One method of increasing yields for tortilla manufacturers, is to maximize the absorption (hydration) rate of mixed tortilla doughs. If the recipe water can be “bound up” by the flour, a higher amount of water can be added to the dough.
The most common method of binding water is through the use of additives. Typically, additives are much more expensive than flour, which means the additional water, is offset by the cost of the additives.
Another method of increasing absorption, is thru the use of “mechanical hydration”. This method uses the intense, mechanical mixing action of the high speed mixer to achieve a higher rate of absorption/hydration, without using additives. The intense mixing action exposes more surface area of the flour particles, and therefore requires additional water in the recipe. Typically, 4-8% higher absorption can be achieved with this type of mixing.
The key to adding this additional water to tortilla doughs is the ability to “bind up” the water in the dough. “Bound up” water means that this moisture does not migrate out during the shelf life period. The usual problems of sticking, cracking, spoilage, etc. are not present in tortillas with “bound up” water.
When the moisture is bound up, it can enhance the tortilla quality, NOT decrease the quality. Higher quality, with a lower ingredient cost is a winning combination.
By: Denny Vincent – President
Advanced Food Systems, Inc.
614-939-0011 x 1