HK1178022A - Dough targeting for enhanced microwave reheating - Google Patents

Description

Dough oriented to enhance microwave reheating

Technical Field

The present invention relates to a dough product having two or more disparate doughs strategically placed or positioned within the dough product to enhance the organoleptic properties of the dough product after baking and subsequent reheating in a microwave oven.

Background

Pre-baked microwaveable frozen dough products are becoming increasingly popular because they require minimal preparation for immediate consumption. However, obtaining desirable organoleptic properties after reheating the baked product in a microwave oven remains difficult due to the different heating profiles of microwave and conventional ovens. In a conventional furnace, the heating profile is from the outside inward, such that the outer skin is the hottest part and the center is the coldest part. In contrast, in a microwave oven, the heating of the food product is random and throughout the entire product, such that the interior or high moisture areas of the dough product absorb microwaves and convert them to heat, creating an opposite heating profile that often makes the exterior the coldest part due to evaporative cooling. As a result, high energy heating zones occur which reduce traditional consumer expectations of the product and produce a product with a wet interior and a tough crust, such as pizza or Panini.

U.S. patent application publication No.2005/0025862 to Morad et al discloses a baked dough product having a two-dimensional structure that includes multiple layers that can be baked in a microwave oven into a unique structure having a soft, moist inner region and a crispy, multi-layer outer region. This indicates that there is a need to modify conventional dough products to improve their resulting properties obtained by conventional or microwave baking.

In particular, however, there remains a need in the industry to improve the texture, taste, appearance, nutrition, color and flavor of dough products that are baked first and then microwave reheated. The present invention satisfies this need in the industry by using one or more different doughs to locate specific locations or positions in the dough product to achieve optimal consumer experience and quality benefits, particularly when the baked dough product is reheated in a microwave oven.

Disclosure of Invention

The present invention relates to a method of improving the organoleptic properties of a baked dough product to be heated using microwaves. The method comprises the following steps: selecting first and second bakery dough portions that are sufficiently viscous to inhibit or avoid their miscibility when placed in contact prior to baking and have properties such that the first bakery dough portion responds differently to microwave reheating than the second bakery dough portion after baking; providing a leavening agent to at least one of said first or second dough portions and requiring proofing of said dough portions prior to baking; combining at least a portion of the first bakery dough portion with the second bakery dough portion in an unbaked configuration, the dough portions being oriented and positioned to provide an improved response of the baked product to microwave reheating; baking the bakery dough portion in a conventional oven to obtain a bakery dough product; and packaging the bakery dough product for shipping and sale. The final bakery dough product after baking is optimally reheated when heated in a microwave oven due to the different response of the baked dough portions to microwave heating, resulting in a baked and reheated dough product for consumption having desirable organoleptic properties compared to dough products that do not utilize such oriented and positioned first and second bakery dough portions.

In one embodiment, the method of the present invention further comprises co-extruding the first and second bakery dough portions such that the second dough portion surrounds the first dough portion. Alternatively, the method further comprises sheeting the first bakery dough portion and placing the second bakery dough portion on, adjacent to, or in a particular position with respect to the sheeted first dough portion.

Depending on the packaging material, the final dough product may be removed from the package and reheated in a microwave oven, or it may be reheated in the package and then removed from the package for consumption.

In another embodiment, the method further comprises forming the first bakery dough portion into a generally flat shape having an edge along its perimeter; and arranging the second dough portion to surround at least a portion of the edge of the first bakery dough portion. For example, a first bakery dough portion may be shaped without a generally circular or rectangular shape, while a second dough portion provides an adjoining strip that contacts the edge. In particular, the dough product may be a pizza dough having a first bakery dough portion forming a central portion of the pizza dough and a second bakery dough portion forming a periphery of the pizza dough. Thus, the skin has a desired texture after reheating in the microwave oven.

In another embodiment, the method of the present invention further comprises forming the first bakery dough portion into a mass having a generally circular, oval, crescent, or polygonal cross-sectional shape; and substantially enclosing the first bakery dough portion with the second bakery dough portion. For example, the first bakery dough portion may have a substantially cylindrical shape and the second bakery dough portion wraps around the first bakery dough portion. The cylindrical cutting surface may then be sliced with the desired external and internal tissues after reheating in a microwave oven.

