Description of batter mixing using near infrared spectroscopy

The aim of the present study was to describe the physicochemical events occurring during batter mixing at different water contents (51.8, 54.4, and 56.7 g of water/100 g of dough) using near infrared (NIR) spectroscopy. An FT-NIR spectrometer over the 1000–2500 nm range with a fibre optic probe was used to record NIR spectra in-line. The analysis of both one-dimensional statistical method (principal components analysis) and two-dimensional statistical methods (generalised two-dimensional correlation spectroscopy) was conducted to evaluate the possibilities of NIR spectroscopy to monitor physical and physicochemical modifications observed during mixing of batter. The NIR results were in agreement with the physical and physicochemical analysis traditionally used to study bread dough mixing (consistency and glutenin depolymerisation). PCA on raw NIR spectra demonstrated that PC₁ describes the same traces as the dough consistency curves. PCA on raw NIR spectra can be used to monitor the batter mixing and to identify the NIR mixing time close to the t_peak.PCA on spectra after second derivative demonstrated that PC₁ and PC₂ traces described different traces compared to the dough consistency curves. The loading spectra associated to PC₁ and PC₂ suggested that almost the same physicochemical and chemical mechanisms occur during the dough mixing at 51.8 or 54.4% water contents, but with kinetic and intensity differences. The 2D COS method allowed a sequence of chemical events occurring during mixing for the batters at 51.8 and 54.4% water contents to be tentatively proposed. The 2D COS did not give clear physicochemical differences between the three batters during mixing. The NIR results for the highly hydrated batter (56.7%) were difficult to analyse due to its high water content.     

Physico-chemical description of bread dough mixing using two-dimensional near-infrared correlation spectroscopy and moving-window two-dimensional correlation spectroscopy

NIR spectroscopy presents a huge interest in exploring chemical changes during dough mixing. The aim of the present study is to investigate the potential of 2D correlation spectroscopy (2D COS) and moving-window 2D (MW2D) correlation spectroscopy to explore the time dependence of NIR spectral responses during wheat flour dough mixing. NIR spectra were continuously recorded (between 1400 and 2325 nm) during mixing of bread type-dough (based on flour, water and yeast), using an FT-NIR spectrometer with a deported probe. The probe was positioned inside the mixer in contact with the dough. The 2D spectra calculated using raw and second derivative NIR spectra were interpreted in terms of physico-chemical events. Nine different industrial flours were used as raw material to validate the analysis. The results obtained using the 2D COS and the MW2D methods give the possibility to ascribe chemical vibrations (starch, water and gluten) to NIR absorbance changes occurring during dough mixing. The analysis of the NIR spectra identified wavelength shift associated to both dough “free water” and protein secondary structure modifications. During this study, only the MW2D method allowed to identify clearly the time dependence of physico-chemical mechanisms from NIR variation bands.     

Mixing history affects gluten protein recovery, purity, and glutenin re-assembly capacity from optimally developed flour–water batters

Batters, from three wheat cultivars, were mixed up to their maximal consistency (t_peak) at different mixing speeds (N) and flour/water ratios [Auger, F., Morel, M.H., Lefebvre, J., Dewilde, M., Redl, A., 2008. A parametric and microstructural study of the formation of gluten network in mixed flour–water batter. Journal of Cereal Science 48, 349–358]. Gluten and starch were extracted from those batters using a process which included two successive steps: dilution and sieving. In order to reveal the specific influence of the mixing step, a standardized gentle washing and sieving procedure was selected. Mixing the batters at t_peak guaranteed a high and stable gluten protein recovery (ca. 82%) irrespective of mixing conditions. SE-HPLC analysis of protein, from flours and batters sampled at t_peak, demonstrated that mixing led to the almost total breakdown of the unextractable glutenin polymers (ca. 80%), whereas their re-assembly occurred during gluten extraction. The extent of glutenin re-assembly in gluten was influenced by the batter mixing history and was mainly related to the number of mixing rotations (N.t_peak). Gluten protein contents were also found related to N.t_peak. We proposed that the leaching of starch from the batter during gluten extraction was controlled by the elasticity of the protein network, i.e. the gluten content in unextractable glutenin. An innovating scheme relating the glutenin re-assembly capacity to the irreversible thiol protein oxidation is proposed.     

