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Journal of the Science of Food and Agriculture J Sci Food Agric 88:1194–1200 (2008)

Use of durum residue flour, a


lower value product of durum milling, by
incorporation into wheat flour dough without
deterioration in baking quality
Mike J Sissons,1,2∗ Ian L Batey,2,3,† Sue Balfe,1 Ray Hare1,2 and
Finlay MacRitchie2,3,‡
1 Tamworth Agricultural Institute, NSW Department of Primary Industries, 4 Marsden Park Road, Calala NSW 2340, Australia
2 ValueAdded Wheat CRC Locked Bag 1345, North Ryde, NSW 1670, Australia
3 CSIRO Plant Industry, Grain Quality Research Laboratory, PO Box 7, North Ryde, NSW 1670, Australia

Abstract

BACKGROUND: During the milling of durum wheat to semolina, about 10–15% of total products produced is
residue flour, a lower value product than the semolina. This study investigated the potential for using the durum
residue flour as an additive in bread-making to improve its potential commercial value.

RESULTS: Incorporation of residue durum flour from 102 breeding lines into a low protein flour and standard
bakers’ flour at 20% incorporation improved the bake loaf volume with minimal change in Mixograph dough
mixing time and peak resistance in many of the lines tested. Loaf yellow b was always increased even with only a
10% incorporation. Baking flours can tolerate 20% incorporation with no deleterious affects on loaf volume and
bake score.

CONCLUSION: The results show a potential for using the lower value durum residue flour for baking bread of
acceptable quality with a slightly higher yellow colour. This would improve the profitability for the miller and
provide alternative ingredients to the baker for preparing specialty breads.
 2008 Crown in the Right of the State of New South Wales and Society of Chemical Industry.

Keywords: durum wheat; semolina; durum clear flour; bread; rheology

INTRODUCTION may be useful to improve the baking quality of a


The best raw material for pasta is durum wheat low protein bakers’ flour or to use it as a cheaper
semolina and, for millers, a high yield of quality flour replacement. Increased usage of the durum flour
semolina is important. During the milling of durum residue in bread making would increase the value of
wheat to semolina about 10–15% of total products this material and improve the profitability of milling
is residue flour also called durum clear flour. This durum wheat. Dekov et al.2 found that by adding
is a lower value product than the semolina and durum flour to a strong soft wheat flour, both the
has been used for sausage filler, combined with output and quality of the bread made from this mixture
semolina to make lower grade pasta or noodles, and (15:85) was improved. Also, Ozen3 reported that up to
in pet food and stock-feed formulations. From an 5% addition of durum residue flour had no deleterious
economic perspective, a study of the utilisation of impact on bread quality. More recent work has found
durum residue flour in bread-making could increase that durum wheat cultivars with strong gluten were
its value and offset the cost of producing semolina. milled and the durum residue flour was added to wheat
Quaglia1 described the extensive use of durum wheat flour at a 25% incorporation rate which produced
in the preparation of breads in southern Italy having bread with acceptable quality.4,5 Recent interest has
a distinct flavour, yellow colour, fine and uniform focused on using durum wheat varieties to make pan
porosity and prolonged storage life. Given the typically breads and to investigate ways to overcome the high
high protein content of durum flour (11–16%), it gluten tenacity which limits the loaf volume of durum


Correspondence to: Dr Mike J Sissons, Tamworth Agricultural Institute, NSW Department of Primary Industries, 4 Marsden Park Road, Calala NSW
2340, Australia
E-mail: mike.sissons@dpi.nsw.gov.au

Present address: Food Science Australia, P.O. Box 52, North Ryde, NSW 1670, Australia

Present address: Department of Grain Science and Industry, Kansas State University, Manhattan, KS 66506-2201, USA
(Received 28 August 2007; revised version received 28 November 2007; accepted 29 November 2007)
Published online 28 March 2008; DOI: 10.1002/jsfa.3197