In yet another embodiment, the method of the present invention further comprises: providing a third bakery dough portion that includes a leavening agent and that requires proofing prior to baking, wherein the third bakery dough portion is sufficiently viscous to inhibit or avoid miscibility in contact with the first and second bakery dough portions, providing the third bakery dough portion with properties such that the third bakery dough portion corresponds to microwave reheating differently than the first and second bakery dough portions after baking and microwave reheating; and arranging a third bakery dough portion to surround at least a portion of the first or second bakery dough portion to form an unbaked configuration for simultaneous baking of the first, second and third bakery dough portions. For example, the unbaked texture can be provided by: (i) forming the first bakery dough portion into a generally polygonal shape having edges and corners; (ii) placing the second dough portion along an edge between corners of a polygon; and (iii) disposing the third bakery dough adjacent to a corner of the polygon. As another example, the unbaked construction is provided by: (i) forming the first bakery dough portion into a mass having a generally circular, oval, crescent, or polygonal cross-section with an outer surface; (ii) placing the second dough portion to surround a portion of the outer surface of the dough piece; and (iii) placing the third dough portion to surround the remainder of the outer surface of the mass such that the second and third bakery dough portions together enclose the first bakery dough portion.

In yet another embodiment, the method of the present invention further comprises encapsulating a filling, such as meat, chicken, fish, starch, vegetables, nuts, milk, sauce, spices, or combinations thereof, within the first and second bakery dough portions.

In yet another embodiment of the method of the present invention, the first bakery dough portion can be formulated to be softer than the second bakery dough portion after baking and microwave reheating. Alternatively, the first bakery dough portion can be formulated to accept moisture transfer without becoming sticky after baking and microwave reheating, while the second bakery dough portion is formulated to prevent hardening and toughening after baking and microwave reheating. In a particular embodiment, the first and second bakery dough portions can be bread dough, wherein the second dough portion is formulated to not form a crust after baking and microwave reheating, such that the final bakery product forms a crust-free bread after baking and microwave reheating.

In other embodiments, the first or second bakery dough portion may include one or more of flour, grains, flavoring agents, coloring agents, texturizing agents (texture agents), fibers, and nutritional additives not included in other bakery dough portions. The first and second bakery dough portions can be formed into a predetermined pattern if desired or needed.

The invention also relates to a microwavable dough product produced by the method of the invention. The product includes first and second bakery dough portions that are sufficiently viscous to inhibit or avoid miscibility thereof when in contact prior to baking, but which have properties such that the first bakery dough portion responds differently to microwave heating than the second bakery dough portion after baking. At least one of the first or second dough portions includes a leavening agent and is proofed prior to baking, wherein at least a portion of the first bakery dough portion is combined with the second bakery dough portion and is oriented and positioned to provide an improved response of the baked dough product to microwave heating. Such baked dough products after heating in a microwave oven are optimally reheated due to the different response of the baked dough portions to microwave heating to obtain a baked and reheated dough product for consumption having desirable organoleptic properties as compared to dough products that do not utilize such oriented and positioned first and second bakery dough portions.

The present invention also relates to the use of first and second bakery dough portions having different responses to microwave heating in a baked and then microwave reheated bakery dough product, wherein the dough portions are oriented and positioned to provide an improved response of the baked dough product to microwave heating to obtain a baked and reheated dough product for consumption having desirable organoleptic properties compared to dough products not utilizing such oriented and positioned first and second bakery dough portions. As described above, at least one of the first or second dough portions includes a leavening agent and is proofed prior to baking, and wherein the baked dough product after heating in a microwave oven is uniformly reheated due to the different responses of the baked dough portions to microwave heating.

Brief description of the drawings

The invention will be better understood with reference to the accompanying drawings, which illustrate preferred embodiments, and in which:

FIGS. 1A, B and C show cross-sectional views of three different Panini embodiments of the present invention, wherein the heavy arrows represent the inner dough portion and the thin arrows represent the outer dough portion;

FIGS. 2A and B show round (A) and square (B) pizza embodiments of the present invention, while FIG. 2C shows a French bread pizza embodiment of the present invention, with thick arrows representing the inner dough portion and thin arrows representing the outer dough portion;

FIG. 3 illustrates top and side views of a pita and tortilla product of the present invention, wherein the heavy arrows represent the inner dough portions and the thin arrows represent the outer dough portions; and

FIGS. 4A, B and C show Nestle' HOTThree different embodiments of sandwich products.

FIGS. 5A and B show the production of a co-extruded dual formulation dough (A) and a cross-section of a slice of bread made from this dough (FIG. 5B).

Fig. 6 shows the equipment (Instron) and the procedure for measuring the toughness of the bread.

Fig. 7 is a diagram showing different positions for taking a toughness measurement on a slice of bread.

Fig. 8 shows the average load (N) required to penetrate a slice of bread at a given speed as a function of penetration. The upper three curves refer to the outer skin portion and the lower three curves refer to the central portion.

