Bakery: Cake Emulsifiers in Gel...

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EKÖMUL MG Series DISTILLED MONOGLYCERIDES EKÖLITE PE & PG Series POLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS Application Guide Bakery: Cake Emulsifiers in Gel Form Introduction PRODUCT NAME Ekömul MG Series Ekölite PE Series Ekölite PG Series KEY BENEFITS n Source of α-crystalline emulsifiers n Source of α-tending emulsifiers for gel stability n Boost cake volume n Providing quick whipping properties n Improved cake batter stability n Improved emulsification of oil and water in cake batter n Imparting uniform, fine crumb structure n Improved cake softness Cake gels are cake improvers comprised of water, emulsifiers and solvents which are used primarily in production of sponge cakes. The key functionalities of cake gel are: To boost cake volume through improved aeration of cake batter, increased cake batter viscosity and preventing coalescence of air bubbles during batter floor time and during baking. To provide quick whipping properties. To allow the use of a single step process or ‘all-in-method’ in industrial cake production, in comparison to the conventional two-stage cake making method. To improve cake batter stability through increased cake batter viscosity to extend batter floor time. To improve emulsification of oil and water in cake batter. To impart a uniform and fine crumb structure. To improve softness of cake products and extend shelf life. Typical Quality Concerns in Cake Gel Cake gel manufacturers encounter a number of challenges during production as there are many processing variables involved that increase the complexity to produce stable and highly functional cake gels. To achieve cake gels with desired shelf life and functionality, some of the factors to be taken into consideration include : Raw material (e.g. quality of water and other ingredients) Cake gel formulation variations Processing facilities and operating conditions Type of emulsifiers used Manufacturers who understand and are able to control these parameters will create cake gels with desired shelf life stability and obtain ideal functionality in the end product. The typical quality concerns in cake gel production include: a) Crystallisation of cake gel b) Cake gel mixture viscosity c) Cake gel setting temperature

Transcript of Bakery: Cake Emulsifiers in Gel...

Page 1: Bakery: Cake Emulsifiers in Gel Formsynercore.co.za/content/uploads/2019/05/CakeGel8pp2018_Single.pdf · Distilled Monoglycerides (DMG) forms the main composition of emulsifiers in

EKÖMUL MG SeriesDISTILLED MONOGLYCERIDES

EKÖLITE PE & PG SeriesPOLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS

Application GuideApplication Guide

Bakery: Cake Emulsifiers in Gel FormIntroduction

PRODUCT NAMEEkömul MG SeriesEkölite PE SeriesEkölite PG Series

KEY BENEFITSn Source of α-crystalline

emulsifiersn Source of α-tending

emulsifiers for gel stability

n Boost cake volumen Providing quick

whipping propertiesn Improved cake batter

stabilityn Improved

emulsification of oil and water in cake batter

n Imparting uniform, fine crumb structure

n Improved cake softness

Cake gels are cake improvers comprised of water, emulsifiers and solvents which are used primarily in production of sponge cakes. The key functionalities of cake gel are:• To boost cake volume through improved

aeration of cake batter, increased cake batter viscosity and preventing coalescence of air bubbles during batter floor time and during baking.

• To provide quick whipping properties.• To allow the use of a single step

process or ‘all-in-method’ in industrial

cake production, in comparison to the conventional two-stage cake making method.

• To improve cake batter stability through increased cake batter viscosity to extend batter floor time.

• To improve emulsification of oil and water in cake batter.

• To impart a uniform and fine crumb structure.

• To improve softness of cake products and extend shelf life.

Typical Quality Concerns in Cake GelCake gel manufacturers encounter a number of challenges during production as there are many processing variables involved that increase the complexity to produce stable and highly functional cake gels. To achieve cake gels with desired shelf life and functionality, some of the factors to be taken into consideration include :• Raw material (e.g. quality of water and

other ingredients)• Cake gel formulation variations• Processing facilities and operating

conditions• Type of emulsifiers used

Manufacturers who understand and are able to control these parameters will create cake gels with desired shelf life stability and obtain ideal functionality in the end product.

The typical quality concerns in cake gel production include:a) Crystallisation of cake gelb) Cake gel mixture viscosityc) Cake gel setting temperature

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Application GuideEKÖMUL MG SeriesDISTILLED MONOGLYCERIDES

EKÖLITE PE & PG SeriesPOLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS

a) Crystallisation of cake gel

Crystallisation in cake gel refers to the appearance of white spots on the gel surface. This occurs due to the inherent instability of α-gels that transforms into a more stable state β-crystalline coagel. The active α-gel contributes to the functionality of aeration and whippability in cake gels. As a result when β-crystalline coagels are formed, the functionality of a cake gel is reduced. The rate of crystallisation in cake gel depends on the gel formulation and its processing conditions. Crystallisation may take place within minutes or up to several months.