Application of two-dimensional cross-correlation spectroscopy to analyse infrared (MIR and NIR) spectra recorded during bread dough mixing

During dough mixing chemical, biochemical and physical transformations occur that allow dough formation to be characterized by common chemical and biochemical methods. Recently, spectrometric methods were used to characterize the dough mixing. The Mid-infrared (MIR) and the Near-infrared (NIR) spectroscopy allow information concerning chemical content and composition of food products to be obtained. The aim of this study is to apply FT-NIR and FT-MIR spectroscopy to monitor dough chemical changes, and to correlate those signals by the 2D Cross-Correlation (2D CORR) method. The 2D CORR was used to emphasize chemical assignment of the NIR band modifications (particularly for protein) during dough mixing.The 2D CORR analysis of the raw NIR and MIR spectra demonstrated that five NIR regions are highly correlated to protein vibrations. The 2D CORR analysis of the NIR and MIR spectra after second derivative demonstrated that the amide bands present high R² for the NIR bands at (1189–1216), (1351–1474) and (1873) nm. A low R² is obtained between the amide I and amide II bands and the (2026–2123) and (2280–2325) nm regions. The amide III band presents a slightly higher R² for those NIR regions.The 2D CORR analysis of NIR and MIR spectra allow more specific NIR regions associated to chemical modifications of protein structure to be identified. The 2D CORR analysis of the second derivative spectra is more precise for the identification of the NIR regions implied in dough mixing compared to the 2D CORR analysis of raw NIR and MIR spectra.     

Application of two-dimensional cross-correlation spectroscopy to analyse infrared (MIR and NIR) spectra recorded during bread dough mixing

During dough mixing chemical, biochemical and physical transformations occur that allow dough formation to be characterized by common chemical and biochemical methods. Recently, spectrometric methods were used to characterize the dough mixing. The Mid-infrared (MIR) and the Near-infrared (NIR) spectroscopy allow information concerning chemical content and composition of food products to be obtained. The aim of this study is to apply FT-NIR and FT-MIR spectroscopy to monitor dough chemical changes, and to correlate those signals by the 2D Cross-Correlation (2D CORR) method. The 2D CORR was used to emphasize chemical assignment of the NIR band modifications (particularly for protein) during dough mixing.The 2D CORR analysis of the raw NIR and MIR spectra demonstrated that five NIR regions are highly correlated to protein vibrations. The 2D CORR analysis of the NIR and MIR spectra after second derivative demonstrated that the amide bands present high R² for the NIR bands at (1189–1216), (1351–1474) and (1873) nm. A low R² is obtained between the amide I and amide II bands and the (2026–2123) and (2280–2325) nm regions. The amide III band presents a slightly higher R² for those NIR regions.The 2D CORR analysis of NIR and MIR spectra allow more specific NIR regions associated to chemical modifications of protein structure to be identified. The 2D CORR analysis of the second derivative spectra is more precise for the identification of the NIR regions implied in dough mixing compared to the 2D CORR analysis of raw NIR and MIR spectra.     

The Determination of Wheat Breadmaking Performance and Bread Dough Mixing Time by NIR Spectroscopy for High Speed Mixers

A non-invasive near infrared (NIR) technique has been used to identify changes in the development of bread dough during mixing. A Perten DA-7000 Diode Array NIR instrument with a fibre optic probe attachment was used. Both breadmaking and biscuit making varieties of wheat were examined. Doughs were mixed using a laboratory scale Chorleywood Bread Process (CBP) mixer and NIR spectra were gathered (one every 2 s). Flour quality data were used to determine the relationship between NIR and breadmaking quality attributes and to study varietal differences in breadmaking performance. Instrumental and sensory techniques were used to establish the important quality attributes of commercially and laboratory produced bread. NIR spectra and mixer torque were measured at different mixing times to obtain an overall picture of the mixing process from the initial hydration of the flour particles through optimum dough development until overmixing had occurred. Loaves were produced and assessed for volume by seed displacement and crumb structure using an image analysis technique. The dough elastic modulus was measured at a range of mixing times using a Bohlin VOR Rheometer. Comparison of results from the NIR spectra, dough properties and bread quality was carried out. Results revealed a relationship between the rheological properties of dough and the final quality parameters of bread. NIR was shown to have considerable merit in following dough changes during mixing which were related to final bread quality and thus has the potential to be used as an on-line method for controlling breadmaking mixers.     