 2008 Crown in the Right of the State of New South Wales and Society of Chemical Industry. J Sci Food Agric 0022–5142/2008/$30.00
Effects of incorporating durum residue flour into wheat flour dough

bread compared to that made with selected hexaploid Blending study


wheats.1 Several workers5 – 10 have shown that the Blends consisted of durum residue flour from durum
baking performance of durum wheat improves as wheat (sets 1 and 3) mixed with two bread wheat
gluten becomes stronger but inferior baking potential flours (set 1) and a standard bakers’ flour (set 3). The
of durum wheat is still obtained. Acceptable bread blending was undertaken with a replacement level of
properties were achieved by blending durum wheat 20% of the bread wheat flour with durum residue
at a 60% incorporation at the sponge stage of dough flour. The flours were blended before analysis and
development in the sponge-dough baking method.10 mixed well to obtain a homogeneous sample. For set
In more recent work, Sapirstein et al.11 found that 2, each of the three bread wheat flours were replaced
when semolina is ground, starch damage is increased with durum residue flour from the three cultivars at
and this increases the farinograph water absorption replacement levels of 10, 15 and 20%.
but loaf volume is unaffected by the particle size of the
granulars, assuming there is sufficient gassing power Physical dough tests and baking procedures
to sustain gas production throughout fermentation. Dough mixing was carried out using a Mixograph
The purpose of this work was to investigate the (National Manufacturing, Lincoln, NB, USA) on a
potential for using the durum residue flour from the 35 g scale. Water absorption was calculated using
milling of semolina on a laboratory scale as an additive a formula which considered protein and moisture
in bread-making. contents of the flour.12 Baking was carried out on
a 35 g scale on set 1 samples.13 For baking, doughs
were mixed for the optimum time as determined by
duplicate measurements in the Mixograph. A subset
MATERIALS AND METHODS
of samples from set 1 was baked on a larger scale
Flour samples
(100 g) in duplicate for more detailed analysis to
Set 1
provide both loaf volume and quality information. The
Set 1 comprised grain from 102 fixed durum breeders’
determination of the bake mixing time and amounts
lines grown at five sites in NSW, Australia in the
of water to be added were derived from relationships
1996–1997 season. Grain was milled into semolina
established in our laboratory with Farinograph dough
using a Buhler Laboratory Mill MLU 202 (Buhler,
development time and corrected water absorption,
Uzwill, Switzerland).12 The three break fractions
respectively.14 Bake score (BS) was a visual assessment
containing durum residue flour were pooled and score (0–10) consisting of external appearance, crust
used in mixing and baking studies. Throughout this colour and texture. Using a procedure developed in-
study, this fraction is referred to as durum residue house, the BS was determined as loaf volume/30+
flour. Two bread wheat control flours were used weighted scores for the three visual measures. Colour
for the incorporation of durum residue flour; a of the bread was measured using a Minolta hand-
standard bakers’ flour with 11.9% protein content held meter (Minolta Chroma Meter model CR-310,
(George Weston Milling, Enfield, Australia) and a Osaka, Japan) calibrated against a white tile as per
low protein (10.3%) flour (BRI Ltd, North Ryde, manufacturers’ instructions. The Chroma Meter was
Australia). placed at two different locations on the freshly cut face
of a loaf and the L, a and b parameters were recorded.
Set 2
Set 2 was durum residue flour was obtained from the Data analysis
milling of durum wheat into semolina as described An analysis of variance was performed on all data to
above from three Australian cultivars, Yallaroi, calculate a least significance difference (LSD). Data
Wollaroi and Kamilaroi. These were from the same presented in the tables are mean values. Statistical
field trials as in set 1 and the residue flour was Analysis System procedures and programs (SAS
incorporated into three different bread wheat control Institute, Cary, NC, USA) were used for data analysis.
flours with varying protein content: (1) standard
bakers’ flour (SP, 11.9%, 14%mb); (2) proline-rich,
high-protein flour (HP, 13.8%, 14%mb); (3) low RESULTS
protein flour (LP, 10.3%, 14%mb) as used in Effect of incorporation of residue flour from a
set 1.
range of durum genotypes into a commercial
and low protein bakers’ flour on dough mixing
Set 3 properties
Set 3 was durum residue flour prepared from The most obvious change in the mixing characteristics
a selection of eight advanced breeding lines and of a bakers’ flour (11.9% protein) when durum residue
two registered Australian varieties, Kamilaroi and flour was incorporated was a tendency for the mixing
Wollaroi. These were selected based on their varying time to be increased. There was a mean increase in mix
pasta-making performance. They were grown in the time of 9 s when durum residue flour was incorporated.
1996–1997 season from one site in NSW, Australia. However, while there were many durum flours that

