Developing a clean label mix for bakery filling

We wanted to find out more about the challenges and solutions when developing a bake stable mix for bakery filling. Read for more information from our Product Development Manager Michal Korzycki in Poland.

Michal, what was your goal when you developed this project?

My goal was to check the possibility of using Lyckeby Careful starch in fruit fillings suitable for baking, says Michal Korzycki. On the Polish market where I work, more and more bakery manufacturers want to have premium products compatible with the 'clean label' trend. My goal was to test the stabilizing system for the production of fillings made with frozen berries such as: strawberry, raspberry or black currant. I particularly wanted to use a single stabilizing system to obtain a ready-to-use product – fruit preparation suitable for internal injection as well as for surface application.

What type of stabilizing system did you use and why?

I have used the clean label starches from Lyckeby Careful portfolio for this project. The first step was to check which of the starch can survive the process of double thermal processing, i.e. the pasteurisation when making the filling and then baking process at 190-200 C. From my observations I concluded that both ranges in Lyckeby Careful portfolio: the barley starch (200 – range) and waxy maize (300 – range) work very well in this process set-up. I always prepared the fillings in hot process using standard pasteurization 88-90oC for 15 minutes. The batch was then cooled down. If the baking step was short (up to 10 minutes), Lyckeby Careful 250 or 350 starches worked the most efficient. Additionally, the barley starch was giving a better 'glossy' effect on the surface of the filling. If the baking process was longer, the better solution was respectively Lyckeby Careful starch 270 or 370.

Recommended dosages with starches?

The dosage dependent on several factors including the type of fruit - different fruits have different quality and pectin content. Black currant required the smallest amount of starch while strawberries the largest. The proportion of fruit in the filling and the sugar content were also very important when determine the starch dosage. E.g. for filling with c.a. 60% of frozen strawberries, I used a 5.7% addition of Lyckeby Careful starch.

What was the most interesting learning in this project?

The most interesting was to obtain the same effect and level of stability as in the case of using chemically modified starches. Very good sensory characteristics of the product, no aftertaste and no-odors are also very important. While working on the project, I also noticed that a very good solution is also synergistic use of clean label starch in combination with potato fiber POTEX CROWN. The fillings obtained when using Potex crown are slightly more pulpy, but in such samples we noticed an even better stability during baking. It seems that the use of fiber positively affects the filling volume after baking. This may be related to the Potex Crown's ability to bind water. An addition of 0,5% Potex Crown reducing starch by the same dosage gave that effect. 

Michal Korzycki, Product Development Manager Culinar Polska

Read more about Lyckeby Careful here. 

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