BR102015016669A2 - process for obtaining a gluten-free stuffed cookie suitable for chocolate-coated celiac from an extruded / expanded rice-based cookie - Google Patents

Abstract

process for obtaining a gluten-free stuffed cookie suitable for chocolate-coated celiac from an extruded / expanded rice-based cookie. A process for making a gluten-free stuffed cookie suitable for celiacs, covered with a chocolate bath from an extruded / expanded rice-based cookie, comprising the steps of: blending the raw materials used in the basic cookie consisting primarily of by a high starch ratio ingredient with the aggregation of ingredients that contribute to the final appearance of the base cracker, protein sources or simple sugars, and colorants, as well as other expansion modification ingredients or some dietary fiber; elaboration in an extruder of the cookies that constitute the substrate with which it is cut and forms a cookie that is stuffed and later bathed with chocolate.

Description

PROCESS FOR OBTAINING A FIT GLUTEN FREE COOKED COOKIE COVERED WITH A CHOCOLATE BATH FROM AN EXTRUDED / EXPANDED RICE BASKET Field of this Invention: Γ001] The present invention relates to a stuffed cookie without. Gluten suitable for celiac and its elaboration obtained from a low moisture extruded rice cracker of organoleptic qualities similar to a conventional stuffed cookie.

BACKGROUND OF THE INVENTION: Stuffed cookie is a product made with a dough consisting primarily of bread flour, starches and water obtained by heating, at high temperature, between two metal plates or in suitable molds which enable a cookie to be obtained. low density, crispy and low unit. The dough can be added with salt, sugars, milk, oily matter, eggs, flavorings and colorings.

Through extrusion, it is possible to obtain a low density expanded wafer from rice flour and using ingredients such as salt, sugar, milk powder, etc.

[004] The present invention relates to a process and a product obtained therefrom which yields a glazed chocolate-filled filled cookie in its composition which would be suitable for celiac.

[00.5] The problem with making a gluten-free stuffed cookie lies in the fact that the traditional technology for assembling the stuffed cookie cracker is not prepared to work with gluten-free rice flour ingredients. This problem was solved using an extrusion process with which it is possible to achieve the characteristics required for this type of low density, crisp and low humidity product.

Brief Description of the Figures (006) Figure 1 shows the process of making an extruded rice wafer.

[007] Figure 2 shows the filling preparation process.

[008] Figure 3 shows the process of assembling and bathing the stuffed cookie.

Detailed Description of the Invention Next, each step is detailed; 1. Making the extruded rice cracker As mentioned in the introduction, the main problem for obtaining a gluten-free product that retains the characteristics required for a stuffed cookie is to achieve a low density crispy cracker. moisture.

[011] In the market, the technology used for the preparation of filled cookie biscuits is part of a liquid dough that is applied over a mold where, by pressing and heating, the product is cooked at temperatures above 200 ° C. This process is designed to work with fluid masses and has a protein content that comes mainly from wheat flour, the source of gluten. If you replace the wheat flour with rice flour, it is not possible to get a crunchy product, the resulting sticky and asymmetrical cracker.

[012] Another existing technology for making gluten-free rice crackers is by expansion at high temperature. This technology starts from whole and / or broken rice grain, which is moistened to a humidity between 15 and 18% and then cooked in a mold, where the rice is subjected to one. pressure and temperatures above 250 ° C and for a period of time between 8 and 10 seconds. With this technology, a wafer of uniform dimensions, but with inadequate organoleptic characteristics is achieved. The cookie is hard and sticky in texture. As the results obtained by the previous technologies could not reach the required organoleptic result for the wafer, it was worked on the process of formation by axtrusàc, in which it was possible to arrive at a product with the required organoleptic characteristics and that would allow to make a free stuffed cookie Gluten The following describes the process.

Extruded Rice Biscuit Manufacturing [013] The biscuit is made from a mixture of high proportion starchy ingredients with rice flour and others, expanded with a single or twin screw extruder using linear inserts for forming a belt. which is cut to the desired size, ordered on a flat surface. Said formulation is given in Table I: Table I

[014] The raw material used for the preparation of the cookies is pre-mixed in a high efficiency horizontal mixer 1, which is fed by pneumatic conveying. The raw materials used in the base wafer are mainly an ingredient with a high proportion of cornstarch, potato, cassava, sorghum or rice flour, with the addition of ingredients that contribute to the final appearance of the base wafer. of protein such as milk powder, whey powder or simple sugars such as sucrose or glucose, salt and colorants. They may also have other expansion modifying ingredients incorporated, such as calcium carbonate, baking powder (sodium bicarbonate and some acidic agent such as calcium monoacid phosphate) or some dietary fiber. All of these ingredients must be gluten free.

