Production technology of flour confectionery products from puff pastry. Homemade Puff Pastry: How to Make Your Own Yeast Puff Pastry Equipment
Quite recently, puff pastry was made in a complex and time-consuming way. For this, a yeast composition was used as a raw material, which was sprinkled on top with chopped butter or margarine and rolled out. But so that the butter or margarine does not melt when rolling out, it was necessary to cool the entire workpiece several times in the refrigerator. Rolling and cooling succeeded each other, it took a considerable time.
Currently, puff pastry is used as a raw material, for example, for baking pies stuffed with jam or meat. The versatility of using a semi-finished product is explained by its insipidity, as a result of which any fillers are equally well suited to it. The production of puff pastry in production has long been put on a machine basis. Thanks to this, in one culinary center they receive such an amount of this semi-finished product, which is enough for several enterprises and catering centers.
But the fresh composition is now made using a simpler technology. It is kneaded with flour, water, and then salt with margarine and vinegar is added to it. Roll out this mixture three times. An emulsifier is additionally added to its composition. In addition, intensive freezing was introduced into the semi-finished product manufacturing technique, thanks to which frozen semi-finished dough products such as dumplings, pancakes, dumplings, khinkali and various types of cutlets are sold in abundance in supermarkets.
The main purpose of quick freezing is to stop the fermentation of raw materials and preserve the semi-finished product for a long time. This allows you to quickly cook pizza, various cakes from puff pastry. Sometimes products made from it are harsh and not very tasty. This is due to cost savings for manufacturers. But when everything is prepared according to strict rules, the product turns out to be crumbly, soft, fragrant.
Our business valuation:
Starting investment: 2,000,000 rubles.
Market saturation is average.
The complexity of starting a business is 5/10.
Technological features of dough preparation
Do not knead the dough for a long time, as this only worsens its quality. Only a person with experience and knowledge of the puff pastry recipe can accurately track the process of preparing a high-quality frozen product. The production of puff pastry involves kneading it in cold water with a temperature not exceeding 5 ° C, and the kneading time usually does not exceed 8 minutes.
Until fermentation begins in the dough, it is subjected to lamination, when they are rolled out by pressing cold blanks with margarine and cooled twice. Preparation of raw materials in this way saves time and allows you to get a semi-finished product with improved taste.
Another version of the puff pastry production technology involves mixing all the main components to obtain a piece, where all layers of the dough are separated by fat fillers.
For the production of puff yeast dough, the mixture that has already fermented is divided into pieces, then they are rolled out and allowed to rest for 10 minutes. The resting should take place with the cooling of the raw material to 20 degrees Celsius. Then the raw materials are divided into pieces of equal weight, rolled into cakes about 2 cm thick, covered with softened butter and stacked on top of each other. To prevent the oil from flowing out, pinch the edges of the product with your hands. Then they roll it out again, fold it in half and place it on a sheet sprinkled with flour.
With further aging in a cold room, the temperature of the dough is brought to 6 degrees Celsius. The waiting time is usually one hour. Then the cold composition is thinly rolled to a thickness of one centimeter. Various blanks for proofing are already being formed from this pancake, which lasts another hour. Then only the finished culinary products are baked. It is very important to observe the specified proportions of butter and margarine in the dough.
Production technology equipment
You can understand in detail how puff pastry is made in production. To obtain it at the enterprises of the food industry, special rolling machines are used. According to the principle of operation, these machines are divided into manual and automatic. If significant volumes of production are required, then entire lines for the production of puff pastry are used. These lines make it possible to obtain up to 500 layers of oil in a batch.
Puff pastry production line
If the dough is rolled out using a machine, then it turns out to be homogeneous with a uniform distribution of layers and with the correct external shape of the general array. Only sheeting machines allow culinary masters to receive large volumes of products every day and bake various products from it in large quantities. These machines can currently be either semi-automatic, automatic, or computer-controlled.
