The technology of wafers and waffles II : recipes, product development and knowhow

427 Pages·2019·11.051 MB·English

by  Tiefenbacher, Karl F

THE TECHNOLOGY OF WAFERS
AND WAFFLES II
THE TECHNOLOGY OF WAFERS
AND WAFFLES II
Recipes, Product Development and Know-how
Edited by
KARL F. TIEFENBACHER
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DEDICATION
To Barbara Elisabeth and my family, a permanent source of inspiration.
PREFACE
Knowledgerestsnotupontruthalone,butuponerroralso.
CarlGustavJung(1875–1961)SwissPsychoanalyst
Informationisacquiredbybeingtold,whereasknowledgecanbeacquiredbythinking.
FritzMachlup(1902–1983)Austrian-AmericanEconomist
Recipes and recipe calculations are important in product development. The book
introducescalculationtoolsforwaferandwafflerecipesandshowstheintegrationofboth
new and established ingredients within the various sets of basic recipes. Proposals for
ingredientselectionandthedesignofmanufacturingplantsareincluded.Technological
ideasandexamplesfromapplyingtheprinciplesofmodernfoodscienceandtechnology
in wafers and waffles can be inspiring for creating new products and business
opportunities.
Karl F. Tiefenbacher
Absam, Austria – August 15, 2018
xi
CHAPTERONE
Introduction and Overview
1.1 WHAT TO EXPECT—WHY THIS BOOK?
1.1.1 Recipes are Confidential
Plenty of books on recipes exist for household and artisan baking. In industrial
manufacturing,however,thelevelofcompetitivenessandthespecializationleavealmost
nospacetobringsuchsensitiveknowhowtopublicawareness.Certainly,aswewillsee
in Chapter 9 of this book, some of the patents or publications from local consultants
release recipe information, at times in a very balanced manner. In both cases, these
are discrete experiences, developed for a certain manufacturing situation.
First, we have to consider some cornerstones of modern industrial recipes for wafer
and waffle manufacturing:
1. The value of single recipes for transferring to another place, even within the same
company, is rather limited (see Section 1.1.3 for details on that)
2. Contemporary food labelling requirements result in a high degree of transparency
regarding components, their relative proportions, and the content of the single
nutrients.
3. Theworkofconsultantsandthedetailedrecipesoftheircustomershavetobeabso-
lutely confidential.
4. Therelevanceofrecipesisgreatlyoverestimated;muchmoreimportantistheknow-
howtocreateagoodresultandadedicatednewrecipefromagivensetofconditions.
So, did you expect too much when buying this book? I think not, as you might learn
about structuring a recipe, adapting it to your local conditions, and how to increase
the stability of the baking operation. In addition you get suggestions for your develop-
ment work. Recipe evaluation and intentional modification are the main ways to
improveanddevelopfurther.Thebookwillbeasingle,valuabletooltoachievethataim.
Spreading general knowledge can encourage further progress and help to improve
efficiency. I will never forget when the head of production in an established factory
for sugar wafers told me: “All of my working life I have spent making these wafers
andIwasveryscepticalwhena‘professor’cameandwantedtotellmeaboutit.However,
since I modified two points in our recipe and process according to your recommenda-
tions, it works better and is more reliable.”
TheTechnologyofWafersandWafflesII ©2019ElsevierInc.
1
https://doi.org/10.1016/B978-0-12-809437-2.00001-0 Allrightsreserved.
2 TheTechnologyofWafersandWafflesII
1.1.2 My Approach to Recipes
Mypersonalcareerdidnotstartinamanufacturingcompanyforwafersorwaffleslearn-
ingthingsfromscratch.Comingfromthefieldofuniversityfoodchemistry,science,and
technology, after years of food technological R&D work, I joined a wafer and waffle
equipmentcompanyforaninterestingtask.Theywantedtobuildtechnologicalknow-
how on the processes and products. I still remember the statement: “Our equipment
works well in countries A, B, C, however in country D there is a complete failure
and we assume the flour is responsible for it.”
Thewhyandwhattodoinsuchacaseandotherskeptmeandmylaterteambusyfor
almost30years.Thousandsofrecipetests,firstonsmalllabtestequipment,followedby
industrial test baking were needed to get some insights. Our work included:
(cid:129) howtheingredients,suchasflour,water,andallthepotentialsmallingredients,react
and may be changed, be applied or not, to resolve the various issues
(cid:129) whatistheroleoftechnicalprovisionsandadjustmentsforimprovingtheresultand
what can be done through technological changes
(cid:129) thatthemostimportantaspectoftroubleshootingistodistinguishwhatisrequiredand
howtotakethefirststepifthecustomerisalreadysittingonapileofwasteproducts
(cid:129) howtheinclusionofnewingredientsandtechnicaldevelopmentspavesthewayfor-
ward(Istillrememberthefirsttestsofnew‘waferenzymes’Ihadfromthedeveloper
in1989onourlabequipment.Todaytheyarestandardinmanyrecipesworldwide)
AsaresultofallthisworkIdaredtowriteabookonbasicrecipesforwafersandwaffles
and their fillings.
1.1.3 The Corner Stones of Recipe Development
Acertainrecipeisnottransferableeasily.Ithastoworkforthelocallygivensetofcon-
ditions in aspects such as the following:
1. Ingredients.Thelocalqualityandavailabilityarecritical.Themaininfluencehere
comesfromthepropertiesofthemainingredients,flourandwater.Thereforetech-
nological adaptions are required to counteract any issues to finally obtain the ‘same’