Comparison of structural features of reconstituted doughs affected by starches from different cereals and other botanical sources

Starch, as the main component of flour products, determines the physicochemical properties of dough. This work investigated the relationship of the physical properties of seven types of starches from various cereals with the structural features of reconstituted dough. Results of mixing and tensile properties analysis and scanning electron microscopy displayed that rice reconstituted flour exhibited maximum water absorption; pea reconstituted flour had higher dough stability; sweet potato dough had higher tensile resistance; highland barley dough had the greatest extensibility. Moisture distribution analysis revealed that various model dough showed remarkably different water distribution, which was distributed at T₂₁ (0.07–0.11 ms), T₂₂ (0.8–2.66 ms) and T₂₃ (10.0–20.82 ms). Correlation analysis indicated that large starch granules associated with good dough stability; amylose content of starch positively affected tensile resistance of dough; crystallinity of starch showed negative effects on water absorption; starch with higher crystallinity associated with greater dough stability.     

Influence of oxygen content of kneading atmosphere on oxygen uptake and relaxation index of bread dough with various additives

The role of oxygen during mixing of bread dough was investigated using a unique air-tight mixer in which oxygen content of the atmosphere surrounding the dough was fixed at different levels ranging from 10 to 30%. Effects of the presence in bread dough composition of various O₂ consumers, such as yeast, lipoxygenase (LOX), and additional glucose oxidase (GOX) and/or soybean or horse bean flour (containing LOX), were studied in order to characterize the competition phenomena for oxygen in the different conditions. O₂ uptake by dough during mixing was followed and relaxation tests were performed on the resulting bread dough. Variation of O₂ level of the gaseous atmosphere had no rheological impact on basic bread dough (with no additional oxidative system), even though this level was found to lead to an increase of O₂ consumption by dough, especially at the beginning of mixing. The competition for O₂ consumption among yeast, LOX and GOX was decreased by kneading under a 30% O₂ atmosphere, enabling GOX to reveal its structuring effect. Finally, mixing bread dough containing GOX under O₂-enriched atmosphere enabled keeping a standard dough relaxation index, even though dough water content was increased. This opens new perspectives for improving bread softness.     

Differential mixing action effects on functional properties and polymeric protein size distribution of wheat dough

A micro Z-arm mixer and a 2g-Mixograph were used to compare the effect of pin and Z-arm-type mixing actions on mixing properties of wheat flour dough. Although the two mixing curves obtained with pin- and Z-arm-type mixing action showed a very similar mixing trace, no significant correlation was found between the two mixers other than the number of revolutions required for optimal dough consistency (peak resistance). Mixing requirement was described by a rate-independent parameter, the number of revolutions to peak dough development and was found to be greater in a Z-arm mixer than in a pin mixer. Mixing requirement showed significant correlation with stability, which is therefore a dough strength parameter. The change in the polymeric structure of gluten proteins of dough as indicated by %UPP (unextractable polymeric protein percentage) was monitored and showed a smaller decrease with Z-arm mixing than with pin mixing. Therefore, pin-mixing action is more energetic than Z-arm mixing. At peak resistance, Z-arm mixing gives a larger quantity of polymeric protein content in the dough relative to pin mixing. The degree of dough development at maximum resistance in the different mixers was shown to be different. A new parameter, delta-_UPPMZ${\mathrm{UPP}}_{\mathrm{MZ}}$ (the difference between %UPP of dough obtained with pin vs Z-arm mixing actions) was identified and proposed to have some relationship to the stability of the polymeric proteins in the dough.     

