174
RELEVANCE OF IMPLEMENTATION OF TECHNOLOGY OF SHOCK FREEZING
OF BAKERY PRODUCTS
Alieva G.S.
- Doctoral student of the Department of Food Technology, Namangan Institute of
Engineering and Technology
Tel . +9989992277094, e-mail: aliyevagulnoza94@gmail.com
Scientific adviser:
Jahangirova G.Z
. - and. o.Professor of the Department of Food Technology, PhD
Tashkent Institute of Chemical Technology, Tashkent, Uzbekistan
Tel . +998971884881, e-mail: djaxangirova77@mail.ru
Every year, more and more food industry enterprises widely use the processing of finished
and semi-finished products by shock freezing. Blast freezing and refrigeration with rapid
temperature reduction is the best technology for preserving the taste and nutritional qualities of food
products, in particular bakery and confectionery products. It minimizes the development of
microorganisms during storage and significantly extends the storage period. The transition of
bakeries to blast freezing technology will help expand the range of bakery products, diversify the
bread basket and increase profitability. [1]
Every year, the demand for products prepared using the technology of shock freezing
increases significantly [2, 3]. According to the data given in the literature of specialists, there is no
obvious difference between products prepared according to traditional technology and products
from frozen semi-finished products. As a rule, when freezing products, natural ingredients are used
without special additives and improvers. Some authors note that if the technology for the production
of bakery products from frozen blanks is observed, the products are more crispy compared to bread
produced in the traditional way [4].
Shock freezing has been widely used in industrial enterprises over the past decade [5-8]. But
at catering establishments that independently produce bread and bakery products, it has not found
wide distribution. Many enterprises use ready-made frozen semi-finished products, and do not
produce them on their own. However, the assortment of such semi-finished products is not
diversified enough: mainly “basic” and most popular products are presented. At the same time,
bread at a catering enterprise can be a fashion product. Therefore, special attention should be paid
to it. According to experts, the transition to quick freezing technology will help increase the
profitability of enterprises, expand the range and diversify the bread basket [1, 9-11].
For catering establishments, it is important not to depend on the industrial production of
bread and bakery products and to always have fresh pastries in stock. However, the production
process is very complex and time-consuming, so freezing products is the best solution to this
problem. Also, thanks to freezing, it is possible to control the volume of products produced in
accordance with the demand of consumers.
There are three ways to implement the technology of shock freezing. The first method
involves freezing dough pieces and includes a number of the following operations: dough kneading
and fermentation, division into pieces, molding (these stages are similar to traditional technology),
preliminary proofing and freezing of dough pieces. After the dough pieces are thawed, subjected to
final proofing and baked.
The second method involves freezing partially baked products. After molding, dough pieces
are subjected to final proofing and baked until 50-90% cooked. Then the partially baked products
are deep- frozen and stored in freezers at a temperature of -18 °C. For the preparation of bread and
rolls, frozen products are thawed and baked until cooked.
The third method is based on freezing ready-made products, which are then subjected to
short-term heat treatment [1, 12].
The freezing process is the transformation of the water molecules contained in the product
into crystals. During shock freezing, the product is exposed to a temperature of -40 ° C. This makes
it possible to reach a temperature of -18 °C in the thickness of the product in a fairly short period of
time: the maximum time required for the implementation of this technology is 240 minutes. When
175
frozen, all water molecules turn into ice crystals, and the faster the process, the smaller the crystals.
Thus, only during microcrystallization , the cells of the product are not damaged. After defrosting,
the loss of liquid will be less, and the consistency and taste of the product will not change.
Another advantage of shock freezing is that in any product left for slow cooling at a
temperature of +65 to +10 ° C, the microflora rapidly multiplies, and with a rapid decrease in
temperature, bacteria do not have time to develop, which significantly increases the shelf life. The
introduction of shock freezing technology into the production process is an effective method, thanks
to which it is possible to carry out the technological process in small areas [9]. Therefore, this
technology is actively used by public catering enterprises in the production of semi-finished
products, mainly vegetable and meat. In the production of bakery products, this technology is not
used so often at public catering establishments.
The purpose of the research is to improve the technology of shock freezing of bakery
products with the establishment of parameters produced in the conditions of bakery enterprises,
including the use of non-traditional vegetable raw materials.
