CETvol87


 
 

 

                                                                    DOI: 10.3303/CET2187004 
 

 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Paper Received: 15 October 2020; Revised: 23 January 2021; Accepted: 18 April 2021 
Please cite this article as: Principato L., Sala L., Duserm Garrido G., Spigno G., 2021, Development of Bakery Formulation for Sprayable Cake 
Preparation, Chemical Engineering Transactions, 87, 19-24  DOI:10.3303/CET2187004 

 CHEMICAL ENGINEERING TRANSACTIONS 
VOL. 87, 2021 

A publication of 

The Italian Association 
of Chemical Engineering 
Online at www.cetjournal.it 

Guest Editors: Laura Piazza, Mauro Moresi, Francesco Donsì
Copyright © 2021, AIDIC Servizi S.r.l. 
ISBN 978-88-95608-85-3; ISSN 2283-9216

Development of Bakery Formulation for Sprayable Cake 
Preparation 

Laura Principato, Luca Sala, Guillermo Duserm-Garrido, Giorgia Spigno* 

DiSTAS – Department for Sustainable Food Process, Università Cattolica del Sacro Cuore, Piacenza (Italy) 

The aim of this work was to create an innovative sprayable bakery mix for foam-style cake preparation. The 
main goal was to obtain a batter liquid enough to be easily and quickly dosed in a spray system but 
maintaining its structure during baking. A commercial liquid batter was selected, and its recipe modified to fit in 
a spray system. The commercial bakery mix was characterized in terms of physical-chemical, thermal, and 
rheological attributes. The product was then diluted with milk or whipping cream at a 3:1 (gproduct/gdiluent) ratio to 
modulate its viscosity to be sprayed in a nitrous oxide loaded siphon system. All the prepared samples were 
characterized in terms of physicochemical properties at different stages of cake production (before and after 
spraying, and after baking) to investigate the effect of dilution on rheology and spray-ability and on the texture 
of final cake. Before cooking, the dilution determined an increase of water content and activity and a 
remarkable difference in colour coordinates compared to the reference. However, the differences in 
physicochemical parameters were minimized after baking due to water content reduction and non-enzymatic 
browning phenomena. Despite that, the diluent type affected thermal characteristic peaks linked to fat melting 
and starch gelatinization phenomena, respectively. In fat melting, whipping cream addition maintained 
enthalpy values similar to control due to the high lipid content balancing the dilution effect. Instead, the 
greatest water amount in milk contributed to fat reduction and enthalpy reduction. In starch gelatinization, both 
milk and cream addition determined a reduction of the associated total energy due to a starch dilution effect. 
From a rheological point of view, a significant decrease in viscosity enabled the diluted batter to be sprayed. 
All samples displayed shear rate dependent and shear-thinning behaviour. When the batter was sprayed the 
values of apparent viscosity suddenly increased, probably due to a reduced droplet size, minor average inter-
particle distance and the interaction of foaming agents and proteins. After baking, sprayed samples showed 
firmness and springiness comparable to the control cake. However, the cakes from both the diluted batters 
presented some cooking defects typical of an incorrect leavening process enforced by yeast dilution and lack 
in aeration stability during baking. 

1. Introduction

Cakes are one of the most consumed bakery products because of their delicious spongy texture and 
organoleptic and sensorial characteristics (Rodríguez-García et al., 2013). The physicochemical properties of 
cakes are largely dependent on the batter and cake structure. Cake batters are complex emulsions of fat or oil 
in an aqueous phase, containing flour (Lee, 2015; Aydogdu et al., 2018), eggs (Hedayati & Tehrani, 2018), 
sugar (Cavalcante & Mendes da Silva, 2015), and minor ingredients. The quality of high air-leavened products 
such as sponge cakes, cupcakes or muffin depends on many factors, including the ingredients used for batter 
preparation, aeration of batters, and processing conditions to guarantee the typical soft and fluffy texture 
(Chaiya & Pongsawatmanit, 2011). Among the ingredients, fats not only contribute to the sensorial in-mouth 
experience but they play a primary role as crumb structurer and stabilizer by entrapping air bubbles formed 
during leaving and cake expansion (Matsakidou et al., 2010)  Egg has several binding, emulsifying and 
foaming functional properties (Wilderjans et al., 2013)  Especially in foam-style cakes, the foam formation is 
provided by eggs in conjunction with other ingredients, such as sugar and acid, in order to delay gluten 
formation and air bubble production (Cavalcante & Mendes da Silva, 2015). Mixing mechanism is also crucial 
for preventing the wheat network and to enhance potential foam formation by eggs (Rodríguez-García, et al., 
2014). During cake batter mixing, the movement of the mixing tool pushes materials aside, creating a void in 