J Sci Food Agric 88:1194–1200 (2008) 1195


DOI: 10.1002/jsfa
M J Sissons et al.

caused a decrease in the mixing time (31 out of 102 peak resistance, although with this parameter, most of
samples), only 10 samples caused the mixing time the samples were not very different from the values
to decrease by more than 5% (Fig. 1). There were obtained for base wheat flour (data not shown).
more which increased the mixing time by at least 5%
(38 samples), and 20 which increased it by 10% or Effect on baking properties
more. The increase in mixing time appeared to be During the milling of durum grain using the Buhler
unrelated to protein content. On the other hand, none laboratory mill, three break flour fractions are
of the samples caused a significant increase in the peak produced. It is possible that there may be slight
resistance, but 21 samples caused a reduction of at compositional differences between these fractions and
least 5% (data not shown). when added to a bakers’ flour, have a different effect
With the low protein flour, almost all of the samples on loaf quality. This was tested by preparing an 80:20
showed an increase in mixing time. Most of these mixture of bakers’ flour and durum break fraction.
increased mixing time by at least 5% (Fig. 2). With There were no significant differences in loaf volume
peak resistance, most of the samples changed this (LV) and bake score (data not shown) between
parameter by less than 5%, but in contrast with the the three durum flour break fractions (Table 1).
standard bakers’ flour, peak resistance also increased Therefore, it was acceptable to pool the three break
by more than 5% with five of the durum flour samples fractions and this helped to provide sufficient sample
(data not shown). A smaller proportion of samples for baking.
showed a significantly lower peak resistance. Typical Loaf volume is one of the main characteristics of
Mixograph curves of wheat flour and wheat flour with bread quality although colour and textural properties
durum residue flour are shown in Fig. 3. are also important. When incorporated into the
The effects on the mixing time and peak resistance standard bakers’ flour, almost all of the durum residue
are independent of durum protein content (Fig. 4). flour samples produced an increase in LV (Fig. 5).
An increase in the mixing time is just as likely to Most of these increased the LV by more than 5%,
occur in a low protein durum flour as in a high some by more than 10%. Only six samples of durum
protein one. Similar observations were made with the residue flour decreased the LV by more than 5%. Full
loaf scoring was not carried out on the 35 g loaves, but
the crumb colour and texture were inspected visually
50 and judged to be acceptable. There was a trend for
Bakers’ flour
the change in LV to be affected by the protein content
40
of the durum flour, but the relationship was poor
(r = 0.25, P < 0.05); clearly other factors are also
Frequency

30
involved.
20 A more detailed analysis was performed to look at
the effects on LV and BS using 100 g pup loaves on
10 samples from set 3. This set contained a range of
durum with varying pasta quality (data not shown).
0 Each of a selected set of 10 durum residue flours
230-250 250-270 270-290 290-320 320-350
was incorporated into a standard bakers’ flour (11.9%
Mixing time range (sec)
protein) and a low protein flour (10.3%). There were
Figure 1. Distribution of mix time in bakers’ flour blends with different highly significant affects on LV and Minolta b∗ due
durum genotypes added at 20% incorporation. to sample (Table 2). For the standard bakers’ flour,

30

25

20
Frequency

15

10
Bakers’ flour

0
260-290 290-320 320-350 350-380 380-410 410-440 440-470 470-500
Mixing time ranges (sec)

Figure 2. Distribution of mix time in low protein wheat flour blends with different durum genotypes added at 20% incorporation.

