The pH of tortillas not only affects their shelf life, but also affects their quality.  The best pH for flour tortillas is from 5.2 to 6.2.  Tortillas outside of this range will either spoil very quickly (above 6.2) or have an acidic taste (below 5.2).  Flour tortillas with a higher pH will tend to have better flavor, aroma and appearance.  As the pH is reduced to increase activity of preservatives and extend the shelf life of flour tortillas, these attributes are lost. It is important to monitor tortilla pH to achieve the code date and to have a product people want to eat. The optimum pH for flour tortillas is around 5.8 with an acceptable range of pH 5.6 – 6.0 to achieve most shelf life requirements and have a good quality tortilla.

The best pH for corn tortillas depends upon the tortilla type.  Table corn tortillas generally have high moisture content and require the lowest pH, that is, between 4.8 and 5.2.  Low-moisture corn tortillas used in frying applications should have a pH from 5.2 to 5.5, if used over several weeks after production.  High-lime corn tortillas should have a pH between 10 to 10.5.

The tortilla pH can fluctuate up or down about 0.1 units without too much concern.  When the tortilla pH fluctuates 0.2 units up or down, you should be concerned and start trouble shooting the problem.  Changes in pH are usually caused by the ingredients (including water).

By: Daniel J. Brooker
Copyright 2010

Ovens are commonly the workhorses of an industrial setting. Whether it is used for baking food products, drying wet surfaces, or hardening coatings, the industrial oven faithfully puts in long hours and delivers finished products day and night.

But the constant progression of products through an oven takes its toll. Crumbs fall from baked products. Lubricants from the conveyor belt may build up and fall to the floor. Fumes from drying products leave residue on the walls and moving parts.

These various debris can become a fire hazard or may begin to fall into and contaminate the products. When this happens, the oven needs to be cleaned.

Some companies try to do the cleaning themselves but most hire professional cleaning firms that specialize in heavy-duty industrial cleaning.

The first step in oven cleaning is to turn the oven off so it can cool enough to permit workers inside. This cooling period may take 8 to 24 hours or even more. When scheduling a cleaning, this has to be calculated into your down time.

If the oven is longer than 30 meters (or 100 feet), fans should be placed at the ends to assist in the air flow through the oven so workers can breathe freely. A failure to do this could create a lack of oxygen for personnel inside.

A second step, if needed, is the removal of interior parts such as shelves or compartments, if this is possible. This is normally done by the factory’s maintenance workers since they are most familiar with the oven. This is only done if the parts are removable and they prevent the workers from fully accessing and cleaning the oven.

The actual cleaning process depends on the type of residue inside the oven. Water is normally not used or is used sparingly to avoid damaging the interior.

Some ovens have chain conveyor systems that use graphite lubricant. Over time graphite powder can build up beneath the conveyor and begin to contaminate products. The cleaning process involves men crawling beneath the conveyor and scooping the graphite into buckets for removal.

If residue buildup is light and flaky, it may come off rather easily with wire brushes, scrapers, and vacuums. If the contaminant is hard, a more aggressive approach, such as grinders or small air-powered chipping hammers known as “air chippers.”

For some applications, if wiping is done, lint-free rags may be necessary so no fibers remain to contaminate products.

Ovens commonly have exhausts ducts that take smoke or fumes outside and these should be considered during the cleaning process. These ducts are often coated with grease or other residue that can be a fire hazard. In extreme cases, debris may partially clog the duct and restrict vital air flow, resulting in a poor baking process or contaminated product (due to lack of air flow or fume evacuation).

Duct cleaning is commonly accomplished through the use of scrapers and air chippers. In some instances ducts can be disconnected and power washed.

Oven cleaning is a critical part of any factory maintenance program and is often done on a regular basis, such as every 6 to 12 months.

by Dan Stradford

Chief Executive Officer, Action Duct Cleaning

 (ORIGINALLY PUBLISHED IN CLEAN INDIA MAGAZINE)

Mold inhibitors are vital to tortilla manufacturers for maintaining the quality and safety of tortillas and providing a high quality product that meets consumer demands. Extending tortilla shelf life can be accomplished simply by implementing good manufacturing practices which could include a mold inhibitor in your process. Which type of mold inhibitor is best for your operation? Liquid or dry, corrosive or non-corrosive, what do you think?

Liquid ingredients provide better dispersion in tortillas to ensure a product that stays fresh on shelves longer. It is easy to implement into an operation because it is a simple one step process that can be completed during the liquid phase of manufacturing. In comparison, a dry ingredient requires several steps within the process to ensure each tortilla is treated consistently by the mold inhibitor.

Non-corrosive ingredients are more environmentally friendly and can be a consideration when reviewing overall manufacturing expenses. Tortilla flavor is not impacted with non-corrosive ingredients, whereas flavor can be negatively impacted with corrosive ingredients. Corrosive ingredients can burn a person’s skin, so using a non-corrosive ingredient can be a safer option when considering employee safety. There are also safety regulations to take into account regarding the amount of corrosive ingredients allowed in a plant which can impact production expenses.

When choosing a mold inhibitor ingredient, consider all aspects of your business from employee safety, safety regulations, liability costs and most importantly the quality and flavor of your tortillas.

By: Betsy Blades | Technical Marketing Manager

Kemin Food Technologies
Website: www.kemin.com

Kemin’s SHIELD® line of mold inhibitors is a liquid, concentrated, non-corrosive preservative solution for your tortilla products.

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
advancedfoodsys.com

Once seen only as a staple of the traditional Hispanic diet, Tortillas have fast become a fixture in the American food industry . Fresh and packaged tortillas can be found virtually anywhere, from burritos at sporting venues to the menu at your favorite fast food chain , as well as dozens of brands of packaged products throughout national supermarkets.

As tortilla manufacturing facilities begin to sprout throughout the United States ,the Tortilla industry , like the bakery industry has to conform to legislation such as the trans fat ban. Partially hydrogenated soybean oil , once a popular ingredient in flour tortillas , has to give way to trans fat free alternatives to meet the labeling of less that 0.5 grams of trans fat per serving.

Trans fatty acids are present in partially hydrogenated vegetable fats such as soy and canola . These fats are put through the hydrogenation process to give them specific properties such as an increased melting point, hardness, plasticity, texture and stability which are essential to the tortilla making process. During the hydrogenation process, however, trans fatty acids are formed. Trans fats are harmful as consumption increases the risk of coronary heart disease by raising levels of “bad” LDL cholesterol and lowering levels of “good” HDL cholesterol.

To combat the trans fat dilemma, many tortilla manufacturers have turned to palm oil shortenings. As palm oil is naturally a semi solid at room temperature, it does not require hydrogenation and therefore does not produce trans fats. Palm Shortening is also well endowed with saturated palmitic fatty acids (44%), monounsaturated oleic (39%) fatty acids and polyunsaturated linoleic acid (10%). This combination of fatty acids provides an ideal mix for stability and an increased shelf life for the tortillas as compared to traditional soy shortening. Many companies have also prefer to use a palm cake and icing , as the mono glycerides , an emulsifier, result in a softer and fresher tortilla.

By: Sean Neman
Western Pacific Oils
(213)232-5117

Western Pacific Oils is one of North America’s leading distributors who supplies a range of oil palm based products. We sell our products through food service distributors and customized orders for large end users. Amongst our wide produce range, is a specialized trans fat free tortilla shortening , which was mentioned in this article.