Fig. 9A-D show that the inner dough formulation significantly spread out when baked unconstrained (fig. 9C and D), while the co-extruded cookie was limited from excessive expansion due to the low expansion of the outer dough (fig. 9A and B).

Detailed description of the preferred embodiments

The present invention relates to a method of improving the organoleptic properties of baked dough products that are microwave reheated by strategically orienting or locating two or more disparate dough types in the product to provide the product with certain attributes that can be enjoyed by the consumer after the product is reheated in a microwave oven. The dough type differences may be in the form of dough recipes, dough mixing, or dough manufacturing or mixing techniques. The dough orientation process of the present invention can deliver relevant texture, taste, appearance, color, flavor and nutritional elements or combinations thereof to the proper location in a microwavable product that cannot be achieved in dough products made from only a single bakery dough or a single recipe due to the unique heating process of a microwave oven.

The present invention also relates to a microwave product produced by the method of the present invention having two or more disparate dough types strategically oriented or positioned in the product to form a three-dimensional structure and provide the product with certain attributes that can be enjoyed by a consumer after the baked product is heated in the microwave. The baked dough product is not uniformly reheated after reheating in a microwave oven, but obtains uniform organoleptic properties as compared to dough products that do not utilize such first and second bakery dough portions. Thus, the consumer may not notice the difference between the first and second dough portions due to the uniform characteristics of the product after reheating in the microwave oven. In contrast, when a single dough formulation is used, the edges, corners and crust of the dough product will be harder than the rest of the product and undesirable for consumption.

The first or second bakery dough portion typically includes one or more of flour, grain, flavoring, coloring, texturizing, fiber, and nutritional additives not included in other bakery dough portions. The flour content is typically from about 30% to 65%, preferably from about 40% to 60%, and more preferably from about 45% to 55% by weight. Preferably, the texturizing agent is egg or egg white. Flavoring agents may be natural or artificial and, when included, are generally present in amounts of about 0% to 5%, preferably about 0% to 1%, by weight.

In yet another embodiment, the first bakery dough portion may be a laminated dough formulated to provide a light, soft outer skin and the second bakery dough portion is a non-laminated dough formulated to provide a firm and rigid outer skin after reheating in a microwave oven.

Coextrusion of the dough portions can be achieved using commercially available extruders such as Rheon Automatic Machinery Company, Ltd., of Utsunomiya, Japan, Hosokawa tape GmbH of Leingarten, Germany, SASIB of Plano, APV Systems of Rosemont, Aasted-MikroverkBaker Equisent of Farum, and extruders sold by others.

In one embodiment, the dough is prepared as a salmon bun (chub pack), cylindrical, or sausage-shaped form. In this form, the center portion of the dough product has a diameter of about 1 to 3 inches and the width of the edge portion is about 0.1 to 1 inch. Preferably, the center portion of the dough product has a diameter of about 1 to 2.5 inches. In a most preferred embodiment, the center portion of the dough product has a diameter of about 1 to 2 inches and the width of the edge portion is about 0.5 to 1 inch.

In another embodiment, the dough product is shaped in the form of a mass having a square, rectangular, triangular, oval or other cross-sectional configuration such that the baked product has a circular or annular baked perimeter. The dough is typically cut into smaller pieces prior to baking.

Specific examples of microwavable products of the present invention include, but are not limited toAnd Panini slices; cakes such as tortillas, pita cakes and corn cakes; round, square and rectangular pizzas; pizza of French bread; anda sandwich is provided. The microwave dough product of the present invention may be a pizza or Panini having a different dough type on the outside of the outer skin than the inside of the outer skin. The consumer may or may not see that there are two different doughs, but they will notice the superior quality of the product made with dough orientation. In addition, the dough orientation of the present invention can also be used to achieve other benefits such as nutrient delivery.

The dough product may be refrigerated or frozen after baking in a conventional oven. Typically, they are refrigerated at temperatures below about 50 ° F (10 ℃), preferably about 32 ° F to 40 ° F (0 ℃ to 4.5 ℃) for storage or display prior to reheating in a microwave oven.

The different dough portions can be obtained in a number of ways generally familiar to the skilled person. Different flours or combinations of flours can be used. Typically, wheat flour is used, but different types of wheat flour and wheat flour combinations can be used to achieve different responses of the baked dough to microwave reheating.