To obtain finished products from puff pastry, various methods are used - from using machines for cutting blanks to twisting them into the desired shapes. Equipment for the production of puff pastry can be completely different in terms of the complexity of its technical equipment and performance.
You can use both special tables for cutting and twisting finished products, as well as automated high-performance lines. Rollers for cutting products can be supplied as a standard type, as well as on customer's order. A fully automated line for the production of food products from dough is also the most hygienic way to prepare a grocery product.
Puff pastry business plan
Due to the high demand for this semi-finished product in public catering systems, the puff pastry business is very profitable. Significant start-up costs are required to launch such production. If the shop for the production of puff pastry is equipped with modern high-performance equipment, then at least two million rubles will be required. If you try to save costs on some equipment or raw materials, then this will be a bad idea. After all, any changes in the recipe will immediately affect the quality of the product.
The equipment can also be used of the classic, conventional type in the form of dough mixers and those devices that are widely used in the bakery industry. You will need both refrigerators for intermediate and final cooling of the product, and press devices for rolling out the dough. With the finished cycle of manufacturing finished products, filling dispensers and manual rolling will also be required.
But in any case, with proper organization of work, the payback period for the primary costs of organizing the production of puff pastry does not exceed one and a half to two years.
A feature of the technology of puff products is the operation of lamination.
Lamination of dough - giving the dough a layered structure by applying butter, margarine or fatty products intended for lamination of the dough to the rolled dough, followed by repeated rolling. The main purpose of lamination is to obtain thin layers of dough, alternating with layers of fat. Fat creates a continuous waterproof film on the surface of the dough layers. The water vapor generated during baking is retained by layers of fat. Under the pressure of water vapor, the layers of dough are “moved apart”, increasing the volume and forming a layered structure of the products.
In the manufacture of puff products, wheat baking flour of the highest grade with a raw gluten content of at least 30% is used.
Puff products are made from yeast-free and yeast dough. The production process of puff pastry products includes several main stages: dough preparation, lamination, cutting, baking, cooling and packaging.
Yeast puff products are made from fermented dough. The dough is prepared by sponge, non-dough or other methods adopted in baking for products made from wheat flour. Modern technologies of puff products mainly provide for short-term fermentation (resting) of the dough at a temperature of about 20 ° C. The temperature of the dough after kneading should be no higher than 16-20 °C, and when cutting the dough on an automated line - no more than 12-14 °C. To do this, when kneading the dough, cold water or ice is added instead of 20-50% of water. If the kneaded dough has a temperature above 20 ° C, then it is cooled to a temperature of 10-12 ° C in a refrigerator.
After kneading, the dough is divided into pieces of equal weight (2-8 kg), formed into rectangular blocks and left to rest for 10-20 minutes at a temperature of 4-10 °C. For uniform cooling of the dough, it is recommended to roll out the dough before resting into a layer 5-7 cm thick.
For lamination of yeast dough, special margarines and butter are used in the amount of 30-70% by weight of flour in the dough. Before lamination, butter is mixed with flour in a ratio of 10:1, rectangular blocks are formed and cooled.
The fat used for lamination must be plastic. To do this, fat, stored in a refrigerator at a temperature of 4-6 ° C, is rolled several times through the rolls of a rolling machine or manually with a rolling pin. Fat and dough should have a similar consistency when laminating. In the room where lamination is carried out, it is recommended to maintain a temperature of 18-20 °C.
During the first lamination, a piece of dough is rolled out to a machine into a rectangular layer about 8 mm thick. A layer of fat is placed on the dough and folded in a certain way in three (“simple” lamination) or four times (“double” lamination). The dough layered with fat is rolled out and placed for resting in a refrigerator at a temperature of 4-6 ° C for 10-15 minutes. Then the lamination cycle is repeated.
The resting of the dough is carried out after each rolling. The number of layers in the yeast dough depends on the type of product and usually varies from 12 to 81. After the final lamination, the dough is rolled out into a layer 3-5 mm thick, wound on a rolling pin and served for cutting. When cutting, blanks are cut out from the dough layer, they are given a given shape, and the filling is added, if provided.
