Sensea Wrap - bringing taste to a new level in flour tortillas

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
Important process parameters for
enzymes
pH
Temperature
Contact
time
Water
Inhibitors
pH effect
Enzyme
dosage
Substrate
Oxygen
Temperature effect
Stabilizers
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
Ingredient
reduction/replacement
Enzymes
L-cystein/SMS
Alpha-amylase
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
No enzyme
Novozymes internal data
Alpha-amylase
Novozymes NEW ALPHA-AMYLASE
-INCREASING dosages INCREASES extensibility
%extensibility maintenance
Four week-old flour tortillas
% maintained mechanical extensibility compared to freshly
baked
100
80
60
70
74
225 ppm Alphaamylase
315 ppm Alphaamylase
76
4 weeks
45
40
20
0
without enzyme
Novozymes internal data
410 ppm Alphaamylase
Novozymes NEW enzyme makes tortillas STRONGER and MORE
EXTENSIBLE at four week-storage
New enzyme
Strong and more extensible
400
350
250
Force
No enzyme
Equipment: TA.XT2-Tortilla Burst Rig
Novozymes internal data
4 weeks
300
Breaks easily, not extensible
200
150
100
50
0
-50
-100
10
20
30
Time/sec
40
50
Alpha-amylase maintains high rollability
scores during four-week storage
without enzymes
Flexible
5.0
5 5
5
Alpha-amylase
5
4.6
4.5
Rollability scores
(1 to 5)
4.2
NOT
flexible
4.5
4.0
4 weeks
3.4
3.0
2.5
2.1
2.0
1.5
1.0
1
3
7
14
Storage days
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
21
28
Four-week old tortillas
INCREASING dosages INCREASES FLEXIBILITY
Rollability scores
(1-5)
Flexible
NOT
flexible
5.0
4.5
4.0
4.8
5.0
3.7
3.0
2.0
1.0
without enzyme 150 ppm Alpha- 250 ppm Alpha- 350 ppm Alphaamylase
amylase
amylase
Novozymes internal data
4 weeks
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
Enzymes
Maintenance of softness and
flexibility of tortillas
Alpha-amylase
Reduction of masa stickiness
Lipase
Processing ease
CORN tortillas
​Ten day-old tortillas
​With enzymes: Flexible, no cracking
​Without enzymes: undesirable cracks
Two-week old corn
tortillas
Force to break the tortilla with Texture Analyzer
Stronger
899.5
900
762.2
​Maltogenic amylase
improves corn tortilla
strength during storage
700
Rollability scores (1-5)
at room temperature
500
40 ppm Alpha-amylase
40 ppm Alpha-amylase
day 5
day 11
​Maltogenic amylase help
to decrease the CMC in
the formula
5.0
4.0
3.0
2.0
1.0
2.3
2.3
0.5% CMC
0.25% CMC+30 ppm
Alpha-amylase
​
1.2
without enzyme
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)
Sticky
dough
Dough stickiness (g)
Masa dough
100
80
60
50
30
40
Nonsticky
dough
Hard
dough
40
40
40 ppm Alphaamylase
20 ppm Lipase
35
20
0
without enzyme
20 ppm Alphaamylase
40 ppm Lipase
Firmness (g force)
100
80
75
61
60
70
40
Soft
dough
20
0
without enzyme
Novozymes internal data-Equipment: TA.XT2
20 ppm Alpha-amylase
40 ppm Lipase
​Less sticky and softer
corn masa obtained with
an Alpha-amylase and a
Lipase
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
Enzymes
Maintenance of softness and
flexibility of flat breads
Alpha-amylase
Bacterial alpha-amylase
Lipases
Lipases
Alpha-amylase maintains and improves flat
bread softness for three days
Very flexible
Day 1
9
Day 3
8.3
7.2
7
5
6.8
6.2
5
5
3
Breaks
1
without enzyme
Novozymes internal data
5 ppm Alpha-amylase
10 ppm Alpha-amylase
A Lipase makes softer Naan dough; softer
final product at four-hour after baking
Naan instrumental softness
(% softness compare to without enzyme)
Naan dough softness
Softer
Softer
10
120
8
8
100
6
128
100
80
5
60
4
40
2
Firmer
140
20
0
without enzyme
Novozymes internal data
250 ppm Lipase
Firmer
0
without enzyme
250 ppm Lipase
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
Softer
10
140
8
6
120
7
100
5
100
80
60
4
40
2
Firmer
122
20
0
0
no enzymes
Novozymes internal data
250 ppm Lipase
Firmer
no enzymes
250 ppm Lipase
Chapatti made with a Lipase showed excellent
dough property and better softness
no enzymes
Firmer
250 ppm lipase
700
600
585
546
500
400
393
391
300
200
100
Softer
0
30 min after baking
Novozymes internal data
3 hrs after baking
Enzymes are natural
​Enzymes can
​Maintain freshly baked quality
of tortillas/flat breads
​Improve dough handling and
machinability
Enhance mixing tolerance
​Replace/reduce chemicals
A good source for
enzymes and tortillas
http://www.aaccnet.org/publications/store/pages/27885.aspx