to the crust.

Another solution to our problem is presented in

EP 383,134, according to which filled short-crust dough systems, such as Quiche Lorraine, can be obtained by providing a dough layer with a layer of an edible film of collagen, whereupon the filling or topping is added to the collagen layer. However, the above solution is insufficient to prevent such products becoming soggy upon microwaving, in particular when the unbaked product is frozen.

From JP 61-260830 it is further known to provide a bottom crust for a pizza in the form of a laminate of a puff pastry as the lower layer and a normal pizza crust as the upper layer. The upper layer is said to absorb moisture from the topping, thus protecting the lower layer. However, it was found that the final product still becomes soggy upon storage and/or microwaving, which is due to the fact that this system does not prevent moisture migration from the topping to the pizza crust.

Edible films, which can be applied as moisture barrier in food products, such as pizza's are disclosed in EP 547.551. These layers are composed of 5 - 40 % starch; 5 - 40 % gelatin; 10 - 40 plasticizer; 5 - 40 % lipid and 5 - 40 % water. Above films are thus rather complicated mixes of many components. This complicates its preparation. Moreover water is mentioned as an essential ingredient. However the presence of water limits the waterbinding capacity of the film composition. The waterbarrier properties of these films are therefor rather limited.

In GB 2 275 171 pizza's are disclosed, wherein the dough layer is provided with an edible water-impermeable coating.

According to the specification the coating comprises a mixture of a glazing agent and an emulsion stabilizer.

Examples thereof are tapioca dextrin and a modified starch

(N-Creamer®) . The coating further contains relatively high amounts of water (about 40 % according to the only example given) . Therefore these coatings will possess very limited waterbinding capacity.

In our Australian patent application 11482/92 we have disclosed a solution to the above-mentioned problem in laminated, filled dough systems. In EP 251,375 we disclosed that incorporation of vegetable fibres in at least the fat layers of laminated doughs leads to laminated doughs having a reduced fat content.

Therefore we studied the problem of how to obtain topped or filled dough systems that, when provided with a moist filling, display excellent properties during microwaving, in particular when the products are frozen and are microwaved without thawing. These products should further be obtainable by an efficient, low-cost method.

Accordingly, our invention concerns in the first instance unbaked or pre-baked, pre-moulded dough, preferably pizza or short-crust dough provided with a moisture barrier layer, wherein the pre-moulded dough comprises:

25 - 65 wt.% of flour

0 - 40 wt.% of fat

0 - 5 wt.% of salt

0 - 7 wt.% of leavener 0 - 35 wt.% of a flour encapsulated in oil

10 - 50 wt.% of water, which dough always contains some fat, preferably at least 3 wt.%, more preferably 5-40 wt.% (calculated on the product) , originating from the fat per se and/or from the flour encapsulated in oil, while the barrier layer comprises less than 5 wt % of water and oil and at least one water binder in a weight ratio of (90:10) to (20:80) as (oil : water binder) while the barrier layer is 0.1-35 wt.%, preferably 1 - 15 wt % of the weight of the dough layer.

_*

In the above-mentioned products the water binder can be selected from the group consisting of flour, natural and/or modified starch, natural gum, gelatin, vegetable fibres, carbohydrate and pectin. Some of these components, e.g. flour, can contain some "natural" water. This natural water is not included in above amount of less that 5 wt % in the barrier layer. The best results were obtained with waterlevels in the barrier layer of 3 wt % or less.

Although acceptable results are obtained in the absence of the flour encapsulated in oil in the products, we found that the best results were obtained when 5-30 wt.% of the flour encapsulated in oil were present. The flour : oil ratio in the flour encapsulated in oil suitably ranges from 10-75 wt.% of flour : 90-25 wt.% of oil.

Any known leavener, so including chemical leaveners, such as NaHC0₃, can be applied. We prefer to use yeast as a leavener, the yeast being used in amounts of 2-5 wt.%.

The moisture barrier layer is provided to one side of the dough layer, whereupon the filling or topping is provided in contact with the barrier layer.

It was found that for the preparation of pizzas it was best first to prepare the pizza crust provided with the barrier layer, to bake this pizza crust and to apply the pizza topping to this baked pizza crust.