[015] The wafers that form the basis for the preparation of the stuffed cookie are made in an extruder 2 (twin screw or single screw), using an insert head that allows to obtain expanded material straps. The expanded material belts exit the extruder with a linear velocity between 10 and 30 m / min, preferably between 15 and 25 m / min. The belts of expanded material have a width between 20 and 60 mm, preferably between 40 and 50 mm and a thickness between 3 and 10 mm, preferably between 6 and 8 mm. The apparent density of the extruded material is in the range 0.08 to 0.13 g / cm 2, preferably 0.10 to 0.11 g / cm 2, which is achieved with extruder process temperatures above 14 ° C.

Using a laminator / cutter 3, the thickness of the expanded material belts obtained from the extruder 2 is adjusted to provide a more even and flatter surface for subsequent application of the cover. At the time of cutting the expanded material belts, the product has a humidity, for example, between 5 and 15%, preferably between 8 and 12% and a temperature, for example, between 50 and 95 ° C, preferably between 70 ° C. and 85 ° C, which gives it the flexibility to cut without the generation of fine powders.

Wafers obtained with rolling mill / cutter 3 are between 4 and 5 cm wide and 5 and 10 cm long, preferably between 4.4 and 4.6 cm wide and 8 to 8 , 2 cm in length. The cut wafers are placed in a vibratory dispenser 4 formed, for example, between 1 and 6 trays, preferably between 2 and 4 vibrating trays, which allow all the wafers to be placed on. a single plan without. that they overlap. The wafers are soon derived for a belt or mesh, where the surface occupied by the wafers in transport is between 20 and 50% of the total surface. A. Belt speed is related to the production of the extruder, which varies the linear speed.

[018] Cookies are delivered to a conveyor belt with one. between 5 and 20 m / min, preferably between 18 and 14 m / min, which delivers them to the oven.

Oven roasting 5 is the drying operation and must be carried out in a short time following the speeds of the preceding equipment. This operation should be performed in a direct flame oven to achieve high heat transfer capacity. The oven residence time is between 2 and 5 minutes with a belt speed between 8 and 20 m / min, although preferably between 10 and 14 m / min. At the exit of the oven is a cooling conveyor 6 in which the wafer is cooled to a temperature close to room temperature. The residence time is between 10 and 20 minutes, preferably between 12 and 15 minutes, preferably between 12 and 15 minutes, then passing to feeder 7. The final moisture of the wafer before feeder 7 is between 2 and 6. %, preferably between 3 and 4%. Value that allows us to achieve a water activity between 0.30 and 0.40, preferably between 0.32 and 0.36, which is suitable for obtaining a crunchy product.

Example No. 1, extruded wafer An extruded wafer based on rice flour (93%), milk powder (3%), salt (2%) and sugar (2%) was made under the following conditions. Extruder process flow: • Dry ingredient flow rate: 300 kg / h • Water added to extruder: 20- kg / h • Spindle speed: 200 rpm (3.33 Hz) • Working temperatures: 160; 130; 130; 100; 70; 30 O f · * [021] The extruder output belts resulted in a speed of 22 m / min, with a width of 45 .mm, a thickness of 8 logs, an apparent density of 0.11 g / cm 2. and 9.5% humidity. By using the laminader, the thickness was reduced to 7 mm.

[022} The straps were cut into 8 cm long by 4.5 cm wide by 0.7 cm thick wafers through the cutter, and were sorted through the distributor to avoid overlapping units, [023] The cookies are delivered through a conveyor belt a. 12 m / min at the direct flame oven with a temperature of 1.80 ° C at a speed of 12 m / min with 3 minutes residence time, where the initial humidity of 15.5% of wet basis has been reduced to 4% wet basis with a water activity. (aw) of 0.36.

[024] Under these process conditions, crackers with a crunchy texture are observed. Stuffing Manufacturing [025] Stuffing is made with a high proportion mixture of sugars and / or solid liquid oily matter, which results in a low moisture value and low water activity (aw), which is critical for maintain product crispness over the life of the product. In addition to the basic ingredients, other ingredients are added to provide texture, color and flavor, such as soy lecithin, milk powder and / or its derivatives, starches, flavors, salt, citric acid, maltodextrin in the proportion shown in Table II.