The final proofing is carried out at a temperature that prevents the fat from melting. When using butter for lamination, proofing is carried out at a temperature of 26-28 ° C for up to 120 minutes. Before baking, the surface of the blanks can be smeared with eggs, sprinkled with crumbs, etc. Puff products are baked at a temperature of 190-200 ° C with steam humidification of the baking chamber, products with egg lubrication and finishing with crumbs - without steam humidification. After baking and cooling, the products can be sprinkled with powdered sugar. Puff products are placed in trays in one row.
Earlier, in Soviet times, the process puff pastry production was quite difficult. It was done something like this: they took ready-made yeast dough, sprinkled it with frozen grated butter, and more often margarine, and rolled it out.
The complexity of this work was that, in the process of rolling, the butter heated up and melted, so the whole mass had to be cooled first in the refrigerator, so the process of cooling and rolling the dough had to be repeated several times.
A simpler version of the production of puff pastry was also popular: it was kneaded from flour, margarine, salt, vinegar and water, that is, it was already unleavened dough. After that, it was rolled out 2 times. Now, at confectionery and baking enterprises, melange is introduced into such dough, which serves as an emulsifier. Thanks to this composition, the dough can be rolled out many times.
Now pies are made from puff pastry with a variety of fillings, ranging from meat to jam. Such versatility of puff pastry due to the fact that now it is unleavened dough, so it goes well with both sweet filling and salty.
However, a great innovation appeared in the technology of its preparation - quick freezing. As you know, freezing small-sized semi-finished products sold by the piece or by weight is now very popular - these are pancakes with various fillings, dumplings, cutlets, cabbage rolls, khinkali, dumplings, etc. - all this is supplied in large quantities to supermarkets.
Fast freezing has become relevant for puff pastry, pizza, and ready-made cakes. Its main goal is to stop the fermentation processes in the dough for a while, so that it can be prepared directly at the points of sale (for example, in biscuits) or stored frozen for a long time.
Previously, only products made from unleavened dough were subjected to quick freezing. And now frozen semi-finished products can be found from different dough, and from puff pastry too. However, there is an important point here: although confectionery and bakery enterprises have begun to use quick freezing of puff pastry without exception, they often do not bother to monitor the quality of their products in finished form. A product made from such a dough is hard ("rubber") and not tasty. And all because often enterprises save money on the introduction of new technologies.
Hence the conclusion: if you give good quality, so that the puff pastry is the way it should be - crumbly and tender, give a rich assortment of products, then a regular customer will be provided to you, as well as success in this business too.
Now let's get down to specifics. Puff pastry does not need to be kneaded for a long time, on the contrary, its quality can noticeably deteriorate with a long kneading. However, the specific cooking process (freezing, storage, transport, longer proofing) will require an increase electricity costs.
You will need technologist who knows firsthand all the subtleties of the process of preparing frozen puff pastry and will monitor the methodical observance of production technology.
Puff pastry for freezing cannot be prepared from ordinary flour, the ability to hold air in such a dough will be small, respectively, the dough will not rise well, and, for example, a pie from it will not be airy and crumbly, but on the contrary, it will have an unsightly appearance.
Therefore, they do this: dry gluten or gluten concentrate is first added to flour with a low protein content. Already in the mixed dough, there should be at least 32% of raw gluten - this fact affects the ability of the dough to rise.
Flour for frozen puff pastry should have an elasticity index close to 100%, the amylase activity of the flour should be low, and the fatty acid content should not be high (therefore, soy flour is not suitable for this case).
The second, after flour, super-important component is yeast. It is this component that is ultimately responsible for the elasticity and porosity of the finished puff pastry product. In this case, when the dough is to be frozen, pressed yeast is used. And there is a difference, which manufacturer's yeast to use. Ideally, for making frozen dough, you need to use special pressed yeast from European manufacturers.
Domestic yeast greatly slows down its action when the temperature drops, so they will need twice as much as yeast from European manufacturers. The latter contain special strains that do not lose their activity even at low temperatures, thanks to which the fermentation process continues successfully.
