ENZYMES in TORTILLAS and FLAT BREADS Dilek Austin, Ph.D. Baking - PowerPoint PPT Presentation

ENZYMES in TORTILLAS and FLAT BREADS Dilek Austin, Ph.D. Baking Technical Services Novozymes North America, Franklinton, NC TIA 2016 Annual Convention and Trade Exposition May 19 th , 2016

Agenda Introduction to Enzymes Enzymes in FLOUR tortillas Enzymes in CORN tortillas Enzymes in FLAT BREADS Q&A

Introduction to Enzymes

Where do the enzymes come from ? 4

An example: E nzymes can increase efficiency, profit, and reduce waste

Enzymes are natural ​ Active proteins ​ In all living organisms • Plant • Animal • Microorganisms-fungal, bacterial ​ Specific ​ Works under mild conditions ​ Can replace/reduce chemicals

How enzymes work

Important process parameters for enzymes Contact Enzyme pH Water Substrate Stabilizers Temperature time dosage Inhibitors Oxygen pH effect Temperature effect

Enzymes maintains tortilla freshness ​ Stale tortillas/flat breads are firm and they crack when folded, become unacceptable to consumers ​ Enzymes can; • Extend shelf-life • Improve dough handling and machinability • Enhance mixing tolerance • Can replace/reduce chemicals

Enzymes in FLOUR tortillas

FLOUR tortillas ​ Short baking time ​ Stale fast ​ Maintenance of flexibility is important ​ Shortenings, emulsifiers, vital gluten, dough relaxers are critical ​ Consumers desire less ingredients ​ Clean label is vital

Enzymes used in FLOUR tortillas Fresh keeping Ingredient Enzymes reduction/replacement Alpha-amylase L-cystein/SMS Maintenance of softness, flexibility Gums and moistness of tortillas up to six Emulsifiers months Vital gluten

FLOUR tortillas ​ Six weeks-old tortillas ​ With enzymes: Flexible, no cracking ​ Without enzymes: Undesirable cracks Novozymes internal data

Novozymes NEW enzyme maintains the flexibility for FIVE-months No enzyme Alpha-amylase Novozymes internal data

Novozymes NEW ALPHA-AMYLASE -INCREASING dosages INCREASES extensibility Four week-old flour tortillas % maintained mechanical extensibility compared to freshly baked 100 %extensibility maintenance 76 74 80 70 4 weeks 60 45 40 20 0 without enzyme 225 ppm Alpha- 315 ppm Alpha- 410 ppm Alpha- amylase amylase amylase Novozymes internal data

Novozymes NEW enzyme makes tortillas STRONGER and MORE EXTENSIBLE at four week-storage Strong and more extensible New enzyme 400 350 4 weeks 300 250 Breaks easily, not extensible 200 Force 150 No enzyme 100 50 0 10 20 30 40 50 -50 Time/sec -100 Equipment: TA.XT2-Tortilla Burst Rig Novozymes internal data

Alpha-amylase maintains high rollability scores during four-week storage without enzymes Alpha-amylase 5 5 5 5 Flexible 5.0 4.6 4.5 4.5 4.2 4.0 Rollability scores 4 weeks 3.4 (1 to 5) 3.0 2.5 2.1 2.0 1.5 NOT 1.0 flexible 1 3 7 14 21 28 Storage days A study by Texas A&M University. Determining the Role of Starch in Flour Tortilla Staling Using α -Amylase J. Novie Alviola and Ralph D. Waniska. Cereal Chemistry. May/June 2008, Volume 85, Number 3

Four-week old tortillas INCREASING dosages INCREASES FLEXIBILITY 5.0 Flexible 5.0 4.8 4.5 Rollability scores 4.0 3.7 4 weeks (1-5) 3.0 2.0 NOT 1.0 flexible without enzyme 150 ppm Alpha- 250 ppm Alpha- 350 ppm Alpha- amylase amylase amylase Novozymes internal data

