Reducing waste on bread roll plants by application of novel technologies

In the current work, the impact of reducing intermediate dough handling steps on bread roll dough processability and quality attributes has been characterized. The effect of traditional dough processing steps: dividing, rounding, resting, pinning and panning, on bread roll crumb and finish was investigated. Data presented here suggests that dough can be divided using alternative technologies (Pressure driven (PD); Pressure vacuum (PV); Extrusion (EX)). PV and EX doughs result in good crumb. However, if the number of intermediate handling steps is reduced, the external finish is poor. Alternative process configurations can be employed to achieve good crumb morphology in bread rolls without oil and dusting flour. However, the external finish suffers. Suggesting dough handling processes required to achieve a good crumb and a smooth surface may not be complimentarily. There is substantial interplay between dividing approach and intermediate handling in the development of dough to achieve both internal and external bread roll quality attributes. A lower energy process with less dough handling may not actually be cost effective yet. As dough smoothing appears to be required, which may not eliminate the use of process aid.