Fresh egg waffles are a sweet convenience product typically baked from eggs, water, sugar, flour, fat, leavening agents, emulsifiers, preservatives, and flavors. In industrial production, waffles are baked continuously in high amounts of up to 200 kg raw material per hour. Therefore, it is important that the waffles do not stick onto the baking plates, which can cause significant product loss and increased costs due to interruption of the baking process, required cleaning procedures, and restarting of the energy‐consuming start‐up phase. Sticking of waffles is greatly influenced not only by baking plate material, release agent, baking temperature, and time, but also by the batter ingredients. In this study, effects of different starches and sugar components were investigated. Within the selected starches, potato starch demonstrated the highest effects on increasing waffle stability and releasing properties compared to wheat and lupine flour (less than 7% sticking waffles). Rice flour performed worst, with almost 50% of sticking waffles. Most of these waffles were broken during take‐off, due to their crumbly texture. Within the sugar components, glycerine was better suitable than sorbitol and crystal sugar was superior compared to powdered sugar. They required less take‐off force. It could be demonstrated that waffles with increased stability and texture were those that showed the least number of sticking waffles, thus the main aim of batter ingredients was to improve waffle quality. Waffle quality was influenced by batter parameters, significant correlations could be found, for example, a positive correlation between pH‐ and L‐value, negative correlations between pH‐ and a‐value, or density and aw‐value. This resulted in significant correlations with take‐off‐force, which was correlated with L*‐ and b*‐value (negative) and positive to a*‐value. Sticking behavior was strongly associated with b*‐value (positive) and to a*‐value (negative).

Background of this study was to understand the factors that contribute to sticking of fresh egg waffles on baking plates. The aim of this study was to investigate the sticking (adhesion) behavior of waffles on 4 different baking plate materials (ductile iron, grey iron, low alloyed steel, and steel with titanium nitrite coating) at different baking parameters (temperature and time) and application of 3 different release agents (different fat compositions). Baking plates from ductile and grey iron showed lower release properties of waffles than the 2 steel baking plates. Baking parameters had to be high enough to allow rapid product crust formation but prevent burning, which again increases sticking behavior. Release agents based on short-chain fatty acids with higher degree of saturation provided better release behavior of waffles than those based on long-chain fatty acids or on emulsifier-acid combinations. Baking plates with increased hardness, good heat storage capacity, and smooth surface seemed to be best suitable. Further research on appropriate coating material might be promising for future.

Fresh egg waffles are continuously baked in tunnel baking ovens in industrial scale. Waffles that partly or fully stick to the baking plates cause significant product loss and increased costs. The aim of this study was, therefore, to investigate the effect of different recipe ingredients on the sticking behavior of waffles. In this second part, ingredients investigated were different leavening agents (sodium acid pyrophosphate, ammonium bicarbonate, magnesium hydroxide carbonate, or monocalcium phosphate), different fat sources (rapeseed oil, cocos fat, butter, or margarine), and different water sources (tap water 12°dH and distilled water). Within the different types of fats, solid fats with high amount of short‐chain fatty acids (cocos fat or butter) decreased the number of sticking waffles compared to liquid oils (rapeseed oil). Regarding leavening agents, magnesium hydroxide carbonate and ammonium bicarbonate were superior to sodium acid pyrophosphate or monocalcium phosphate. Between the two water sources, effects were small.