Many other types of flours can be used, alone or in combination, to provide baked dough with different responses to microwave reheating. These include amaranth flour, bean flour, white and brown rice flour, buckwheat flour, chestnut flour, chickpea flour, potato flour, corn flour, ground nut flour from oily nuts, pea flour, peanut flour, rye flour, tapioca flour or soybean flour. The flour can also be prepared from arrowroot, taro, cattail, acorn, quinoa, seeds, etc. The skilled artisan is able to best determine any particular flour formulation and its response to microwave heating by preparing the formulation, baking it routinely and then reheating it in a microwave oven. Since the product of the present invention uses multiple dough portions, the product can be made using two, three, four or even more different dough portions, which are then baked and finally reheated to measure the relative properties of the different baked dough portions. The examples illustrate some preferred combinations.

Another way to achieve the desired differential response to microwave heating is to control the moisture content of the dough portions while still taking into account the occurrence of moisture migration. This can be done by simply changing the amount of water in the formulation or by adding water-retaining additives to the dough. For example, adding fibers is one of the ways. The fiber may be added to one of the dough portions or different fibers may be added to different dough portions. Dietary fibre is usually soluble or insoluble. Soluble fibers are present in varying amounts in all vegetable foods, including legumes (peas, soybeans and other legumes), oats, rye, sage and barley, certain fruits and juices (including the interior of plum juice, plums, berries, bananas and apples and pears), certain vegetables such as broccoli, carrots and jerusalem artichokes, roots such as potatoes, sweet potatoes and onions, and psyllium seed husk. Sources of insoluble fiber include whole grain foods, wheat and corn bran, nuts and seeds, potato peel, linseed, lignans, certain vegetables such as mung bean, cauliflower, zucchini (small cucumber), celery, and cactus, and certain fruits such as tomato peel. An amount and/or type of fiber may be added to the dough portion to obtain a different response to microwave heating and, thus, a desired dough texture after heating.

Another additive included in the dough portion is a conventional product known as Micro Sure 2.5, sold by Caravan Ingredients of Lenexa (Kansas). Micro Sure 2.5 is a combination of dough conditioners including gluten, oat fiber, sodium stearoyl lactylate, monoglycerides, guar gum, algin, xanthan gum and enzymes.

The dough may also be improved by using different flour types, such as rye, hard or soft wheat, tricale, barley, oats, corn, quinoa, spelt, buckwheat, rice, kamut or amaranth.

Another embodiment of the invention is the unrolling control of a cookie that incorporates different doughs for microwave heating. Cookie doughs formulated to provide increased softness/moisture are typically more spread out due to higher moisture content and the presence of emulsifiers, humectants such as sugar. In microwave baking, this can be a problem. To address this problem, two formulations of inner dough and outer dough are used to make the co-extruded dough. The inner dough remains soft when heated in the microwave, while the outer dough is more compact and resists spreading when heated in the microwave. These two formulations differ in that the addition of dough conditioner to a single dough mixture does not result in the desired end result of a microwave heated cookie having a firmer outer portion and a softer inner portion.

Another way to modify or formulate doughs such that they provide different microwave reheating performance is to vary the fat content of the dough. For example, increased fat content can make bread or pizza dough softer. Such dough formulations can be used to form regions of the product that would otherwise be too chewy or chewy.

Yet another group of functional formulations that can improve microwave reheat performance are enzymes, particularly proteases. These enzymes act by weakening the gluten structure, thereby reducing the tendency of the reheated dough to chew untoward. Also, such dough formulations can be used in portions of the product that would otherwise become chewy.

Examples

The following examples illustrate various preferred ways of formulating different dough portions for orientation and positioning in a bread loaf product to achieve the benefits of the invention.

Dough oriented into Panini products (co-extruded or hand-made)

To deliver nutritional benefits, the inner dough is made from whole wheat. Due to the masking effect of the position filling or topping, the nutritional benefits of whole grain can be achieved without whole wheat or whole grain flavor.

To enhance the microwave reheating characteristics of Panini, the inner dough is designed to accommodate moisture transfer from the filling or topping without becoming sticky during microwave heating. In addition, the outer dough is designed to prevent hardening and toughening during microwave heating, which is a common problem during microwave reheating of dough products.

As shown in fig. 2B, the inner dough may be made from white italian wheat, while the outer dough imparts an crusty-free character, which is particularly desirable for children.

As shown in fig. 1C, color and appearance benefits can be achieved by formulating the inner dough as a colored white bread and the outer dough as a whole wheat bread to present a hair-like appearance, such as a face designed to be pleasant.

When the outer dough is made of butter, salty, or garlic flavored bread, flavor benefits can be realized by adding a filling experience to the edges of the slice of bread.