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which the batter flows and small pockets of gases are entrained decreasing the density of batter. Low batter 
density is associated with good air incorporation and good bubble retention during mixing. On the other hand, 
during baking the batter viscosity controls air and leavening gas retention, that is important to guarantee the 
creation of a stable sponge structure that will not collapse after baking (Sahi & Alava, 2003). Assuring correct 
level of overrun in a liquid phase is the most critical factor in cake manufacturing and failing to do so could 
lead to several problems in final product standardization. A possible solution is to develop a mix in which air or 
gases are already incorporated into to the system during dosing. Sprayable formulation can modulate the right 
number of bubbles inside the structure providing the right elasticity and fluffiness of the bakery product. 
Some sprayable solutions already exist for pancakes (Batter Blaster, USA) and on 2014 a start-up (Spray 
Cake, USA) developed an idea to manufacture a sprayable cake batter, even if more recent updates were not 
found. The idea of sprayable cake is to create a ready-to-bake product easy to dose and quick to prepare, 
using a siphon loaded with pressurized gases (nitrous oxide or carbon dioxide) to spray the product and bake 
it in the oven or in the microwave (Lostie et al., 2002a, 2002b). During spraying, the batter-gas mix is expelled 
from the siphon, the gas quickly expands due to the pressure difference between the inside of the siphon and 
the outside at atmospheric pressure, making the product obtain a consistency like whipped cream. However, 
the main limitation is that cake batters possess a very high viscosity. Therefore, to spray them, the product 
must be diluted with suitable ingredients (e.g., dairy products such as milk or fresh whipping cream) that 
contain foaming agents that can drop the bulk density and promote air formation (Blankart et al., 2020; Green 
et al., 2013). The aim of this research was then to develop an innovative ready-to-bake product suitable to be 
sprayed.  A commercial liquid batter was selected and opportunely diluted with milk or whipping cream at a 3:1 
(gproduct/gdiluent) ratio in recipe to reduce the viscosity and to be used in a nitrous oxide loaded siphon system. 

2. Materials and Methods

2.1 Materials 

Commercial refrigerated liquid batters for cakes (Soffice Margherita, Cameo), whole milk (Coop), and fresh 
cream for dessert (Centrale del latte) were purchased from local market. A cross-nozzle stainless-steel siphon 
(Upstartech, USA) was used as spray system loading nitrous oxide cartridge at 8.9 atm. 

2.2 Sample preparation 

Liquid commercial batter was selected as a control reference. 150 g of cake mix were diluted adding 50 g of 
milk or fresh whipping cream at a 3:1 (gproduct/gdiluent) ratio according to preliminary tests. The batter was then 
homogenized for four minutes in a lab scale planetary mixer (Imetec Zero Glu, Italy). After mixing, the batter 
was scraped out from the walls and the bottom of the bowl to recover all the material and to obtain the 
samples before spraying (t0). Subsequently, the liquid was poured into a nitrous oxide-loaded siphon and 
sprayed to obtain the final batter (t1). The mixture was shaken for 10 seconds before use. All samples 
(control, t0 and t1 batters) were baked in a semi-industrial oven Wind+ 6040/5 (Polin, Italy) for 30 minutes at 
165°C using aluminum (20x30cm) vessels. Three replicates were performed for each sample. 

