AU2013270528A1 - Method of processing a starch to make a product base and products prepared therefrom. - Google Patents

Abstract

PotatoMagic Ptsj Ltd 59 Yule str Dulwich Hill 22o N5W AU5TKALIA A.C.N. I 10029288 Web www.potatomagic.com Tel Int 61 +12501987 Austo+i 2501987 Patent Application ref : Kraft 1 Abstract Potato processing has in the past been restricted to low sheer processing to avoid the undesirable "glue" that the material becomes when over worked. This over processing ruptures the starch cells in potato and the qualities of the desired product are lost and the material ruined and discarded. The present invention overworks the material in an innovative step that further over works the potato to rupture the starch to the maximum extent possible. The resultant glue material is chilled and allowed to retrograde. These process produce a gel product that has all the nutritional benefits of cooked potato and more. The retrograde process has made the starch resistant starch and the product low GI. These are desirable qualities in modern potato food products. Confidential Page 1 12/11/2013

Description

AUSTRALIA 5 Patents Act 1990 0 PROVISIONAL SPECIFICATION 5 FOR THE INVENTION ENTITLED: 0 METHOD OF PROCESSING A STARCH TO MAKE A PRODUCT BASE 5 AND PRODUCTS PREPARED THEREFROM 30 Applicant: PotatoMagic Pty Ltd Ref: Kraftl 35 Inventor Andrew M Dyhin 0o Confidential - 1 - 11/12/2013 The invention is described in the following statement: 5 METHOD OF PROCESSING A STARCH TO MAKE A PRODUCT BASE AND PRODUCTS PREPARED THEREFROM 0 Technical field This invention relates to a method of processing a starch to make a product base and 5 products prepared there from. Reference cited PCT/USOO/30048, WIPO No WOO1/35763, Process of producing a sheetable potato 0 dough from raw potato stock. Background of the invention The information provided herein and references cited are provided solely to assist the .5 understanding of the reader, and do not constitute an admission that any of the references or information is prior art to he present invention. Potato food innovation has not seen a step change since the potato chip and the French fry. Historically the potato fry was invented as early as 1680 in Belgium, then in 1853 30 George Crum invented the potato crisp in New York. So if it took 173 years for second step change "modern" in potato usage. The next if we follow the same time frame is due by 2026. We are determined to make it happen in 2013-2014. Potato appears in our diets and products around us in many forms but predominately, 35 as fries, crisps, baked or boiled. The prevalence of obesity and "superfoods" is changing our diets and impacting on the consumption of potato and potato products. The majority Confidential -2- 11/12/2013 of potato dishes deliver a lot of fat with the delicious tuber. These tubers and starches generally have suffered an image issue as a result. Its time for a makeover that gives a potato delivery platform that is fat free and open to great healthy eating. 5 To date there are a number of ways to produce starch based product bases, however few if any use the "glue" produced by overworking the starch in high shear processing. Bellows et al in PTC/USOO/30048, WO 01/35763 discloses use of a flowable gel produced by high sheer processing of dehydrated cooked potato, to produce sheetable feed stock. The feed stock is the base for the production of dough for cooking, for the 0 production of fried or baked food. With the declining favour of starchy fatty potato products as a desirable healthy food source we have undertaken to develop alternative methods of producing potato and or starch based food products. These food products are destined to excite our taste buds 5 and deliver great healthy nutrition. Summary of the invention Potato processing has in the past been restricted to low sheer processing to avoid the 0 undesirable "glue" that the material becomes when over worked. This over processing ruptures the starch cells in potato and the qualities of the desired product are lost and the material ruined and discarded. The present invention overworks the material in an innovative step that further over works the potato to rupture the starch to the maximum extent possible. The resultant glue material is chilled and allowed to retrograde. These ?5 process produce a gel product that has all the nutritional benefits of cooked potato and more. The retrograde process has made the starch resistant starch and the product low GI. These are desirable qualities in modern potato food products. The present invention provides a process for processing starch resulting in the 30 manufacture of a base material with a texture not dissimilar to a solid gel or cheddar cheese. According to the second aspect of the present invention the solid gel can be used as a food base with a diverse set of applications. Confidential -3- 11/12/2013 According to the third aspect of the present invention the solid gel can be used as an industrial or food base with a diverse set of applications. 5 According to the fourth aspect of the present invention it provides a material that mimics cheddar cheese in some applications. Cheddar cheese delivers 1700kj/100g while potato delivers 263kj/100g that's a 6.5 to 1 difference in Kj/100g. According to the fifth aspect of the invention it provides a material that mimics a thermo 0 plastic and can be used as a plastic, thermo adhesive or a feed material for a 3D printer. According to the sixth aspect of the present invention it can provide a potato food base that is RS3 resistant starch, Low GI and 15.4% of the Kj of cheddar cheese for use in 5 innovative low KJ low GI and resistant starch formats. 0 Definitions 1. Starch Gelatinisation: is a process that breaks down the intermolecular bonds of starch molecules in the presence of water and heat, allowing the hydrogen bonding sites (the hydroxyl hydrogen and oxygen) to engage more water. This 5 irreversibly dissolves the starch granule. 2. Retrograde Starch: Cooked, unmodified starch, when cooled for a long enough period, will thicken (or gel) and rearrange itself again to a more 0 crystalline structure; this process is called starch retrogradation. Detailed Description of Preferred Embodiments of the Invention. 