Pizza products (co-extrusion, sheeting or hand-crafted) oriented in circles, squares and rectangles and methods Dough for bread pizza products (co-extruded or hand-made)

To enhance the microwave reheating characteristics of the dough product, the inner dough is designed to accommodate moisture transfer of the topping or filling without becoming sticky and wet during microwave heating, while the outer dough, which forms the rings or edges in a rectangular or square pizza, is designed to prevent stiffening and toughening during microwave heating. Further improvements can be achieved by using a third different dough at the corners of square and rectangular pizzas to prevent hardening and toughening of the corners where significant microwave energy is concentrated (fig. 2B). The corner dough portion is formulated to be suitable for full-time moisture transfer, while the edge dough portion has a moderate moisture retention level.

In the case of a circular pizza, the inner dough portion and the outer dough portion are arranged in concentric circles, with the inner circle having a radius of 4.5 inches and the outer circle having a thickness of 1.5 inches, forming a stick-shaped piece. Each pizza slice is cut from the bar, placed in a pan, beaten to flatten it if necessary, allowed to rise for a predetermined period of time, and baked in a conventional oven. Thereafter, the prebaked pizza is frozen and packaged.

To deliver nutritional benefits, the inner dough is made from whole wheat. Due to the masking effect of the position lidstock, the nutritional benefits of whole grain can be delivered without whole wheat or whole grain flavor. The outer dough is formulated using a conventional pizza dough formulated with oat fiber to enhance microwave performance.

The textural benefits can be achieved by formulating the inner dough to be suitable for topping or filling moisture transfer without becoming sticky during microwave or conventional heating. In addition, the outer dough may have inclusions such as vanilla and sun-dried tomato to improve the color and appearance of the pizza product. To enhance the flavor of pizza, the outer dough can be formulated as butter, salty, or garlic flavored bread to add a filling experience to the edges of the slice of bread.

Dough oriented into pita and tortilla products

To enhance the microwave reheating characteristics of the pita and tortilla products shown in fig. 3, the inner dough is formulated to accommodate moisture transfer of the topping or filling without becoming sticky during microwave heating, while the outer dough is formulated to prevent hardening and toughening during microwave heating.

To improve the nutritional value of these products, the inner dough is made from whole wheat, with the whole wheat or whole grain flavor masked by the filling or topping in place.

The texture, color and browning of the inner dough portion and the outer dough portion may be optimized for reconstitution. Based on consumer preference, the inner dough may be formulated with enhanced flavor, while the outer dough is formulated as butter, salty, or garlic flavored bread to add a filling experience to the edges of the slice of bread.

Oriented as nests Sandwich product dough (sheeting or hand-made)

Of nests as shown in figure 4AThe sandwich is composed of a dual-structure dough, wherein the lower dough portion is of a different type than the upper dough portion. The filling may be any filling ranging from ham and cheese to pizza.

To deliver nutritional benefits, the lower dough portion is made from whole wheat and/or has added fiber. Due to the masking effect of the filling or browning of the lower skin at this location, whole wheat or added fiber is delivered without the flavor of whole wheat or whole grain.

To improve microwave reheating characteristics, the upper dough portion is formulated to provide additional crispness and tenderness during microwave reheating, while the lower dough portion is formulated to accommodate moisture transfer of the filling without becoming sticky during microwave heating. Higher impact and potential cost savings can be achieved by specifically formulating the upper dough portion to emit flavor without changing the formulation of the lower dough portion. In addition, to achieve color and appearance benefits, the upper dough portion can have reduced sugar for better baking and browning, while the lower dough portion can be formulated for compactness, rigidity, and baking optimization.

The textural benefits may also be achieved by formulating the upper dough portion as a laminated, soft upper skin while formulating the lower dough portion as a non-laminated, firm and rigid lower skin.

Of nests as shown in figure 4BSandwiches consist of a two-tissue dough, wherein the ends of the sandwich have a different dough than the middle.

To improve the microwave reheating characteristics, the end dough is formulated to resist hardening or reduce hardening during reheating in a microwave oven to address the problems commonly caused by highly concentrated microwave energy in the ends of the sandwich in rectangular products. The intermediate dough is also formulated to prevent hardening and toughening during microwaving.

To deliver textural benefits, the end portions and the intermediate dough portion are each formulated to optimize texture based on proximity to the filling.

The end dough portions typically have the color of white bread, while the middle dough portion is formulated to produce a different color than the end dough portions. The difference in color between the middle dough portion and the end dough portions may be enhanced by a coloring agent such as lactose.

HOT of Nestle as shown in figure 4CThe sandwich is composed of three dough portions of different textures, namely a center block upper dough portion, a center block lower dough portion, and end dough portions. Positioning or orienting different dough portions at different locations provides a way to improve the microwave performance of the dough product by eliminating both hard edges and corners, thereby providing a better eating experience for the consumer.

