Sourdough production in industrial baking requires control of fermentation conditions to reproduce sensory characteristics and maintain consistency from batch to batch. Unlike inactive sourdough, which contributes attributes such as flavor and aroma, active sourdough fermentation involves the development and activity of a microbial culture.

Before selecting a technology, it is important to distinguish between two approaches: using inactive sourdough to incorporate sensory characteristics into a formulation or actively carrying out fermentation with an active sourdough culture or a starter culture developed in-house by the manufacturer.

This article focuses on the second approach, covering the controls required to incorporate sourdough fermentation into industrial bread production.

Why Does Sourdough Require Process Control in Industrial Baking?

Sourdough fermentation depends on the activity of yeasts and lactic acid bacteria present in the culture. The balance and behavior of these microorganisms are influenced by factors such as temperature, time, hydration, flour composition, and the culture’s feeding conditions.

In artisan baking, bakers can adjust individual steps based on how the dough responds. In an industrial production line, however, the process requires defined parameters, records, and evaluation criteria to ensure reproducibility at scale.

Variations in culture maturation can affect acidity, aroma profile, and fermentation behavior. These differences may influence dough development and the final characteristics of the bread.

Therefore, standardizing sourdough does not mean eliminating biological activity. It means establishing process conditions that are compatible with the desired product profile and monitoring the variables that influence the results.

Active Sourdough or Starter Culture: Which Should You Choose?

The choice depends on the manufacturer’s production structure and the level of control it intends to maintain over culture preparation.

Ready-to-Use Active Sourdough

NAMP, part of the PMAN Group, offers Activivo, a ready-to-use liquid active sourdough. With this option, manufacturers receive a standardized culture without having to maintain their own culture through continuous feeding and maturation cycles.

This alternative can simplify the integration of sourdough fermentation into the production process. Even so, application conditions, formulation, and fermentation parameters must be evaluated to adapt the product to the industrial operation.

Starter Cultures for In-House Sourdough Production

Starter cultures are intended for manufacturers that want to produce their own sourdough. This approach allows them to develop an in-house process and work toward a specific sensory profile based on the culture’s characteristics and the conditions adopted.

In this case, the operation must establish routines for preparation, feeding, and maturation, while monitoring culture stability throughout successive cycles.

The choice between Activivo and starter cultures should take into account operational capacity, available monitoring resources, and the intended fermentation profile.

Which Parameters Should Be Controlled During Sourdough Fermentation?

To standardize sourdough in industrial baking, fermentation must become a monitored process. This involves establishing parameters, recording results, and assessing variation between batches.

Key control points include:

• Maturation time and temperature: Influence culture activity and the development of its characteristics.
• Hydration: Changes the conditions of the fermentation medium and can affect fermentation behavior.
• Raw materials: Flour and water characteristics can influence process consistency.
• Feeding routine: For an in-house culture, feeding frequency, proportions, and conditions must follow defined criteria.
• Storage conditions: Must be compatible with the culture being used and the applicable technical guidelines.
• Dough and bread characteristics: Acidity, aroma, flavor, texture, and color help assess the resulting product profile.

These parameters should not be evaluated in isolation. For example, a change in temperature can alter the time required for maturation and the sensory profile developed by the culture.

For this reason, R&D and Quality teams must establish acceptance criteria, while Production teams should follow documented procedures to reduce operational variation.

How Can Sourdough Fermentation Be Scaled Up for Industrial Production?

Moving to industrial production requires defining the desired bread profile and selecting a fermentation strategy that fits the operation.

The first step is to determine which characteristics need to be reproduced, such as acidity, aroma, and flavor. The next steps are to select the culture, assess its application in the formulation, and define maturation and fermentation conditions.

When using an in-house culture, feeding routines and monitoring each cycle become part of process control. With ready-to-use active sourdough, the focus shifts to application conditions and interactions with the other ingredients and production stages.

In both cases, application trials and process records help identify deviations, compare results, and adjust parameters. Monitoring should consider not only the culture itself but also dough behavior and bread characteristics after baking.

If the formulation also includes baker’s yeast, the product’s labeling should be reviewed by the regulatory team in light of its composition and applicable legislation.

How Can NAMP Support Sourdough Fermentation in Industrial Baking?

Standardizing sourdough depends on selecting the right culture and controlling the conditions that influence its activity. The technology must align with the production structure and the characteristics the manufacturer wants to develop in the bread.

NAMP, part of the PMAN Group, offers two approaches for this application: Activivo, a ready-to-use liquid active sourdough, and starter cultures for in-house sourdough production.

Selecting the most suitable option requires considering the production routine, available process-control resources, and desired sensory profile.

Does your facility want to incorporate sourdough fermentation into its production process with greater control and consistency? Talk to a PAMN specialist to assess the application and identify the approach best suited to your operation.