1196 J Sci Food Agric 88:1194–1200 (2008)


DOI: 10.1002/jsfa
Effects of incorporating durum residue flour into wheat flour dough

1200 1200
(A) (C)
1000 1000
800 800
600 600
400 400
200 200
0 0
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
Time (min) Time (min)

1200 1200
(B) (D)
1000 1000
800 800
600 600
400 400
200 200
0 0
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
Time (min) Time (min)

Figure 3. Mixograph curves of each control wheat flour with the same durum residue flour incorporated at 20%: (A) bakers’ flour, (B) bakers’ flour
plus durum flour, (C) low protein flour, and (D) low protein flour plus durum residue flour. The units on the Y axis are arbitrary units from the output
of the Mixograph.

600 60
Bakers’ flour
50
500 40
Frequency

30
400 20

10
300
0
140-160 160-180 180-200 200-220
LV range (cc)
200
8 12 16 20 Figure 5. Distribution of loaf volume in bakers’ flour blends with
different durum genotypes added at 20% incorporation.
Figure 4. Plot of mixing time (, in seconds) and peak resistance (,
in arbitrary units) against protein content of durum residue flours
incorporated into doughs with bakers’ flour. control, 27.6) to the control flour and only bread made
from 100% durum residue flour (Wollaroi) had a much
Table 1. Effects of the incorporation of 20% durum residue flour from
reduced LV and BS (18.9) compared to the control
each break on the volume of loaves prepared from a bakers’ flour baker flour, having an external appearance with rough
edges, a dark crust and coarse texture. The crumb
Sample Loaf volume (cm3 ) yellow colour of loaves made with durum residue flour
100% bread wheat flour 718 were all significantly higher than the standard bakers’
80% bread flour:20% durum first break 715 flour. This is due to the higher xanthophyl content
80% bread flour:20% durum second break 725 of durum endosperm compared to hexaploid wheat.
80% bread flour:20% durum third break 718 With the standard bakers’ flour, the 100% wheat flour
loaves had yellowness (Minolta b-value) of 18.9, while
the loaves with durum flour ranged from 20.8 to 23.0.
six of the ten durum residue incorporated flours The increase was relatively small, compared with the
had significantly greater LV compared to the 100% yellowness of a 100% durum loaf (33.0) but may still
standard bakers’ flour (Table 2). Only bread made be unacceptable to the baker. This would be one of
from 100% durum residue flour had significantly lower the main drawbacks in using durum residue flour for
LV. These results confirmed the 35 g trials in that bread baking although it would be possible to bleach
generally loaf volume was improved. All of the durum out the yellow pigment if acceptable on health and
incorporated flours had a similar BS (26.6–28.1 vs. safety grounds.

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M J Sissons et al.

Table 2. Effect of durum residue flour incorporation into a standard


bakers’ flour (11.9% protein) upon loaf quality

Sample Loaf volume (cm3 ) Crumb Minolta b

100% Control flour 708 18.92


Kamilaroi 733 21.56
Wollaroi 720 20.84
930132 725 22.24
930433 738 22.29
930614 708 21.89
930983 733 21.92
940293 730 21.8
940844 753 23.04
940955 743 22.55
940996 740 22.65
100% Wollaroi flour 655 33.01
P value 0.0001 <0.0001
LSD 23 1.12