Co-extrusionBread with double formulas

The breadsticks were made from two different dough formulations (Table 1). The inner portion had 30% whole grain flour (referred to as "inner dough" or "formula 1") while the outer portion had 100% white wheat flour and bread improver to reduce toughening during microwave reheating (referred to as "outer dough" or "formula 2"). These samples were referred to as "combined dough". Samples were also prepared from either formulation 1 alone or formulation 2 alone.

TABLE 1 dough formulation

The dough was mixed in a Hobart mixer, rested, formed into balls, relaxed, and then formed into loaves. The dual formula dough was coextruded using Rheon (fig. 5A), using a combination of an outer die having a diameter of 60mm and an inner die having a diameter of 36 mm. The coextruded product was then cut to the appropriate length and placed in a pan at 85 ° F at 85% Relative Humidity (RH) for 50-55 minutes. Optionally, a half-inch deep slit may be formed through the outer dough. The coextruded product was then baked at 350 ° F for 22 minutes, cooled at room temperature for 2 hours, frozen for storage for a period of time, thawed, and finally cut into 5/8 "pieces.

The sections (about 40-45g per section) were then heated in a 1100W microwave oven for 30 seconds, one at a time, and allowed to cool for 3 minutes before the tissues were evaluated. Fig. 5B shows a cross-section of a slice of bread in which the outer dough 52 surrounds the inner dough 51. The texture of the bread was evaluated using an Instron equipped with a plastic blade (width 20 mm) and a platform with elongated holes (38 x 8 mm) (fig. 6). The blade penetrated the edge or center portion of the slice of bread at a speed of 3 mm/sec. The fracture has more tear properties than cut and the maximum load (N) has previously been shown to correlate well with toughness as measured by a trained sensory panel. Several measurements were made for each slice of bread (fig. 7, positions 1, 2, 3, and 4) and several slices were evaluated for each sample. The maximum load (N) required to penetrate the slice of bread at a given speed is recorded. The measurements at positions 1, 2 and 3 are combined into the outer skin tissue and the measurement at position 4 is combined into the tissue of the central part. The average maximum load is used as a measure of the tissue.

As shown in fig. 8, the skin toughness as measured by the Instron varied from sample to sample. Slices of the long bread made from formulation 1 had a higher crust toughness than slices made from formulation 2 or the long bread using formulation 2 as the outer dough (the "combined dough" sample). The toughness of the center was much lower than that of the sheath in all samples, demonstrating that the center tissue was less sensitive to microwave reheating at that location.

TABLE 2 for three different varieties (formulation 1, formulation 2, combined dough)

Average maximum load at different positions (skin, center)

As shown in table 2, the combination of two different dough formulations can achieve the benefits of improved texture (reduced crust toughness) and also combine a significant portion of the nutrition of a whole grain containing dough. The interior of the slice does not experience the same textural effects as the outer skin portion, and therefore, the dough making up the inner portion can be formulated to other standards, such as higher nutritional value and further suitability for moisture transfer.

Examples of Co-extruded cookie dough

Two different dough formulations were combined by co-extrusion in Rheon 080808. The dough was extruded on a round bar and cut into 50g cookies manually or into 50g pieces automatically by a spacer device (irisdevice) on a Rheon machine. Baked in a 1100W Sharp microwave oven for 40 seconds.

The outer dough was formulated to spread less and thus less open when baked in the microwave, while the inner dough was formulated to be more soft/moist (table 3).

TABLE 3 two different dough formulations for co-extruded cookie dough

Composition (I)	Outer dough	Inner dough
				%	%
Wheat flour	35%	16%
			Chocolate crumb, semi-sweet		21%
Butter oil	23%	13%
			Candy	29%	29%
EggYellow powder	1.1%	1.0%
			Molasses for health protection	1.8%	1.7%
Starch syrup dry powder	1.7%	1.5%
			Cocoa powder		4.4%
Rice flour		1.5%
			Sugar beet fibre		0.2%
Corn starch	2.5%	3.2%
			Emulsifier		0.7%
Methyl cellulose	0.6%	0.6%
			Sodium bicarbonate	0.2%	0.2%
Salt (salt)	0.4%	0.4%
			Vanilla essence	0.08%	0.06%
Water (W)	Balance of	Balance of
			Total of	100%	100%

Both the outer dough and the inner dough comprise wheat flour, butter, sucrose, water, egg yolk, molasses, corn syrup solids, starch, methyl cellulose, sodium bicarbonate, salt, and vanilla. However, the inner dough additionally contained distilled monoglycerides (0.7%), rice flour (1.5%), sugar beet fibre (0.2%), cocoa powder (4.4%) and chocolate tablets (21%).