The selection of emulsifiers and a balanced gel formulation is of critical importance:1. To create a stable, active gel phase for longer shelf life of

cake gels.2. To provide the ideal aeration and whipping functionality

during batter mixing.3. To impart the ideal crumb structure, volume and softness

to sponge cakes.

Cake Gel(after crystallisation)

Cake Gel(before crystallisation)

Note: Cake gel before and after crystallisation after a period of storage.

b) Cake Gel Mixture Viscosity

Cake gel mixture viscosity is an important factor in cake gel processing as it impacts the homogeneity during mixing stage and the removal of air bubbles during filling stage, to produce a stable cake gel with ideal batter and cake functionality. The

mixture viscosity also has an indirect impact on the gel setting temperature, where a more viscous product tends to gel at a higher temperature which is not favourable.

Thick, not flowy mixSmooth and flowable mix

Note: Cake gel mixture during mixing stage.

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Application Guide EKÖMUL MG SeriesDISTILLED MONOGLYCERIDES

EKÖLITE PE & PG SeriesPOLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS

Application Guide

a) Ekömul MG series Distilled Monoglycerides

% F

ATTY

ACI

D

EKÖMUL MG 95 HP

0

20

40

60

80

100

C16 C18

Distilled Monoglycerides (DMG) forms the main composition of emulsifiers in a cake gel formulation and is the source of α-crystalline emulsifiers. DMG is hydrated into lamellar phases at elevated temperatures and forms the desired α-gel when cooled. Active α-gels are highly functional in promoting

aeration, whippability and emulsification in cake batter. In cakes, DMG complexes with starches in cake batter during baking, to impart a fine, uniformed crumb structure and aids in extending the shelf life of baked goods.

Emulsifiers for Cake Gel

i) Comparative Fatty Acid Composition of Ekömul MG series Distilled Monoglycerides

Futura Ingredients has developed Ekömul MG series Distilled Monoglycerides with different fatty acid compositions that can improve and extend the quality of both cake gels and cake.

Ekömul MG products with higher C18 fatty acid compositions demonstrate improved cake gel stability and functionality in the final baked product.

EKÖMUL MG 95 HO

EKÖMUL MG 95 PS

EKÖMUL MG 95 HV

EKÖMUL MG 95 HR

Note: Fatty Acid Composition of Distilled Monoglycerides are determined by raw material source.

Ekömul MG Series Distilled Monoglycerides Total monoglyceride content: min. 95%Acid value: max 3 mg KOH/gIodine value: max 2 g I2/100g

c) Cake Gel Setting Temperature

The setting temperature of cake gels is important as it determines the filling temperature of cake gel and condensation in packaging. Water hardness greatly influences cake gel setting temperatures, as hard water will reduce gel

setting temperature. A lower setting temperature minimises condensation and ensure smoother cake gel setting, thus improving operational and supply chain considerations.

Page 4: Bakery: Cake Emulsifiers in Gel Formsynercore.co.za/content/uploads/2019/05/CakeGel8pp2018_Single.pdf · Distilled Monoglycerides (DMG) forms the main composition of emulsifiers in

Application GuideEKÖMUL MG SeriesDISTILLED MONOGLYCERIDES

EKÖLITE PE & PG SeriesPOLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS

iii) Comparative Batter and Cake Functionality of Ekömul MG series Distilled Monoglycerides

CAKE

SPE

CIFI

C VO

LUM

E (C

M3 /G

)

EKÖMUL MG 95 HP

0.5

EKÖMUL MG 95 HO

EKÖMUL MG 95 PS

EKÖMUL MG 95 HV

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0.05

0.10

0.15

0.20

0.25

0.35

0.40

0.30

BATT

ER S

PECI

FIC

GRA

VIT

Y

SPECIFIC VOLUME SPECIFIC GRAVITY

Note: Cake gels made with different DMG variants tested with basic sponge cake recipe at 5% cake gel.

ii) Comparative Structures of Cake Gels using Ekömul MG series Distilled Monoglycerides

Ekömul MG 95 HP Ekömul MG 95 HO

Ekömul MG 95 PS Ekömul MG 95 HV

Note: Structure of cake gels made with DMG variants observed via Polarised Light Microscopy.

