DU R I NG BAKE RS DAY AT TH E TTZ I N B R E M E RHAVE N, K AI HEUBERGER, I N NOVATION DI R ECTO R B A K E R Y P R O D U C T S C S M B A K E R Y S O L U T I O N S E U R O P E H O L D I N G B . V, P R E S E N T E D A N E W B O I L I N G PROCEDU R E FOR DON UTS. TH E E XPE RT TE LLS MOR E ABOUT TH E TECH N IC AL BACKGROU N D AN D TH E PRODUCT TOG ETH E R WITH K E R S T I N S C H M I D T , CSM B US I N E SS DI R ECTO R BAKE RY PRODUCTS ++ figure 1
++ figure 1
Results of the consumer survey
on donuts; 5 countries; 250 consumers
source: CSM
22
Borchfeld: Mr Heuberger, why were you looking for a
new boiling procedure? What did you dislike about the current methods? + Heuberger: It was more about how to improve the current methods. When the project took off five years ago, the focus was generally on alternative baking methods.
There, the demands to a donut different from those in Europe.
Our consumer tests in the United States showed that greasy fingers and the taste of fat are rather appreciated in America. + Heuberger: One explanation for this could be that US consumers generally consume more fried products than Euro pean ones, which leads to different expectations.
+ Borchfeld: You questioned more than 250 consumers in five
European countries and performed tests. What are your results? + Schmidt: After it became clear that the new procedure has the potential to replace the present boiling procedure for donuts, we performed consumer surveys. Our initial focus was on What do consumers associate with donuts?. + Heuberger: The results of the consumer survey are as follows: donuts are luxury articles and consumers pose high demands to enjoyment when eating a donut. For us, this was a challenge to make the donut healthier without changing the typical donut flavour.
+ Borchfeld: The new pastry was to be like a normal donut,
but containing at least 20% less fat, at least 30% less saturated fatty acids and leave no aftertaste after eating. What were the greatest challenges in product development? + Heuberger: The greatest challenge was mostly in transferring the procedure from lab scales into a large technical process. Regarding taste, the difficulty was in finding the balance between taste and fat reduction. Technically, it is possible to reduce the fat content by up to 60%, but then the donut would taste rather like a milk roll.
+ Borchfeld: Dont consumers differ by country or age?
+ Heuberger: We are profiting from a mobile society today. This means that while there are differences, they are mostly due to age. The typical donut consumer is male, younger than 35, and living in a family. In contrast to Berliner-Krapfen, for example, donuts are a relatively young pastry in Europe, and a very homogeneous flavour profile has developed.
+ Borchfeld: If all donut-eaters want enjoyment & health,
isnt there always also some counter-trend? + Schmidt: We have found the counter-trend in the USA. BAKING+BISCUIT ISSUE 04 2014
+ Borchfeld: How did you achieve the reduction specifically?
+ Heuberger: When we had managed to produce a heat transfer that is similar to that of boiling, the next steps were comparatively simple.
+ Borchfeld: How high is the oil absorption of a normal
donut body with approx. 40 g before trying and how high is the absorption of the new pastry? + Heuberger: The average fat absorption in a conventionally produced donut, depending on the recipe and process, is approx. 78 g per donut at a starting weight of 40 g. The average fat absorption of a donut produced in the new b oiling
23
PRODUCTION
++ figure 2
++ figure 2
CSM Sensory Test; Comparison
Standard vs. Next Generation donut
source: CSM
basic size: Perfect donut
rocedure is at approx. 45 g, depending on the d
p esired boiling impression.
+ Borchfeld: Has this been made possible only by the new
procedure, or did you have to modify the recipe? + Heuberger: The reduction is achieved only by the procedure. But of course, the applied recipe has been adjusted to the new process as well. + Borchfeld: What does the process modification look like? + Schmidt: We wet the products to be fried with boiling
only be possible if accepting high contamination of the boiling
medium. Berliner-Krapfen with water-containing stuffing that does not boil out during the process are now possible as well.
+ Borchfeld: Did the consumer perceive any changes in the
new donuts in the subsequent tests? + Schmidt: Yes, the donuts were perceived as tasting purer. This feedback was provided by our Heavy Users. Average consumers noticed fewer changes. Instead, they talked about more pleasant consumption. + Borchfeld: Are the new pastries already being sold? + Schmidt: The donuts are sold in England, Italy and France
medium and then produce a very high heat transfer similar
to boiling by infrared and hot air flow. This gives us the boiled taste but reduces the contact time of the boiling medium and the boiled goods.
under the Sunfry brand. The product launch in Germany is
planned.
+ Borchfeld: Which technique is used and how does the heat
transfer work? + Heuberger: This is a hot-air chamber in which a very high temperature is achieved. This way, we can produce a heat transfer similar to boiling.
+ Borchfeld: Another question: Should all plants be switched
to the new procedure now? + Schmidt: Since our present customers and we at CSM believe that the procedure will prevail, we plan to convert the corresponding boiling systems to the new procedure.
+ Borchfeld: What influences does the choice of boiling
+ Borchfeld: Ms Schmidt, Mr Heuberger, thank you for the
interview. +++
medium have on the fat absorption?
+ Heuberger: Generally, the new procedure enables us to control the fat absorption depending on time and surface of the boiled goods. We have set the absorption of our products to minus 40% of the standard by sensors. The process generally does not depend on the boiling medium but we have agreed to use sunflower oil for boiling based on examinations of our development colleagues from the area of special margarines & boiling fats.
+ Borchfeld: Can the new boiling procedure also be applied
to other pastries such as Berliner-Krapfen? + Heuberger: The procedure can be extended to any other boiled product as well; it enables us to produce donuts with added chocolate or nuts in the dough as well. This used to
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