CA1045890A - Cereal process - Google Patents
Cereal processInfo
- Publication number
- CA1045890A CA1045890A CA235,414A CA235414A CA1045890A CA 1045890 A CA1045890 A CA 1045890A CA 235414 A CA235414 A CA 235414A CA 1045890 A CA1045890 A CA 1045890A
- Authority
- CA
- Canada
- Prior art keywords
- starch
- slurry
- gelatinized
- hydrolyzed
- cereal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Abstract
NOVEL CEREAL PROCESS
Abstract of the Disclosure A process for obtaining a dehydrated, readily reconstitutable cereal product by fully gelatinizing the starch in a portion of a cereal slurry, cooling the part of the slurry containing gelatinized starch, and thereafter subjecting the cooled gelatinized starch to enzymatic-induced hydrolysis, followed by further conventional processing to produce a dehydrated cereal product of superior reconstitution characteristics, and the novel cereal slurry required to obtain the aforementioned product.
Abstract of the Disclosure A process for obtaining a dehydrated, readily reconstitutable cereal product by fully gelatinizing the starch in a portion of a cereal slurry, cooling the part of the slurry containing gelatinized starch, and thereafter subjecting the cooled gelatinized starch to enzymatic-induced hydrolysis, followed by further conventional processing to produce a dehydrated cereal product of superior reconstitution characteristics, and the novel cereal slurry required to obtain the aforementioned product.
Description
1()45890 This invention relates to the preparation of a unique precooked, dehydrated grain cereal product that can be either salt-free or contain a low salt content, as well as higher conventional levels of salt. More particularly, the process of this invention provides a dehydrated product that is rapidly reconstitutable with liquid to form a homogeneous smooth textured cereal mass with the distinctive flavor of the original cereal grain and being especially suitable for infant feeding.
Precooked, dried products, which lend themselves to easy reconstitution or rehydration to yield a smooth, fluffy textured, edible mass when mixed with a liquid such as milk or water, have found increasing use in the feeding of infants and adults who require geriatric or post-operative care. Dehydrated products of this general type are available to the consumer in the cereal form.
These dehydrated products can be produced by preparing a paste or thick suspension, i.e., a slurry or puree, obtained by heating the raw materials to form a pulp which may be strained or sieved to ensure uniform particle size. The slurry or puree is then applied to the surface of conventional drying equipment such as a drum dryer, where substantially all (90-98%) of the water contained therein is removed. The dried product is conveniently flaked and packaged for use. -One conventional process for precooked, dehydrated grain cereal production involves the initial controlled heating of a slurry of raw (or steamed) cereal grain to a temperature suitable for the simultaneous gelatinization of the starch molecules present and where enzyme activity can accomplish the conversion of the gelatinized starch to dextrins and sugars. This enzyme process results in an increased cereal production rate and a product that is reconstitutable with an amount of liquid that is readily ascertainable and, most importantly, reproducible. However, such a conventional process suffers from the disadvantage of requiring
Precooked, dried products, which lend themselves to easy reconstitution or rehydration to yield a smooth, fluffy textured, edible mass when mixed with a liquid such as milk or water, have found increasing use in the feeding of infants and adults who require geriatric or post-operative care. Dehydrated products of this general type are available to the consumer in the cereal form.
These dehydrated products can be produced by preparing a paste or thick suspension, i.e., a slurry or puree, obtained by heating the raw materials to form a pulp which may be strained or sieved to ensure uniform particle size. The slurry or puree is then applied to the surface of conventional drying equipment such as a drum dryer, where substantially all (90-98%) of the water contained therein is removed. The dried product is conveniently flaked and packaged for use. -One conventional process for precooked, dehydrated grain cereal production involves the initial controlled heating of a slurry of raw (or steamed) cereal grain to a temperature suitable for the simultaneous gelatinization of the starch molecules present and where enzyme activity can accomplish the conversion of the gelatinized starch to dextrins and sugars. This enzyme process results in an increased cereal production rate and a product that is reconstitutable with an amount of liquid that is readily ascertainable and, most importantly, reproducible. However, such a conventional process suffers from the disadvantage of requiring
- 2 _ . ~
1045~30 close control of processing variables such as enzyme concentration, concentration of the solids in the cereal slurry, reaction temper-ature, reaction time and ultimate dryer speed when dehydrating the slurry into a continuous cereal sheet. Furthermore, in such ;~ conventional processing it has been shown that the salt in the formula does more than merely enhance the flavor; lt also aids in the drying operation, particularly for rice cereal. However, since evidence has recently been presented which tends to show that excessive salt in the diet may cause hypertension, it has been desirable to investigate cereal formulas with both reduced and completely eliminated salt content. Attempts to eliminate salt from the slurry have heretofore resulted in completely unsatis-factory moisture evaporation rates for the cereal slurry.