And then he gets up question of price: domestic yeast is worse, but cheaper, and imported yeast is better, but more expensive, respectively, the finished product will cost more. Our confectionery enterprises fall for this bait, they want to save on raw materials and, thus, increase their profits: they use Russian yeast, often dry yeast (which cannot withstand low temperatures), and end up with products of mediocre quality.
If you do everything according to the rules, that is, use special dry yeast, increase the proofing time of the dough so that the product turns out to be flawless in taste and appearance. In the event that you use regular yeast, increase their amount - only the production technologist can determine how much yeast is needed.
As mentioned above, puff pastry can be prepared without yeast, but yeast puff pastry is recognized as the best.
If the dough is not prepared with yeast, it becomes fluffy thanks to butter or margarine. During baking, the dough absorbs fat and separates into layers. When choosing margarine, it is better not to save money, but to choose a product of good quality, pleasant in taste - with it, then the layers of dough will turn out to be thin and crumbly.
The technologies for preparing yeast and unleavened puff pastry are very similar: in both cases, each layer of dough must be rolled out in the form of a square, put a layer of fat (butter or margarine) on it, then close the edges, roll this layer out again, etc. The more layers , the finished product will be more airy and tastier.
In yeast dough, although much less margarine is used, laying the layers with margarine prevents these layers from sticking together. In unleavened dough, fat is used more.
The next important components of puff pastry are eggs, water, salt, sugar. As a rule, in industrial confectionery, egg powder is used instead of eggs, it is more practical, it is easier to store. Sugar in yeast dough is a necessary component, since fermentation is faster with it. Water should be purified and cooled to about zero degrees.
In addition to all the components already listed, improvers are added to the puff pastry that will be frozen, they contain ascorbic acid, oxidizing agents, reducing agents, lecithin, which acts as an emulsifier.
Improvers increase the ability of the dough to retain gases, from which the dough rises even while it is baking.
How is unleavened (without yeast) puff pastry prepared?
Chilled water, a solution of lactic or citric acid, egg powder or melange, salt, whey or milk powder, chilled flour, improver, liquid margarine or vegetable oil are added to the container of the dough mixing equipment. The dough is kneaded in a dough mixer for 15-20 minutes until it turns into a completely homogeneous mass. Then the dough remains to lie for another half an hour at a temperature not exceeding 18 degrees. This stage is called preliminary resting.
How is yeast puff pastry prepared?
First, the container of the mixing equipment is filled with very cold water (usually in the form of crushed ice). Then a solution of eggs, fat, acid solution, sugar, salt and chilled flour with an improver are added to the mass. Yeast, previously diluted in cold water, is added last.
I am writing this article for those skeptics who say that it is already expensive to start a business now and all niches are occupied, it was necessary earlier, time has been lost, etc. etc. Here I will tell you how you can open your own business for the price of an iPhone.
Puff pastry trade
Here, all the key points for starting a business with a small initial capital came together.
- Low entry threshold, 1.5 - 2 thousand dollars
- High margin, from 100%
- Excellent product demand
What else do you need to start your successful business?
Oh, detailed instructions! Well, hold on.
First, consider the format of the outlet. It can be a street cafe, a tent, a Tonar-type trailer. Almost any building will do. Area from 4 sq. meters. That is, the cost of rent is sufficient, adequate.
Location of objects. These are the central streets of the city, district, railway stations, next to educational institutions. And in the markets (here housewives immediately take about ten puffs for the house).
We need the following equipment:
Convection oven, proofer (needed for defrosting and raising the dough), 400 liter chest freezer (we store frozen semi-finished products in it). This is the main equipment. And one more plus: the hood for these furnaces is not needed.
An oven with a proofer will set you back about a thousand dollars. There is our equipment, there is imported equipment (for example, Italian, by SMEG). A chest freezer can be bought used for 5 - 8 thousand rubles.
