Proofer and process for producing extended shelf life yeast-raised baked goods and extended shelf life yeast-raised baked goods

Abstract

A proofer is disclosed for making yeast-raised baked goods having an extended shelf life. The proofer includes a proofing chamber in which heat, humidity, and airflow are more uniform. A process is provided for proofing the raw dough to provide an extended shelf life yeast-raised product. Additionally, an extended shelf life product is provided.

We claim:  
     
         1 . A proofer for making yeast-raised baked goods having an extended shelf life, the proofer comprising: 
 an insulated housing having a sealable door therein;    a proofing chamber within the housing sized to received a rack for holding a raw dough product;    a controller;    a dehumidifying device located within the housing on an airflow path and in communication with the controller;    a heat source located within the housing on the airflow path and in communication with the controller;    a humidifying device located within the housing on the airflow path and in communication with the controller,    an air circulator located within the housing in a position to direct air on the airflow path into the proofing chamber, the air circulator in communication with the controller; and    at least one sensor comprising a relative humidity sensor or a temperature sensor located within the proofing chamber, the at least one sensor in communication with the controller, the controller operative to control the dehumidifying device, the heat source, and the humidifying device to condition the air to proof the raw dough product.    
     
     
         2 . The proofer of  claim 1 , wherein the sensor is located on an inside surface of the sealable door.  
     
     
         3 . The proofer of  claim 1 , wherein the sensor is located at a midpoint on an inside surface of the sealable door.  
     
     
         4 . The proofer of  claim 1 , wherein the sensor is located on an inside rear surface within the proofing chamber.  
     
     
         5 . The proofer of  claim 1 , wherein the sensor is located at a midpoint on an inside rear surface within the proofing chamber.  
     
     
         6 . The proofer of  claim 1 , wherein the sensor is mounted on an arm extending from an inside rear surface within the proofing chamber.  
     
     
         7 . The proofer of  claim 1 , wherein the sensor is mounted in a protective housing.  
     
     
         8 . The proofer of  claim 1 , wherein the sensor comprises a temperature sensor.  
     
     
         9 . The proofer of  claim 8 , wherein the temperature sensor has an accuracy of ±1° F.  
     
     
         10 . The proofer of  claim 1 , wherein the sensor comprises a relative humidity sensor.  
     
     
         11 . The proofer of  claim 10 , wherein the relative humidity sensor has a 15 second response time for a 90% change in relative humidity.  
     
     
         12 . The proofer of  claim 10 , wherein the relative humidity sensor has an accuracy of at least ±2%.  
     
     
         13 . The proofer of  claim 1 , further comprising a second sensor comprising a relative humidity sensor or a temperature sensor.  
     
     
         14 . The proofer of  claim 13 , wherein the at least one sensor is located on an inside surface of the sealable door and the second sensor is located on an inside rear surface within the proofing chamber.  
     
     
         15 . The proofer of  claim 13 , wherein the at least one sensor comprises a relative humidity sensor and the second sensor comprises a temperature sensor.  
     
     
         16 . The proofer of  claim 15 , wherein the relative humidity sensor and the temperature sensor are located on an inside surface of the sealable door.  
     
     
         17 . The proofer of  claim 13 , further comprising a third sensor located on an inside rear surface within the proofing chamber.  
     
     
         18 . A proofer for making yeast-raised baked goods having an extended shelf life, the proofer comprising: 
 an insulated housing having a sealable door therein;    a proofing chamber within the housing sized to received a rack for holding a raw dough product;    a controller;    at least one component located within the housing on an airflow path and in communication with the controller to provide an airflow conditioned for proofing the raw dough product, the at least one component comprising a dehumidifier, a heating unit, or a humidifier, the at least one component operative to return to a desired set point within no more than fifteen minutes after unsealing a preheated proofing chamber; and    an air circulator located within the housing in a position to direct air on the airflow path into the proofing chamber, the air circulator in communication with the controller.    
     
