Cauvain / Young The Chorleywood Bread Process

1. Auflage 2006
ISBN: 978-1-84569-143-1
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: 6 - ePub Watermark

E-Book, Englisch, 192 Seiten

Reihe: Woodhead Publishing Series in Food Science, Technology and Nutrition

The introduction of the Chorleywood Bread Process was a watershed in baking. It sparked changes in improver and ingredient technology, process and equipment design which have had a profound impact on baking processes and the structure of the industry. Written by two of the world's leading experts on the process, this important book explains its underlying principles and ways of maximising its potential in producing a wide range of baked products.After a brief review of the basic principles of bread making, the book outlines the development and fundamental characteristics of the Chorleywood Bread Process. The following group of chapters review the key steps in the process, beginning with ingredient quality and quantities. Other chapters consider dough mixing and processing. Building on this foundation, the authors then review common quality defects and how they can be prevented or resolved. The book then considers how knowledge-based software systems can help to manage the process. The concluding chapters review the range of bakery products that can be produced using the process, how it can best be applied in different kinds of bakery and likely future developments.The Chorleywood Bread Process is a standard work for all bakers around the world wishing to maximise the potential of the process, and for scientists, technologists and students wanting a better understanding of the process and its place in commercial bread making. - The first book to describe the Chorleywood Bread Process - Reviews ingredient quality and quantities - Considers how knowledge-based software systems can help manage the process

Prof. Cauvain is owner of BakeTran, a renowned independent Baking Industry Consultancy in Witney, UK. He was a director of Cereals & Cereal Processing Division at CCFRA until December 2004. A leading authority in the bread and baking industry, Stanley was also President of the International Association for Cereal Science and Technology between 2004 and 2006. He is a frequent Woodhead Publishing Limited author having written or edited six titles previously.

Autoren/Hrsg.

Cauvain, Stanley P.