It has now been found that the salt concentration of the grain cereal slurry can be substantially reduced or actually entirely eliminated, without adversely affecting the ultimate product quality or overall efficiency of product dehydration, by completely hydrolyzing a portion, e.g., from about 30% to 70%, ,' by weight, of the total starch in the slurry composition.
Furthermore, it has been found that improved results are obtained whether the remaining non-hydrolyzed starch is separated prior to lnitial gelatinization and then returned to the slurry in an ungelatinized form prior to enzyme hydrolysis, or separated after total gelatinization from the slurry portion to be hydrolyzed and thereafter re-added to the hydrolyzed portion of the slurry when enzyme conversion has been completed. With either procedure, the resulting slurry is readily dried and exhibits highly desirable reconstitution characteristics including an appetizing flavor.
Grain starch granules are formed of two basic types of starch molecule, i.e., the linear maltose polymer-amylose and the branched maltose polymer-amylopectin. The size of the maltose .
~ - 3 -104589[) polymer and the amount of each type of the polymer that is present in the starch granule determine the specific properties of the individual starch. Both types are normally synthesized by and are present in plants. Most starch granules, as produced by nature, contain approximately 20 to 30% of the amylose-type molecule, with the balance being amylopectin-type molecules.
The starch granules are formed by attractive forces between these large carbohydrate molecules, i.e., the linear portions of the molecule tend to associate together into micelles which bind the various molecules together into a crystalline-like structure. Such a structure is fairly rigid and insoluble in cold water. However, when the temperature of a suspension of starch in water is increased to or above a critical point, called the gelatinization temperature, water penetrates the granules, causing them to swell and produce a vis-cous mass. Gelatinization temperatures vary from about 140-167 F
depending upon the particular type of starch involved. By increas-ing the temperature above that required for gelatinization, i.e., to about 220 F, adequate gelatinization of the cereal grain is thus insured.
Treatment of gelatinized starches with an enzyme such as amylase converts the starch, i.e., hydrolyzes it, to produce lower viscosity types of molecules such as dextrins and maltose.
Ultimate enzyme conversion with an enzyme such as amylase results in the starch molecule being depolymerized to maltose and, de-pending upon the structure of the starch, various higher sugars such as maltotriose, maltotetrose, etc. The present novel pro-cess involves conventional gelatinization and subsequent hydrolysis, but in a manner whereby the ultimate portion reduced to dextrin and maltose is readily controlled within the concen-tration required to obtain satisfactory slurry properties and reconstitution characteristics, even in the absence of conventional 1~45890 concentrations of salt. The susceptibility of the ultimate packaged cereal product to cakin~ when subjected to storage humidities in excess of 70% relative humidity is directly related to the maltose content. sy employing the present process, maltose concentration is readily controlled at the optimum concentration of about 14o of the packaged product, i.e., 14%
of the solids in the slurry. Thus, when the enzyme is allowed to react on previously gelatinized starch molecules, cooled to a temperature in the range of normal enzyme activity, the time of reaction, the enzyme concentration and the temperature of the reaction do not require the precise control that was heretofore mandatory in conventional gelatinization/hydrolysis cereal processes.