     
         19 . The proofer of  claim 18 , wherein the at least one component comprises a dehumidifier and the set point comprises a relative humidity.  
     
     
         20 . The proofer of  claim 18 , wherein the at least one component comprises a humidifier and the set point comprises a relative humidity.  
     
     
         21 . The proofer of  claim 18 , wherein the at least one component comprises a heating unit and the set point comprises a temperature.  
     
     
         22 . The proofer of  claim 18 , wherein the controller includes a deadband adjustable to provide a desired tolerance on the set point while maximizing efficiency of the at least one component.  
     
     
         23 . A proofer for making yeast-raised baked goods having an extended shelf life, the proofer comprising: 
 an insulated housing having a rear wall, side walls, and a front sealable door therein;    a proofing chamber within the housing sized to received a rack for holding a raw dough product;    a controller;    at least one component located within the housing on an airflow path and in communication with the controller to provide an airflow conditioned for proofing the raw dough product, the at least one component comprising a dehumidifier, a heating unit, or a humidifier;    an air circulator located within the housing in a position to direct air on the airflow path into the proofing chamber, the air circulator in communication with the controller; and    a rear partition disposed in the proofing chamber and spaced from the rear wall, and an airflow chamber defined between the rear partition and the rear wall, the rear partition comprising two side panels, each side panel including a plurality of openings disposed therein in at least two vertical columns.    
     
     
         24 . The proofer of  claim 23 , wherein the openings are approximately 0.5 inch long and 0.25 inch high.  
     
     
         25 . The proofer of  claim 23 , wherein each of the side panels includes a pair of inwardly facing vertical louvers.  
     
     
         26 . The proofer of  claim 25 , wherein one of the louvers of the pair of louvers is directed at 90° to the plane of the rear partition and the other of the pair of louvers is directed at 45° to the plane of the rear partition.  
     
     
         27 . The proofer of  claim 25 , further comprising a plurality of vertical slots disposed in the side panel adjacent the louvers.  
     
     
         28 . The proofer of  claim 27 , wherein the slots are approximately 4.25 inches long.  
     
     
         29 . The proofer of  claim 27 , wherein pairs of the slots are vertically spaced by approximately 1.5 inches.  
     
     
         30 . The proofer of  claim 27 , wherein pairs of the opening are vertically aligned with respect to the pairs of the slots.  
     
     
         31 . A proofer for making yeast-raised baked goods having an extended shelf life, the proofer comprising: 
 an insulated housing having a sealable door therein;    a proofing chamber within the housing sized to receive a rack for holding a raw dough product;    a controller and at least one component in communication with the controller to provide an airflow conditioned for proofing the raw dough product; and    a rack positioning device within the proofing chamber disposed to contact the rack and fix the rack in a desired position within the proofing chamber upon closure of the sealable door.    
     
     
         32 . The proofer of  claim 31 , wherein the rack positioning device comprises a strip mounted along a rear surface of the proofing chamber in a position to limit travel of the rack toward the rear surface.  
     
     
         33 . The proofer of  claim 31 , wherein the rack positioning device comprises a strip mounted along a side surface of the proofing chamber in a position to limit sideways travel of the rack toward the side surface.  
     
     
         34 . The proofer of  claim 31 , wherein the rack positioning device comprises strips mounted along side surfaces of the proofing chamber in positions to limit sideways travel of the rack toward the side surfaces.  
     
     
         35 . The proofer of  claim 31 , wherein the rack positioning device comprises a rear strip mounted along a rear surface of the proofing chamber in a position to limit travel of the rack toward the rear surface and side strips mounted along side surfaces of the proofing chamber in positions to limit sideways travel of the rack toward the side surfaces.  
     
     
         36 . The proofer of  claim 31 , wherein the rack positioning device comprises angled strips mounted inside the proofing chamber to receive corners of the rack in snug engagement.  
     
