Development of an Innovative Technology for the Production of Yeast-Free Bakery Products with Plant-Based Ingredients Through Mechanical Aeration Methods

This study investigates a mechanically aerated, yeast-free bread technology incorporating apple-derived plant ingredients (juice, purée, and powder) in response to the growing demand for clean-label bakery products. The global bakery sector represents one of the largest food markets worldwide, with the baking yeast segment alone accounting for several billion USD annually, while interest in yeast-free and yeastless-dough products continues to expand. To address technological limitations associated with yeast exclusion, dough aeration was achieved using a two-stage whipping protocol (1000 rpm for 4 min, followed by 500 rpm for 1 min and stabilization at 500 rpm for 1 min under 4.0 ± 0.1 MPa gauge pressure), forming a stable protein–carbohydrate foam system. Rheological evaluation using Mixolab 2 showed that formulations containing 3–5% apple purée exhibited the most favorable dough development characteristics, with stability increasing from 3.30 ± 0.15 min in the control to 8.90 ± 0.20 min. Texture profiling using a CT-2 analyzer equipped with a cylindrical probe (50% compression, 60 mm/min, slices 25 mm thick, n = 5) revealed a significant reduction in crumb firmness, from 3.01 ± 0.15 N in the control to 2.12 ± 0.10 N in the purée- and powder-enriched samples (p < 0.05). Nutritional assessment indicated improvements in vitamin C content (up to 2.23 mg/100 g) and protein quality: the amino acid score, calculated according to FAO/WHO reference patterns on a mg/g-protein basis, increased from 76.5 ± 1.8% to 89.2 ± 2.3%. Microbiological analysis showed reduced total aerobic mesophilic counts after 72 h of storage—4.7 × 103 CFU/g in the control versus 1.8–3.4 × 103 CFU/g in apple-enriched breads. Overall, the results demonstrate that mechanical aeration combined with apple-derived ingredients enhances the structural, nutritional, and microbiological quality of yeast-free bread, offering a promising clean-label approach for functional bakery products.