The functional α-gels or lamellar phase dispersions are normally observed as streaky structures under polarised light microscope while for β-crystalline coagel or cubic phase, no structures can be observed. All the micrograph structures of

cake gels made with different DMG variants shows a similar streaky α-structure trend although they were smeared in slightly different directions on the object glass.

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Application Guide EKÖMUL MG SeriesDISTILLED MONOGLYCERIDES

EKÖLITE PE & PG SeriesPOLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS

Application Guide

The difference in polyglycerol characteristics between Ekölite PE 03 P and Ekölite PE 02 P impacts the cake gel mixture viscosity. Cake gels made with Ekölite PE 02 P typically yields a cake gel mixture with slightly lower viscosity which may be favourable to cake gel manufacturers seeking lower gel

setting temperatures. Despite having different polyglycerol characteristics, both Ekölite PE 03 P and Ekölite PE 02 P have excellent performance in terms of batter aeration, cake volume and crumb structure.

Ekömul MG 95 PS and Ekömul MG 95 HV with higher C18 fatty acid compositions provides a superior performance in both aeration and cake volume as compared to Ekömul MG 95 HP and Ekömul MG 95 HO.

The aeration of cake batter is measured by specific gravity (SG), where batter with a lower SG is indicative of greater air incorporation thus yielding a lighter, fluffier cake.

b) Ekölite PE series Polyglycerol Esters

Polyglycerol Esters function as α-tending emulsifiers to stabilise the α-crystalline structure of monoglycerides. The addition of Ekömul PE series into a cake gel formulation helps delay the transition of short-stability whipping-active α-gels to the non-whipping active β-coagel. By stabilising the

active α-crystalline structure of monoglycerides, Ekömul PE series prolongs cake gel shelf life, which in turn influences the softness and crumb structure of the final product. Ekömul PE series is used to boost aeration and foam stabilisation of Ekömul MG series Distilled Monoglycerides.

i) Comparative Batter and Cake Functionality of Ekölite PE series Polyglycerol Esters

CAKE

SPE

CIFI

C VO

LUM

E (C

M3 /G

)

EKÖLITE PE 03 P

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

0.05

0.10

0.15

0.20

0.25

0.30

BATT

ER S

PECI

FIC

GRA

VIT

Y

0.0

EKÖLITE PE 02 P

SPECIFIC VOLUME SPECIFIC GRAVITY

Note: Cake gels made with different Polyglycerol Esters variant tested with basic sponge cake recipe at 5% cake gel.

Page 6: Bakery: Cake Emulsifiers in Gel Formsynercore.co.za/content/uploads/2019/05/CakeGel8pp2018_Single.pdf · Distilled Monoglycerides (DMG) forms the main composition of emulsifiers in

Application GuideEKÖMUL MG SeriesDISTILLED MONOGLYCERIDES

EKÖLITE PE & PG SeriesPOLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS

ii) Comparative Crumb Structure using Ekölite PE series Polyglycerol Esters

Ekölite PE 02 PEkölite PE 03 P

Note: Cake gels made with different Polyglycerol Esters tested with basic sponge cake recipe at 5% cake gel.

c) Ekölite PG 95 S Propylene Glycol Monoester

Propylene Glycol Monoesters function as an α-tending emulsifier to stabilise the α-crystalline structure of monoglycerides. Ekölite PG 95 S performs a similar function to Ekölite PE series in terms of delaying the transition of short- stability whipping-active α-gels to the non-whipping active β-coagel. However, Ekölite PG 95 S has superior aeration

capabilities and foam stabilisation properties than Ekölite PE series. Thus, yielding cakes with a super fine crumb structure. Typically, Ekölite PG 95 S is incorporated together with Ekölite PE series for ideal functionality in aeration, volume and crumb structure.

i) Comparative Cake Gel Aeration between Ekölite PE series and Ekölite PG 95 S

Note: Test conducted using cake gel aeration test. Percentage of α-tending emulsifiers in the cake gel formulation totals 10%.

