The Technology of Wafers and Waffles II

Recipes, Product Development and Know-How

Karl F. Tiefenbacher

• Publisher: Academic Press
• Year: 2018
• Print ISBN: 9780128094372
• eBook ISBN: 9780128119723
• Topic: Technology & Engineering
• Subtopic: Food Science
• Index: Technology & Engineering

The Technology of Wafers and Waffles: Recipes, Product Development and Knowhow is the definitive reference book addressing new product development in wafers and waffles. As a companion manual to The Technology of Wafers and Waffles: Operational Aspects, it provides a varied selection of recipes for different types of wafers, waffles, and fillings. This book discusses flat and shaped wafers, ice cream cones, cups, wafer reels, wafer sticks, stroop waffles, and North American frozen waffles. A separate chapter focuses on recipe calculations for wafer and waffle batters, doughs, and fillings, which allows estimating output, cost, and main nutrient content.Finally, there is also an overview on the patent and food science literature on wafers and waffles in chronological order.- Brings a selection of recipes for different types of wafers, waffles, and fillings, along with information on relevant patents and literature- Includes a chapter on recipe calculations for wafer and waffle batters, doughs and fillings, along with a glossary of terms in wafer and waffle science and technology- Explores recipe calculation for estimating cost and final composition in main nutrients for wafers and waffles- Provides tables that help keep nutrient targets during new product development processes

Chapter One

Introduction and Overview

Abstract

This chapter explains the rationale for writing such a recipe book. The chapter then provides an overview of how the book is organized and what kind of information can be obtained from the book.

Keywords:

Recipes; Food labelling; Recipe calculations; New product development (NPD); New product manufacturing (NPM); Publications; Patents; Glossary

1.1 What to Expect—Why This Book?

1.1.1 Recipes are Confidential

Plenty of books on recipes exist for household and artisan baking. In industrial manufacturing, however, the level of competitiveness and the specialization leave almost no space to bring such sensitive knowhow to public awareness. Certainly, as we will see in Chapter 9 of this book, some of the patents or publications from local consultants release recipe information, at times in a very balanced manner. In both cases, these are discrete experiences, developed for a certain manufacturing situation.

First, we have to consider some cornerstones of modern industrial recipes for wafer and waffle manufacturing:

1. 1. The value of single recipes for transferring to another place, even within the same company, is rather limited (see Section 1.1.3 for details on that)
2. 2. Contemporary food labelling requirements result in a high degree of transparency regarding components, their relative proportions, and the content of the single nutrients.
3. 3. The work of consultants and the detailed recipes of their customers have to be absolutely confidential.
4. 4. The relevance of recipes is greatly overestimated; much more important is the knowhow to create a good result and a dedicated new recipe from a given set of conditions.

So, did you expect too much when buying this book? I think not, as you might learn about structuring a recipe, adapting it to your local conditions, and how to increase the stability of the baking operation. In addition you get suggestions for your development work. Recipe evaluation and intentional modification are the main ways to improve and develop further. The book will be a single, valuable tool to achieve that aim.

Spreading general knowledge can encourage further progress and help to improve efficiency. I will never forget when the head of production in an established factory for sugar wafers told me: “All of my working life I have spent making these wafers and I was very sceptical when a ‘professor’ came and wanted to tell me about it. However, since I modified two points in our recipe and process according to your recommendations, it works better and is more reliable.”

1.1.2 My Approach to Recipes

My personal career did not start in a manufacturing company for wafers or waffles learning things from scratch. Coming from the field of university food chemistry, science, and technology, after years of food technological R&D work, I joined a wafer and waffle equipment company for an interesting task. They wanted to build technological knowhow on the processes and products. I still remember the statement: “Our equipment works well in countries A, B, C, however in country D there is a complete failure and we assume the flour is responsible for it.”

The why and what to do in such a case and others kept me and my later team busy for almost 30 years. Thousands of recipe tests, first on small lab test equipment, followed by industrial test baking were needed to get some insights. Our work included:

• • how the ingredients, such as flour, water, and all the potential small ingredients, react and may be changed, be applied or not, to resolve the various issues
• • what is the role of technical provisions and adjustments for improving the result and what can be done through technological changes
• • that the most important aspect of troubleshooting is to distinguish what is required and how to take the first step if the customer is already sitting on a pile of waste products
• • how the inclusion of new ingredients and technical developments paves the way forward (I still remember the first tests of new ‘wafer enzymes’ I had from the developer in 1989 on our lab equipment. Today they are standard in many recipes worldwide)

As a result of all this work I dared to write a book on basic recipes for wafers and waffles and their fillings.