[026] Formulation is of paramount importance, where an appropriate balance of ingredients is required to achieve a water activity. (aw) between 0.40 and 0.50, preferably between 0.45 and 0.48, which is required to obtain a crunchy product.

Table II

[027] The oily raw materials used for filling are mixed in a preparation tank 8, which is fed with liquid oil by a pump system and weighed in tank 8. At this stage, the oil is heated to a temperature between 40 and 80 ° C, preferably between 60 and 65 ° C. When the liquid oil reaches the desired temperature, the hydrogenated vegetable oil it has is added. melting point between 35 and 55 ° C, preferably between 40 and 45 ° C, this mixture is kept stirring until it reaches the final temperature between 55 and 70 ° C, preferably between 60 and 65 ° C. It is important to completely fuse the solid oily matter.

Once the oil mixture is prepared, it is passed to a homogenization tank 9 which has a vane stirrer and maintains the temperature between 35 and 50 ° C, preferably between 4.0 and 45 ° C, in which the rest of previously weighed ingredients in the following order: sugar, milk powder, starch, yogurt was powder, rn.altodextr.ina, citric acid-, salt, essence. Stirring is continued until a homogeneous mixture is obtained for 30 to 60 minutes, preferably 40 to 45 minutes. At this stage, it is important to achieve a uniform, lump-free mixture for the correct dispersion of ingredients.

At the end of homogenization, once the desired temperature is reached, the soy lecithin is added and mixed for 20 minutes.

Once the mixing of all ingredients is completed, the. mixing which is carried out in a vertical ball mill 10 having a production capacity of between 150 and 200 Jcg / hour, mill rotor speed of 300 rpm (5 Hz), working temperature between 40 and 55 ° C, preferably between 40 and 44 ° C, wherein the ultimate goal is to achieve a product whose particle size does not exceed 50 microns, preferably between 30 and 40 microns, with a. purpose of achieving a smooth and creamy texture to the taste. 1031] Once the required particle size is reached, the product is stored in the storage tank 11 at a controlled temperature between 30 and 40 ° C, preferably at 35 ° C for later use in the stuffed cookie assembly line.

Example No. 2, Filling A filling was prepared based on: Table III

[033] The process conditions are: * Preparation of oily matter mixture: Mixing temperature 63 ° C * Ingredient mixing tank: Mixing temperature 42 ° C Mixing time 40 min. * I o i no h o d. and spheres: Working capacity 150 kg / h Working speed 300 rpm (5 Hz) Working temperature 42 ° C Maximum particle size 35 microns.

Under these process conditions, a creamy filling was obtained with a water activity of 0.48.

Stuffing and Bathing Stuffed Cookies [035] The cookies that are obtained in the extrusion step are 4r5 cm wide by 8 cm wide? length and 0.7 cm thick. These are placed in the cookie feeder 12, which has the function of continuously feeding, and the units that will form the stuffed cookie sandwich are sorted. This machine has 8 cookie feeding channels and should work one. between 20 and 40 wafers / minute per channel, preferably 30 to 36 wafers / minute per channel, to maintain proper distribution in the next sandwich forming step.

[03-6] In the stuffed biscuit sandwich former 13 the feeder biscuits 12 enter. This equipment receives the biscuits in an aligned manner and automatically alternately dispenses the filling from the filling manufacturing line at a rate that is the same. . half of that of the cookie feeder, between 10 and 20 doses / minute per channel, preferably between 15 and 18 doses / minute per channel. The amount of filling to be sandwiched should be between 5 and 10 g / preferably between 6 and 7 g, at a dosage temperature of from 20 to 30 ° C, preferably from 2.3 to 27 ° C, which is the appropriate temperature for obtaining a good distribution of the filling in the formation. When the filling is completed, the machine 2 automatically applies the second biscuit to the filling and the sandwich that passes to the bathing stage is formed.

[037] .14 Stuffed cookie beater receives sandwich a. a rate of 1.5 to 18 units / min. per channel, which are automatically covered, whose melting point should be between 30 and 4.5 ° C, preferably between 34 and 40 ° C. In this one. At this stage, the product must be completely covered throughout. surface for which a chocolate coating dosage of between 6 and 12 g / unit is required, preferably from 8 to 9 g / unit. This dosage is achieved by regulating the bath feed rate between 2 and 3 kg / minute and a conveyor belt speed between 1.8 and 2.2 meters / minute. On leaving the bath, the stuffed cookie surface has a temperature between 34 and 40 ° C, and must be cooled to solidify the bath.

