ENZYMES in TORTILLAS and FLAT BREADS
Dilek Austin, Ph.D. Baking Technical Services Novozymes North America, Franklinton, NC TIA 2016 Annual Convention and Trade Exposition May 19th, 2016
Agenda
Introduction to Enzymes
Enzymes in FLOUR tortillas
Enzymes in CORN tortillas
Enzymes in FLAT BREADS
Q&A
Introduction to Enzymes
Where do the enzymes come from ?
4
An example: Enzymes can increase efficiency, profit, and reduce waste
Enzymes are natural
Active proteins
In all living organisms
• Plant
• Animal
• Microorganisms-fungal, bacterial
Specific
Works under mild conditions
Can replace/reduce chemicals
How enzymes work
pH Temperature Contact time Water Enzyme
dosage Substrate Stabilizers
Inhibitors Oxygen
pH effect Temperature effect
Important process parameters for enzymes
Enzymes maintains tortilla freshness Stale tortillas/flat breads are firm and they crack when folded, become unacceptable to consumers
Enzymes can; • Extend shelf-life
• Improve dough handling and machinability
• Enhance mixing tolerance
• Can replace/reduce chemicals
Enzymes in FLOUR tortillas
FLOUR tortillas
Short baking time
Stale fast
Maintenance of flexibility is important
Shortenings, emulsifiers, vital gluten, dough relaxers are critical
Consumers desire less ingredients Clean label is vital
Enzymes used in FLOUR tortillas
Fresh keeping Maintenance of softness, flexibility and moistness of tortillas up to six months
Enzymes Alpha-amylase
Ingredient reduction/replacement L-cystein/SMS Gums Emulsifiers Vital gluten
FLOUR tortillas
Six weeks-old tortillas
With enzymes: Flexible, no cracking
Without enzymes: Undesirable cracks
Novozymes internal data
Novozymes NEW enzyme maintains the flexibility for FIVE-months
Alpha-amylase No enzyme
Novozymes internal data
Novozymes NEW ALPHA-AMYLASE -INCREASING dosages INCREASES extensibility
Novozymes internal data
4 weeks 45
70 74 76
0
20
40
60
80
100
without enzyme 225 ppm Alpha-amylase
315 ppm Alpha-amylase
410 ppm Alpha-amylase
%ex
ten
sib
ility
mai
nte
nan
ce
Four week-old flour tortillas % maintained mechanical extensibility compared to freshly
baked
Equipment: TA.XT2-Tortilla Burst Rig
Novozymes NEW enzyme makes tortillas STRONGER and MORE EXTENSIBLE at four week-storage
-100
-50
0
50
100
150
200
250
300
350
400
10 20 30 40 50
Fo
rce
4 weeks
Time/sec
New
en
zym
e N
o e
nzy
me
Novozymes internal data
Strong and more extensible
Breaks easily, not extensible
Alpha-amylase maintains high rollability scores during four-week storage
5
4.2
3.4
2.5
2.1
1.5
5 5 5
4.6 4.5 4.5
1.0
2.0
3.0
4.0
5.0
1 3 7 14 21 28
Ro
llab
ility
sco
res
(1 to
5)
Storage days
without enzymes Alpha-amylase
Flexible
NOT flexible
A study by Texas A&M University. Determining the Role of Starch in Flour Tortilla Staling Using α-Amylase J. Novie Alviola and Ralph D. Waniska. Cereal Chemistry. May/June 2008, Volume 85, Number 3
4 weeks
Four-week old tortillas INCREASING dosages INCREASES FLEXIBILITY
3.7
4.5 4.8
5.0
1.0
2.0
3.0
4.0
5.0
without enzyme 150 ppm Alpha-amylase
250 ppm Alpha-amylase
350 ppm Alpha-amylase
Rol
lab
ility
sco
res
(1
-5)
Novozymes internal data
4 weeks
NOT flexible
Flexible
Enzymes in CORN tortillas
CORN tortillas
Short baking time
Stale faster than flour tortillas
Maintenance of flexibility is important
