PRODUCTION

New boiling procedure for donuts

DU R I NG BAKE RS DAY AT TH E TTZ I N B R E M E RHAVE N, K AI HEUBERGER, I N NOVATION DI R ECTO R
B A K E R Y P R O D U C T S C S M B A K E R Y S O L U T I O N S E U R O P E H O L D I N G B . V, P R E S E N T E D A N E W B O I L I N G
PROCEDU R E FOR DON UTS. TH E E XPE RT TE LLS MOR E ABOUT TH E TECH N IC AL BACKGROU N D AN D TH E
PRODUCT TOG ETH E R WITH K E R S T I N S C H M I D T , CSM B US I N E SS DI R ECTO R BAKE RY PRODUCTS
++ figure 1

++ figure 1

Results of the consumer survey

on donuts; 5 countries;
250 consumers

source: CSM

22

Borchfeld: Mr Heuberger, why were you looking for a

new boiling procedure? What did you dislike about
the current methods?
+ Heuberger: It was more about how to improve the current
methods. When the project took off five years ago, the focus
was generally on alternative baking methods.

There, the demands to a donut different from those in Europe.

Our consumer tests in the United States showed that greasy
fingers and the taste of fat are rather appreciated in America.
+ Heuberger: One explanation for this could be that US
consumers generally consume more fried products than Euro
pean ones, which leads to different expectations.

+ Borchfeld: You questioned more than 250 consumers in five

European countries and performed tests. What are your results?
+ Schmidt: After it became clear that the new procedure has
the potential to replace the present boiling procedure for donuts,
we performed consumer surveys. Our initial focus was on
What do consumers associate with donuts?.
+ Heuberger: The results of the consumer survey are as
follows: donuts are luxury articles and consumers pose high
demands to enjoyment when eating a donut. For us, this was
a challenge to make the donut healthier without changing
the typical donut flavour.

+ Borchfeld: The new pastry was to be like a normal donut,

but containing at least 20% less fat, at least 30% less saturated
fatty acids and leave no aftertaste after eating. What were
the greatest challenges in product development?
+ Heuberger: The greatest challenge was mostly in transferring the procedure from lab scales into a large technical process. Regarding taste, the difficulty was in finding the balance
between taste and fat reduction. Technically, it is possible to
reduce the fat content by up to 60%, but then the donut
would taste rather like a milk roll.

+ Borchfeld: Dont consumers differ by country or age?

+ Heuberger: We are profiting from a mobile society today.
This means that while there are differences, they are mostly
due to age. The typical donut consumer is male, younger
than 35, and living in a family. In contrast to Berliner-Krapfen,
for example, donuts are a relatively young pastry in Europe,
and a very homogeneous flavour profile has developed.

+ Borchfeld: If all donut-eaters want enjoyment & health,

isnt there always also some counter-trend?
+ Schmidt: We have found the counter-trend in the USA.
BAKING+BISCUIT ISSUE 04 2014

+ Borchfeld: How did you achieve the reduction specifically?

+ Heuberger: When we had managed to produce a heat
transfer that is similar to that of boiling, the next steps were
comparatively simple.

+ Borchfeld: How high is the oil absorption of a normal

donut body with approx. 40 g before trying and how high is
the absorption of the new pastry?
+ Heuberger: The average fat absorption in a conventionally produced donut, depending on the recipe and process, is
approx. 78 g per donut at a starting weight of 40 g. The average
fat absorption of a donut produced in the new b oiling

23

PRODUCTION

++ figure 2

++ figure 2

CSM Sensory Test; Comparison

Standard vs. Next Generation donut

source: CSM

basic size: Perfect donut

rocedure is at approx. 45 g, depending on the d

p
esired
boiling impression.

+ Borchfeld: Has this been made possible only by the new

procedure, or did you have to modify the recipe?
+ Heuberger: The reduction is achieved only by the procedure. But of course, the applied recipe has been adjusted to
the new process as well.
+ Borchfeld: What does the process modification look like?
+ Schmidt: We wet the products to be fried with boiling

only be possible if accepting high contamination of the boiling

medium. Berliner-Krapfen with water-containing stuffing that
does not boil out during the process are now possible as well.

+ Borchfeld: Did the consumer perceive any changes in the

new donuts in the subsequent tests?
+ Schmidt: Yes, the donuts were perceived as tasting purer.
This feedback was provided by our Heavy Users. Average
consumers noticed fewer changes. Instead, they talked about
more pleasant consumption.
+ Borchfeld: Are the new pastries already being sold?
+ Schmidt: The donuts are sold in England, Italy and France

medium and then produce a very high heat transfer similar

to boiling by infrared and hot air flow. This gives us the
boiled taste but reduces the contact time of the boiling medium
and the boiled goods.

under the Sunfry brand. The product launch in Germany is

planned.

+ Borchfeld: Which technique is used and how does the heat

transfer work?
+ Heuberger: This is a hot-air chamber in which a very high
temperature is achieved. This way, we can produce a heat
transfer similar to boiling.

+ Borchfeld: Another question: Should all plants be switched

to the new procedure now?
+ Schmidt: Since our present customers and we at CSM believe that the procedure will prevail, we plan to convert the
corresponding boiling systems to the new procedure.

+ Borchfeld: What influences does the choice of boiling

+ Borchfeld: Ms Schmidt, Mr Heuberger, thank you for the

interview. +++

medium have on the fat absorption?

+ Heuberger: Generally, the new procedure enables us to
control the fat absorption depending on time and surface of
the boiled goods. We have set the absorption of our products
to minus 40% of the standard by sensors. The process generally
does not depend on the boiling medium but we have agreed
to use sunflower oil for boiling based on examinations of our
development colleagues from the area of special margarines
& boiling fats.

+ Borchfeld: Can the new boiling procedure also be applied

to other pastries such as Berliner-Krapfen?
+ Heuberger: The procedure can be extended to any other
boiled product as well; it enables us to produce donuts with
added chocolate or nuts in the dough as well. This used to

KOENIG Motiv4 NTS 91x53.qxd

12.02.2007

11:10 Uhr

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BAKING+BISCUIT ISSUE 04 2014