Although the present invention is not intended to be limited to any specific theoretical concept, it appears that enzyme hydrolysis is limited to that portion of the cereal slurry starch that has previously been gelatinized. Furthermore, ~ -by heating the starch slurry to a temperature significantly above the gelatinization temperature of the starch, i.e., in about the range of 160-220 F, not only will all the starch present be gelatinized, but any naturally occurring enzymes will be in part permanently inactivated or destroyed. The process of this invention is particularly useful where the grain requires high temperature gelatinization, higher than the inactivation temperature of most diastatic enzyme systems. Thus grains such as long grain rice can now be utilized more readily in cereal preparation.
As a result, subsequent quantity control of the amount of gelatinized starch that is allowed to be subjected to enzyme conversion, will enable the hydrolysis to be conducted without stringent process conditions, i.e., hydrolysis of the gelatinized starch can go to completion. The ultimate effect of such uniformly complete hydrolysis appears to be that the de~Ytrins are more com-1045890 - ~-pletely hydrolyzed. Therefore, de~ydration is not dependent on ~h~ presence of salt as an aid thereto.
Thus, the invention contemplates a process for preparing a precooked, dehydratecl product which comprises adjust-ing the temperature of a slurry of gelatinized starch into the range of activity exhibited by an amylase enzyme, contacting sufficient of the amylase enzyme with the slurry to substantially hydrolyze the gelatinized starch, combining a quantity of a slurry of non-hydrolyzed starch with a quantity of a slurry of the substantially hydrolyzed starch wherein the combined quantities of ingredients create a maltose concentration of about 14% based on total weight of slurry solids, and drying the combined slurry to provide the dehydrated product.
The invention also contemplates the gelatinized starch being completely hydrolyzed by the amylase.
As mentioned above, the enzyme amylase is such a ` cereal grain enzyme that converts to starch.
; .
Turning now to the process in more detail, two alter-native procedures have been found to be satisfactory. The first ` 20 involves dividing a slurry of ungelatinized starch into a first and second stream in a ratio of about 3-7:7-3, and preferably ~ about 30-45 to 70-55. The second stream is independently subjected ; to high temperature gelatinization. Thereafter, the hot gelatin-ized starch slurry is cooled by incorporating therewith the first stream of unheated ungelatinized starch. The combined starch slurry is then contacted with an enzyme and the gelatinized r-portion converted to the hydrolyzed product. Finally, the converted starch-containing slurry is subjected to conventional dehydration - such as on a drum dryer.
The alternative procedure which has been found to be similarly effective in overcoming the shortcomings of prior art processes involves the initial high temperature gelatinization in the total cereal slurry. Thereafter, the gelatinized starch is divided into a first and second stream, the second stream cooled, for example, in conventional heat exchange equipment such B ::
., . . ............ . ...... . ...... ~ .
.. ~ .. ~ . ~ .. ..
10458~90 a5 a line heat exchanger to a temperature of approximately 90F.
The cooled stream is then subjected to enzyme conversion. Upon completion of enzyme hydrolysis, the streams are recombined and subjected to conventional dehydration such as on a drum dryer.
Where hydrolysis can be carried out at temperatures of 80 F or lower, satisfactory results have been obtained without dividing the gelatinized starch into a first and second stream, but in allowing hydrolysis to occur upon the total slurry.
Conventional drum drying involves the application of lQ a liquid material in the form of a solution or slurry to a revolv-ing heated metal drum that conducts heat to the wet material during a partial revolution of the drum to reduce the water content there-of by evaporation. The dried material is thereafter scraped from the surface of the drum by a stationary knife (doctor blade) spaced around the drum periphery from the point of application by an arc-uate distance corresponding to that desired to allow for drying.
In this manner, the product is exposed to heat during the brief time r required for the drum to rotate around this arc between the point of application and the fixed location of the knife. -In the fluid cereal slurry industry, the drying is usually accomplished with atmospheric double drum dryers, i.e., a pair of closely spaced cylindrical drying surfaces that are heated internally such as by steam. Drums are conventionally employed that have the same radius and are in parallel alignment with their axes of rotation on the same level.
The cereal slurry to be dried is disposed as a "puddle'l or pool in the space (trough) formed between the upper ad-jacent surfaces of the two drums. The puddle, normally in direct contact with the upper adjacent surfaces of both drums, provides a thin film that is deposited on the drums as they rotate down-'; ~
:
-.... ~ .
