Product: wirecute cookies
Product is egg and milk cookies and facing issue of crumbliness, softness. we tried to adjust from reducing fat quantities and from mixing sequence but issue still persisting.
product is getting crumbly, it means crumbs particals appear in packed product. what can be the root causes and possible solutions to solve the issue on permanent basis??
Dear Mr. Khan
You can try several more things to decrease crumbliness in your product:
1. Change flour, maybe take high protein flour and mix it with low protein flour.
2. you can try increasing water by 1-2% in your formulations.
3. you can try substituting some amount of sugar with liquid sugar, they will act as humectants.
These are some things you can try to reduce crumbliness.
More water is not recommended in this regard it make product more soft and breakable.
A couple of things that may help you. Firstly are you using biscuit dust/crumb in your recipe ? If not, a simple trick is to add it. Up to 10% of the flour weight is normal with typically an extra 2 kgs of water for 10 kg of dust/crumb as a rough guide. The second thing is to look at the crumb to crust ratio. The thicker the crust the more likely you are to get crumb particles through your wrapping machines and on into the pack. If you reprofile your bake to allow a reduction of heat in the early stages of the oven you should avoid formation of a thick crust .
Sorry forgot to mention that if you find the addition of crumb works for you (it usually does) then you will need to check the impact on your acrylamide level as it is bound to increase.
respected John, We are already adding the crumb (rework) in biscuit. with rework addition and without it is same. kindly advise further in this regards??
Are you using plasticised fat ? Do you have any way of reducing the dough temp ...... replacing some of the water with ice perhaps. If the dough easily coats your hand in oil then it would suggest the problem is fat related..... either reduce fat and or dough temp and possibly you may need to reduce the amount of fat in the recipe even further than you already have.
Also worth trying... reduce water (which will reduce diameter) and then close extraction dampers in Z1 (and possibly Z2) to compensate.