AU2014100235A4 - Snack Food - Google Patents

Abstract

Abstract A flavoured corn chip or tortilla chip prepared from corn masa, wherein at least part of said flavouring is incorporated in the corn masa.

Description

1 SNACK FOOD Technical Field [0001] The invention relates to the field of commercial dry snack food manufacture. In particular, the invention relates to a corn chip having enhanced flavour. Background of the Invention [0002] Corn chips and/or tortilla chips are a well-known snack food. They are usually made from corn kernels that have been de-husked and soaked, followed by grinding into masa, a dough-like state, sheeting, cutting to shape and cooking (usually frying and toasting). [0003] The 'plain' corn chip has a crunchy texture that then develops in to a pasty chewy texture during chewing by the consumer. It has a distinctive 'corny' flavour that tends to emerge during chewing. Some consumers like this 'corny' flavour and some do not. [0004] Flavoured versions of these chips are also manufactured. Some of the flavouring materials include cheese powder, tomato flavourings, etc. They are typically applied to the chip after cutting or after frying. These flavours provide variety to the consumer and can offset the 'corny' flavour, at least to some extent. However, their effect is to release their flavour initially as the surface of the chip contacts the tongue, but chewing of the chip tends to release the 'corny' flavours which linger in the mouth after swallowing. [0005] Approaches to improve the flavour profile of flavoured chips to those who do not like the 'corny' flavour have been tried. These include searching for better or stronger seasonings/flavours and attempting to use a flavoured oil to assist in 'sticking' the flavour particles on to the chip surface. [0006] However, none of these have been successful in removing the 'corny' flavour profile to meet the approval of those people who do not like it. [0007] Accordingly, it is an object of the invention to provide a flavoured corn chip or tortilla chip that ameliorates at least some of the problems associated with the prior 2 art, such as that of having a somewhat off-putting corny flavour and/or aftertaste to some consumers. Summary of the Invention [0008] According to a first aspect of the invention, there is provided a flavoured corn chip or tortilla chip prepared from corn masa, wherein at least part of said flavouring is incorporated in the corn masa. In a preferred embodiment, the flavouring incorporated in the corn masa is a cheese flavour. [0009] When prepared this way, the flavour profile of the chip is substantially enhanced in ways not associated with the prior art. The incorporation of at least part of the flavouring inside the corn masa allows the flavour to infuse the entire chip, and ends to mask the 'corny' flavour of the chip. In this way the cheese flavour is experienced throughout chewing by the consumer, and does not give way to the 'corny' flavour as is known in the prior art. [0010] This masking or neutralising of the 'corny' flavour also has the advantage of allowing any flavourings or seasonings incorporated on the surface of the chip to be enhanced, as the 'corny' flavour does not develop in the mouth, as it tends to in the prior art. [0011] Advantageously, the cheese flavour is a spray-dried parmesan cheese powder. This type of cheese flavouring is well suited to incorporation with corn masa, and it has a flavour strength that will 'cut through' the 'corny' flavour of the masa. [0012] Preferably, the cheese flavour is incorporated in to the masa at a rate of between 0.13% and 1.4% by mass of finished chips. Outside these ranges, the flavour may not be strong enough, or the chips may become brittle due to a lower moisture content. [0013] According to another aspect of the invention, there is provided a method of preparing a flavoured corn chip or tortilla chip from corn masa, including the steps of: preparing a corn masa in a masa mill; forming the corn masa into a sheet; cutting said sheet into shapes; and toasting said shapes; wherein a cheese flavour is incorporated into the corn masa prior to forming the masa into a sheet.

3 [0014] This point of addition of the flavour allows it sufficient time to be mixed in to the masa completely, prior to the forming of the masa into sheets. [0015] Now will be described, by way of a specific, non-limiting example, a preferred embodiment of the invention. Detailed Description of the invention [0016] The typical process for manufacturing flavoured corn or tortilla chips involves at least the following steps: [0017] 1. Cooking the dry corn kernels for 3-5 minutes in a 1% lime solution, which causes hydration and expansion of the kernel, and a releasing of the husk. [0018] 2. Soaking the kernels in a 1% lime solution for 1'-18 hours. [0019] 3. Washing the soaked kernels and subjecting them to a milling step in a 'masa' mill, a traditional type of stone mill, which breaks down the kernel into what is called 'corn masa' - a damp dough-like substance. [0020] 4. The masa is then 'sheeted' (made in to sheets) and cut to the desired size/shape. [0021] 5. The cut shapes are then toasted through a multiple pass toaster at temperatures up to 4000C. [0022] 6. The cut shapes are then 'proofed', i.e. allowed to sit so the moisture in the chip can equilibrate. [0023] 7. The shapes are then fried in oil. [0024] 8. After frying, the chips are seasoned - usually by having the various seasonings/flavours applied in a tumbler including spraying topical oil, which ensures an even coating. [0025] In one embodiment of the present invention, there is an extra step between 3 and 4 above, where a flavour, preferably a spray-dried parmesan cheese powder, such as that available from Ballantyne Foods Pty Ltd, 39 Ballantyne St, South 4 Melbourne, Victoria, is added via a metering system post-milling. This is then mixed into the masa for even dispersion via a continuous mixing system. The mixture is then sheeted. [0026] The rate of addition can vary from between 0.13% to 1.4% of finished (dried) product, depending on the flavour requirements. [0027] As the cheese powder may be lower in moisture than the normal final moisture of the chips, addition rates higher than 1.4% of final product may cause the chips to be too dry, leading to cracking. [0028] The flavour of chips produced according to the invention is very 'cheesy' and they do not tend to develop the 'corny' flavour of prior art chips. The 'cheesy' flavour persists throughout chewing. [0029] It will be appreciated by those skilled in the art that the above described embodiment is merely one example of how the inventive concept can be implemented. It will be understood that other embodiments may be conceived that, while differing in their detail, nevertheless fall within the same inventive concept and represent the same invention.

Claims (5)

1. A flavoured corn chip or tortilla chip prepared from corn masa, wherein at least part of said flavouring is incorporated in the corn masa.

2. The flavoured corn chip or tortilla chip of claim 1, wherein the flavouring incorporated in the corn masa is a cheese flavour.

3. The corn chip or tortilla chip of claim 2, wherein the cheese flavour is a spray-dried cheese powder.

4. The corn chip or tortilla chip of claim 3, wherein the cheese flavour is incorporated in to the masa at a rate of between 0.13% and 1.4% by mass of finished chips.

5. A method of preparing a flavoured corn chip or tortilla chip from corn masa, including the steps of: preparing a corn masa in a masa mill; forming the corn masa into a sheet; cutting said sheet into shapes; and toasting and frying said shapes; wherein a cheese flavour is incorporated into the corn masa prior to forming the masa into a sheet.