Our invention also concerns the use of a barrier layer comprising an oil and at least one water binder for the prevention of water transport between the pre-moulded dough and the filling, wherein the barrier layer comprising less than 5 wt % of water and oil and water binder in a weight ratio of (90-20) oil : (10-80) water binder is used to improve the microwavability of the product.

Another embodiment of our invention is a process for the preparation of unbaked or pre-baked, pre-moulded dough products, wherein :

(1) a dough is made from : 25 - 65 Wt.% of flour

0 - 40 wt.% of fat 0 - 5 wt.% of salt 0 - 7 wt.% of leaveners 10 - 50 wt.% of water;

(2) optionally, an oil and flour are mixed in a weight ratio of 90-25% oil to 10-75% flour;

(3) the flour encapsulated in oil obtained in step (2) is added to the components of step (1) in an amount of 0-35 wt.% (calculated on the total product) , while in step (1) or in step (3) always some fat is added;

(4) water binder and oil are mixed in a weight ratio of (90:10) to (20:80), resulting in a barrier layer with less than 5 wt % of water;

(5) the dough of step (3) is provided with the barrier layer of step (4) , using so much barrier layer that in the end product 1-35 wt.% of barrier layer is present (on the dough layer) ;

(6) while optionally the product of step (5) is baked at at least 150°C for at least 15 minutes and optionally

(7) a topping is provided to the baked or unbaked dough of the products from step (5) or (6) in contact with the barrier layer.

It will be clear from the above that the pre-moulded dough system always contains some fat. This fat can be added per se to the dough or it can be the fat originating from the flour encapsulated in oil.

Microwavable, baked, pre-moulded doughs provided with a water-containing topping or filling are also part of the invention. EXAMPLES

I Preparation of a pizza

Three pizzas were prepared, using the recipes according to the Table mentioned below.

Recipes

Comparative According to According to Example A invention B invention C fin wt.%) fin wt.%) fin wt.%)

Flour 58.4 53.2 58.4

Fat 5.3 0 5.3

Yeast 4.7 4.7 4.7

Water 30.4 30.4 30.4

Salt 1.2 1.2 1.2

Flour encapsulated 0 10.5 0 in oil (ratio 30:70)

Barrier layer No Yes Yes (oil:flιour 1:1)

The doughs were prepared by mixing of the ingredients (Comparative Example A and Example C) in an Eberhardt mixer (2 minutes slowly; 3 minutes fast) . The dough temperature was 20°C. The doughs were allowed to rest for 10 minutes, rolled out to 1.8 mm thickness and allowed to rest again for 10 minutes. The doughs were cut into circles of 21 cm diameter.

In Example C a barrier layer was prepared by mixing of oil and flour in a 1:1 weight ratio.

The barrier layer was lubricated onto the pre-moulded dough in a layer of about 1.5 mm.

The circles of doughs were provided with the barrier layer (one side) . The laminate obtained was proofed for 20 minutes at 35°C and R.H. : 70%. The products were baked for 17 minutes at 160°C (top) to 230°C (bottom) .

The baked products were provided with a topping and stored at -20°C for 14 days.

After this storage, the products were microwaved. Product A of the Comparative Example was soggy, while product C remained crispy and dry.

The procedure was repeated; however, fat and flour were mixed separately in a 70 fat : 30 flour weight ratio. A flour encapsulated in fat was obtained. This was used according to recipe B, replacing the fat according to recipe C.

The results obtained by this process were similar to the results according to Example C.

II. Preparation of apple pie

The following recipe was applied :

Short crust wt.%

Flour 55 Water 29

Salt 1

Flour encapsulated in fat 15 (30 : 70 ratio)

The flour encapsulated in fat was prepared by mixing of the components.

The ingredients according to the recipe were mixed in an Eberhardt mixer. The dough was rolled out to 3 mm. This dough was cut into pieces of 23 x 40 cm. These pieces of dough were provided with a barrier layer of oil and flour (weight ratio 1:1) of about 1.5 mm thickness. An apple filling was brought onto the laminate in contact with the barrier layer. The dough was folded around the apple filling. Sugar was applied on top of the folded dough and the product was baked for 60 minutes at 180°C.

