Toast Bread Production Issues and Emulsifier Solutions

Date:2025-04-07

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Toast bread is a staple in many households thanks to its soft texture, uniform crumb, and easy slicing. However, Bread manufacturers often encounter various technical issues during the production of toast bread, such as poor volume, coarse texture, and rapid staling. Fortunately, some food emulsifiers can effectively address these challenges.

In this blog, we explore the most common problems encountered in toast bread production and offer practical solutions using food-grade emulsifiers such as GMS, SSL, and DATEM.

Common Issues in Toast Bread Manufacturing

➤ Uneven crumb structure and coarse texture

The bread may have irregular holes or a rough crumb, making it less appealing and harder to slice.

➤ Collapsed or shrunken loaves after baking

The bread loses volume during cooling, often resulting in a sunken top or misshapen loaf.

➤ Short shelf life and quick staling

Starch retrogradation is the primary cause of bread staling, leading to firmness and loss of softness within 1-2 days. Moisture migration and microbial growth can reduce bread’s shelf life.

➤ Off-flavors or oxidation

Poor emulsification can lead to unpleasant flavors from oil separation or fat oxidation.

➤ Inconsistent batches

Even with the same recipe, variations in dough behavior or final bread quality are common.

➤ Difficult demolding and surface cracks

Bread sticks to molds or tears during removal, affecting its appearance and process efficiency.

GMS (Glycerol Monostearate) in baking

Emulsifier Solutions for Improving Toast Bread Quality

Emulsifiers play a critical role in improving dough handling, gas retention, crumb texture, and shelf life. Here’s how specific emulsifiers can help address each of the issues above:

✅ Improve Crumb Structure & Softness

●Recommended emulsifiers: GMS (Glycerol Monostearate), SSL (Sodium Stearoyl Lactylate)

●How they work: Strengthen the gluten network and enhance gas retention, leading to finer, more uniform crumb.

●Suggested dosage: 0.3%–0.5%

✅ Increase Loaf Volume & Prevent Collapse

●Recommended emulsifier: DATEM (Diacetyl Tartaric Acid Esters of Mono- and Diglycerides)

●How it works: Improves dough strength and elasticity, helping the bread maintain shape during baking and cooling.

●Suggested dosage: 0.3%–0.5%

✅ Delay Staling & Extend Shelf Life

●Recommended emulsifiers: GMS, SSL, CSL (Calcium Stearoyl Lactylate)

●How they work: Interact with starch to slow down retrogradation and moisture loss, keeping bread soft longer.

●Suggested dosage: 0.3%–0.5%

✅ Enhance Flavor & Stability

●Recommended blend: GMS + SSL

●How they work: Improve emulsification of fats and water, reducing oxidation and preserving fresh taste.

●Suggested dosage: 0.2%–0.3% each

✅ Improve Dough Handling & Process Consistency

●Recommended emulsifiers: DATEM, SSL

●How they work: Provide dough with better extensibility and resistance to mechanical stress during mixing and shaping.

●Suggested dosage: 0.3%–0.5%

✅ Improve Mold Release & Surface Appearance

●Recommended emulsifier: GMS e471

●How it works: Reduces surface tension, resulting in better pan release and smoother crust.

●Suggested dosage: 0.2%–0.3%

DATEM in Bread CHEMSINO

Practical Tips for Using Emulsifiers

Use blends for better synergy: Combining GMS with SSL or DATEM often yields superior results.

Adjust the recipe accordingly: Emulsifiers may affect dough hydration; water, fat, and yeast levels may need fine-tuning.

Consider pairing with enzymes: Lipase or xylanase can work alongside emulsifiers to improve freshness and softness.

Conclusion

Producing high-quality toast bread requires more than just the right flour and equipment—it depends on effective functional ingredients. Emulsifiers like GMS, SSL, and DATEM offer versatile and proven solutions to common production challenges, helping manufacturers deliver consistent, delicious, and long-lasting bread.

If you're seeking expert guidance or customized emulsifier solutions for your bakery, feel free to contact us. CHEMSINO Company provides technical support and ingredient recommendations tailored to your formulation needs.

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