     
         37 . The proofer of  claim 31 , wherein the rack positioning device comprises a first strip mounted within the proofing chamber to limit rearward movement of the rack, and a further strip mounted on an inside surface of the sealable door in a location to press the rack against the first strip.  
     
     
         38 . A baker's rack for holding raw dough to be proofed within a proofing chamber, the baker's rack comprising: 
 a wheeled frame including vertical bars disposed to define four corners of the frame; and    a plurality of tiers of pairs of horizontal members extending between pairs of the vertical bars along two opposed sides, each horizontal member including inwardly extending screen holding shoulders, horizontally opposed pairs of screen holding shoulders disposed to receive screens thereon;    wherein the screen holding shoulders having a vertical spacing therebetween of at least 82 mm.    
     
     
         39 . The baker's rack of  claim 38 , further comprising 17 tiers of horizontal members.  
     
     
         40 . The baker's rack of  claim 38 , further comprising a top cover disposed to cover the horizontal top of the baker's rack.  
     
     
         41 . The baker's rack of  claim 38 , further comprising a bottom cover disposed to cover the horizontal bottom of the baker's rack.  
     
     
         42 . A process for making yeast-raised baked goods having an extended shelf life, the process comprising: 
 providing a dough of mixed dry ingredients and at least one liquid ingredient, the dough at 85° F. ±3° F., the dry ingredients including yeast;    letting the dough rest for 45 minutes;    forming the dough into desired shapes;    proofing the dough; and    baking the dough to produce a final baked good.    
     
     
         43 . The process of  claim 42 , wherein the providing step comprises: 
 bringing the at least one liquid ingredient to a predetermined temperature prior to adding the at least one liquid ingredient to the dry ingredients, wherein the appropriate temperature is determined by the formula:      T   liquid   =T   control −( T   room   +T   mix   +T   ff )    where:    T liquid  is the predetermined temperature of the at least one liquid ingredient prior to mixing with the dry ingredients,    T control  is a predetermined temperature control factor,    T room  is the room or ambient temperature,    T mix  is the temperature of the dry ingredients prior to the addition of the at least one liquid ingredient, and    T ff  is a predetermined friction factor based on a mixer used to mix the at least one liquid ingredient and the dry ingredients.    
     
     
         44 . The process of  claim 43 , wherein T contol  is 255° F.  
     
     
         45 . The process of  claim 43 , wherein T ff  is 45° F.  
     
     
         46 . The process of  claim 43 , wherein the at least one liquid ingredient comprises water and the providing step comprises bringing the water to a predetermined temperature prior to adding the water to the dry ingredients.  
     
     
         47 . The process of  claim 42 , further comprising the step of loading the desired shapes of the formed dough onto a baker's rack.  
     
     
         48 . The process of  claim 47 , wherein the desired shapes of the formed dough are loaded onto the baker's rack from a center tier outwardly alternately toward the top and bottom.  
     
     
         49 . The process of  claim 42 , wherein the proofing step further comprises sealing the formed dough in a proofer for the duration of the proofing cycle.  
     
     
         50 . The process of  claim 42 , wherein the step of letting the dough rest further comprises letting the dough rest until it passes a crease test.  
     
     
         51 . The process of  claim 42 , wherein the step of forming the dough further comprises: 
 rolling the dough into a sheet;    shrinking the dough; and    cutting the dough into the desired shapes.    
     
     
         52 . A formulation of dry ingredients for a yeast-raised baked good having an extended shelf life, the dry ingredients comprising: 
 at least 74 weight % flour;      6 .5-9 weight % dextrose;      6 -8 weight % soybean oil    0.75-1.25 weight % nonfat dry milk or milk replacement;    0.04-0.06 weight % yeast flavor;    0.2-0.4 weight % blend of gums;    0.5-1.0 weight % vital wheat gluten    0.1-0.4 weight % distilled monoglycerides    0.6-1.0 weight % blend of enzymes;    0.06-0.18 weight % konjac flour; and    0.1-0.4 weight % methylcellulose.    
     