2.3 Sample Characterization 

Moisture Content, aw, pH and Color 

The moisture content was determined as weight loss of samples (5 g) after 24 h in an oven at 105 °C.  The pH 
was measured using a pH meter (Hanna instruments, Italy) equipped with a Bluetooth probe system. The 
probe was inserted inside the batter and the pH value was recorded. Demineralized water was used to clean 
the probe after usage. Water activity (aw) was measured using an aw analyzer (AcquaLab, Astori tecnica, 
Italy). The sample was placed in a plastic cup filling half of its volume and then allocated into the instrument 
chamber to perform the measurement at a constant temperature of 25 °C. Color was measured using a 
colorimeter (Hunter lab D25 NC, USA). Sample was placed in plastic Petry dish and measured in different 

point. Trichromatic coordinates L*, a* and b* and color change or ∆E value (√∆ ∗ + ∆ ∗ + ∆ ∗ ) after baking 
were obtained. All the analyses were performed in triplicates (five replicates for color analysis). 

Rotational Rheology 

Rotational measurements were carried out using a controlled-stress rheometer (MCR 302, Anton Paar, 
Austria) provided by cup and bob device. A sample volume of 25 mL was poured into a 27 mm cup and bob 
attachment (cell height 40 mm, annular diameters 26.65 and 28.92 mm).  Measurements were performed at 
25 °C ± 0.1. The shear rate was set between 0.01-100 s-1. Samples were loaded into the cell and exposed to 
pre-shear of 10 s-1 for 10 s followed by 10 s rest according to the method by Taylor et al. (2009). All the 
measurements were carried out in triplicates.  

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Differential Scanning Calorimetry 

A microcalorimeter (Setaram, France) equipped with a 3D Calvet sensor was used to perform the analysis. 
The sample (0.5 g) was weighed in Hastelloy cells. The following thermal ramp was selected according to 
previous studies (Rodríguez-García et al., 2014; Turabi et al., 2010) with slight modification. The sample was 
hold at 20°C for 10 minutes. Then, temperature was increased up to 160°C at 0.8°C/min rate. Finally, after 5 
min holding at 160°C, a cooling ramp was set to reach 50°C at 1°C/min rate. All tests were carried out in 
duplicates. 

Texture Profile Analysis (TPA) 

TPA analysis of final cakes in double compression was performed one hour after baking, with a Texture 
Analyzer TVT 6700 (Perten, Sweden). A 75 mm cylindrical probe was used to compress the sample up to 
30% of the initial volume. The test speed was set at 2 mm/s. A holding time of 15 s was selected between the 
first and the second compression. Each sample was cut in rectangular 3x3 cm pieces with 1.5 cm height. 
According to Salehi and Kashanine (2018) method, the upper crust was removed in order not to bias the 
measurements. Firmness and springiness attributes were computed by instrument software. Measurements 
were carried out at 25 °C ± 0.1 and with five replicates for each sample.  

Statistical analysis 

Results are reported as mean values of the replicates with their corresponding standard deviations. The 
influence of leavening agent on characteristics of doughs and cakes was evaluated through one-way analysis 
of variance (ANOVA) followed by Tukey’s post-hoc test for means discrimination, at p ≤ 0.05 level, using 
statistical software SPSS® (version 21.0, SPSS Inc., Chicago, IL, USA). 

3. Results and Discussion

Moisture Content, aw, pH and Color 

The main results are resumed in Tab 1. All diluted samples show higher water activity and moisture content 
compared to the reference both before (0.92<aw<0.94, 34.64<moisture%<42.86) and after baking 
(0.84<aw<0.90, 25.49<moisture%<36.68). The greatest values were detected for milk dilution due its higher 
water content compared to whipping cream. Moreover, the commercial product already possesses a high 
water activity (0.85), and a further increase could cause a negative effect on stability and decrease the product 
shelf-life (Podolak et al., 2010). However, after baking a decrease was observed in both parameters for all 
samples. Contrarily, all sprayable cakes exhibited the highest moisture content, that could improve the 
sensorial score of final products in terms of firmness and elasticity (Chuang & Yen, 2006).  Furthermore, the 
dilution with both milk and cream led to change in color for batter from an intense yellow to a lighter color. This 
fact was shown by the increase in L* that further increased after spraying. The change of all trichromatic 
coordinates at t1 seemed to indicate an effect related to the incorporation of air into the batter. The baking 
process lowered the L* and b* values and increased a*. The latter result is correlated to the browning 
phenomena induced by Maillard reactions during cooking. Among all, milk samples exhibited darker color 
(expressed by higher ∆E), probably due to the higher amount of lactose that promotes browning (Table 1). 