1.1.3 The Corner Stones of Recipe Development

A certain recipe is not transferable easily. It has to work for the locally given set of conditions in aspects such as the following:

1. 1. Ingredients. The local quality and availability are critical. The main influence here comes from the properties of the main ingredients, flour and water. Therefore technological adaptions are required to counteract any issues to finally obtain the ‘same’ result. Another example is the type and local costing of filling cream ingredients if sweetness reduction is a target.
2. 2. The equipment situation. The size of the baking oven, the baking plate reedings, the condition of the baking moulds, as well as other equipment parts, are frequently different from place to place – all are parameters of importance to the resulting wafer quality.
3. 3. The manufacturing ambience. Never underestimate the influence of ambient conditions such as temperature, humidity, or location and of the education and motivation of operators on the performance and efficiency of manufacturing. The making, for example, of European high quality wafers in places of high temperature and humidity can be a challenge on its own.
4. 4. Consumers’ preferences. The perception of consumers on the ‘right’ wafer or waffle quality differs from country to country. Is it the texture, the sweetness, or the ‘right’ character of a vanilla or chocolate flavour? Do you and your marketing team know?

1.1.4 Basic Recipes—What Does That Mean?

In the recipes in Chapters 3–7 of the book, I try to outline the range of ingredients as well as their typical ratios applicable for a certain type of wafer biscuit, waffle, or cream filling. The intentions are:

• • to disseminate basic information, although this will require some fine tuning for your factory
• • to avoid any reticence for changes in case of recurring issues
• • to motivate changes and new product development (NPD) in order to develop the market further
• • to provide a reference book of recipes.

All the batter and dough recipes are presented in bakers’ percentages (bakers’ maths; flour basis). Compared with the percentage format, the advantages are:

• • small changes in recipe water as frequently required do not change the percentage of all other components
• • the comparability of recipes improves—transferring to different batch sizes is easy
• • flour is the principal solid ingredient by far, thus recipe details such as the sweetness or saltiness become clearly visible.

1.1.5 Today a Lot of Information is Public

When analysing today's food labels, a lot of information on recipes can be gained. Since 2014, the EU regulations on the provision of food information to consumers has been in force. Here, the information on food labels regarding ingredients and nutrients has been expanded. For the United States, the ingredient list and the nutrition facts label offers additional information (links retrieved August 2018):

https://eur-lex.europa.eu/legal-content/EN/TXT/PDF/?uri=CELEX:32011R1169&from=EN

https://www.fda.gov/downloads/food/labelingnutrition/ucm511646.pdf

https://www.fda.gov/downloads/Food/GuidanceRegulation/GuidanceDocumentsRegulatoryInformation/UCM265446.pdf

The labelling of ingredients has to be in descending order. In combination with the nutrient data for many single wafer and waffle products, a lot of information on the recipe can be deduced.

1.1.6 Who This Second Book Is Written for

Recipe selection and modification is one of the main ways to improve and develop in the baking industry. The second book will be of interest to various people within companies: owners, technologists, quality assurance staff, operators as well as for food scientists in general. Until now, a reference work on these subjects has been missing from the market. Further interest could come from libraries and academics in food and bakery science and technology.

1.2 H...

Table of contents

• Cover image
• Title page
• Table of Contents
• Copyright
• Dedication
• Preface
• Chapter One: Introduction and Overview
• Chapter Two: The Calculation Matrix to Follow Up Recipes
• Chapter Three: Recipes for No/Low Sugar Wafers
• Chapter Four: Recipes for Sugar Wafers
• Chapter Five: Recipes for Wafer Disks and Crunchy Waffle Cookies
• Chapter Six: Recipes for Filling Creams
• Chapter Seven: Waffle Recipes
• Chapter Eight: New Products Require New Thinking—Ideas and Examples
• Chapter Nine: The Existing Stock of Knowledge: Patents & Publications
• Chapter Ten: Glossary of Terms in Wafers, Waffles and Adjuncts
• Index
• Short table of contents of book I