Young, L S

Leseproben

2 A brief history of the Chorleywood Bread Process
The origins of the CBP lie with research work carried out in the late 1950s and early 1960s by the British Baking Industries Research Association (BBIRA) based at Chorleywood, Hertfordshire, UK. The BBIRA was one of many research associations which were active in the UK at that time. The basis of its formation in 1946 was a government–industry partnership in which the value of the subscription income raised by an industry sector (in this case, baking) was matched with equal funding from the UK government. The intention was to carry out ‘generic’ research on behalf of the baking industry which would then have equal access to the output of that research to apply within individual member companies. The UK baking industry of the 1950s was very different from that seen today. At that time the BBIRA was active in studying the fundamentals of dough mixing which would ultimately lead to the development of the CBP bread and other fermented products that were made in a large number of relatively small family-owned bakery businesses. Today, the UK baking industry is dominated by a small number of large industrial plant bakeries and in-store bakeries in supermarkets with relatively few family-sized ‘traditional’ bakery businesses. The 1950s were a time of great change for the UK baking industry. Typically bulk fermentation for 2 or 3 h was used to make bread at that time. The Weston Company considered that they needed to import flour direct from Canada to make the best bread. This action provoked millers into protecting their sales of flour by buying up many independent plant bakeries and so the UK milling and baking groups that we know today were born. It was also a time of great experiment in the UK baking industry. There was much interest in the continuous mixing of bread doughs which was seen as a natural progression for the plant bakery, although in most cases with some fermentation after mixing. Continuous mixers came to the UK in large numbers. For example, from the USA came the Wallace and Tiernan Do-Maker (1957), the Amflow and the Oakes special bread process (Williams, 1975). The lack of sustainable success of these processes in the UK was associated with the uniform structure and weak crumb structure that they produced. American bread characteristics were in sharp contrast with the leaner formula and denser UK bread products of the time and they found little favour with UK consumers. The early work of BBIRA concentrated on ingredient and equipment testing and providing services and consultancy to baker members. One area of study during their early years was that of dough mixing. Indeed BBIRA Report 42 (Collins et al., 1959) provides data on their early investigations into the possibilities of using mechanical dough development using a brew system and continuous development to replace bulk fermentation. BBIRA had many members, mainly small and independent bakers but in the later 1950s the nature of the BBIRA client base began to change as companies became larger and started to build their own research facilities. Into this changing picture came Dr George Elton as the newly appointed Director of Research at BBIRA in 1958. He quickly recognised that he needed to change the pattern of work at the BBIRA if he was to retain their members. To achieve this, Elton identified six research areas for BBIRA activity and one of these was continuous mixing (Elton and Devlin, 1959). He chose T.H. (Bill) Collins as the bakery technologist to work on continuous mixing. In the early days, Bill worked alone on the task but quickly he began to organise and increase his work rate by ‘acquiring’ more help. Elton recognised the value of the work that was coming from Bill and quickly added to his team. In 1959, Dr Norman Chamberlain had joined BBIRA as Scientific Liaison Officer but very soon Elton was to ask Chamberlain to join with Collins to lead a task force concentrating on dough mixing and bread making. At first the team continued to work with continuous mixers carrying out two or three experiments a day. Even in those early days the critical nature of work input was appreciated when they discovered that the quality of bread could be improved by taking a continuous mixed dough and then giving it further mixing in a laboratory Morton Z-blade mixer (Fig. 2.1). The duration of the second mixing step appeared to be critical and Elton made the crucial observation that the quantity of work might be important. Soon they found that they could obtain the same quantity of work from the laboratory Z-blade mixer as they could from the continuous mixer (Fig. 2.2). Ever eager to increase the number of experiments that they could perform in a day the team switched their attention to the small-scale mixer and improved their experimental output by an order of magnitude. Fig. 2.1 Laboratory-scale Z-blade mixer fitted with timer. Fig. 2.2 Laboratory-scale Z-blade mixer in the BBIRA bread bakery fitted with a watt–hour meter. With around 30 mixings a day they made rapid progress towards establishing the key features of the mixing and development processes. In keeping with the attitudes of the time they published their work in a series of ground-breaking BBIRA Reports (see Further reading for details). In some ways the team would come to regret the openness with information because it later prevented them from patenting the process that they had developed and from deriving direct financial benefit for the BBIRA. However, it should be appreciated that the BBIRA had an obligation to its members to inform them how the research monies were being spent. To some extent the BBIRA were obliged to disseminate freely the results of their work to their members. During their work on dough mixing, the BBIRA team was to show that they could make bread from controlled-energy batch mixing without bulk fermentation which was identical with or superior in quality (as defined by bread volume, softness and cell structure) to that they made with low-speed mixing and bulk fermentation. They could not say the same for the comparison between continuously mixed doughs and bulk fermented doughs. While working with a variety of mixers the BBIRA team found that, although the crumb cell structure varied from one mixer to another, the optimum work input (in terms of bread volume) remained essentially the same (the relationship between cell structure and bread volume and the contribution of different mixing actions is now more fully understood; see Chapter 5). The BBIRA team calculated energy levels in the dough and found that the optimum for the range of flours available at that period of time was 0.4hp min/lb (Collins et al., 1960), equivalent to 5 Wh/lb, 11 Wh/kg or 42 kJ/kg of dough in the mixer (Fig. 2.3). Fig. 2.3 Effect of work in the CBP: upper line, left to right, from 0.1 to 0.5hp min/lb; bottom line, left to right, from 0.6 to 1.0hp min/lb, in steps of 0.1hp min/lb. The BBIRA team knew they were on to a new process but needed to scale up to convince bakers of its commercial value. They had a number of discussions with existing bread mixer manufacturers without being able to raise significant interest from any of them who remained steadfast to existing low-speed batch and continuous mixers. This was a time of frustration for all concerned but then serendipity intervened. A former colleague of Norman Chamberlain who worked for J. Sainsbury asked Chamberlain if he would like to see the high-speed mixer that they used for making paste for pies. It performed the job in 20s. Norman Chamberlain and Bill Collins immediately went to see the machine and quickly recognised its potential for delivering the required energy at the required rate. They borrowed a mixing machine on the basis that, if it failed to match their requirements, they would return it. The mixer arrived at the Chorleywood site from the Tweedy factory in Lancashire complete with green painted lid and galvanised bowl. With the mixer in place at Chorleywood the BBIRA team set about dough making, checked temperature rises during mixing and realised that the machine did indeed have the potential for delivering the energy that they required in the time that they required. The resident physicist at Chorleywood, John Cornford, obtained and wired up a watt–hour meter and the team began to prove their small-scale findings. Once proven, the team needed a better-looking mixer and within 6 weeks with the help of the engineering skills of Ken Pickles a stainless steel version was produced to the BBIRA specification. In early 1961 the team began to identify the key features of this new bread-making system and agonised over what to call it. Eventually they settled on a name and in July 1961 the BBIRA team launched the Chorleywood Breadmaking Process named after the town in which BBIRA was located. The launch of the new process was heralded with the publication of BBIRA Report 59 (Chamberlain et al., 1961). From 1961 the pace of development increased as the BBIRA team set off with the mixer in a van to demonstrate this new process to bakers around the UK. Even by today’s standard the schedule was tough. The team would arrive at a new location and would have to solve all sorts of problems related to working space and power, and to work with all sorts of ovens, but they managed well. All in all, the team demonstrated to over 1000...