Rotational and Oscillatory Rheology 

Figure 1 shows the curves of the apparent viscosity at 25°C versus the shear rate for control and batters at 
different conditions of dilution before and after spaying. All samples display shear rate dependency and shear-
thinning behaviour. As shown in Figure1a, after dilution, samples exhibit lower apparent viscosities compared 
to the reference. When the batter is sprayed, the values of apparent viscosity suddenly increase due to a 
reduction in droplet size, a minor mean interparticle distance and a greater interaction by foaming agents and 
proteins (Zhao, et al., 2013; Lim, et al., 2008). An inverse relationship between viscosity and fat droplet size in 
whipped system was reported by Chanamai & McClements (2000). Same results were found in more recent 
study performed by Zaho et al. (2012) using high pressure homogenization (HPH): increasing HPH pressure 
determines a higher interparticle resistance. In addition, the reduction of droplet size enhances the amount of 
the adsorbed protein fraction resulting in higher apparent viscosity. Amiri et al. (2018) confirmed the latter 
result for sonicated whipped cream: sonication decreases the particle size distribution of fat globules, losing 
the grapelike structures observed in untreated samples and causing a limited opening of protein chains and 
the formation of new bonds to cover the fat cells, and the resulting interactions can somewhat increase 
viscosity. Finally, sprayed samples show a rapid drop of viscosity at high values of shear rate compared to 
diluted batters, underlining the greater instability of whipped systems.  

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Table 1: Evaluation of the water activity, moisture and colour difference ∆E of the analysed samples. The 
values are expressed as mean value± d.s. Different letters within each column indicate significant differences 
between the samples (ANOVA and Tukey's post-hoc test with α <0.05). 

Sample Before Baking After Baking 
aw [-] Moisture [%] ∆E [-] aw [-] Moisture [%] ∆E [-] 

Control 0.855 ± 0.006a 26.02 ± 0.34a 0.0 0.746 ± 0.021a 22.21 ± 0.26a 0.0 

t0 cream 0.921 ± 0.004b 34.92 ± 1.69b 11.0 0.839 ± 0.008b 25.49 ± 0.99b 1.5 

t1 cream 0.924 ± 0.004b 34.64 ± 1.08b 46.7 0.841 ± 0.006b 26.63 ± 0.30b 2.5 

t0 milk 0.943 ± 0.001c 40.95 ± 0.10c 40.1 0.896 ± 0.004c 34.39 ± 1.03c 10.5 
t1 milk 0.944 ± 0.004c 42.86 ± 0.07c 47.1 0.903 ± 0.001c 36.68 ± 0.40d 9.0 

Figure 1: Flow curves of samples: apparent viscosity (Pa*s) as function of shear rate (s-1) at 25°C obtained for 
the control (black circle), after dilution(t0) with cream (black squared) and milk (black triangles), and sprayed 
milk (white triangles) and cream (white squared) (t1) batter. 

Differential Scanning Calorimetry 

Before baking, all t0 batters show thermograms like the reference. Two characteristic endothermic peaks at 
60°C and 80-90°C are detected. The enthalpy (∆H) and the onset (Ton), peak (Tp) and offset (Toff) 
temperature of each peak are reported in Table 2. According to Truong et al. (2018), the peak obtained at 
60°C corresponds to the melting of fats. In fat melting, cream batter maintains its enthalpy value like the 
control due to its high lipid content that balances the dilution effect. Instead, the greatest water amount in milk 
contributes to fat reduction and lower energy. The second encountered peak is related to starch gelatinization 
phenomena as obtained from previous studies (Rodríguez-García et al., 2014; Turabi et al., 2010). Milk and 
cream addition determine the onset of phenomenon at lower temperatures. Moreover, enthalpies involved are 
smaller than the control confirming a reduction of the starch content due to dilution.  