The internal dough formulation was significantly softer and wetter after baking in the microwave and spread out more when baked without constraint (fig. 9C and 9D). In contrast, co-extruded cookies, when baked, constrain excessive expansion by low expansion of the outer dough which acts as a container for the more flowable inner dough (fig. 9A and 9B).

It is to be understood that the invention is not limited to the precise construction herein illustrated and described. Accordingly, all expedient modifications readily attainable by one of ordinary skill in the art from the disclosure set forth herein, or by routine experimentation therefrom, are deemed to be within the spirit and scope of the invention as defined by the appended claims.

Claims (20)

1. A method of improving the organoleptic properties of a baked dough product to be reheated using microwaves, said method comprising:

selecting first and second bakery dough portions that are sufficiently viscous to inhibit or avoid their miscibility when placed in contact prior to baking and have properties such that the first bakery dough portion responds differently to microwave reheating than the second bakery dough portion after baking;

providing a leavening agent to at least one of said first or second dough portions and requiring proofing of the dough portions prior to baking;

combining at least a portion of the first bakery dough portion with the second bakery dough portion in an unbaked configuration, wherein the dough portions are oriented and positioned to provide an improved response of the baked product to microwave reheating;

baking the bakery dough portion in a conventional oven to obtain a bakery dough product; and

packaging the bakery dough product for transport and sale;

wherein the final bakery dough product after baking is uniformly reheated when heated in a microwave oven due to the different response of the baked dough portions to microwave heating, a baked and reheated dough product for consumption is obtained that has uniform organoleptic properties compared to dough products that do not utilize such oriented and positioned first and second bakery dough portions.

2. The method of claim 1, further comprising co-extruding the first and second bakery dough portions such that the second dough portion surrounds the first dough portion.

3. The method of claim 1, further comprising removing the final dough product from the package and reheating the final dough product in a microwave oven or reheating the final dough product in the package and removing the reheated product from the package for consumption.

4. The method of claim 1, further comprising:

(a) forming the first bakery dough portion into a generally flat shape having an edge along its perimeter; and arranging the second dough portion to surround at least a portion of the edge of the first bakery dough portion; or

(b) Forming the first bakery dough portion into a mass having a generally circular, oval, crescent, or polygonal cross-sectional shape; and substantially enclosing the first bakery dough portion with the second bakery dough portion.

5. The method according to claim 4, wherein the first bakery dough portion is shaped in a substantially circular or rectangular flat shape and the second dough portion provides an abutting strip in contact with the edge, e.g. wherein the dough product is a pizza dough, the first bakery dough portion forming a central portion of the pizza dough and the second bakery dough portion forming a periphery of the pizza dough.

6. The method of claim 4, wherein the first bakery dough portion has a substantially cylindrical cross-sectional shape and the second bakery dough portion surrounds the first bakery dough portion, optionally encapsulating a filling within the first or second bakery dough portion, wherein the filling comprises meat, chicken, fish, starch, vegetables, nuts, dairy, sauce, spices, or combinations thereof.

7. The method of claim 1, wherein:

(a) the first bakery dough portion is formulated to be softer than the second bakery dough portion after baking and microwave reheating; or

(b) The first bakery dough portion is formulated to accept moisture transfer without becoming sticky after baking and microwave reheating, and the second bakery dough portion is formulated to prevent hardening and toughening after baking and microwave reheating; or

(c) The first and second bakery dough portions can be bread dough and the second dough portion is formulated to not form a crust after baking and microwave reheating such that the final baked product forms a crust-free bread after baking and microwave reheating; or

(d) One of the first or second bakery dough portions includes one or more of flour, grain, flavoring, coloring, texturizing agent, fiber, and nutritional additives not included in the other bakery dough portion.

8. A microwavable dough product obtainable from the method of any preceding claim.

9. A baked dough product comprising first and second bakery dough portions that are sufficiently viscous to inhibit or avoid their miscibility in contact prior to baking but that have properties after baking that cause the first bakery dough portion to respond differently to microwave heating than the second bakery dough portion, wherein at least a portion of the first bakery dough portion is combined with the second bakery dough portion and is oriented and positioned to provide an improved response of the baked dough product to microwave heating; wherein the baked dough product is uniformly reheated after heating in a microwave oven due to the different responses of the baked dough portions to microwave heating to obtain a baked and reheated dough product for consumption having uniform organoleptic properties as compared to a dough product that does not utilize such oriented and positioned first and second bakery dough portions.