Showcase, shelving - this is done for a specific point. Here the costs are small. Maybe you can rent a pavilion where everything is already there.
Cash register (optional)
Thus, I lay 1.5 USD for all this.
The good thing about products is that semi-finished products are stored for about 3 months. You don't need a lot of money to buy. And the profitability, most importantly, is high.
On average, the purchase of one product will cost 5 rubles apiece, the selling price is 12-15 rubles a piece.
That is, they sold 500 puffs with an extra charge of 5 rubles, they made a profit - 2,500 rubles a day, which amounts to 75,000 rubles a month. Minus costs (rent, electricity, salary). Thousand fifty clean from one point remains. We develop a network, multiply profits.
Now another very important point where people had problems with this business.
Product quality!
Not all suppliers of semi-finished products have quality products. As a result, people try and never come back. Try the products and most importantly, collect reviews about them when you look for a supplier. There will be delicious puffs, get regular customers. And, accordingly, profit.
More advice. Here you have opened the first point, brand it right away. Come up with a nice name, something like "Fedotika", etc. It will be easier to spin new points. Brand awareness is a big advantage.
You see, nothing complicated. Gather information on the topic, write a small business plan and go!
The base dough is a tough dough made from wheat flour, which is then flaked. Although yeast-free puff pastry does not have a sweet taste, it is used for confectionery products, like cake layers, slices with further filling with cream, for curd pies and yurts, sharudels and small pastries, like “pig ears”.
The rise of yeast-free dough during baking occurs only due to a physical process - water vapor and melted fat create layers in the final product.
In Western Europe, there are 3 types of puff pastry.
German: fat is wrapped in dough
French: dough "wrapped" in fat
Dutch: pieces of fat are laid out on the dough
All views of the variant are then toured.
The French version is almost never used. With this method, it is necessary to introduce about 10% flour into the oil and process it in a cold state. Toured like German puff pastry, but the rest phases may be shorter.
The Dutch version is the fastest. 1 coarse pieces of fat are laid out on the kneaded and rolled dough, the dough is folded and put to rest in the cold for 20 minutes. The dough is then toured without rest phases.
The dough for puff pastry without yeast is kneaded on a spiral mixer and all dough components should be as cold as possible. 5% flour must first be added to the lamination fat, a rectangular block should be formed and cooled. Oil for touring should have a temperature of 15 ° C, it is recommended to add 10% flour to the oil.
After touring, the dough is rolled out to a thickness of approximately 2 mm and then shaped according to the desired product. It is important that cutting or cutting is done with a sharp knife - do not squeeze the layers in the cut. Molded dough pieces should receive a final proofing in the cold for about 30 minutes so that the dough rests and the layers do not “pull together” during baking.
Rice. nine.
To achieve the quality of a typical puff pastry product, it must be properly baked: a baking temperature of 200 to 220°C and a baking time of 20 to 30 minutes. Baked in most cases with steaming.
Yeast-free puff pastry does not age quickly like yeast and yeast puff pastry, so it can be produced rationally in large quantities and stored in a cold or freezer, remembering to cover the dough with a film to protect the surface of the dough from drying out. steam held back by a waterproof layer of fat - the physical principle of loosening.
In puff pastries made from yeast dough, in addition to the physical leavening with steam, the biological leavening of the dough is added due to the work of the yeast.
Puff pastry kneading
For the production of puff pastry, intensive dough kneading is required, which contributes to the maximum development of the gluten framework: obtaining cold dough to slow down the start of fermentation; preparation of dough with a very strong consistency to limit the phenomenon of spreading during defrosting; exclusion of yeast fermentation until freezing.
When kneading yeast-free puff pastry, cold water, a solution of lactic or citric acid are poured into the bowl of the dough mixing machine, egg powder or melange, whey or milk powder, salt, then chilled flour and flour improver are added, then vegetable oil or liquid margarine is added and the dough is kneaded for 10-20 minutes (depending on the mixer) until a homogeneous mass is obtained.