35 The present invention provides the basis for a material with a high number of known and an unknown number of yet to be explored uses. The unique nature and characteristics of the material should lend itself to a very diverse number of applications. In the present invention there is provided the a method of making a material that can be 10 formed into process blocks, sheets or extruded for further processing or direct use. Confidential -4- 11/12/2013 In the present invention there is provided a method of adding additives to the base material to modify the appearance, mouth feel, texture or physical or chemical characteristics of the material. In one embodiment 1 kg of washed skin on Desiree potatoes are microwaved using a 5 1200w oven for 8 -10 minutes depending on the season and type and size of potato, but at least until the potatoes yield to light pressure and the skin wrinkles when pinched. The starch in these potatoes should be fully cooked and gelatinised. The cooked potatoes are placed in a refrigerator at 1-3 deg C with free air movement around them and raised on racks to avoid free water for no less than 2 hours and 0 preferably 12 hours. This allows the starch in the potatoes to retrograde. On having cooled the potatoes for 12 hours they are sliced in half and peeled and mashed through a ricer. ( A process known in the art.) The mashed potato is then processed in a Robot Coup Blixer processor at 3000rpm until the potato mash forms a very sticky material that congregates at the rotor stem and 5 not the outer walls off the bowl and does not flow. The time will vary seasonally for potato and potato varieties. Average time to achive the required level of starch cell rupture is in the order of 2-5 minutes. This high sheer process warms the potato mash and smashes the starch cells releasing the starch to form a very sticky material. The resultant very sticky material is transferred to a stainless steel tray and sheeted flat with ?0 a silicone spatula. The material is then refrigerated for a minimum of 12 hours before usage. This process allows the sticky material to form into a gel in the retrogradation process. The nature of the gel is governed by the Amylose, Amylopectin concentrations in the potato starch. These ratios can be manipulated in the feed stock to design gells for ?5 various applications. During cooling, starch molecules gradually aggregate to form a gel. Molecular associations occur: Amylose-Amylose ; Amylose-Amylopectin; Amylopectin-Amylopectin.. High amylose starches require more energy to break up Confidential -5- 11/12/2013 bonds to gelatinize into starch molecules, leading to a rigid and stiff gel. Due to strong associations of hydrogen bonding, longer amylose molecules will form a stiff gel. Amylopectin molecules with longer branched structure, increases the tendency to form strong gels. High amylopectin starches will have a stable gel, but will be softer than high 5 amylose gels. Retrogradation restricts the availability for amylase hydrolysis to occur so when products made of retrograded starch are eaten they tend not to be digested in the small intestine. This type of starch is beneficial to health and is lower GI than non retrograde or non resistant starch. 0 This present invention provides a gel that can be solely potato. This present invention thereby provides a gel that can be solely potato with RS3 resistant starch and a very desirable food product offering a new dimension for potato usage. This present invention thereby provides a gel that can be solely potato with a wide area 5 of application including 3D printing, thermoplastic material and thermoplastic glues for industrial applications and food. In one embodiment of the present invention the sheeted material is sliced and use it as a snack food accompanied or un accompanied. The mouth feel and texture is cheddar cheese, with a potato flavour. O In another embodiment of the present invention the thermoplastic glue nature of the material is utilised as a food. Two 3mm cubes of the material were placed on a wafer cracker, a second wafer cracker was placed on top of the cubes. The wafers were microwaved in a 1200 watt microwave for 20 seconds. The crackers were pressed together. The resultant bond could not be broken without destroying the crackers. ?5 In another embodiment of the present invention the sheeted material was knife shredded to resemble grated cheese and grilled on bread under a gas griller for 1-2 minutes. The material browned and melted in a manner that resembled cheddar cheese. The mouth feel and texture were that of cheddar cheese, the smell, of toasted potato. 30 In another embodiment of the present invention a small amount of knife grated material was pan fried with a fine spray of olive oil. The material rapidly melted and adhered to a fork when swirled just like cheddar cheese. The taste and texture were just like cheddar cheese with a fried potato smell. In another embodiment of the present invention the material was formed into a 20mm 35 thick sheet and cubed. The cubes were used as cubed potato to prepare a potato salad. Confidential -6- 11/12/2013 In another embodiment of the present invention the material was shredded and used as the "cheese" component of a pizza. The result produced melted runny "potato cheese" and areas of toasted potato. Both delicious. In another embodiment of the present invention the material was used in slices with a 5 pizza base smeared with tomato paste as the potato for a potato and rosemary pizza. The result produced melted like runny "potato cheese" and other areas became toasted potato all infused with fresh rosemary. Both delicious. In another embodiment of the present invention a loose corner of wallpaper was stuck back in place by placing a thin film of material under the loose corner then applying a 0 hot iron on top of a protective linen cloth. In another embodiment of the present invention a 6mm square prism approximately 20mm long of material was placed in the barrel of a hot melt glue gun and extruded. The resultant "hot glue" bead acted like the slither under the wall paper and provided good adhesive qualities. 5 In another embodiment of the present invention small cubes were added to coconut milk and served as a jelly desert. Delicious. Although these specific embodiments are disclosed as a series of batch steps, it is understood that each embodiment can be practiced in a continuous or semi-continuous process using methods currently available in the food and manufacturing industries. 