Other new technologies are emerging for both retarder-to-oven and freezer-to-oven processes. Caravan Ingredients has a particular range of dough conditioners that enable bakers to make yeast-raised products, such as pizza, bagels or sweetgoods that go straight from the freezer to the oven. “This is becoming increasingly important in foodservice operations where time and skills are scarce resources,” says Kerrie Medlicott, marketing director, Caravan Ingredients. “What makes this technology so special is that frozen dough manufacturers don't need to make any changes to their existing formulation or process, so their customers can have the same eating qualities, but in a more convenient format.”

Finishing the process
Frozen dough should be stored and distributed at -10°F to 0°F (-23°C to -18°C). All frozen dough needs a thawing period (retarding) for 12 hours to 16 hours at 36°F to 40°F (2°C to 4°C), notes Bohm.

“From here it is allowed to come to a temperature of around 55°F (13°C) before getting the final proof in a chamber slightly lower in temperature and humidity than what is commonly used for make-and-bake product, 90°F to 95°F (32°C to 35°C) and 80 percent to 85 percent relative humidity,” adds Bohm. “Proof time is generally about 25 percent shorter than that of conventional dough, because the dough is getting some proofing in the retarding stage.”

Freeze/thaw cycling should be avoided during storage and distribution. Thawed frozen dough should not be refrozen. Usually, there is a maximum proof time, which should not be extended indefinitely, van Eijk notes. Maintaining some semblance of control over the thawing and proofing processes is one of the biggest challenges associated with frozen dough. Many variables can fluctuate, from time and temperatures to the equipment used to product rotation by the distributor.

Robbins responded to a product complaint from a customer who “didn't understand the process.” In wanting to keep store shelves fully stocked, the store manager told his employee to place extra product in the cooler on Friday so it would be available for Sunday. Although the product was fine on Saturday, by Sunday no yeast activity was left. “As you delve further and further, hopefully you find the problem and try and correct it,” Robbins says. “Even if we're absolutely perfect on our end, there could be problems between the distributor and the end user that need to be ironed out.”

Pros and cons
Many bakers are capitalizing on the benefits frozen dough provides. Distribution can be extended beyond regional boundaries and inventory cost is reduced because of the lower volume and higher density associated with dough before it has been proofed or baked. “A typical carton of frozen dough weighing 30 lb. and containing about 240 individual rolls takes considerably less space than its fully baked and packaged counterpart,” Bohm says. In addition, because frozen dough has an extended shelf life, bakers can draw off of inventory as customer demand calls for it.