ENZYMES in TORTILLAS and FLAT BREADS Dilek Austin, Ph.D. Baking - - PowerPoint PPT Presentation

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

pH

Temperature

Contact time Water Enzyme dosage Substrate Stabilizers Inhibitors Oxygen

pH effect Temperature effect

Important process parameters for enzymes

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

Enzymes

Alpha-amylase

Ingredient reduction/replacement

L-cystein/SMS 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

Alpha-amylase No enzyme

Novozymes internal data

Novozymes NEW ALPHA-AMYLASE

• INCREASING dosages INCREASES extensibility

Novozymes internal data

4 weeks

45 70 74 76 20 40 60 80 100 without enzyme 225 ppm Alpha- amylase 315 ppm Alpha- amylase 410 ppm Alpha- amylase %extensibility maintenance

Four week-old flour tortillas % maintained mechanical extensibility compared to freshly baked

Equipment: TA.XT2-Tortilla Burst Rig

Novozymes NEW enzyme makes tortillas STRONGER and MORE EXTENSIBLE at four week-storage

• 100
• 50

50 100 150 200 250 300 350 400 10 20 30 40 50

Force

4 weeks

Time/sec

New enzyme No enzyme

Novozymes internal data

Strong and more extensible Breaks easily, not extensible

Alpha-amylase maintains high rollability scores during four-week storage

5 4.2 3.4 2.5 2.1 1.5 5 5 5 4.6 4.5 4.5 1.0 2.0 3.0 4.0 5.0 1 3 7 14 21 28 Rollability scores (1 to 5) Storage days without enzymes Alpha-amylase Flexible NOT flexible

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

4 weeks

Four-week old tortillas INCREASING dosages INCREASES FLEXIBILITY

3.7 4.5 4.8 5.0 1.0 2.0 3.0 4.0 5.0 without enzyme 150 ppm Alpha- amylase 250 ppm Alpha- amylase 350 ppm Alpha- amylase Rollability scores (1-5)

Novozymes internal data

4 weeks

NOT flexible Flexible

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

Maintenance of softness and flexibility of tortillas Reduction of masa stickiness Processing ease

Enzymes

Alpha-amylase Lipase

CORN tortillas

​Ten day-old tortillas ​With enzymes: Flexible, no cracking ​Without enzymes: undesirable cracks

Two-week old corn tortillas

​Maltogenic amylase improves corn tortilla strength during storage ​Maltogenic amylase help to decrease the CMC in the formula ​

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)

Stronger

762.2 899.5 500 700 900 40 ppm Alpha-amylase 40 ppm Alpha-amylase day 5 day 11

Force to break the tortilla with Texture Analyzer

1.2 2.3 2.3 1.0 2.0 3.0 4.0 5.0

without enzyme 0.5% CMC 0.25% CMC+30 ppm Alpha-amylase

Rollability scores (1-5) at room temperature

Masa dough

​Less sticky and softer corn masa obtained with an Alpha-amylase and a Lipase

Sticky dough Non- sticky dough 50 30 40 40 35 20 40 60 80 100

without enzyme 20 ppm Alpha- amylase 40 ppm Alpha- amylase 20 ppm Lipase 40 ppm Lipase

Dough stickiness (g)

Hard dough Soft dough

Novozymes internal data-Equipment: TA.XT2

75 61 70 20 40 60 80 100 without enzyme 20 ppm Alpha-amylase 40 ppm Lipase

Firmness (g force)

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

Maintenance of softness and flexibility of flat breads Bacterial alpha-amylase Lipases

Enzymes

Alpha-amylase Lipases

Alpha-amylase maintains and improves flat bread softness for three days

Very flexible Breaks 5 6.2 6.8 5 7.2 8.3 1 3 5 7 9 without enzyme 5 ppm Alpha-amylase 10 ppm Alpha-amylase Day 1 Day 3

Novozymes internal data

Softer Firmer Softer Firmer

A Lipase makes softer Naan dough; softer final product at four-hour after baking

Novozymes internal data

5 8 2 4 6 8 10 without enzyme 250 ppm Lipase

Naan dough softness

100 128 20 40 60 80 100 120 140 without enzyme 250 ppm Lipase Naan instrumental softness (% softness compare to without enzyme)

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 Firmer Softer Firmer 5 7 2 4 6 8 10 no enzymes 250 ppm Lipase 100 122 20 40 60 80 100 120 140 no enzymes 250 ppm Lipase

Novozymes internal data

Chapatti made with a Lipase showed excellent dough property and better softness

546 585 393 391 100 200 300 400 500 600 700 30 min after baking 3 hrs after baking no enzymes 250 ppm lipase

Firmer Softer

Novozymes internal data

Enzymes are natural

​Enzymes can ​Maintain freshly baked quality

• f tortillas/flat breads

​Improve dough handling and machinability Enhance mixing tolerance ​Replace/reduce chemicals

http://www.aaccnet.org/publications/store/pages/27885.aspx

A good source for enzymes and tortillas