Table 3. Effect of durum residue flour incorporation into a low protein


flour (10.3%) upon loaf quality

Sample Loaf volume (cm3 ) Crumb Minolta b

100% Control flour 698 18.03


Kamilaroi 695 21.88
Wollaroi 700 21.77
930132 673 22.45
930433 730 22.31 Figure 6. Pup loaves (100 g) prepared from standard bakers’ flour
930614 690 21.98 (panel A) and a low protein flour (panel B). Panel A: Bread made from
930983 680 22.27 bakers’ flour (16); bakers’ flour with a 20% incorporation of durum
940293 688 22.82 residue flour (from selected genotypes), loaves 14 (940955), 24
940844 715 22.71 (930614) or 100% Wollaroi residue flour (6). Panel B: low protein
baker flour (15); low protein flour with a 20% incorporation of durum
940955 688 23.18
residue flour, loaves 7 (930433), 10 (930132) or 100% Wollaroi
940996 700 22.95
residue flour (6). Corresponding loaf volumes (in cm3 ) are 16 = 710,
100% Wollaroi flour 668 33.87 14 = 755, 24 = 700, 6 = 665; and lower panel: 6 = 660, 15 = 695,
P value 0.0195 <0.0001 7 = 740, 10 = 655.
LSD 28 0.45
evident from these photographs that there is much
Loaf volume for the lower protein bakers’ flour was visual difference between the 20% durum residue
only slightly lower than the standard bakers’ flour incorporated breads despite differences in LV, unless
(698 vs. 708 cm3 ) (Table 3). Although there was a a trained eye scores the loaves. From a consumer’s
significant effect of sample on LV as determined viewpoint, these loaves might be quite acceptable.
by ANOVA, there were no changes in the LV of Flavour was not considered in the analysis.
durum residue incorporated flours except for an
increase using 930 433. The LV of 100% durum Effect of incorporation of different rates of durum
flour bread was inferior to the control and five of residue flour on bakers’ flour performance
the durum residue incorporated samples. Bake score Durum residue flour was incorporated into high
for the durum incorporated flours ranged from 23.4 to (13.8%), standard (11.9%) and low (10.3%) protein
26.4 (cf. control flour, 24.8) while bread made from bakers’ flours at three different rates of incorporation
100% durum flour had a very low bake score (19.3). (10, 15, 20%) to determine the optimum incorpo-
Once again, bread made with the durum residue flour ration rate. The ANOVA found that the base flour
always had a higher yellow colour, highest for the protein level and the durum residue flour rate used
100% durum bread sample. Yellow colour for the were significant for LV (Table 4). As the protein level
20% durum residue flour loaves ranged from 21.8 to went from high to medium to low, LV of all the samples
23.2. Figure 6 shows selected breads (Tables 2 and 3) declined significantly. LV of the bread made from the
made from bakers’ flour and with 20% incorporated low protein flours were lower than the corresponding
durum residue flour or made from 100% durum flour samples from the SP and HP base flours. Comparing
(Wollaroi). It is clear from these pictures that the 100% the effect of durum residue rate on LV within each base
durum flour has a lower loaf height, a different crust flour class, the results did not show a consistent trend
and is more yellow in appearance than the control despite a significant effect. For example, for Wollaroi
and 20% incorporated loaves. However, it is less in the HP flour, increasing amounts of the durum flour

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Effects of incorporating durum residue flour into wheat flour dough

Table 4. Effect of durum residue flour incorporation at three different rates and from three cultivars into a high, standard and low protein bakers’
flour upon loaf quality

Loaf volume (cm3 ) Minolta b value

Sample HP SP LP HP SP LP

100% Baker’s flour 800 745 728 19.45 19.61 18.90


Y @ 10% 770 728 718 21.13 21.04 21.36
Y @ 15% 803 715 688 21.54 21.69 21.88
Y @ 20% 750 716 700 22.34 22.53 22.32
W @ 10% 785 743 708 21.31 20.93 21.24
W @ 15% 785 750 718 22.01 24.45 21.41
W @ 20% 770 740 718 22.37 22.69 22.70
K @ 10% 755 743 703 21.24 20.88 20.79
K @ 15% 788 738 708 21.57 21.80 21.70
K @ 20% 785 730 713 22.55 22.93 22.86
LSD protein level (P value from ANOVA) 7.3∗∗∗ (<0.001) 0.20 (0.91)
LSD durum flour rate 13.4∗∗∗ (<0.001) 0.36∗∗∗ (<0.001)
LSD sample 23∗ (0.023) 0.63 (0.34)

Protein percentages: HP = high protein baker’s flour with 13.8% protein; SP = standard bakers’ flour 11.9% protein; LP = low protein flour, 10.3%.
Y = Yallaroi residue flour; W = Wollaroi residue flour; K = Kamilaroi residue flour. Significance at ∗ = 5% and ∗∗∗ = 0.1%.