To impart functional properties to bakery products, raw materials of various origins are
used, including mono- and complex additives of essential micronutrients deficient in human
nutrition [13]. However, such technologies are difficult to apply in small enterprises and are aimed
at large-scale production. An analysis of various information sources made it possible to determine
the trend in the use of fruit and berry raw materials as the most promising for nutrition. It promotes
both an increase in the level of the technological potential of the ingredients of the recipe, and an
increase in the nutritional and biological value of bakery products [2, 14-17]. In this case, the
introduction of fruit and berry and vegetable raw materials in the form of dry powders is mainly
considered [18–20].
There is information in the literature that the freezing of bakery semi-finished products must
be carried out with the addition of various cryoprotectants [21]. Such substances include pectin,
which is contained, for example, in persimmons. Pectin, fixing water in a bound state, optimizes the
ratio of free and bound water in the dough. This increases the water absorption capacity of flour,
which is explained by the formation of protein-polysaccharide complexes. When such products are
frozen, smaller ice crystals are formed, which do not destroy the gluten structure and make it
possible to obtain high quality bakery products. There is evidence that the greater the amount of
muffin in the product, the better it tolerates the freezing process [22].
In the products manufactured by bakery enterprises, a significant share is occupied by
bakery products made from yeast dough, which, due to their high taste properties, are popular with
the population. Consumer properties of products made from yeast dough depend on many factors:
the quality of raw materials, the correctness of its use, production technology, and so on. Bakery
products made from yeast dough have high taste properties, but the process of their production is
very complex and time consuming . In their production, there are a number of tasks, the solution of
which depends on ensuring the competitiveness of the products on the market.
Vegetable raw materials are a rich source of a number of nutrients necessary for the div,
the supply of which cannot be provided only at the expense of animal raw materials. These are
pectin substances, fiber, amino acids, vitamins and minerals [18].
Modern nutrition science considers vegetables, fruits and berries as vital foods. Vegetables
are the natural and main supplier of various vitamins, mineral salts, organic acids, pectins, dietary
fiber, as well as proteins, fats and carbohydrates. Fruits and berries are characterized by a complex
of useful substances balanced in terms of vitamin, mineral and antioxidant composition. The daily
presence of plant foods in the diet allows you to get the nutritional components necessary for the
div. In this regard, it is advisable to make vegetable additives in bakery products.
Persimmon processing products were chosen as herbal supplements. They refer to products
available on the territory of Uzbekistan.
The preventive properties of persimmon are due to the special substances contained in it -
trace elements, vitamins and antioxidants. Persimmon is rich in such substances as calcium,
potassium, phosphorus, magnesium, iron, iodine, glucose. It contains carbohydrates, beneficial
176
acids, proteins, tannins, ash, vitamins A, C, and R. ... In addition, the benefits of persimmons are the
presence of a substance such as pectin. According to the chemical composition and content of
useful substances and compounds, persimmon is useful in the content of iodine and antioxidants.
About iodine in general as iodine-131 . In terms of the ability to accumulate iodine, this fruit is
second only to feijoa , but at the same time it clearly bypasses the latter in terms of availability in
stores and markets, and does not have such a strong seasonal link. It is worth noting that the ability
to accumulate and the content is not the same thing, in order to contain iodine, the persimmon tree
must grow in conditions where iodine is available in the environment, and this is not the case
everywhere. The main therapeutic effect of persimmon is due to the fact that it contains a wide
range of substances with antioxidant activity. Only the lazy have not heard about antioxidants
today. Living organisms are under constant oxidative stress due to the action of free radicals,
reactive forms of oxygen compounds and pro-oxidants (enhancers of oxidative processes),
generated exogenously (heat and light) and endogenously (hydrogen peroxide and transition metal
cations). Therefore, most biological objects contain antioxidant systems to control the content of
free radicals, catalyze lipid oxidation, oxidation intermediates, and secondary degradation products.
Antioxidants are classified into primary (long acting) and secondary ( synergistic ). Secondary are
divided into substances that quench singlet oxygen (sulfites, vitamin C, etc.), compounds that form
chelate complexes (citric acid, lecithin, etc.), specific antioxidants ( thiodipropionic acid, nitrites,
zinc, selenium, etc. .)