[038] The coated stuffed cookie passes through a cooling tunnel 15 which should be at a temperature between 5 and 1.5 ° C, preferably between 8 and 10 ° C for 4 minutes, which is the appropriate residence time for the surface. of the stuffed cookie is below 20 ° C and completely solidify the chocolate bath.

[039] After cooling step 15 is completed, the plated stuffed cookie is transported to the filling line 16, where the process is completed.

Example N ° 3, Assembly and stuffed cookie bath: [01.0] Stuffed biscuits made from cookies and filling were made according to the process described in the previous points. Worked on the following process conditions; * Feeding cookies; 32 wafers / minute per channel * Sandwich Formation: Filling Dosage; 6 g / unit Filling temperature: 25 ° C

Rhythm; 16 sandwiches / minute per channel. * Stuffed bike scooter: Bath temperature: 37 ° C

Conveyor Belt Speed: 1.9 m / nin Bath Feeding Flow: 2.3 kg / min • Cooler: Residence Time: 4 min Tunnel Temperature; 8 “C

Surface temperature of the product: 18 ° C [041] Under these conditions, a product with 9 g of chocolate bath was obtained, which allowed to completely cover the surface of the product.

Claims (46)

1. Process for making a gluten-free stuffed cookie suitable for celiacs, covered with a chocolate bath from an extruded / expanded rice-based cookie, characterized in that it comprises the steps of; mix in one. mixer of the raw materials used in the basic wafer consisting mainly of a high starch ingredient such as cornstarch, potato, cassava, sorghum or rice flour, with the addition of ingredients that contribute to the final appearance of the wafer with protein sources such as milk powder, whey powder or simple sugars, such as sucrose or glucose, salt and colorants, as well as other ingredients for expansion modification such as calcium carbonate, baking powder (bicarbonate) sodium hydroxide and some acidic agent such as calcium monoacid phosphate) or an alkali; elaboration in an extruder of the wafers that constitute the substrate with. which forms the stuffed cookie using a head with. inserts, which allows obtaining a belt of expanded material; adjusting the thickness of expanded material straps in a rolling mill and cutting to form the wafers; placing the biscuits on a vibrating distributor in a single plane without overlapping them and delivering the biscuits. a conveyor belt, baked in the oven and then cooled in a belt; transporting the cookies to the cookie feeder; continuous and orderly feeding of the cookies bathed with. the chocolate icing and, once covered, passed through a cooling tunnel; At the end of the cooling step, the stuffed biscuit is transported to the filling line, where the process is completed, Process according to Claim 1, characterized in that the expanded material belts exit the extender with a linear velocity of between 10 and 30 ni / min. Process according to Claim 1, characterized in that the expanded material belts exit the extruder with a linear velocity of between 15 and 25 m / min. 4. Process according to. claim 1, characterized in that the straps of expanded material have a width between 20 and 60 mm. Method according to Claim 1, characterized in that the straps of expanded material have a width of between 40 and 50 mm; Process according to Claim 1, characterized in that the straps of expanded material have a thickness of between 3 and 10 mm. A method according to claim 1, wherein the expanded material straps have a thickness of between 6 and 8 mm. Process according to Claim 1, characterized in that the straps of expanded material have an apparent density between 0.08 and 0.13 g / cm3. Process according to Claim 1, characterized in that the expanded material belts have an apparent density between 0.10 and 0.11 g / erró. Process according to Claims 8 and 9, characterized in that said bulk density is obtained at extruder process temperatures above 140 ° C. Process according to Claim 1, characterized in that, when cutting the strips of expanded wafer forming material without the generation of fine powders, the product has a moisture content of between 5% and 1 .cg. x «J-: ¾ * Process according to claim 1, characterized in that when cutting the strips of expanded wafer forming material without the generation of fine powders, the product has a moisture content of between 8% and 12%. Process according to claim 11 or. 12, characterized in that, when cutting the straps of expanded wafer forming material without the generation of fine powders, the. product has a temperature between 50 ° C and 95 ° C, Process according to claim 11 or. 12, characterized by the fact that when cutting the expanded material belts for the formation of biscuits without a. generation of fine powders, the product has a temperature between 7-0 ° C or R3 ° Γ Process according to Claim 1, characterized in that the straps are cut between 4 and 5 cm wide and 5 and 10 cm long. Process according to Claim 1, characterized in that the straps are cut between 4.4 and 4.6 cm wide and 8 and 8.2 cm long. Process according to Claim 1, characterized in that the cookies are delivered to a conveyor belt at a speed of between 5 and 20 ra / min. Process according to Claim 1, characterized in that the cookies are delivered to a conveyor belt at a speed of between 18 and 14 m / min. Process according to Claim 1, characterized in that the oven roasting is performed on. a direct flame oven with residence time between 2 and 5 minutes. 