At Frontline Food Consultants and Engineers, we offer complete solutions for the development and production of high-quality fermented biscuits. From sourcing premium ingredients like flours, leavening agents, and natural flavors to crafting recipes that ensure a balanced texture and flavor profile, we ensure your product is unique and market-ready. We optimize the fermentation process to enhance the biscuits’ texture, flavor, and digestibility while maintaining consistency across batches.

Our services include Regulatory Compliance Guidance, ensuring your fermented biscuits meet food safety standards, and Sustainability Consulting to help you adopt eco-friendly practices in sourcing and production. We also provide Packaging Solutions that preserve freshness and extend shelf life, while our R&D team works closely with you to develop innovative biscuit flavors and textures. With thorough sensory testing and stringent quality control, we guarantee your fermented biscuits deliver consistent taste, texture, and quality to meet consumer expectations.

What are Fermented Biscuits?

These hard dough biscuits have a flaky texture and crunchy bite and are made with fermented doughFermented biscuit processing starts with mixing flour, water, and a leavening agent, often natural yeast or a sourdough starter. The dough is then left to ferment for a specific period, allowing the yeast or bacteria to break down the sugars in the flour, which develops a distinct flavor and contributes to the texture.

After fermentation, the dough is rolled out and cut into the desired shapes. The biscuits are then baked at a controlled temperature to ensure they are evenly cooked, resulting in a crisp exterior and a light, airy interior. The fermentation process can be adjusted to vary the intensity of the flavor, making each batch unique.

Types of Fermentation in Biscuits

Fermentation in biscuits can be achieved through different methods, primarily involving the use of natural starters or commercial yeast. The primary types of fermentation include:

  • Lactic Acid Fermentation: Utilizes lactic acid bacteria (LAB) such as Lactobacillus spp.
  • Ethanol Fermentation: Involves yeast such as Saccharomyces cerevisiae.
  • Mixed Fermentation: Combines both bacteria and yeast for complex flavor profiles.

Scientific Procedures and Formulas

The production of fermented biscuits involves several key steps, each requiring precise scientific techniques to ensure the desired quality. Here is a detailed look at these processes:

  1. Selection of Raw Materials
    Flour:

    • Type: High-gluten flour (wheat flour) is preferred for its protein content, which aids in fermentation and dough structure.
    • Storage: Flour should be stored in a cool, dry place to prevent contamination and moisture absorption.
  2. Other Ingredients:
    • Water: Pure, filtered water to avoid contaminants that could hinder fermentation.
    • Salt: Enhances flavor and controls yeast activity.
    • Starter Cultures: Natural sourdough starter or commercial yeast (Saccharomyces cerevisiae) and lactic acid bacteria (LAB).
  3. Preparation of Starter Culture
    Natural Sourdough Starter:

    • Ingredients: Equal parts of flour and water.
    • Procedure: Mix and let sit at room temperature (20-25°C) for 5-7 days, refreshing daily with fresh flour and water.
  4. Commercial Yeast and LAB:
    • Yeast Activation: Dissolve yeast in warm water (35-38°C) with a pinch of sugar, let sit for 5-10 minutes until frothy.
    • LAB Preparation: Commercial LAB cultures can be added directly to the dough.
  5. Dough Preparation
    Mixing:

    • Ingredients: Combine flour, water, salt, and starter culture.
    • Procedure: Mix thoroughly to form a homogeneous dough. The hydration level (percentage of water to flour) typically ranges between 60-70%.
  6. Fermentation:
    • Temperature and Time: Allow the dough to ferment at room temperature (20-25°C) for 4-6 hours. For enhanced flavor, a cold fermentation (4-8°C) for 12-24 hours can be used.
    • Kneading and Folding: During fermentation, perform periodic folding of the dough (every 30-60 minutes) to develop gluten and redistribute the yeast and bacteria.
  7. Dough Shaping and Proofing
    Shaping:

    • Procedure: After fermentation, shape the dough into desired biscuit shapes. Roll the dough to a uniform thickness of 4-6 mm.
  8. Proofing:
    • Temperature and Humidity: Proof the shaped dough at a controlled temperature (25-28°C) and humidity (75-85%) for 1-2 hours.
    • Final Proofing: Ensure the dough has risen adequately and displays a slight spring-back when gently pressed.
  9. Baking Process
    Baking:

    • Oven Temperature: Preheat the oven to 180-200°C.
    • Baking Time: Bake the biscuits for 10-15 minutes, rotating halfway through to ensure even baking.
    • Browning and Crispiness: Ensure a golden-brown color and crisp texture.
  10. Cooling:
    • Procedure: Transfer the baked biscuits to a cooling rack and let cool completely. Proper cooling ensures the texture stabilizes and moisture levels balance.

Health Benefits and Nutritional Considerations

Fermented biscuits offer several health benefits:

  • Improved Digestibility: Fermentation breaks down complex carbohydrates and proteins, making them easier to digest.
  • Enhanced Nutritional Value: Fermentation can increase the bioavailability of vitamins and minerals.
  • Probiotic Benefits: Depending on the fermentation method, biscuits can contain beneficial bacteria that support gut health.

Considerations:

  • Allergic Reactions: Ensure ingredients are free from common allergens unless specified.
  • Storage: Store biscuits in airtight containers to maintain freshness and prevent moisture absorption. 

Processes

Fermentation Conditions:

  • Starter Culture Maintenance: Starter Refresh Ratio = 1 part flour / 1 part water
  • Dough Fermentation:
    • Fermentation Temperature: 20-25°C
    • Cold Fermentation Temperature: 4-8°C
    • Fermentation Time: 4-6 hours (room temperature), 12-24 hours (cold)
    • Optimal fermentation conditions vary based on the desired flavor profile and texture. Cold fermentation allows for more complex flavor development.

Baking Formulas and Conditions:

  • Baking Conditions:
    • Oven Temperature: 180-200°C
    • Baking Time: 10-15 minutes
    • Baking time and temperature must be adjusted to achieve the desired crispiness and color. Rotation ensures even baking.