7.5

7.0

6.5

6.0

5.0

4.5

4.0

2 MIN

SPEC

IFIC

VO

LUM

E (C

M3 /G

)

8.5

3 MIN 4 MIN 5 MIN 6 MIN

5.5

8.0

100% EKÖLITE PE 03 P

INGREDIENTS DOSAGE (%)

Water 60.0

Icing Sugar 38.0

Cake Gel 2.0

Total 100.0

50% EKÖLITE PE 03 P +50% EKÖLITE PG 95 S

Page 7: Bakery: Cake Emulsifiers in Gel Formsynercore.co.za/content/uploads/2019/05/CakeGel8pp2018_Single.pdf · Distilled Monoglycerides (DMG) forms the main composition of emulsifiers in

Application Guide EKÖMUL MG SeriesDISTILLED MONOGLYCERIDES

EKÖLITE PE & PG SeriesPOLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS

Application Guide

ii) Comparative Cake Specific Volume Between Ekölite PE series and Ekölite PG 95 SSP

ECIF

IC V

OLU

ME

(CM

3 /G)

100% EKÖLITE PE 03 P3.0

3.1

3.2

3.3

3.4

3.5

3.6

3.7

50% EKÖLITE PE 03 P + 50% EKÖLITE PG 95 S

Note: Test conducted with basic sponge cake recipe at 5% cake gel.

iii) Comparative Crumb Structure Between Ekölite PE series and Ekölite PG 95 S

Note: Test conducted with basic sponge cake recipe at 5% cake gel.

100% Ekölite PE 03 P

50%Ekölite

PE 03 P +50%

EkölitePG 95 S

General Compositions of Cake GelINGREDIENTS DOSAGE FUNCTIONS

Distilled Monoglycerides (DMG)Ekömul MG 95 HPEkömul MG 95 HOEkömul MG 95 PSEkömul MG 95 HVEkömul MG 95 HR

13-25%

- Source of α-crystalline emulsifiers (most active phase for aeration)- Aeration of batter- Emulsification of oil and water in batter- Retards staling- Provides improved crumb softness

α-tending EmulsifiersEkölite PE 03 PEkölite PE 02 PEkölite PG 95 S

5 – 15%- α-tending emulsifier: stabilises DMG in its active α form- Form films with α-gel structures- Enhance aeration and foam stability

Polar Solvents / Humectant 25 – 40 %

- Retain moisture- Control microbial and chemical activities by reducing the system’s water activity- Compositions depend on desired functionality, cost and legislation- Examples: Glycerol, Sorbitol, Propylene Glycol

Water 40 – 55 %

Other additives .. Additives such as sodium soap, sodium chloride and potassium hydroxide are used to regulate gel formation

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Application GuideEKÖMUL MG SeriesDISTILLED MONOGLYCERIDES

EKÖLITE PE & PG SeriesPOLYGLYCEROL ESTERS & PROPYLENE GLYCOL ESTERS

DisclaimerThe information and recommendations contained herein are to the best of our knowledge reliable. However, nothing herein is to be construed as a warranty of representation in respect of safety in use, suitability, efficacy or otherwise including freedom from patent infringement. Users should conduct their own tests to determine the suitability of our product for their own specific purposes and the legal status for their intended use of the product.

BRAND NAME

PRODUCT NAME MONOESTER IODINE

VALUE

MELTING POINT,

APPROX.

RSPO CERTIFIED

FEEDSTOCKMB SG

EKÖMUL

Distilled Monoglycerides & Mono and Di-glycerides MG-Series

MG 95 HP Min. 95% Max. 2 65oC a a Palm

MG 95 HO Min. 95% Max. 2 66oC a a Palm

MG 95 PS Min. 95% Max. 2 67oC a Proprietary Blend

MG 95 HV Min. 95% Max. 2 69oC a Soya

MG 95 HVX Min. 95% Max. 2 69oC Non Palm Soya

MG 95 HR Min. 95% Max. 2 69oC a Rapeseed

EKÖLITE

Propylene Glycol Esters PG - Series

PG 95 S Min. 95% Max. 3 44oC Non Palm Rapeseed

Saponification Value

Iodine Value

Melting Point,

approx.

RSPO Certified

Fat SourceMB

Palm SG

Polyglycerol Esters PE - Series

PE 03 P 130-160 Max. 3 58oC a Palm

PE 02 P 125-145 Max. 3 58oC a Palm

Product Specifications

HEADQUARTERSFutura Ingredients

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01-00 Singapore 609914o +65 6829 5115f +65 6720 0158

w futuraingredients.come enterpriseservices@ futuraingredients.com

MANUFACTURING SITEEcolex Sdn Bhd

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Pulau Indah Industrial ParkPulau Indah 42920 Selangor

Malaysiao +603 3258 3000f +603 3258 3160

Winner ofFrost & Sullivan’s

2018 Best Practices AwardFood Ingredients

Company of the Year

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2016 Best Practices AwardEntrepreneurial Company

of the Year