Rheological characteristics of native and steamed wheat flour suspensions

Several Indian snack foods consist of an outer coating made with a wheat flour batter and a sweet or savoury filling. In order to study the possibilities of improving the rheological characteristics of batters used in the batter-coated products, wheat flour was steamed for varying periods of time (5, 15 and 30 min). The studies indicated that SDS-sedimentation values decreased from 35 to 24·5 mL, gluten forming protein was completely denatured, gel mobility increased and solubility of gliadin in the β-region decreased with an increase in the steaming period.The steamed wheat flour was used to make batters having 30, 33 and 36% solids suspended in water. The apparent viscosities of the batter increased from 9·6 to 19·2 Pa·s; the yield stress increased from 5·3 to 7·15 Pa; the consistency index increased from 27·86 to 78·31 Pa·sⁿ. The maximum values of all three parameters were observed in the batter which had a solids concentration of 36%, and which had been made with a flour steamed for 30 min. On the other hand, the flow behaviour index decreased slightly with duration of steaming and with increasing solid concentrations in the batter.     

Fluorescence and NIR spectroscopic study on the water interaction in polycarbonate film

Water interactions in polycarbonate films have been studied using fluorescence and NIR Fourier transform spectroscopy. During water sorption process, the fluorescence emission spectra showed sensitive changes with the peak at 332 nm red shifted by 18 nm with water sorption. This red-shifted peak could be due to phenyl-2-phenoxybezoate, which is one of two major thermal degradation products in polycarbonate. In the spectra of phenyl-2-phenoxybenzoate in dimethyl formamide solution, a progressive red shift was also observed with the water addition. By using the NIR spectra, hydrogen-bonding interactions of the sorbed water with polycarbonate were investigated. It was found that water can be analyzed as free water S₀ or single hydrogen bonded water, S₁ while double hydrogen bonded water was negligible. During water immersion, most water species which are present as S₀ species decrease slightly, with a small increase in S₁ species. During desorption, S₀ species decrease sharply, while S1 species is reduced gradually. Two examples of S₁ structure in water-sorbed polycarbonate are proposed.     

Detection of low-level gluten content in flour and batter by near infrared reflectance spectroscopy (NIRS)

Near infrared spectroscopy (NIRS) has been used as a valuable tool for quality control in the food industry. The aim of the present study was to investigate the possibility of developing a NIRS calibration for gluten determination in flour and batter, suitable for the analysis of gluten-free food products. Reflectance data was used for calibration based on modified partial least squares (MPLS) regression. Independent prediction equations were developed for flour and for batter. Spectral models using mean spectra of two scans (average spectra), were compared with those using the two individual spectral data. The best model obtained for flour was using the average spectral data (R² = 0.985; r² = 0.967) and for batter samples was using the individual spectral data (R² = 0.926; r² = 0.825). It is concluded that the application of NIRS methodology can predict accurately the concentration of gluten content in flours and batters, but it should not be considered as a reliable method for determining gluten contamination in gluten-free products.     

Substrate selectivity and inhibitor sensitivity affect xylanase functionality in wheat flour gluten–starch separation

Addition of xylanases (EC 3.2.1.8) that varied in their substrate selectivities and/or wheat xylanase inhibitor sensitivities in dough batter gluten–starch separation of wheat flour showed the importance of these enzyme characteristics for their functionality in this process. A xylanase from Aspergillus aculeatus (XAA) with selectivity for hydrolysis of water extractable arabinoxylan (WE-AX), which is not inhibited by wheat flour xylanase inhibitors decreased batter viscosity and improved gluten agglomeration behaviour. In contrast, a xylanase from Bacillus subtilis (XBS_i) with selectivity for hydrolysis of water unextractable arabinoxylan (WU-AX), which is in vitro inhibited by wheat flour xylanase inhibitors had a negative effect on gluten agglomeration at low enzyme dosages. As expected, solubilisation of WU-AX increased batter viscosities. At higher dosages however, this enzyme also improved gluten agglomeration because of degradation of both WE-AX and enzymically solubilised AX. A mutated B. subtilis xylanase (XBS_ni) with selectivity for hydrolysis of WU-AX comparable to XBS_i but which is not inhibited by wheat flour xylanase inhibitors, increased the level of large gluten aggregates as well as the total gluten protein recovery, even at lower dosages. Because of its inhibitor insensitivity, the solubilisation and degradation of AX proceeded further. An XBS_ni dosage approximately 4 times lower than XBS_i performed as well as its inhibited counterpart. The degradation of both WE-AX and WU-AX by XBS_ni improved the gluten agglomeration behaviour to a larger extent than the XAA treatment which primarily resulted in hydrolysis of WE-AX. The results confirm the detrimental impact not only of WE-AX, but also of WU-AX, on gluten agglomeration in a dough batter gluten–starch separation process. At the same time, they provide firm evidence that xylanases are not only inhibited by xylanase inhibitors in vitro, but are also partly inhibited in the industrial process in which they are used.     

