Formulating for sustainability

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Formulating for sustainability

25 Oct 2023

Joanie Spencer

Since 2008, Joanie Spencer has covered the retail and wholesale sides of the baking industry.
Serving associations such as the American Society of Baking (ASB) and BEMA, Joanie is also in demand as an industry presenter on bakery operations and trends. She holds a bachelor’s degree in communication from Rockhurst University and a master’s degree in journalism from the University of Missouri.

When she’s not running or playing soccer, Joanie spends her time with her husband and 11-year-old son.

MUNICH — Sustainability can be a highly subjective term, and its interpretation will drive how a baking company operates. It’s about more than just the environment; it’s also a matter of economics and how companies can sustainably carry their businesses into the future.

At its root, though, sustainability requires bakers to rethink how they make their products.

At iba, taking place October 22-26 in Munich, Steven Anderson, bakery applications manager for Lallemand Baking, discussed how enzyme technology can impact sustainability in areas such as water reduction and shorter bake times.

“Looking at fluctuating prices for energy and raw materials, they’re rising, and they’re volatile,” Anderson said. “So, how can we apply our microorganisms and enzymes to help address this?”

Lallemand has introduced BTR, an enzyme-based dough solution that can optimize dough for reduced bake time, which increases throughput while potentially reducing the bakery’s carbon footprint.

The solution is a two-pronged approach that starts with a proprietary enzyme-based blend formulated to reduce both overdosing of certain ingredients and reliance on ingredients that are not label-friendly.

“It challenges you to look at dosage levels,” Anderson said. “How concentrated can you go?”

Reducing that dosage means using fewer raw materials and, subsequently, making a smaller impact in areas like shipping and storage.

During the presentation, Anderson shared case studies in which BTR was used in the production of par-baked crusty rolls; pan bread; high-top sandwich bread; Danish high-top sandwich bread; artisan baguettes; mixed-wheat bread (30% rye); and rusks, breadcrumbs and croutons.

In these applications, adding the enzyme solution allowed bakers to reduce water usage in the formula. Typically, that would send up a red flag in terms of dough rheology and the impact on throughput. But with extensive testing and R&D, the Lallemand team dialed in the enzyme to essentially solve for the rheology, which reduces the impact on yield.

At its root, sustainability requires bakers to rethink how they make their products.

“When we add the enzyme solution, the water is no longer being absorbed someplace but is available in another,” Anderson said. “If we take out that water, then it will reduce the bake time because we haven’t got as much water to drive off of the dough.”

When the water is not being driven out of the dough, Anderson explained, the product is not losing weight, which means production can be scaled.

“At worst, the yield stays the same,” he said. “But more often, you can get a few extra rolls or loaves out of your dough.”

The case studies represented a reduced bake time from 15 minutes to 10 minutes for crusty rolls; 19 minutes to 17 minutes for pan bread; 35 minutes to 25 minutes for high-top sandwich bread; 32 minutes to 27 minutes for Danish high-top sandwich bread; 22 minutes to 18 minutes for fresh artisan baguettes; 24 minutes to 19 minutes for retarded dough; 45 minutes to 30 minutes for mixed-wheat bread; and no change in bake time for rusks, breadcrumbs and croutons.

Another critical component is ensuring these reductions do not impact product quality, which required Lallemand to conduct extensive testing. For example, with Danish high-top sandwich bread, the team conducted panel tests with a customer, as well as tests for moisture content, water activity and shelf life impact.

“Softness is a big thing we always make sure is in line,” Anderson said. “But we also look for shelf life because that is really important as well.”

Regardless of product type, the biggest concern comes down to yield. It’s an area in which Lallemand has placed a heavy emphasis.

“When we’re taking water out, a baker will immediately think of yield,” Anderson said. “But we’re reducing the scale weight each time, so it doesn’t lose yield. In fact, once you reduce the bake time and get that optimized, you can get more loaves out. You’re putting in less water and lowering the hydration. You’re baking less because there’s less water to drive off, so your end product is the same in terms of softness and water content.”

For more information, visit the Lallemand website.

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