result. Another example is the type and local costing of filling cream ingredients if
sweetness reduction is a target.
2. Theequipmentsituation.Thesizeofthebakingoven,thebakingplatereedings,the
conditionofthebakingmoulds,aswellasotherequipmentparts,arefrequentlydifferent
fromplacetoplace–allareparametersofimportancetotheresultingwaferquality.
3. The manufacturing ambience. Never underestimate the influence of ambient
conditionssuchastemperature,humidity,orlocationandoftheeducationandmoti-
vationofoperatorsontheperformanceandefficiencyofmanufacturing.Themaking,
for example, of European high quality wafers in places of high temperature and
humidity can be a challenge on its own.
IntroductionandOverview 3
4. Consumers’preferences.Theperceptionofconsumersonthe‘right’waferorwaf-
fle quality differs from country to country. Is it the texture, the sweetness, or the
‘right’ character of a vanilla or chocolate flavour? Do you and your marketing
team know?
1.1.4 Basic Recipes—What Does That Mean?
IntherecipesinChapters3–7ofthebook,Itrytooutlinetherangeofingredientsaswell
astheirtypicalratiosapplicableforacertaintypeofwaferbiscuit,waffle,orcreamfilling.
The intentions are:
(cid:129) todisseminatebasicinformation,althoughthiswillrequiresomefinetuningforyour
factory
(cid:129) to avoid any reticence for changes in case of recurring issues
(cid:129) to motivate changes and new product development (NPD) in order to develop the
market further
(cid:129) to provide a reference book of recipes.
Allthebatteranddoughrecipesarepresentedinbakers’percentages(bakers’maths;flour
basis). Compared with the percentage format, the advantages are:
(cid:129) smallchangesinrecipewaterasfrequentlyrequireddonotchangethepercentageof
all other components
(cid:129) the comparability of recipes improves—transferring to different batch sizes is easy
(cid:129) flouristheprincipalsolidingredientbyfar,thusrecipedetailssuchasthesweetnessor
saltiness become clearly visible.
1.1.5 Today a Lot of Information is Public
Whenanalysingtoday’sfoodlabels,alotofinformationonrecipescanbegained.Since
2014,theEUregulationsontheprovisionoffoodinformationtoconsumershasbeenin
force.Here,theinformationonfoodlabelsregardingingredientsandnutrientshasbeen
expanded. For the United States, the ingredient list and the nutrition facts label offers
additional information (links retrieved August 2018):
https://eur-lex.europa.eu/legal-content/EN/TXT/PDF/?uri¼CELEX:32011R1169&
from¼EN
https://www.fda.gov/downloads/food/labelingnutrition/ucm511646.pdf
https://www.fda.gov/downloads/Food/GuidanceRegulation/GuidanceDocuments
RegulatoryInformation/UCM265446.pdf
The labellingofingredientshasto bein descendingorder.Incombinationwith the
nutrientdataformanysinglewaferandwaffleproducts,alotofinformationontherecipe
can be deduced.
1.1.6 Who This Second Book Is Written for
Recipeselectionandmodificationisoneofthemainwaystoimproveanddevelopinthe
bakingindustry.Thesecondbookwillbeofinteresttovariouspeoplewithincompanies:
4 TheTechnologyofWafersandWafflesII
owners, technologists, quality assurance staff, operators as well as for food scientists in
general.Untilnow,areferenceworkonthesesubjectshasbeenmissingfromthemarket.
Furtherinterestcouldcomefromlibrariesandacademicsinfoodandbakeryscienceand
technology.
1.2 HOW TO EVALUATE A RECIPE—THE CALCULATION MATRIX
TABLES (CHAPTER 2)
In product development for the following up of recipes, common calculation
programmesareusedwidely.However,muchmoreinformationcanbeextractedwhen
combingthepuredocumentationofrecipesandtotestresultswithsomeingredientdata
input and calculations added on.
1.2.1 Extracting Much More Data Linked to the Recipes
Whenusingpubliclyavailablefoodcompositiondatabases,activelymanagedindifferent
countries, the most important nutrient data can be combined with the recipe figures.
Theninafirstapproximation,valueslaterimportanttolabellingareobtainedeasily,such
astheenergycontentandthevaluesonmoisture,fat,protein,carbohydrates,minerals,or
fibre, to pick out the most interesting. Such an overview in a ‘calculation matrix table’
makeslifeeasierandmoreinformativeinNPD,andthisisapplicableforbatters,doughs,
andfillingsaswellasforfinishedwaferbiscuits,forexample.Thecalculationofthemain
nutrients,developedwithinasinglepageExcelsheet,helpstomaintainnutrienttargets
from the beginning of a NPD process.
Furtheroptionsaretoextractdatafromthereforestimatingtheoutputandcostingif
the basic parameters for that are backed up.
1.2.2 Some Examples of Calculation Tables
Chapter2ofthebookhasinformationonandexamplesofcalculationmatrixtables.Cal-
culationtablesforthe‘bigseven’nutrientsinEUfoodlabellingforthedifferentwaferand
wafflebatters,andforfillingcreams,doneonExcelsheets,arepresented.Thenafollow
upofnutritionaldatatocontroltheresultsinrecipedevelopmentcanbedoneaccording
to your personal preferences and needs.
Inthissecondchapter,theuseofrecipematricesisshown,developedheretogetan
immediate, initial, however already quite precise estimation of various nutritional data
such as energy content, the percentages of fat, protein, carbohydrates, minerals, fibre
and the moisture content in tabular form.
1.2.3 Differences in Nutrition Labels Between Europe and North America
DuetopersistentdifferencesinnutrientcalculationandlabellingbetweenNorthAmerica
and the European Union, the columns and data sets have to be organized differently