Samples of baked products from yeast dough prepared in various ways, including using
shock freezing technology. The quality of raw materials and finished products was evaluated by a
combination of organoleptic and physico-chemical parameters using standard methods.
Recipes for products made from yeast dough with additives from dried persimmon peel,
modes and parameters of shock freezing and subsequent baking of bakery products in the
conditions of catering establishments have been developed. It has been established that the dosages
of persimmon peel powder, which provide the best indicators of the quality of finished products, are
6% of persimmon peel powder to the mass of flour. The effect of baking time on the quality of
frozen bakery products was studied, and the time required for freezing products and subsequent
baking was determined .
Based on the totality of quality indicators, the modes and parameters of shock freezing of
bakery products at network catering enterprises were established. For freezing products weighing
50 g after 10 minutes of baking in a convection oven at a temperature of 180 °C, the duration of
freezing was 50 ± 2 minutes at a temperature of -40 °C, the duration of after-baking of bakery
products was 10 minutes at a temperature of 180 °C.
At the first stage of the work, a recipe and technology for the production of a bakery product
with the addition of vegetable and berry puree was developed. The production technology included
the following operations. The persimmon was washed, peeled and the pulp was transferred for
drying, and the skin was cut into small cubes and dried at a temperature of 60 0
C
, cooled, then
crushed in a laboratory mill. Flour , pressed yeast diluted in water heated to 40 ° C, salt and sugar
diluted in water, as well as prepared persimmon peel powder were poured into the bowl of the
dough mixer . Everything was stirred for 7-8 minutes. Then the chilled melted margarine was
introduced and the dough was kneaded until it acquires a uniform consistency and easily separates
from the walls of the bowl .
The prepared dough was placed in a proofer for 2.5-3 hours for fermentation at a
temperature of 35-40 °C. As soon as the dough increased in volume by 1.5 times, it was punched
for 1-2 minutes and again left for fermentation, during which the dough was punched 1-2 more
times.
The yeast dough was cut into pieces weighing 112 g, giving them a round shape, placed on
greased sheets and put on proofing at a temperature of 31-40 °C for 30-40 minutes. Products were
baked in a convection oven at a temperature of 180 °C for 10 minutes.
In order to determine the optimal dosage of persimmon peel powder, we studied the effect of
various amounts of powder on the quality of yeast dough products (for example, the Boychechak
177
bun ) . Additives were added in amounts from 1 to 15% of the powder to the mass of flour in
increments of 5%. It has been established that the total organoleptic assessment corresponding to
the quality category "satisfactory" and higher was observed when adding 5-15% beetroot and 5-
10% cranberry puree to the mass of flour. The best organoleptic indicators were noted in samples in
which the ratio of persimmon peel powder to flour was 97:3, 95:5 and 90:10%, respectively. The
maximum tasting score for each indicator is 5, total - 25.
Analysis of the organoleptic profiles of the samples showed that the quality of the samples,
in which the persimmon peel powder dominates in a percentage of 10%, can be explained by the
high content of cryoprotectants in persimmon. With an increase in the amount of powder from the
peel of persimmon to the mass of flour, the quality of the products is significantly reduced: the
products lose their shape, the crumb becomes sticky and raw . Samples with a powder content of
10% and 7% received the highest scores.
Baked products were subjected to physical and chemical analysis. The following indicators
were determined: mass fraction of moisture, acidity, specific volume and form-holding ability. The
data are presented in table 1.
Table 1. Physical and chemical parameters of baked goods ( n =5)
Samples (ratio of flour and
persimmon peel powder)
Moisture
content, %
Acidity, hail
Specific
volume, cm
3
/g
Formo
holding
capacity
Control
3 7 .0±1.5
2.2 ± 0.15 _ _ _
_
3.85 ± 1.5
0.70 ± 0.05 _ _
_
97:3
3 7 , 3 ±1.5
2 , 3 ± 0 , 1 5
3.75 ± 1.5
0.60 ± 0.05 _ _
_
95:5
3 7 , 5 ±1.5 2.4 ± 0.15 _ _ _
_ _
3.45 ± 1.5
0.58 ± 0.05 _ _
_
90:10
3 7 , 8 ±1.5 2.4 ± 0.15 _ _ _
_ _
3.60 ± 1.5
0.65 ± 0.05 _ _
_
From the analysis of the data in the table, it can be seen that the values of the moisture and
acidity indicators of the test samples differ slightly from the values of these indicators of the control
sample. The values of dimensional stability and specific volume decrease with an increase in the
amount of additive introduced in the form of a powder, which confirms the organoleptic
assessment. High quality indicators have products with a content of 10% persimmon peel powder to
the mass of flour, because. these samples are distinguished by the highest rates of specific volume
and dimensional stability .