The apple pie so obtained, or pieces thereof obtained after cutting it, displayed excellent properties after microwaving (crisp and dry), even after frozen storage.

III Quiche Lorraine

A Quiche dough was prepared, using the following recipe :

wt.%

Flour 38 Salt 1

Water 18

Flour encapsulated in fat 43 (30:70 ratio)

Cubes of flour encapsulated in fat were made by mixing and cutting of the fat/flour mixture.

These cubes were mixed with the other ingredients (30 seconds slowly; 30 seconds fast) .

The dough obtained was rolled out to 2.75 mm.

A square portion of this product (11 x 11 cm) was cut out and put into an aluminium tray with φ = 10 cm.

This dough was provided at the top with a layer of the barrier layer of oil and flour (ratio 1:1) as applied in Example I. 42 g of a standard Quiche Lorraine filling was put on top of the barrier layer. The Quiche was baked at 210°C for 25 minutes. The product obtained displayed excellent crispness and dryness when microwaved after storage for 14 days at -20°C.

Claims

1. Unbaked or pre-baked, pre-moulded dough, preferably pizza or short-crust dough provided with a moisture barrier layer, wherein the pre-moulded dough comprises:

25 - 65 wt.% of flour 0 - 40 wt.% of fat 0 - 5 wt.% of salt 0 - 7 wt.% of leavener 0 - 35 wt.% of a flour encapsulated in oil or fat 10 - 50 wt.% of water, which dough always contains some fat originating from the fat per se and/or from the flour encapsulated in oil or fat while the barrier layer comprises less than 5 wt % of water and oil and at least one water binder in a weight ratio of

(90:10) to (20:80) as (oil : water binder) and the barrier layer is 0.1-35 wt.% of the weight of the dough layer.

2. Pre-moulded dough according to Claim 1, wherein the water binder is selected from the group consisting of flour, natural and/or modified starch, natural gum, gelatin, vegetable fibres, carbohydrate and pectin.

3. Pre-moulded dough according to Claim 1 or 2, wherein 5-30 wt.% of the flour encapsulated in oil is present.

4. Pre-moulded dough according to Claims 1-3, wherein the leavener is yeast, which is present in 2-5 wt.%.

5. Pre-moulded dough according to Claims 1-4, wherein the flour encpasulated in oil comprises flour and oil in a ratio of 10-75 wt.% of flour: 90-25 wt.% of oil.

6. Microwavable, pre-moulded dough, wherein a baked pre-moulded dough with the composition according to Claim 1 in the form of a baked crust is provided with a water- containing topping.

7. Use of a barrier layer comprising an oil and at least one water binder for the prevention of water transport between a pre-moulded dough and a filling, wherein the barrier layer comprising less than 5 wt % of water and oil and water binder in a weight ratio of (90-20) oil : (10-80) water binder is used to improve the microwavability of the product.

8. Process for the preparation of an unbaked or pre- baked, pre-moulded dough product with the composition according to Claims 1-7, wherein

(1) a dough is made from

25 - 65 wt.% of flour

0 - 40 wt.% of fat 0 - 5 wt.% of salt

0 - 7 wt.% of leaveners

10 - 50 wt.% of water;

(2) optionally an oil or fat and flour are mixed in a weight ratio of 90-25% oil to 10-75% flour;

(3) the flour encapsulated in oil or fat obtained in step (2) is added to the components of step (1) in an amount of 0-35 wt.% (calculated on the total product), while in step (l) or in step (3) always some fat is added;

(4) water binder and oil are mixed in a weight ratio of (90:10) to (20:80), resulting in a barrier layer with less than 5 wt % of water;

(5) the dough of step (3) is provided with the barrier layer of step (4), using so much barrier layer that in the end product 1-35 wt.% of barrier layer is present (on dough layer) ;

(6) while optionally the product of step (5) is baked at at least 150°C for at least 15 minutes. and optionally

(7) a topping is provided to the baked or unbaked dough of the products from step (5) or (6) in contact with the barrier layer.