Innovative chocolate coating

Electrostatic spraying provides a thin layer of sugar/cacao on biscuits

  • New product with low chocolate cost

  • Excellent adhesion

  • Minimum waste

Sugar cacao 1

 

Electrostatic spray heads reciprocate across the width of the conveyor

For more information contact Baker Pacific at bakerman@dircon.co.uk

 

Process Guide for Marie

Marie is a classic hard sweet biscuit. Other examples of hard sweet biscuits are Petit Buerre, Rich Tea, Arrowroot, Morning Coffee. They are characterised by an even, attractive colour and texture and good volume. Doughs for hard sweet biscuits have the following features:

Button   Doughs have strong, developed gluten which gives an elastic dough, which is sheeted and cut. It often shrinks in the first stage of baking

Button   Doughs have low sugar and fat

Button   Doughs have water contents typically of around 12%

Button   Biscuits are normally baked on a wire-mesh band (except for Marie which is traditionally baked on a steel band)

Button   Humidity in the first part of the baking is important to achieve good volume and a smooth surface sheen

Button   Biscuits are baked to low moisture contents, around 1.5% – 3.0%

1 Hard sweet biscuits

 

Process for Marie

2 Marie biscuit

 

Description

Marie is a classic biscuit made throughout Europe and Asia. It has a light, crisp, delicate texture, with pale colour and clear smooth surface.

 

Product specification

Dimensions:                            66.0 mm diam.

Thickness:                                6.0 mm

Weight:                                     8.3 g

Appearance:                            Smooth surface, clear printing

Colour:                                     Pale golden

Texture:                                  Crisp and light

Moisture:                                1.5%

 

Formulation               (1)                         (2)

Flour                                        100.00                         100.00

Cornflour                                 4.41                             4.10

Maize flour                             14.70               –

Granulated sugar                    25.59                           21.67

Invert syrup 80%                     7.94                             6.67

Butter                                      –                                   4.87

Whey powder              –                                               1.67

Margarine                               –                                   10.00

Shortening                                11.03                           –

Lecithin                                      0.57                           0.50

Salt                                              0.88                           0.70

Soda                                            0.67                            0.58

ACP                                             0.08                           0.16

Protease                                     0.02                           0.02

SMS 10% solution                    0.02                           0.02

Whole liquid egg                         –                                3.33

Ammonium bicarbonate         0.73                            0.33

Water                                         26.47                           17.95

 

Recipes

Recipe (1) is a good standard Marie, Recipe (2) is a higher quality product.

 

Critical ingredients

1. Flour should not exceed 9.0% protein. Higher protein will result in a hard biscuit.

2. Cornflour and maize flour are used to reduce the total gluten content and make a more tender eating biscuit.

3. SMS will modify the protein to make a soft extensible dough.

4. Marie biscuits are made with medium protein flour and contain SMS to develop a soft extensible dough. The doughs are mixed on horizontal mixers to a temperature of 40-42 degrees C. The dough is sheeted and cut and is traditionally baked on a steel band.

 

Mixing

An “all in one mix” on a horizontal mixer. Mixing is critical to developing the soft extensible dough. A mixing action which kneads the dough without too much tearing and extruding is ideal. Mixing time on a typical high speed mixer will be 20-25 minutes. Marie doughs are mixed until the required temperature is achieved. The dough should reach 40-42oC. At this temperature it should be well kneaded and of correct consistency for machining. Higher dough temperatures result in unstable doughs. The dough is used straight away without standing and it is important to maintain the temperature.

Crackers 3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Baker Perkins High Speed Horizontal Dough Mixer

Forming

The dough may be laminated, but doughs made with SMS are usually sheeted without lamination. Dough scrap incorporation is very important and should be very even and consistent. The temperature of the scrap dough should be as close as possible to the temperature of the new dough. Dough sheet reduction should be gentle and should not exceed the ratio of 2.5:1.

Typical roll gaps are:

Forcing roll gap on sheeter:               18.0 mm

Gauging gap on sheeter:                    9.0 mm

1st gauge roll                                         5.7 mm

2nd gauge roll                                       2.5 mm

Final gauge roll                                     1.1 mm  (Cutting thickness: 1.3 mm)

The doughs shrink and require good relaxation before cutting. Separate cutting and printing rolls on the rotary cutter are recommended to achieve good, clear printing and docker holes, (piercing of holes in the dough pieces).

4 Errebi cutter design

 

 

 

 

 

 

 

 

 

 

Cutter design for Maria showing the docker pin arrangement. Note the dough piece is cut as an oval shape to compensate for shrinkage during baking. Drawing and design by ErreBi Technology

 

Crackers 4

Baker Perkins forming line with rotary cutting machine

Baking

Steam may be used at the oven entry to achieve a high humidity. This will improve the surface finish of the biscuit.

Baking time:                5.0 – 6.5 minutes

Temperatures:             200 / 220 / 180oC

Moisture:                       Less than 1.5%

A hybrid oven is ideal with Direct Gas Fired zones followed by Indirect Radiant or Convection zones. The convection zones will dry the product well and ensure an even bland colour, but care must be taken to ensure a low moisture gradient between the centre of the biscuit and the surface, otherwise the product will be prone to “checking”. Adequate baking and cooling time are required.

7 DGF  IR oven

 

Baker Pacific Direct Gas Fired / Indirect Radiant oven

Cooling

A ratio of cooling to baking time should be at least 1.5:1. This will help to avoid checking (cracking of the biscuits after packaging due to an internal moisture gradient).

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