I am trying to produce a chocolate biscuit for the use with ice cream, most importantly it should have the cake like texture when added to icecream.
Firstly, I do not know if this type of biscuits is made with rotary moulders or with hard biscuit machine like marie biscuit.
So I tried both, but for rotary moulders, the biscuit kept on developing cracks the next day (cooling time is 2 times oven time) and also did not absorb enough water from the icecream to make the cake like texture needed. (It was left frozen with the icecream for more that 3 days).
For hard biscuit, the I could not make the biscuit taste chocolaty enough, as when I increase the amount of cocoa powder the dough becomes less elastic. And also did not make the cake like textured desired after freezing it with icecream for more tha 3 days.
Thank yoy for your help
The biscuit base is normally rotary moulded using a recipe containing a high level of invert sugar to assist in absorbing moisture after baking
The cracking of the biscuits is probably due to small amounts of moisture migrating from the ice cream into the dry biscuits prior to the ice cream freezing which results in stresses generated in the biscuit whilst this moisture equalises causing cracks.
Due to the freezing process, you won’t achieve the cake like texture in the biscuit if you use dry biscuits because the water in the ice cream freezes soon after the sandwiching process and therefore cant migrate into the biscuits. To achieve the soft cake like texture you need to add in a biscuit "conditioning" step after baking, using the following process
· Bake the biscuit bases to 2 – 3% moisture
· After cooling place, the biscuits in perforated trays (like bread trays)
· Store the trays in a high humidity room until the biscuit moisture is approximately 8% or higher (this may take 1 – 2 days). A steam generator may be required.
· Sandwich the pre-hydrated biscuits with ice cream and freeze.
I hope this helps
Dear Mr. Zeidan,
Making the best ice cream sandwich biscuit requires a highly hygroscopic product. I don't think rotary molded biscuits are preferred due to the high fat content. The most successful sandwiches are made with hard biscuits .
Cracks in finished biscuits are usually faced due to moisture gradient so you have to make sure the minimum water is being trapped in in your biscuits by allowing water to escape in earlier baking zones in the oven. Longer cooling time is also helpful.
To allow for higher migration of moisture from ice cream to biscuit shell delayed freezing will be helpful once the product is frozen below 18 degree C very little water can migrate to the biscuits. To improve the intensity of chocolate flavour I suggest using highly alkalized cocoa powder. Use of some salt is useful as a flavour enhancer.
You can reach me for further discussions.
Dear Mr. Zeidan
Ice cream wafers are more difficult to manufacture than most folks think if you never made them before . Baking profile, docker pattern on biscuit , maintaining a low finished product moisture , cooling of biscuit is critical to minimize and eliminate product checking post bake prior to shipping.
Typically ice cream wafers are straight sheeted , cut on a rotary type cutter. It is very important to maintain a 2:1 reduction ratio during machining. Also the use of meta bisulfiite to manage SnapBack that will facilitate machining and manage product dimensions.
Hi Mr Ziedan
I have a few more comments to add. on biscuit checking. This is an issue which can be difficult to eradicate but a few areas worth investigation that have helped reduce this problem are as follows:
Ingredient variation particularly flour - protein should be in the range 8 -10% and water absorption should be low (soft milling wheats used where possible).
Dough processing - take care to not overmix the dough as gluten development can cause distortion of the dough pieces after cutting (thicker in some areas) which can cause checking. The dough piece should also have docker pin holes that don’t close up during baking and the addition of SMS (or enzymes) to the dough can be beneficial.
Baking - a flat baking curve is recommended with biscuits preferably baked on a wire oven band, typically 8 minutes baking time using the following zone temperatures - 150˚C, 180 ˚C, 175˚C , 150˚C and baked to 2.5% moisture
Cooling – this is best done in ambient temperatures and the cooling time needs to be at least 1.5 times the baking time. Avoid the use of fans and check for draughts on the product during cooling.