only lowered LV at the 20% rate while for Kamilaroi a tendency for a slight increase in mixing time
in the LP base, LV actually increased with increas- although some samples decreased this while others
ing durum flour addition. In no case was the LV of had no affect. Generally peak resistance was only
the durum incorporated flours higher than the control increased slightly. In another study using much higher
flour. In the HP base flour, two samples had equivalent incorporation rates (25, 50, 75%), Farinograph mixing
LV to the control and seven flours were significantly time and extensograph resistance were decreased in
lower in LV. For the SP base, five flours had equiva- flour blends.5 The improvement in our studies in
lent LV to the control and four flours were lower and LV was not obtained with a low protein base flour
for the LP base, three flours had equivalent LV to the substituted with 20% durum residue flour and again,
control while six flours had lower LV. The BS of the crust b was increased significantly. Thus it seems
durum incorporated flours ranged from 27.9 to 29.0 that the durum flour addition cannot overcome the
(cf. control flour, 28.9) showing that loaves of equiv- deficiency of the base flour. Durum wheat has naturally
alent appearance to the control flour were produced. higher levels of xanthophylls in the endosperm which
There were no differences between the 100% base account for a higher Minolta b-value in semolina
flour samples and those with added durum residue compared to wheat flour. The durum residue flour
flour for whiteness (L) and redness (a) values of the also has a yellow appearance because it is derived
crust (data not shown). The base flours had similar from the endosperm. Thus it is no surprise that
yellow colour. The addition of durum residue flour at addition of durum residue flour to a wheat base flour
any dose and source, significantly increased yellowness increased b, as observed. The improvement in LV is
(b) values of the loaves in all situations. As the dosage presumably due to the high gluten strength of the
of durum residue flour was increased, the b value durum residue flour. Indeed, Joesephdes et al.7 stated
increased, as to be expected and so levels below 10% that the durum genotype contributes to the effect of
incorporation would be needed to avoid this change. durum residue flour on bread quality when used in
The data shows that there can be a negative impact on combination and ascribed this to the gluten strength.
LV using some combinations of these durum residue Harris and Sibbitt15 found that when common wheat
flours while in other cases no reduction in LV was flour was substituted with durum flour below a 20%
obtained. However, in all situations, the yellow colour incorporation, there was no impact on loaf volume,
of the bread was significantly increased by the durum mixing requirements or crumb colour indicating this
flour addition even at a low 10% incorporation. dosage can be tolerated. Our results show there is a
difference in crumb colour. However, Boggini and
Pogna6 reported an increase in loaf volume of a
DISCUSSION 25% durum flour addition to flours with poor bread-
The analysis of many different durum genotypes (set 1) making quality. Similarly, Dekov et al.2 used durum
found that the substitution of 20% bread wheat flour residue flour in a soft wheat flour blend (15%) which
in a baking mixture with durum residue flour from improved bread-making quality. Our results show that
semolina milling in general, increased loaf volume loaf volume changes are dependent on the source of the
with no change in bake score but an increase in durum residue flour, there being differences between
crust and crumb yellowness. The effects on dough cultivars. Possible reasons are differences in protein
mixing as measured using the Mixograph showed content of the durum residue flours and differences in

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the gluten strength and amount of insoluble glutenin Overall, there appears to be merit in studying further
which are linked to loaf volume.11 Results in Table 4 the use of durum residue flour as an additive in the
show that no improvements in LV and BS were production of the normal range of wheat breads to
obtained using the three durum varieties compared to improve the value of this by-product to the durum
the wheat flour control loaves but increases were noted miller. Providing loaf volume is not adversely affected,
with other sources (Tables 2 and 3). At the lowest the baker could reduce costs by decreasing the amount
incorporation rate used, all the breads had significantly of flour, since the durum residue is likely to be a
higher b-values compared to the control. Whether this cheaper ingredient. However, the additional yellow
increase in yellowness is unacceptable would depend colour might require a different market.
upon the market and there would always be the option
to bleach the flour if acceptable for health and safety.
Ozen3 reported the use of up to 5% durum residue ACKNOWLEDGEMENTS
flour in a baking formula had no deleterious effects This work was supported by a grant (DAN 238) from
on dough properties and bread quality. In our work, the Grains Research and Development Corporation.
there was no attempt to measure the effect of durum
residue flour on staling.
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DOI: 10.1002/jsfa

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