The developed bakery products with the addition of powder had organoleptic characteristics
corresponding to the quality requirements.
At the second stage of the work, the possibility of freezing the developed bakery product
was evaluated and the parameters of freezing and subsequent cooking were determined . Products
subjected to partial or complete baking were pre-cooled to the temperature of the workshop in order
to evenly distribute moisture in the volume. It has been determined that the duration of freezing
depends on the volume of the loaded product, the recipe composition, and also on the duration of
baking of the products subjected to freezing. Experimentally, the time required for the developed
products to reach a temperature in the thickness of the crumb of -18 ° C, and the time required for
the subsequent baking of bakery products, were determined. The results obtained are presented in
table 2.
Table 2. Optimal parameters of shock freezing of bakery products
Freezing methods
Freezing time, min
Finishing time , min
Freezing immediately after
proofing
26±2
15
Freezing the product after:
5 min baking (30% baking)
46±1
12
178
10 min baking (60% baking)
50±1
10
Freezing finished products (100%
baking)
53±1
3
The partial baking time was chosen based on data available in the literature. Considering
that for bakery products the optimal mass of products is 100 g, we focused on this volume of the
product and chose the time that most closely corresponds to 30 and 50% baking, i.e. 5 and 10
minutes, respectively. The post-baking time was determined to achieve the required appearance
indicators.
Based on the totality of quality indicators, it has been established that the technology of
shock freezing of bakery products using an additive in the form of powder from persimmon peel
can be used in bakeries and for public catering.
As a result of the research, the following were determined:
- recommended freezing stage: after 10 minutes of baking in a convection oven at 180 °C;
- the duration of freezing in a shock freezer is 50 ± 2 minutes at a temperature of -40 °C;
- after-baking for 10 minutes in a convection oven at a temperature of 180 °C.
The transition of enterprises to the technology of shock freezing of products using non-
traditional raw materials will help increase profitability, expand the range of bakery products and
diversify the bread basket.
List of used literature:
1. Shock freezing of bakery products using non-traditional vegetable raw materials at public
catering enterprises / E. V. Roshtsna , R. Z. Grigorieva, S. Yu. Baranets [et al.] // Technique and
technology of food production. - 2020. - V. 50, No. 3. - S. 439-449.
2. Belyakova, M. S., Efremenko I. A., Grigoryeva R. Z. The use of shock freezing
technology in the production of bakery products at public catering enterprises // Food innovations
and biotechnologies: materials of the V International Scientific Conference / Kemerovo
Technological Institute of Food Industry. - Kemerovo, 2017. - S. 274-276.
3. Kiryukhina, A. N. Current state and prospects for the development of bread and bakery
products in Russia / A. N. Kiryukhina, R. Z. Grigorieva, A. Yu. Kozhevnikova // Technique and
technology of food production. - 2019. -T. 49, No. 2. - S. 330-337. DOI:
https://dof.org/10.21603/2074-9414-2019-2-330-337.
4. Labutina, N. V. Technology of production of bakery products from frozen semi-finished
products: monograph / N. V. Labutina. - Smolensk: Universum, 2004. - 236 p.
5. Suvorov, O. A. Modern technologies of bread and bakery products. Market prospects / O.
A. Suvorov, N. V. Labutina, M. S. Nazaretyan // Technology and commodity science of innovative
food products. - 2011. - T. 11, No. 6. - S. 78-83.
6. Laptenok , N. S. Innovative technologies in bakery / N. S. Laptenok , L. I. Sevastey //
Food industry: science and technology. - 2017. - V. 36, No. 2. - S. 20-28.