Non-invasive Monitoring of Dough Mixing by Near Infrared Spectroscopy

A novel, non-invasive method of monitoring dough development using a diode array near infrared spectrometer has been developed. The variation in two specific absorbance wavelengths in the second derivative spectrum (1160 nm and 1200 nm) as the dough is mixed is shown to follow the same trend as mixer power consumption. Both absorbance features show a reduction in peak area as dough mixing progresses, reaching a minimum at optimum dough development, and an increase as the dough mixing continues past peak mixer power consumption. Consistent results were obtained for un-yeasted and full formula doughs made from flours of different strengths using three different laboratory mixers of different mixing action (spiral, z-arm and pin). In the case of the z-arm and pin mixers, the NIR mixing curves predicted longer mixing times than the power consumption curves, and both methods differentiated between flours of different strength. The spiral mixer showed no statistical difference between the mixing times measured by each method, and further, there was no statistical difference between the mixing times for each flour when measured using either method. These differences may be due to mixer design or mixing intensity. The data presented shows the potential of the technique for providing information on the chemical processes that occur during dough development in relation to flour strength and mixing action and intensity. dough, near infrared, mixing, spectroscopy.     

Effects of composition on dough development and air entrainment in doughs made from gluten-starch blends

Gluten and starch are the two main ingredients of a wheat flour dough and it is expected that the extent of air occlusion into the dough would be affected by differences in their relative ratios. The objectives of this paper were to investigate the hydration and development of gluten and how these key events in dough mixing affected air occlusion in gluten-starch doughs. For gluten-starch doughs of the same gluten content, decreasing the water absorption shortened development time and decreased dough density. For formulations of the same water absorption, decreasing the gluten content prolonged the time to development and increased dough density, reflecting less net air entrainment into the dough. The ratios of gluten, starch and water strongly influenced the development of the dough into a good gas-holding material, with the extent of gas entrainment during mixing being evident in measurements of both dough consistency and dough development time.     

Mixing behaviour of a zero-developed dough compared to a flour–water mixture

The Z-blade mixing behaviour of zero-developed (ZD) doughs from the flours of two wheat cultivars of different gluten strength was compared to that of conventionally mixed dough made from the same flours. In farinograph experiments, use of ZD dough led to shorter development time (with less energy requirement), less stability time, and consequently earlier breakdown compared to conventional mixing of the corresponding flour–water mixture. Mixing of ZD doughs led to an almost similar decrease of glutenin macro-polymer (GMP) wet weight as that of doughs prepared from flour–water mixtures. However, comparison of wet weight of re-assembled GMP revealed that until time-to-peak (TTP) mixing, there was no difference in GMP recovery with respect to the starting material used in the z-blade mixing experiments. Beyond TTP, recovery of GMP in doughs prepared from both starting materials was reduced. The results of large-strain deformation rheology showed strong visco-elastic behaviour as characterised by the highest values of fracture properties (except ε_H), followed by a decline in those properties upon further mixing for doughs mixed from both flour–water mixture and ZD dough from both types of wheat cultivars. It was concluded that at mixing regimes before TTP, there was no difference between ZD doughs and flour–water mixtures in the mixer. When ZD dough is used as a starting material for dough preparation instead of flour, extra care should be taken not to over-mix the developing dough.     