Well-kneaded dough is left in the bowl for 20-30 minutes to swell proteins (preliminary resting). For a yeast-free dough, its temperature at any time during the kneading and resting process should not exceed 18 degrees.
When kneading yeast puff pastry, pour especially chilled water (in the form of ice crumbs), an acid solution, an egg solution and fat, sugar and salt into a bowl, then chilled flour, an improver. At the very end, yeast is loaded, previously diluted in a portion of cold water. Very important is the uniform distribution of yeast in the dough mass and a very good kneading.
After kneading, the dough for proofing is not left in the bowl, but laid out on the table in the refrigerator. The main concern when preparing yeast puff pastry is to prevent premature awakening of the yeast cells and the start of the yeast. At the same time, it is obligatory to rest the dough to form a gluten framework, so all processes must take place at a temperature not exceeding 12 degrees.
In various recipes, dough temperatures of 20 degrees or more are indicated. When using butter according to outdated technologies, you really have to keep the dough warm, otherwise the butter or regular margarine will not be soft and will crumble in the dough, the layers will stick together. In a warm dough, the yeast begins to work and there can be no question of any subsequent freezing of the semi-finished product.
The use of specialized puff margarines eliminates these disadvantages. This stage is the main one. It follows immediately after the formation of dough pieces. The final freezing temperature should be - 30-35gr.S. Lower temperatures can lead to irreversible negative effects.
- - processing temperature in a quick-freezer at -(50-65)°C for 20 minutes (up to a temperature of 0°C in the thickness of the dough;
- - an air exchange rate of at least 4m/s, which results in a freezing rate of approximately li p.C per minute.
Principles of storage and transportation
The duration of storage can be from several days to several months. It directly depends on the quality of raw materials (flour, yeast, improvers) and on compliance with the rules of the production cycle (kneading, molding, freezing).
Store frozen dough at temperatures from -12 to -20 ° C.
This operation is the most vulnerable in the correct and efficient technology. The chain of storage of dough pieces in the cold must not be interrupted in any case. Particular attention should be paid to the fragility of frozen semi-finished products, and the consequent risk of breakage.
Placement of the delivered blanks at the place of baking should be done in freezers (lari) with a temperature of at least -10 C. Re-freezing of defrosted semi-finished products is not allowed. If accidental defrosting occurs during transportation, then this batch can be stored in the refrigerator at a temperature of 0 degrees for only a couple of days.
Defrosting, proofing and baking products:
- 1. Immediate defrosting in the proofer. This is a fairly common method in Russia, however, even at a moderate temperature (about 28 ° C), heating too quickly reactivates the yeast on the surface of the dough piece, while in the core the lifting force remains small, where the temperature remains still low. As a result, finished products may have uneven crumb density, which is a defect.
- 2. Defrosting at room temperature, followed by fermentation in a proofer. This method is a disadvantage of the first method and the airing of the surface of the dough pieces is added to it, due to a long stay in the air.
- 3. Defrosting in a cabinet programmed to perform a defrosting first (at 0°C - the inevitable effect of condensation is minimized), while the process of thawing and swelling of proteins and starches takes place. Then the stage of proofing takes place (with a gradual increase in temperature to 30-32°C), while it is necessary to ensure maximum humidity in the proofer. This method is the most correct and is widely used abroad.
There is a delayed baking method. After cutting, the finished products are not frozen immediately, but before that they are sent for defrosting. In the latter case, the preparation time for baking is significantly reduced: such products are thawed for 15-20 minutes at room temperature and baked immediately without additional proofing.
Typically, rotary or rack conventional ovens are used. The surface of the baking trays must be in perfect condition to prevent the phenomenon of product sticking. It is best to line with SILIDOR silicone paper.
Due to the excess fermentable sugars, the baking temperature should be slightly lower than usual in order to limit the browning of the surface of the products too quickly. The baking time will therefore be somewhat longer than usual.
Typically, the baking temperature is set at 180-200°C, and the baking time is 15-18 minutes (the surface of the products should be evenly colored to a golden color).