7. Katusov , D.N. Production of frozen bread / D.N. Katusov , L.S. Shalygina // Innovative
science. -2017. - T. 2, No. 3. - S. 35-37.
8. Kitissu , P. A. Quick-frozen dough / P. A. Kitissu // Bakery of Russia. - 2005. - No. 5. - S.
30-31.
9. Gerasimova, E. O. Cryogenic technologies in bakery / E. O. Gerasimova, N. V. Labutina
// News of higher educational institutions. Food technology. - 2019. - T. 367, No. 1. - S. 6-9.
10. Kiryukhina , AN Specific development of the baking industry in Kemerovo oblast / AN
Kiryukhina , NM Guk // Foods and Raw Materials. - 2013. - Vol. 1, No. 2. - R. 89-95. DOI:
https://doi.org/10.12737/2061.
11. Obolensky, N.V. The use of frozen semi-finished products as an effective technology of
bakery production in the conditions of economic intensification / N.V. Obolensky, O.V.
Golovacheva // Vestnik NGIEI. - 2012. -T. 11, No. 4. - S. 70-79.
12. Danilova, I. A. Types of freezing semi-finished bakery products / I. A. Danilova //
Young scientist. -2014. - T. 77, No. 18. - S. 233-235.
179
13. Davydenko, N. I. Justification of the need for complex enrichment in the development of
functional bakery products / N. I. Davydenko, V. A. Nesterova, A. I. Karchevnaya // Polzunovskiy
Vestnik. - 2012. - No. 2-2. -WITH. 200-205.
14. Shaburova, G. V. Fruits and berries in the technology of bakery and flour confectionery
products / G. V. Shaburova, E. A. Lukyanova // Innovative technique and technology. - 2018. - V.
17, No. 4. - S. 35-38.
15. Dashrath, B. Wild fruits and vegetables: a great source of micronutrients / B. Dashrath,
J. Shashi // 44th Annual National Conference of the Nutrition Society of India “Current Trends in
Food Security to meet National Nutritional Challenges” / Sri Venkateswara University. - Tirupati,
2012. - P. 158-159.
16. Current trends in the enhancement of antioxidant activity of wheat bread by the addition
of plant materials rich in phenolic compounds / D. Dziki , R. Rózylo , U. Gawlik-Dziki [et al.] //
Trends in Food Science and Technology . - 2014. - Vol. 40, No. 1. -P. 48-61. DOI:
https://doi.org/10.1016/j.tifs.2014.07.010.
17. Fiber enrichment of wheat bread with Jerusalem artichoke inulin: Effect on dough
rheology and bread quality / IA Rubel, EE Pérez, GD Manrique [et al.] // Food Structure. - 2015. -
Vol. 3. - P. 21-29. DOI: https://doi.org/10.1016/j.foostr.2014.11.001.
18. Bibik, I. V. On the possibility of using berry semi-finished products in the production of
bread / I. V. Bibik, E. V. Loskutova, N. V. Babiy // Technology and commodity science of
innovative food products. - 2013. - T. 21, No. 4. -S. 7-13.
19. Marpalle , P. Effect of flaxseed flour addition on physicochemical and sensory
properties of functional bread / P. Marpalle , SK Sonawane , SS Arya // LWT - Food Science and
Technology. - 2014. - Vol. 58, No. 2. - P. 614-619. DOI: https://doi. org
/10.1016/j.lwt.2014.04.003.
20. Ermosh , L. G. Technology of bakery products from frozen semi-finished products using
Jerusalem artichoke flour / L. G. Ermosh , I. P. Berezovikova // Technique and technology of food
production. - 2012. - T. 27, No. 4. -S. 11-17.
21. Kenijz , NV Pectic substances and their functional role in bread-making from frozen
semi-finished products / NV Kenijz , NV Sokol // European Online Journal of Natural and Social
Sciences. - 2013. - Vol. 2, No. 2. - P. 253-261.
22. Kiryukhina, A. N. Study of the influence of technological factors on the commodity
properties of frozen test semi-finished products and bakery products from them: dis . ... cand. those.
Sciences: 05.18.15 / Kiryukhina Anzhelika Nikolaevna. - Kemerovo, 2005. - 175 p.
