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Development of a benchtop baking method
for chemically leavened crackers
Meera Kweon, Louise Slade*, Harry Levine*, and Edward Souza
USDA, ARS, Soft Wheat Quality Lab., Wooster, OH, USA* Food Polymer Science Consultancy, Morris Plains, NJ, USA
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Comparison of ingredients
Ingredient Cookie Cracker
Sucrose high low
Fat high low
Water low low
Flour unchlorinated unchlorinated(requires gluten strength)
TS high low
%S very high low
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Objective
Develop a benchtop baking method to predict contribution of
gluten functionality and performance to overall flour performance
for chemically leavened crackers
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What are the hurdlesin developing a cracker-baking method?
Difficulty to find ideal diagnostic flours that differ only in gluten functionality (same SRC values, except SRC-LA)
Absence of a powerful benchtop mixer, like a commercialplant-scale cracker mixer, to enable gluten development with low TS and %S formulas.
Absence of a powerful 2-4 roll sheeter and reduction systemto enable gluten development during machining.
Absence of a suitable two-zone benchtop oven.
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In spite of the hurdles, if we want to develop a cracker-baking method,
what will be the criteria?
The method should be simple and user-friendly.
The method should be reliable, in terms of reproducibility and accuracy.The method should be diagnostic for gluten functionality of flour samples.
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Equipment used for experiments
Hand cutter (2.25 x 1.65 inch, 7 docker pins)
Univex sheeterBaking rack
Mixer: Pin mixer with 100g mixing bowl
Oven: Standard National lab baking oven
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Basic ingredients and formula
Ingredient Formula (g)Flour 100.0
FG Sugar 9Salt 0.75
Sodium bicarbonate 1.25Ammonium bicarbonate 1.25Monocalcium phosphate 1.25
Shortening 12.0Water 29.0
TS 38% S 23.7
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Cracker-making procedure
Remaining ingredients
Ammonium bicarbonatePre-dissolved sugar Shortening
Dough mixing (10 min)
Dough sheeting - 5 times, roll gap from 5.59 to 0.54mm,
w/o folding and rotation of sheet between passes
Dough cutting
Baking (5-6 min at 500 F)
Measuring cracker width, length, and height
Ingredient mixing (1 min)
Measuring dough weight
*Calculated parameters:cracker height/dough weight & cracker width/length
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Effect of leavening agents
Soda: 0MCP: 0ABC: 0
Soda: 0MCP: 0ABC: 1.25
Soda: 0MCP: 1.25ABC: 0
Soda: 1.25MCP: 0ABC: 0
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Effect of ammonium bicarbonateBranson SRW SG FL: 23.7%S, 38 TS, 10-min mixing
Soda 1.25 g & MCP 1.25 g
Dough/piece Cracker/pieceWeight Height Weight Length Width Height
0 3.85 0.172 25.96 2.85 5.23 4.17 0.3550.625 3.75 0.172 27.03 2.74 5.20 4.26 0.3981.25 3.87 0.172 27.38 2.81 5.17 4.25 0.448
Moistureloss
ABC(g)
0.00 0.625 1.25
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Flour usedfor developing the formula and procedure
SRCFlour
Water LA SC Suc
Branson 46.9 94.8 60.7 86.9
Gluten performance ratio:
SRC LA/(SC+Suc) = 0.644
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Mixograph
Effect of sucrose on gluten during mixing
(Used with permission from Louise Slade)
Can we use very low sugar concentration forfaster gluten development in a cracker-baking method?
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Sugar Concentration (%)
0 10 20 30 40 50 60
Cra
cker
Hei
ght/D
ough
Wei
ght (
cm/g
)
0.1
0.2
0.3
0.4
Cra
cker
Wid
th/L
engt
h
0.5
0.6
0.7
0.8
0.9CH/DW W/L
Cracker geometry at various %S, 38TS
Softer dough Crumblier dough
Crackers baked with too much water (lower %S at constant TS) resulted in blisters
Cutter W/L
Blisters
L ↑ & W ↓
L ↓ & W ↑
L ↑ & W ↑
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Total Solvent
32 34 36 38 40 42 44 46 48
Cra
cker
Hei
ght./
Dou
gh W
eigh
t (cm
/g)
0.05
0.10
0.15
0.20
0.25
0.30
0.35
Cra
cker
Wid
th/L
engt
h
0.5
0.6
0.7
0.8
0.9
1.0
Cracker geometry at various TS, ≈ 23.7%S
Crumblier dough Softer dough
The formula with 23.7%S, 38TS was chosen for testing various flours
Cutter W/L
= Round Cracker
L ↑ & W ↓
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Force/Distance with Kieffer Rig
0 2 4 6 8 10 12 14 16 18 20
Cra
cker
Hei
ght/D
ough
Wei
ght
0.08
0.10
0.12
0.14
0.16
0.18
0.20
Force/Distance with Kieffer Rig
0 5 10 15 20
Cra
cker
Hei
ght/D
ough
Wei
ght
0.095
0.100
0.105
0.110
0.115
0.120
Rheological test for 2007 QEC flour
Evaluate extent of gluten development during mixing and machining- Force/Distance of dough in the direction of sheeting was related to
both cracker height/dough weight and cracker width/length.