Gums are critical
Consumers desire STRONG and FLEXIBLE tortillas
Enzymes used in CORN tortillas
Fresh keeping Maintenance of softness and flexibility of tortillas Reduction of masa stickiness Processing ease
Enzymes Alpha-amylase Lipase
CORN tortillas
Ten day-old tortillas
With enzymes: Flexible, no cracking
Without enzymes: undesirable cracks
Two-week old corn tortillas
Maltogenic amylase improves corn tortilla strength during storage
Maltogenic amylase help to decrease the CMC in the formula
Combining Maltogenic Amylase with CMC or Wheat Gluten to Prevent Amylopectin Recrystallization and Delay Corn Tortilla Staling Francisco J. Bueso , Lloyd W. Rooney , Ralph D. Waniska , and Laura Silva. Cereal Chemistry. September/October 2004, Volume 81 (5)
Stronger
762.2
899.5
500
700
900
40 ppm Alpha-amylase 40 ppm Alpha-amylase
day 5 day 11
Force to break the tortilla with Texture Analyzer
1.2
2.3 2.3
1.0
2.0
3.0
4.0
5.0
without enzyme 0.5% CMC 0.25% CMC+30 ppmAlpha-amylase
Ro
llab
ility
sco
res
(1-5
) at
ro
om
tem
per
atu
re
Masa dough
Less sticky and softer corn masa obtained with an Alpha-amylase and a Lipase
Sticky dough
Non-sticky dough
50
30 40 40 35
0
20
40
60
80
100
without enzyme 20 ppm Alpha-amylase
40 ppm Alpha-amylase
20 ppm Lipase 40 ppm Lipase
Dough stickiness (g)
Hard dough
Soft dough
Novozymes internal data-Equipment: TA.XT2
75
61 70
0
20
40
60
80
100
without enzyme 20 ppm Alpha-amylase 40 ppm Lipase
Firmness (g force)
Enzymes in FLAT BREADS
FLAT BREADS
Difficult to retain softness even for one day
Quickly becomes stale and chewy
No technology offers longer freshness
Reheating of frozen flat bread results in a very dry and elastic bread
Maintenance of softness is important Enzymes can help to retain the softness
Enzymes used in FLAT BREADS
Fresh keeping Maintenance of softness and flexibility of flat breads Bacterial alpha-amylase Lipases
Enzymes Alpha-amylase Lipases
Alpha-amylase maintains and improves flat bread softness for three days
Very flexible
Breaks
5
6.2 6.8
5
7.2
8.3
1
3
5
7
9
without enzyme 5 ppm Alpha-amylase 10 ppm Alpha-amylase
Day 1 Day 3
Novozymes internal data
Softer
Firmer
Softer
Firmer
A Lipase makes softer Naan dough; softer final product at four-hour after baking
Novozymes internal data
5
8
0
2
4
6
8
10
without enzyme 250 ppm Lipase
Naan dough softness
100
128
0
20
40
60
80
100
120
140
without enzyme 250 ppm Lipase
Naan instrumental softness (% softness compare to without enzyme)
FROZEN Naan -A lipase gives 22% more mechanical and sensorial softness compared to those without enzymes after 40 days of storage under frozen condition at -20 0C
Softer
Firmer
Softer
Firmer
5
7
0
2
4
6
8
10
no enzymes 250 ppm Lipase
100
122
0
20
40
60
80
100
120
140
no enzymes 250 ppm Lipase
Novozymes internal data
Chapatti made with a Lipase showed excellent dough property and better softness
546 585
393 391
0
100
200
300
400
500
600
700
30 min after baking 3 hrs after baking
no enzymes 250 ppm lipaseFirmer
Softer
Novozymes internal data
Enzymes are natural
Enzymes can Maintain freshly baked quality of tortillas/flat breads Improve dough handling and machinability
Enhance mixing tolerance
Replace/reduce chemicals
http://www.aaccnet.org/publications/store/pages/27885.aspx
A good source for enzymes and tortillas