“Pointers, Indicators, and Measures of

Tortilla Quality”
Tom Jondiko, Ph.D.

5690 Lindbergh Lane • Bell, CA • 90201

Phone: 562-806-7560 • www.solvaira.com
 Tortilla Quality
Consumers perspective:
• The definition of a good quality tortilla encompasses the
ability to retain its flexibility, remain strong so there is no
cracking or tearing, and of course, taste good. (Waniska et al 2004,
Jondiko et al 2016).

Tortilla Producers perspective:

• Quality includes uniform shapes, toast marks, soft, fluffy,
adequate shelf life for distribution and sales.

Overall perspective:
• Quality = Quality raw material + Quality processing +
Quality of personnel.
 Tortilla Formula Composition
Batch Pack:
Salt, Sugar, Leavening
Dough Conditioners & Preservatives
5.0%
6.0%

29.0%
60.0%

Flour Water Shortening Batch Pack

 Defining Quality
Tortillas must meet consumer expectations.
• Physical parameters (Soft, pliable).
• Good diameter, uniform, toast marks and long shelf life.
 Flour: Starch Quality
• Good quality tortillas produced using wheat flour of
intermediate protein and low level of starch damage
(Waniska et al 2004) .

Starch characteristics:
– Measured using rapid visco analyzer.
– Peak and final viscosity.
– Affect cooking conditions.
– Tortilla flexibility.
– Tortilla shelf stability.
 New Flour Starch Quality
Pastry Flour

New Flour 1

New Flour
2

All
purpose

High
Protein

James Chapa 2016, Solvaira R&D

• Evaluate quality of new flour compare to standard.

• Starch is gelatinized causes rise in viscosity.
• Tortillas start sticking on each other.
 Protein Quality vs Quality
Protein Content
• Good quality can be produced using wheat flour of
intermediate protein content (Waniska et al 2004).

Protein content is not an adequate indicator of tortilla

quality
• Protein content can not simultaneously predict both
diameter and rollability LU
2.5

• Look at protein fractions? 2.25

2.0
Absorbance at 210 nm 1.75
1.5
1.25
1.0
LU 10 15 20 25
1.4
1.3
1.2
1.1
1.0
0.9
0.8
10 15 20 25
Elution time (min)
 Flour protein fraction and tortilla quality
• Wheat protein fractions in gluten play a significant role in tortilla
making (Jondiko et al. 2012)

• Variation of flour protein molecules can improve tortilla quality.

• Tortilla diameter can be predicted using a protein molecule content

and dough rheological properties

• Tortilla softness depends on the ratio of the gluten protein

molecules

Parameter Range
Glutenin: Gliadin Ratio 0.5 – 0.9
Mono & Polymeric proteins 12 – 65
HMW & LMW – GS 0.3 -0.6
 Total Protein content and Functionality
Relationship of tortilla diameter, flexibility & flour protein
Acceptable
Good Flexibility
Diameter
Small diameter
Flexibility

Not
Acceptable:
Not Acceptable:
Falling apart
Very week, sticky
and sticking
dough, brittle tortillas
 Gluten Acid Test
Correlation Between Protein Content and Viscosity at 3 minutes Measured in the Wheat Gluten Acid Tests
14
High Protein
13 y = 0.0028x + 7.9225 Flour
Protein Content (%)

R² = 0.9948
12
All Purpose
All Purpose
11 Flour 1
Flour 2
New High Protein
10 Flour Samples

9 Pastry Flour
James Chapa 2016, Solvaira R&D
8
250 450 650 850 1050 1250 1450 1650 1850 2050
Viscosity (cP)
• New High protein flour 13% total protein has only 11% functional protein
• Can result in tortilla quality defects
• Evaluate the functionality of new flour when received
 Gluten Quality: Viscosity & Temperature

High Protein
Flour

All Purpose
Flour
New Protein
Flour

Pastry Flour

James Chapa 2016, Solvaira R&D

Quality variation:
 Higher viscosity means higher gluten quality
 Tortilla Sticking
 Oven temperature adjustment
Functional Protein Content & Flexibility

Intermediate Functional Protein

Content
(10.5 % – 12.0%)

Low Functional Protein

Content
(8.0 – 10.5% )
Predicting Flour Functionality for Tortillas

Area F_25

1) Prediction value > or = 0: Suitable flour for quality tortilla

2) Prediction value < = 0: Unsuitable for good tortilla

Good Rollability and Diameter =

-10.15 – 0.19*Weight + 10.58Glu:GliRatio – 0.05*IPP –
0.22*Area + 1.4*F_25 + 0.36*F_100 + 0.02*CompForce;
 Water Quality
• The second largest component of tortillas.

• Optimum tortilla moisture content: 29 – 32% affects:

– Tortilla Texture
– Shelf‐life
– Excess water create steam and weakens tortilla structure

• Monitor microbial counts on water used.

• Water temperature of used to make dough.

• Water pH:
– Depending source water can be treated to adjust pH hence
measure pH regularly
– Measure conductivity to determine hardness
 Shortening/ Fat Quality

An important component of tortillas

• Type used:
– liquid oil
– Solid shortening

• Affect tortilla texture:

– Slow staling
– Interact with flour components – starch & protein

• Improves dough machinability & reduce stickiness

• Provide desired flavor in tortillas

• Prevents & reduces tortilla sticking during storage

 Functional Ingredients

Raw Material Quality:

 Bake tests for functionality
 Test for pH, CO2, Sodium, moisture
 Sticking test
 Microbial loads
 Flexibility, & Accelerated Shelf life
 Particle Size distribution
 Purity tests
 Processing and storage conditions

• Temperature reduction after baking, during

packaging, in transportation and in storage.

• Monitor and document parameters:

– Dough mixing
– Dividing & rounding
– Pressing method – hand stretch, hot press or die cut
– Oven
– Cooling
– Packaging
 Other aspects of shelf stability

• pH: Ideal between 5.2 – 5.8 flour tortillas.

• Preservatives: Sorbates and propionate effective at

low pH where as Parabens at high pH (Questions
around safety of Parabens).

• Microbial load: Establish & monitor COA limits for

all suppliers.
 Conclusion

The recipe to deliver good quality tortillas

 Quality of Flour.
 Quality of Water.
 Quality of Shortening/ Oil
 Quality of functional ingredients.
 Quality of personnel: qualification, training &continuous
improvement.
 Consistent documentation and monitoring of data.