Salt reduction in sheeted dough: A successful technological approach

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The challenge of reducing the salt content while maintaining shelf life, stability and acceptability of the products is major for the food industry. In the present study, we implemented processing adjustments to reduce salt content while maintaining the machinability and the saltiness perception of sheeted dough: the homogeneous distribution of a layer of encapsulated salt grains on the dough during the laminating process. During sheeting, for an imposed deformation of 0.67, the final strain remained unchanged around 0.50 for salt reduction below 50%, and then, increased significantly up to 0.53 for a dough without salt. This increase is, in fine, positive regarding the rolling process since the decrease of salt content induces less shrinkage of dough downstream, which is the main feature to be controlled in the process. Moreover, the final strain was negatively correlated to the resistance to extension measured with a texture analyzer, therefore providing a method to evaluate the machinability of the dough. From these results, a salt reduction of 25% was achieved by holding 50% of the salt in the dough recipe to maintain the dough properties and saving 25% as salt grains to create high-salted areas that would enhance the saltiness perception of the dough. The distributor mounted above the rollers of the mill proved to be able to distribute evenly salt grains at a calculated step of the rolling out process. An innovative method based on RX micro-tomography allowed to follow the salt dissolving and to demonstrate the capability of the coatings to delay the salt dissolving and consequently the diffusion of salt within the dough piece. Finally, a ranking test on the salted perception of different samples having either an even distribution of encapsulated salt grains, a single layer of salt grains or a homogeneous distribution of salt, demonstrated that increasing the saltiness perception in salt-reduced food product could be achieved by a technological approach.