0 While the invention has been particularly shown and described with reference to a preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. 5 30 Claims What is claimed is: 1. A process for processing a starch based material resulting in the 35 manufacture of a starch based material comprising the following steps: 1 subjecting the starch to cooking so as to fully gelatinise and cook the starch. 2 chilling the cooked starch to allow the starch to retrograde. Confidential -7- 11/12/2013 3 subjecting the cooked starch to high sheer so as to rupture the starch cells and create a material with a very gluey non flowing texture. 4 sheeting or forming the gluey material to a desired shape. 5 chilling the shaped material to allow it to retrograde and form a solid gel. 5 2. A method according to claim 1 wherein step 2 is omitted. 3. A method according to claim 1 or 2 wherein the starch based material is potato or potato starch. 4. A method according to claim 1 or 2 wherein the starch based material is a 0 starch other than potato or potato starch. 5. A method according to claim 1 or 2 or 3 or 4 where a mixture of flavours, herbs and spices is added to the starch based material. 6. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of other vegetables or a vegetable is added to the starch based material. 5 7. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of fruits or a fruit is added to the starch based material. . 8. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of dairy or dairy flavoured material is added to the starch based material. 9. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of proteins or 0 a protein is added to the starch based material. 10.A method according to claim 1 or 2 or 3 or 4 wherein a mixture of synthetic or natural colour or flavour is added to the starch based material. 11.A method according to claim 1 or 2 or 3 or 4 wherein a mixture of non toxic edible material is added to the starch based material. 5 12.A method according to claim 1 or 2 or 3 or 4 wherein a mixture of material is added to the starch based material to modify its electrical or physical characteristics. 13.A method according to claim 1 to 12 where the material exhibits insolubility in water at temperatures of 0 deg C to 40 deg C. 0 14.A method according to claim 1 to 12 where the material exhibits plasticity at temperatures exceeding 40 deg C. 15.A method according to claim 1 to 12 where the material exhibits thermoplastic heat melt behaviour above 60 Deg C. 16.A method according to claim 1 to 12 where the material exhibits thermoplastic 35 heat melt glue behaviour at temperatures above 100 deg C Examples Example 1 10 1 kg of washed skin on Desiree potatoes are microwaved using a 1200w oven for 8 -10 minutes. The cooked potatoes are placed in a refrigerator at 1-3 deg C with free air movement around them and raised on racks to avoid free water for 12 hours. Confidential -8- 11/12/2013 The potatoes are then sliced in half and peeled and mashed through a ricer. ( Method known in the art.) The mashed potato is processed in a Robocop Blixer processor at 3000rpm until the potato mash forms a very sticky material that congregates at the rotor stem and not the 5 outer walls off the bowl and does not flow. The mix time is in the order of 2-5 minutes. The material is transferred to a stainless steel tray and sheeted into a 2cm sheet with a silicone spatula. The material is refrigerated for a minimum of 12 hours before usage The resultant material is cubed, mixed with one part mayonnaise, three parts thick 0 Greek yogurt, diced fermented cucumber, chopped chives, chopped fresh dill, salt and pepper to taste and served cold with soft boiled peeled eggs on top. Example 2 1 kg of washed skin on Desiree potatoes are microwaved using a 1200w oven for 8 -10 minutes. 5 The potatoes are then sliced in half and peeled and mashed through a ricer. The mashed potato is processed in a Robot Coup Blixer processor at 3000rpm until the potato mash forms a very sticky material that congregates at the rotor stem and not the outer walls off the bowl and does not flow. The mix time is in the order of 2-5 minutes. The material is transferred to a stainless steel tray and sheeted into a 3cm sheet with a ?0 silicone spatula. The material is refrigerated for a minimum of 12 hours before usage Confidential -9- 11/12/2013 The resultant material is cut into thin slices and used to cover a pizza base that has had a thin film of tomato paste speared across it and , sprayed lightly with olive oil. The pizza is then given a liberal coating of fresh rosemary, sprayed lightly with olive oil again and salted to tyaste. 5 The pizza is cooked for 2-3 minutes in a very hot oven ( >240 deg C ) or until done. Example 3 500g kg of washed skin on Desiree potatoes are microwaved using a 1200w oven for 8 -10 minutes. 0 The cooked potatoes are placed in a refrigerator at 1-3 deg C with free air movement around them and raised on racks to avoid free water for 12 hours. The potatoes are then sliced in half and peeled and mashed through a ricer. The mashed potato is processed in a Robot Coup Blixer processor at 3000rpm until the potato mash forms a very sticky material that congregates at the rotor stem and not the '5 outer walls off the bowl and does not flow. The mix time is in the order of 2-5 minutes. The material is transferred to a stainless steel tray and sheeted into a 1cm sheet with a silicone spatula. The material is refrigerated for a minimum of 12 hours before usage Method 1 ?0 The material is cut into 20 cm lengths and 6mm square to fit a hot melt glue gun. Confidential -10- 11/12/2013 The 20mm length is fed into the preheated glue gun, it is 'rammed' with a dowel or pencil sanded back to the dimensions of a glue rod. The hot glue is applied as required to form an edible shape or to glue food or other surfaces together. With gluing use the highest workable temperature setting, apply pressure until the glue cools. For food 5 shapes requiring crisp products, Use the highest heat setting and allow to harden. For soft gel products use the lowest heat setting that gives a workable melt and fridge set the gel product. Method 2 ( For parts that can be microwaved ie non metal or food items) 0 The materiel is cut into 2, 3 cm cubes. The cubes are placed between two wafer crackers and microwaved for 20 seconds in a 1200 watt microwave, then pressed firmly together. The resultant bond is stronger than the crackers and edible. Confidential -11- 11/12/2013