20. Procedure according to a. claim 1, characterized in that the oven roasting is carried out in a direct flame oven with the residence time between 10 and 14 minutes, Process according to claim 1, characterized in that the cooling in a belt is carried out at room temperature with a residence time of between 10 and 20 minutes. Process according to claim 1, characterized in that the cooling in a belt is carried out at room temperature with a residence time of between 12 and 15 minutes. Process according to Claim 2: 2, characterized in that the final moisture of the cookie prior to assembly of the filled cookie is between 2 and 6%. Process according to Claim 22, characterized in that the final moisture content of the cookie prior to the assembly of the filled cookie is between 3 and 4%. Process according to Claim 23, characterized in that said moisture allows to achieve a water activity between 0.30 and 0.40. Process according to Claim 24, characterized in that said moisture allows to achieve a water activity between 0.32 and 0.36. Process according to Claim 1, characterized in that the cookies are transported to one. feeder whose function is to continuously and orderly feed the units that will form the stuffed cookie sandwich. Process according to claim 27, characterized in that said feeder has 8 wafer feed channels and works at a rate of between 20 and 40 wafer / minute per channel. A method according to claim 27, characterized in that said feeder has 8 wafer feed channels and works at a rate between 30 and 36 wafer / minute per channel. Method according to claim 28 or 29, characterized in that the feeder alternately dispenses the filling provided from the filling line at a rate that is half that of the cookie feeder. Process according to Claim 30, characterized in that the amount of filler to be sandwiched must be between 5 and 10 g. Process according to Claim 30, characterized in that the amount of filler to be sandwiched must be between 6 and 7 g. Process according to Claim 31 or 32, characterized in that the dosage temperature must be between 20 and 30 ° C. Process according to Claim 31 or 32, characterized in that the dosage temperature must be between 23 and 27 ° C. 3 5. Process and agreement as in clause 1, characterized in that once the sandwich is formed it is covered with a bath whose melting point must be between 30 and 45 ° C. 3-6. Process according to Claim 1, Character:! The fact that once the sandwich is formed, it is covered with one. melting point must be between 34 and 40 ° C. A process according to claim 36, characterized in that the cover size is between 6 and 12 g / unit. Process according to Claim 36, characterized in that the cover dosage is between 8 and 9 g / unit. Process according to claims 37 and 38, characterized in that, at the outlet of the bath, the filled cookie is superficially at a temperature between 34 and 40 ° C and must be cooled to solidify the bath. Process according to Claim 39, characterized in that the plated filled cookie is cooled in a cooling tunnel at a temperature between: 5 and 15 ° C, Process according to Claim 39, characterized in that the plated filled cookie is cooled in a cooling tunnel at a temperature between 8 and 10 ° C. Process according to Claim 40 or 41, characterized in that the filled cookies must be cooled for 4 minutes so that the surface of the filled cookies is below 20 ° C and completely solidifies the chocolate bath. Process according to Claim 42, characterized in that the plated filled cookies are transported to a filling line. 44. A gluten-free stuffed cookie suitable for celiac prepared by the procedure of claim 1, characterized in that it is formed from a low moisture extruded rice cracker. Stuffed cookie according to claim 44, characterized in that the cookies are formed with a mixture of ingredients with a high proportion of starch products, preferably rice flour in a proportion of 90 to 95%, skimmed milk powder. between 6 and 4%, leaves between 0.5 and 2% and sugar between 0.5 and 2%. Stuffed cookie according to claim 44, characterized in that the cookies are filled with a high proportion mixture of sugars and / or liquid and solid oily matter. 40 to 50% refined sugar, 25 to 30% sunflower oil, 5 to 10 hydrogen vegetable oil, 5 to 8% milk powder, 6 to 8% cornstarch, Yogurt powder 1 to 3% maltodextrin 2 to 4.5%, iecithin 0.1 to 0.3%, anhydrous citric acid 0.1 to 0.5%, salt 0.3 to 0.6% and essence at 0.3%,