10. The final baked dough product of claim 9, wherein the first and second bakery dough portions are co-extruded such that the second dough portion surrounds the first dough portion.

11. The final baked dough product of claim 9 packaged in a package that can be removed to allow the final dough product to be reheated in a microwave oven; or in packaging that can be reheated in a microwave oven, wherein the reheated final dough product is removed from the packaging for consumption after reheating.

12. The final baked dough product of claim 9, wherein the first bakery dough portion is generally flat in shape having an edge along its perimeter; and the second dough portion surrounds at least a portion of the edge of the first bakery dough portion; or wherein the first bakery dough portion forms a mass having a generally circular, oval, crescent, or polygonal cross-sectional shape; and the second bakery dough portion substantially encases the first bakery dough portion.

13. The final baked dough product of claim 12, wherein the first bakery dough portion is substantially round or rectangular flat in shape and the second dough portion provides an abutting strip in contact with the edge, e.g., in the form of a pizza dough, wherein the first bakery dough portion forms a center portion of the pizza dough and the second bakery dough portion forms a perimeter of the pizza dough.

14. The final baked dough product of claim 123, the first bakery dough portion having a substantially cylindrical cross-sectional shape and the second bakery dough portion surrounding the first bakery dough portion, optionally comprising a filling enclosed within the first or second bakery dough portion, wherein the filling comprises meat, chicken, fish, starch, vegetables, nuts, dairy, sauce, spices, or combinations thereof.

15. The final baked dough product of claim 12, further comprising a third bakery dough portion that includes a leavening agent and that requires proofing prior to baking, wherein the third bakery dough portion is sufficiently viscous to inhibit or avoid miscibility in contact with the first and second bakery dough portions, wherein the third bakery dough portion has the property of being responsive to microwave reheating differently than the first and second bakery dough portions after baking and microwave reheating; and wherein the third bakery dough portion is arranged to surround at least a portion of the first or second bakery dough portion to form an unbaked configuration for simultaneous baking of the first, second and third bakery dough portions to obtain the final baked dough product.

16. The final baked dough product of claim 12, wherein:

(a) the first bakery dough portion is formulated to be softer and softer than the second bakery dough portion after baking and microwave reheating; or

(b) The first bakery dough portion is formulated to allow moisture transfer without becoming sticky after baking and microwave reheating, and the second bakery dough portion is formulated to prevent hardening and toughening after baking and microwave reheating; or

(c) The dough product is in a crust-free bread form after baking and microwave reheating, wherein the first and second bakery dough portions are bread doughs and the second dough portion is formulated to not form a crust after baking and microwave reheating; or

(d) The first or second bakery dough portion includes one or more of flour, grain, flavoring, coloring, texturizing agent, fiber, and nutritional additives not included in other bakery dough portions.

17. Use of first and second bakery dough portions having different responses to microwave heating in a bakery dough product that is baked and then microwave reheated, wherein the dough portions are oriented and positioned to provide an improved response of the baked dough product to microwave heating to obtain a baked and reheated dough product for consumption that has uniform organoleptic properties compared to dough products that do not utilize such oriented and positioned first and second bakery dough portions.

18. The use of claim 17, wherein both the first and second dough portions comprise a leavening agent and are proofed prior to baking, and wherein the baked dough product has a uniform texture after heating in a microwave oven even though the baked dough portions respond differently to microwave heating, and the product optionally comprises a filling encased in the first or second bakery dough product, wherein the filling comprises meat, chicken, fish, starch, vegetables, nuts, milk, sauce, spices, or combinations thereof.

19. The use of claim 17, further comprising a third bakery dough portion that responds differently to microwave reheating than the first and second bakery dough portions; and wherein the third bakery dough portion is arranged to surround at least a portion of the first or second bakery dough portion to form an unbaked configuration for simultaneous baking of the first, second and third bakery dough portions to obtain the final baked dough product.

20. The use according to claim 17, wherein:

(a) the first bakery dough portion is formulated to be softer than the second bakery dough portion after baking and microwave reheating; or

(b) The first bakery dough portion is formulated to accept moisture transfer without becoming sticky after baking and microwave reheating, and the second bakery dough portion is formulated to prevent hardening and toughening after baking and microwave reheating; or

(c) The dough product is in a crust-free bread form after baking and microwave reheating, wherein the first and second bakery dough portions are bread doughs and the second dough portion is formulated to not form a crust after baking and microwave reheating; or

(d) The first or second bakery dough portion includes one or more of flour, grain, flavoring, coloring, texturizing agent, fiber, and nutritional additives not included in other bakery dough portions.