Claims (16)

1. A process for processing a starch based material resulting in the manufacture of a starch based material comprising the following steps: 1 subjecting the starch to cooking so as to fully gelatinise and cook the starch. 2 chilling the cooked starch to allow the starch to retrograde. 3 subjecting the cooked starch to high sheer so as to rupture the starch cells and create a material with a very gluey non flowing texture. 4 forming the gluey material to a desired shape. 5 chilling the shaped material to allow it to retrograde and form a solid gel.

2. A method according to claim 1 wherein step 2 is omitted.

3. A method according to claim 1 or 2 wherein the starch based material is potato or potato starch.

4. A method according to claim 1 or 2 wherein the starch based material is a starch other than potato or potato starch.

5. A method according to claim 1 or 2 or 3 or 4 where a mixture of flavours, herbs and spices is added to the starch based material.

6. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of other vegetables or a vegetable is added to the starch based material.

7. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of fruits or a fruit is added to the starch based material. .

8. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of dairy or dairy flavoured material is added to the starch based material.

9. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of proteins or a protein is added to the starch based material.

10. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of synthetic or natural colour or flavour is added to the starch based material.

11. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of non toxic edible material is added to the starch based material.

12. A method according to claim 1 or 2 or 3 or 4 wherein a mixture of material is added to the starch based material to modify its electrical or physical characteristics.

13. A method according to claim 1 to 12 where the material exhibits insolubility in water at temperatures of 0 deg C to 40 deg C.

14. A method according to claim 1 to 12 where the material exhibits plasticity at temperatures exceeding 40 deg C.

15. A method according to claim 1 to 12 where the material exhibits thermoplastic heat melt behaviour above 60 Deg C.

16. A method according to claim 1 to 12 where the material exhibits thermoplastic heat melt glue behaviour at temperatures above 100 deg C Confidential Page 1 12/11/2013