(Used Kieffer Rig with TAXT)
Samples w/o blisters
Force/Distance with Kieffer Rig
0 2 4 6 8 10 12 14 16 18 20
Cra
cker
Wid
th/L
engt
h
0.78
0.80
0.82
0.84
0.86
0.88
Dough Sheeting direction Perpendicular sheeting
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Cultivar w/o enz. 1X 1A 0.5X + 0.5AD8006W 48.5 44.9 48.5 46.8
Caledonia 47.1 43.9 47.0 45.6Crystal 47.2 44.8 47.1 46.1Jewel 51.1 47.7 51.1 49.3
GA96603-4E16 49.2 46.3 49.5 47.9Jamestown 51.9 46.9 51.6 49.3AGS 2000 52.4 46.7 52.0 49.1USG 3209 55.8 48.6 55.9 51.8
Jensen 48.7 44.9 48.8 47.0MPV 57 47.9 43.3 48.0 45.5
Effect of enzyme treatment on water SRC
Used xylanase (X) and alpha-amylase (A)
These very soft wheats did not generate damaged starch during milling, so alpha-amylase was not needed.
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Sample
D 8006WCaledonia
CrystalJewel
GA96603-4E06
Jamestown
AGS 2000
USG 3209Jensen
MPV 57
Cra
cker
Hei
ght/D
ough
Wei
ght (
cm/g
)
0.00
0.05
0.10
0.15
0.20
0.25w/o enzyme 1X1A0.5X + 0.5A
Effect of enzyme treatment on cracker baking
**
** Blisters
* Indicates too much water, when arabinoxylanshave been depolymerized. Reduction in waterand sucrose is typically required.
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Reduction of blistersby baking crackers with flour blend
(GA 96603-4E16:MPV 57=1:1)GA 96603-4E16 GA+MPV MPV 57
SRC CrackerWater LA SC Suc
LA/(SC+Suc) CH/DW
0.660.560.47
0.1040.1192
0.1942
96.094.993.8
W/L1
GA 96603- 49.2 105.9 64.4 0.8171G+1M 48.5 89.5 63.5 0.823MPV 57 47.9 73.0 62.7 0.790
Flour
Notes: 1 Cutter W/L was 0.73.2 Crackers with blisters. But, the crackers with flour blend showed much smaller and fewer blisters.
Photos show L dimension
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The effect of mixing time on blisters(MPV 57)
5 min 10 min
20 min15 min
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Cra
cker
Ht.
/Dou
gh w
t (cm
/g)
0.08
0.10
0.12
0.14
0.16
0.18
0.20
D 8006WCaledonia
CrystalJewel
GA96603-4E06Jamestown
AGS 2000USG 3209
JensenMPV 57
LA/(S
C+S
uc)
0.4
0.5
0.6
0.7
0.8
LA S
RC
(%)
40
60
80
100
120
LA/(SC+Suc) LA SRC
Cracker baking with 2007 QEC flours
Blisters
The gluten performance ratio, SRC LA/(SC+Suc), accounted for the ratio of cracker height to dough weight, but gluten functionality alone, individual SRC LA, did not.
?
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Cra
cker
Ht./
Dou
gh W
t. (c
m/g
)
0.08
0.10
0.12
0.14
0.16
0.18
0.20
MO 11126
Coral (E2017)
VA01W-205
VA03W-434
Ambassador (E0028)
Hopewell
D8006W
Pur 02444A1-23-9
Amber (D8006R)
Pur 99600A2-4-32W 1377
Pur 04287A1-10
Envoy (E1009)
Pioneer XW 06M
USG 3209
Pur 03112A1-7-3
VA03W-409Bess
LA/(S
C+S
uc)
0.4
0.5
0.6
0.7
0.8
LA S
RC
(%)
40
60
80
100
120
Blisters
Cracker baking with 2008 QEC floursThe gluten performance ratio, SRC LA/(SC+Suc),
accounted for the ratio of cracker height to dough weight, but gluten functionality alone, individual SRC LA, did not.
?
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Conclusions• Based on preliminary investigation of the effects of total solvent and sugar concentration, 38TS and 23.7%S were selected as a diagnostic formula to distinguish differences in gluten functionality or performance and overall flour performance for chemically leavened crackers.
• The gluten performance ratio of SRC LA/(SC + Suc) was a better predictor of cracker geometry than the individual gluten functionality value of LA SRC alone. Flours with a gluten performance ratio smaller than 0.52 resulted in blistering.
• Use of alpha-amylase and xylanase demonstrated the effect of enzymes on improved cracker-baking performance, as a result of decreased crumbliness of dough and increased height of cracker.
• Cracker-dough rheology (Force/Distance) in the direction of sheeting showed a negative relationship with the ratio of cracker height to dough weight, but a positive relationship with the ratio of cracker width to length.
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Acknowledgements
Ron MartinTom DonelsonScott Beil
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THANK YOU!THANK YOU!