Xylanase Induced Changes to Water- and Alkali-Extractable Arabinoxylans in Wheat Flour: Their Role in Lowering Batter Viscosity

The effect on the viscosity of wheat flour batter following treatments with a crude pentosanase-containing enzyme preparation and an endo-xylanase purified from the same preparation, was studied in relation to changes to the chemical features of the water- and Ba(OH)₂-extractable arabinoxylan fractions. Addition to batter of the crude enzyme or the pure xylanase caused a consistent and identical decrease in batter viscosity, demonstrating that the viscosity change was caused by the selective action of the xylanase in the crude enzyme preparation. The lowering of batter viscosity upon addition of enzyme was attributed to partial hydrolysis of the arabinoxylans in the water-extractable fraction which lead to an increase in the proportion of lower molecular weight water-extractable arabinoxylans possessing an increased xylose/arabinose ratio. There was no detectable change in the monosaccharide composition of either the water- or Ba(OH)₂-extractable arabinoxylan fraction after enzyme treatment and no indication of any increase in the amount of the water-extractable arabinoxylan fraction at the expense of the Ba(OH)₂-extractable fraction. It is concluded that the xylanase can extensively degrade arabinoxylan to small oligosaccharides in vitro. However, such degradation does not take place in situ, in the enzyme treated batters, where only a very small shift in the molecular weight profile of the water-extractable arabinoxylans was necessary to effect major changes to batter viscosity.     

Muffins with resistant starch: Baking performance in relation to the rheological properties of the batter

The effect on baked muffins of progressively replacing wheat flour with resistant starch (RS) was studied. Muffin volume and height and the number and area of gas cells decreased significantly when the RS level reached about 15% (by weight of total formulation) or higher. Rheological properties of the raw batters were studied: the mechanical spectra of batters at 25 °C, the evolution of the dynamic moduli (G′ and G″) with rising temperatures (from 25 to 85 °C) and the mechanical spectra at 85 °C were obtained from oscillatory rheological tests. The decrease in the viscosity and in the elastic properties of the muffin batter as the flour was increasingly replaced by RS was related to the baking performance of the final baked products.     

Effect of arabinoxylans and laccase on batter rheology and quality of yeast-leavened gluten-free breads

The supplementation effects of maize fiber arabinoxylans (MFAX, 0%–6%), laccase (0–2 U/g flour) and water absorption level (90%–100%) on gluten-free (GF) batter rheology and bread quality were analyzed. From viscoamylograph analysis, lower starch amount in GF flour due to MFAX addition decreased peak viscosity and retrogradation. Surface response plots showed that laccase did not have significant effect on GF batter rheology and bread quality, whilst water was the most important variable. Higher levels of water absorption benefited bread texture. Higher water level (>100 mL/100 g flour) was needed in the experimental design to evaluate correctly the effect of 6% MFAX replacement on GF bread quality. Further analyses were carried in order to adjust water absorption of batters according to their consistency index (K ≈ 100 Pa sⁿ), resulting an optimal water absorptions of 95%, 100% and 105% for control flour and flours supplemented with 3% or 6% MFAX, respectively. Thus, MFAX addition enhanced water-binding capacity of flour and yielded GF breads with higher specific volume and softer crumb texture. These quality parameters were best rated with 6% MFAX addition to flours. This research demonstrated the potential of MFAX to develop GF breads with improved quality, when optimal water level is used.     

Influence of process parameters on yield and composition of gluten fractions obtained in a laboratory scale dough batter procedure

The influence of process parameters during the dough formation step on wheat flour gluten agglomeration and composition in a laboratory scale gluten–starch separation process was studied. In the process, in which a dough was transformed into a batter then poured over a set of vibrating sieves (400, 250 and 125 μm), increasing water contents, mixing times and speeds during dough development all had a positive effect on gluten agglomeration as indicated by an increased gluten protein recovery on the 400 μm sieve. This showed the importance of optimal gluten hydration and development at the dough making stage of the process. The total level of gluten recovered on the three sieves was not affected significantly by the variables. Changes in gluten agglomeration behaviour coincided with changes in the carbohydrate composition of the gluten fractions. When the gluten protein recovery on the 400 μm sieve increased, the arabinose and xylose contents of the fractions decreased, while the starch content increased.