Texture Profile Analysis (TPA) 

Low deformation (up to 50%) tests are suitable to assess the texture attributes of elastic bakery product such 
as bread and cake (Hesso et al., 2015). In a double compression TPA analysis “firmness” is defined as the 
force required to reduce the sample volume in the first and second compression, respectively. Once those two 
data were obtained, "springiness" is calculated as the ratio between firmness values. Springiness is an index 
related to the elasticity of the sample (Hesso et al., 2015). In particular, if the values of firmness in first and 
second compression are similar, the sample will be highly elastic. In Figure 2a firmness values are reported 
comparing the baked diluted sample before (t0) and after spraying (t1) to the control sample. Batters with the 
only addition of cream and milk (t0) are significantly higher than the control. Especially t0 milk-diluted samples 
exhibit a value of hardness four times greater than the control. However, sprayed samples (t1 milk and t1 

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cream) show firmness comparable to the not diluted batter. No significant differences are detected in elasticity 
neither due to the dilution effect or to spraying. Nevertheless, Figure 2b reports the pictures of internal crumb 
of all sample after baking. It can be noticed that both t0 and t1 samples present some cooking defects which 
typically appear when the leavening has not taken place correctly. This result might be since addition of cream 
or milk decreased the concentration of yeast of the original formulation. Moreover, it is possible that the 
spraying action does not improve softness because the structure is not able to keep the added air during 
baking. In any case, a further optimization of formulation by thickeners addition or increasing yeast 
concentration should avoid leavening problems, enhancing final structure quality.  

Table 3: Evaluation of the characteristic endothermic peaks of fat melting and starch gelatinization obtained by 
DSC analysis for batters before baking. The values are expressed as mean ± d.s. Different letters within each 
column indicate significant differences between the samples (ANOVA and Tukey's p post-hoc test with α 
<0.05). 

Sample Fat melting Starch Gelatinization 

Heat (J/g) Ton (°C) Tp (°C) Toff (°C) Heat (J/g) ton (°C) Tp (°C) Toff (°C) 
Control 0.434 ± 0.03a 57.2 ± 0.48a 59.4 ± 0.14a 61.9 ± 1.16a 2.54±0.04c 87.14±1.97b 93.80±0.08c 97.74±6.25a 
t0 milk 0.333 ± 0.02b 58.4 ± 0.66a 59.7 ± 0.44a 61.2 ± 0.11a 1.74±0.00a 74.78±0.12a 79.73±0.07a 84.63±0.09a 
t0 cream 0.434 ± 0.01a 57.9 ± 0.16a 59.9± 0.53a 62.2 ± 1.07a 1.92±0.02b 83.97±0.19b 89.52±0.22b 95.00±0.42a 

Figure 2: a) Evaluation of the firmness expressed in force grams (gf) of the analysed baked samples. The 
values are expressed as mean ± d.s. Different letters indicate significant differences between the samples 
(ANOVA and Tukey post-hoc test with α <0.05). b) Pictures of internal crumb of cake samples obtained from 
control, t0 and t1 diluted batters and baked at 165°C for 30 min. 

4. Conclusions

The aim of this work was to create a sprayable bakery mix for foam-style cake preparation diluting a 
commercial liquid batter with milk or whipping cream at a 3:1 (gproduct/gdiluent) ratio, to be dispensed in a spray 
system. Before cooking, dilution mostly determines an increase in water content and water activity that can 
affect shelf-life but also increase the sensorial score of final products. Diluent type affects also thermal 
characteristic peaks linked to fat melting and starch gelatinization phenomena. From a rheological point of 
view, a significant decrease in viscosity enables the diluted batter to be sprayed at the selected ratio. All 
samples displayed shear rate dependency and shear-thinning behavior. However, when batters are sprayed, 
the values of apparent viscosity suddenly increase due to a reduction of the droplet size, a minor average 
interparticle distance and a possible interaction of foaming agents and proteins. After baking, sprayed samples 
(t1 milk and t1 cream) show firmness and springiness comparable to the reference. Although, both t0 and t1 
cakes present some cooking defects typical of an incorrect leavening process, enforced by yeast dilution and 
lack in aeration stability during baking: a further optimization of the formulation by adding thickeners or 
increasing yeast concentration should avoid leavening problems, enhancing final structure quality. 

a b a
a 

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