Enzymes in CORN tortillas

CORN tortillas ​ Short baking time ​ Stale faster than flour tortillas ​ Maintenance of flexibility is important ​ Gums are critical ​ Consumers desire STRONG and FLEXIBLE tortillas

Enzymes used in CORN tortillas Enzymes Fresh keeping Alpha-amylase Maintenance of softness and flexibility of tortillas Reduction of masa stickiness Lipase Processing ease

CORN tortillas ​ Ten day-old tortillas ​ With enzymes: Flexible, no cracking ​ Without enzymes: undesirable cracks

Two-week old corn Force to break the tortilla with Texture Analyzer tortillas 899.5 Stronger 900 762.2 ​ Maltogenic amylase 700 improves corn tortilla strength during storage 500 40 ppm Alpha-amylase 40 ppm Alpha-amylase day 5 day 11 ​ Maltogenic amylase help 5.0 to decrease the CMC in Rollability scores (1-5) at room temperature 4.0 the formula 3.0 ​ 2.3 2.3 2.0 1.2 1.0 without enzyme 0.5% CMC 0.25% CMC+30 ppm Alpha-amylase Combining Maltogenic Amylase with CMC or Wheat Gluten to Prevent Amylopectin Recrystallization and Delay Corn Tortilla Staling Francisco J. Bueso , Lloyd W. Rooney , Ralph D. Waniska , and Laura Silva. Cereal Chemistry. September/October 2004, Volume 81 (5)

Dough stickiness (g) Sticky Masa dough dough 100 80 60 50 40 40 35 ​ Less sticky and softer 30 40 corn masa obtained with 20 Non- an Alpha-amylase and a 0 sticky without enzyme 20 ppm Alpha- 40 ppm Alpha- 20 ppm Lipase 40 ppm Lipase dough Lipase amylase amylase Firmness (g force) Hard dough 100 75 80 70 61 60 40 20 Soft dough 0 without enzyme 20 ppm Alpha-amylase 40 ppm Lipase Novozymes internal data-Equipment: TA.XT2

Enzymes in FLAT BREADS

FLAT BREADS ​ Difficult to retain softness even for one day Quickly becomes stale and chewy No technology offers longer freshness Reheating of frozen flat bread results in a very dry and elastic bread ​ Maintenance of softness is important ​ Enzymes can help to retain the softness

Enzymes used in FLAT BREADS Enzymes Fresh keeping Alpha-amylase Maintenance of softness and flexibility of flat breads Lipases Bacterial alpha-amylase Lipases

Alpha-amylase maintains and improves flat bread softness for three days Day 1 Day 3 Very flexible 9 8.3 7.2 6.8 7 6.2 5 5 5 3 Breaks 1 without enzyme 5 ppm Alpha-amylase 10 ppm Alpha-amylase Novozymes internal data

A Lipase makes softer Naan dough; softer final product at four-hour after baking Naan instrumental softness Naan dough softness (% softness compare to without enzyme) Softer Softer 140 128 10 120 8 100 8 100 6 80 5 60 4 40 2 20 Firmer 0 0 Firmer without enzyme 250 ppm Lipase without enzyme 250 ppm Lipase Novozymes internal data

FROZEN Naan -A lipase gives 22% more mechanical and sensorial softness compared to those without enzymes after 40 days of storage under frozen condition at -20 0 C Softer Softer 10 140 122 120 8 7 100 100 6 5 80 60 4 40 2 20 0 0 Firmer Firmer no enzymes 250 ppm Lipase no enzymes 250 ppm Lipase Novozymes internal data

Chapatti made with a Lipase showed excellent dough property and better softness no enzymes 250 ppm lipase 700 Firmer 585 600 546 500 393 391 400 300 200 100 0 Softer 30 min after baking 3 hrs after baking Novozymes internal data

Enzymes are natural ​ Enzymes can ​ Maintain freshly baked quality of tortillas/flat breads ​ Improve dough handling and machinability Enhance mixing tolerance ​ Replace/reduce chemicals

A good source for enzymes and tortillas http://www.aaccnet.org/publications/store/pages/27885.aspx