Baking & Snack - April 2010 - 49

ENCAPSULATES
◀ Photomicrographs reveal how microcapsules [top] often use multiple coating layers
[bottom] to protect their contents.
BALCHEM ENCAPSULATES

to what degree, the active ingredient begins to work.
"Most encapsulation processes
today encapsulate 100% of the active
ingredient, offering no variation or
customization to meet unique applications," he continued. "However,
our patent-pending encapsulation
system varies the level of coating
used to encapsulate the active ingredient, allowing the release to occur
in stages. Much like a double-acting baking powder, the level
of coating allows multiple-phase release of the active ingredient, releasing part of the ingredient in the blending stage and
a second phase in the oven. The degree of release at each stage
of the process is unique to each product and designed to fit
the needs of the baking manufacturer."
Mr. Tongue added, "IFP's proprietary process involves
an angled impact spray pattern. The impact between coating droplet and active particles creates a moving particle
that spreads the coating layers evenly over the surface of
the active core material. We minimize the gaps and voids
that conventional fluid-bed processes create, producing
particles with less coating that consistently provide equal or
greater protection from moisture or abrasion."
USEFUL APPLICATIONS. As with value-added products,
encapsulation usually increases the price of an ingredient.
Thus, bakers must determine if there is any benefit to using
the encapsulated version of an ingredient.
"By using encapsulated fortifying ingredients such as
vitamins, minerals and omega-3 oils, a baker ensures the
consumer that these nutrients are present in the final product," said GuoHua
Feng, manager of bakery ingredient innovation, Caravan Ingredients, Lenexa,
KS. "Not only do they remain viable,
they also won't oxidize and cause offflavors during shelf life."
The market for frozen and refrigerated dough, for both food service and
at-home baking, continues to grow as
both operators and home bakers seek
out convenience solutions.
"Encapsulated ingredients make
sense when the raw ingredient can neg▶ To assure survival of water-sensitive ingredients
in whole-grain bread, encapsulation can be
adjusted to release these materials during the late
stages of baking.
CLABBER GIRL INGREDIENTS

BAKING & SNACK / April 2010

atively interact with other ingredients or the environment,"
Mr. Tongue said. "For instance, take-and-bake or self-rising
pizza crusts are subject to advance preparation and must
ensure performance when taken home and baked. Encapsulating either or both of the chemical leavening agents
delays interaction until the crust temperature exceeds the
melt point of the coating, typically 145°F. This allows perfect
leavening every time.
"Similarly, makers of commercial breadings have a quality challenge regarding first and last product produced in a
batch," he continued. "If their batch size is small, there could
be minimal deviation in loss of leavening, but if an extended
time period is in play, an encapsulated leavening system can
provide process time flexibility."
Ms. Lukasik explained, "Encapsulation of sodium bicarbonate is particularly important in refrigerated and frozen
batters and doughs that contain free soluble acids from ingredients such as fruit, cocoa, molasses and buttermilk because
encapsulation prevents premature leavening and undesirable
color changes. Shelf life can be extended and performance
improved, even if these products are freeze-thaw abused."
Using encapsulated leavening agents in refrigerated
dough sold in pressurized tubes allows the manufacturer to
mix the dough without gassing prematurely or excessively.
"Two different leavening agents are used," Mr. Watson explained. "The encapsulated acid activates once the dough is
in the cardboard tubes, where it quickly rises and excludes
the excess air in the tube."
Sometimes the least likely of ingredients can benefit from
encapsulation. "By providing a protective coating on watersoluble ingredients such as sanding sugar and pretzel salt, the
problem of 'melt away' can be reduced or eliminated, thereby
extending the shelf life of fresh baked foods such as muffins,
donuts and pretzels," Ms. Lukasik said. "By encapsulated certain acids, it is possible to deliver a vibrant sourdough flavor
to delicate laminated doughs while minimizing process time."

Baking & Snack - April 2010

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