     
         53 . The formulation of  claim 52 , further comprising: 
 60.5 weight % hard wheat flour;    17.33 weight % soft wheat flour    8.55 weight % dextrose;    6.6 weight % soybean oil    1.0 weight % nonfat dry milk or milk replacement;    0.05 weight % yeast flavor;    0.25 weight % blend of gums;    0.5 weight % vital wheat gluten    0.1 weight % distilled monoglycerides    0.6 weight % blend of enzymes;    0.08 weight % konjac flour; and    0.18 weight % methylcellulose.    
     
     
         54 . The formulation of  claim 52 , wherein the yeast flavor comprises a spray dried beer flavor.  
     
     
         55 . The formulation of  claim 52 , wherein the enzyme blend includes novo maltogenic amylase and novo xylanase.  
     
     
         56 . The formulation of  claim 52 , wherein the enzyme blend comprises 7.59 weight % enzymes.  
     
     
         57 . The formulation of  claim 52 , wherein the gum blend includes cellulose gum, guar gum, carrageenan, gum acacia, or xanthan, or a combination of cellulose gum, guar gum, carrageenan, gum acacia, and xanthan.  
     
     
         58 . The formulation of  claim 52 , further comprising: 
 1-2 weight % salt;    0.1 weight % color;    0.5-0.9 weight % sodium acid pyrophosphate;    0.6-1.4 weight % soy flour;    0.25-0.4 weight % vanilla flavor; and    0.01 weight percent I-cysteine.    
     
     
         59 . A dough comprising the formulation of  claim 52  and further comprising: 
 yeast at a ratio of approximately 4% of the weight of the dry ingredients; and  
 water at a ratio of 43-46% of the weight of the dry ingredients.  
 
     
     
         60 . A baked good comprising the baked dough of  claim 52 .  
     
     
         61 . A baked good comprising the baked dough of  claim 52  having a shelf life of at least eight hours.  
     
     
         62 . A baked good comprising the baked dough of  claim 52  having a shelf life of at least twenty-four hours.  
     
     
         63 . A baked good proofed in the proofer of  claim 1 .  
     
     
         64 . A baked good proofed in the proofer of  claim 18 .  
     
     
         65 . A baked good proofed in the proofer of  23 .  
     
     
         66 . A baked good proofed in the proofer of  31   
     
     
         67 . A baked good proofed on the baker's rack of  claim 38 .  
     
     
         68 . A baked good made by the process of  claim 42 .  
     
     
         69 . A proofer for making yeast-raised baked goods having an extended shelf life, the proofer comprising: 
 an insulated housing having a rear wall, side walls, and a front sealable door therein;    a proofing chamber within the housing sized to received a rack for holding a raw dough product;    a controller;    at least one component located within the housing on an airflow path and in communication with the controller to provide an airflow conditioned for proofing the raw dough product, the at least one component comprising a dehumidifier, a heating unit, or a humidifier;    an air circulator located within the housing in a position to direct air on the airflow path into the proofing chamber, the air circulator in communication with the controller; and    a partition disposed in the proofing chamber and spaced from at least one wall of the rear wall and the side walls, and an airflow chamber defined between the partition and the at least one wall, the partition comprising a panel including a plurality of openings disposed therein in at least two separate regions.    
     
     
         70 . The proofer of  claim 69 , wherein the partition is a rear partition and the region comprise side panels in the rear partition, the plurality of openings disposed in each side panel in at least two vertical columns.  
     
     
         71 . The proofer of  claim 69 , wherein the partition is a side partition spaced from one of the side walls, and the regions comprise an upper region of perforations having a first pattern and a lower region of perforations having a second pattern different from the first pattern.  
     
     
         72 . The proofer of  claim 71 , further comprising a second side partition spaced from the other of the side walls.