1~45890 wardly toward the nip ~ormed between their adjacent outer surfaces.
Drying of the film continues throughout the aforementioned arcuate interval while the sheet is in contact with the heated drum sur- _~
face prior to being scraped from each drum by respective stationary ~ -blades Flaking is either accomplished s-i~ultaneously with the scraping or is produced subsequently with separate apparatus.
It is advantageous for the dehydrated sheet to have a thickness of about 4-7 mils. However, the film thickness will obviously be dependent upon the space provided between the drums drier. In addition, the film thickness can be varied by modifica-tions in drum speed and/or steam pressure within the drum. With respect to the steam pressure, conventional equipment advantageously utilizes steam in the range of 30-90 p.s.i.g. Tension or draw-off rollers may be employed to assist in the removal of the sheet from the drum surface.
The resulting dry cereal sheet can be prepared for packaging and ultimate consumption by flaking into various sizes depending, of course, on the re-hydration characteristics desired.
The flaking can be accomplished on standard equipment such as a 10-mesh U.S. sieve series screen (0.030 inch wire).
The present invention is useful with any cereal grain flour normally modified with enzymatic hydrolysis. Typical examples, in addition to rice, include oat, wheat, corn, barley and the like, and mixtures thereof, in an amount of about 5-25%, and preferably 10-15% by weight of the total weight of slurry formulation.
589(~
Any enzyme th~t hyd~ol~zes gelatinized grain starch can be employed l~n amounts up to about 1.0% ~ total weight of slurry formulat~on. Although ~l~gher amounts can also be used w-ith no adverse affects, amounts in the ~ange of 0.25-0.75% by weight are espec~ally ad~antageous. The enzyme can be introduced ~nto the cereal slurry e~ther prior to gelation ~with the result that a portion of the enzyme is inact~vated by the high temperature) or subsequent to gelatinization. Holding times for enzyme conversion have been varied from 10-25 minutes with satisfactory results.
- The rate and completeness of hydrolysis of the gelatinized slurry is dependent upon temperature conditions as well as time of conversion (digestion). Although it is preferred to accomplish the conversion at about 120 F, the temperature can be varied, depending upon the amount of starch that has been gelatinized. For example, when only 30% of the starch is gelatinized, it is desirable to maintain a temperature of about 120 F. Conversely, when the gelatinized portion approaches or exceeds 50%, a lower temperature down to about 90 F can be advantageously employed.
The use of fluid milk, and preferably whole milk or non-fat dry milk powder in amounts up to 25~, and particularly from about 5 to about 15~, by weight of the slurry, can also be employed to significantly improve and enhance the natural flavor of the product.
Vegetable oils, such as soya oil, lecithin, sesame oil, rice oil and the like, may also be desirable ingredients when employed in amounts of about 1 to 3% by weight of the slurry.
The ~egetable oil also aids in release of the dried sheet, improves the general character of the sheet, and results in a more desirable flake.
1~45890 The o~ject of dehxdrating is~ to remove ~s much o~
the watex present ~n the pur~e a~ possl~ble w~ithout detri~entally affect~ng ~ts q~uality~. Theref~rer the final products en~isioned b~ this invent~on u~uall~ conta~n at least qO% solids and preferably from 95 to ~8~ sol~ds.
To further ~llus*rate the novel process of this invention, the follo~ing examples are prov~ded. It should be understood that the details thereof are not to be regarded as limitations as they may be varied as will be understood by one skilled in this art. The percentages included throughout this disclosure are based on the total weight of the formulation prior to cooking, unless otherwise indicated.
, EXAMPLE I
A formulation was prepared in the following proportions:
Quantity percent Ingredient by weight*
.
Rice Flour 70.0 Rice Polish 25.0 Dicalcium Phosphate2.6 Sodium Iron Pyrophosphate .8 Rice Oil .7 Vitamin Mix .2 Malt 7 100.0 *Solids content only ~10--.
' `
104S8gO
Suffici~ent ~ater ~a~ added to xeduce the oye~all sol~ds content to about 22.6%. The s~lui~ry~at about room temperature, ~as pumpea t~rous~ a l~ne stra~ner hav~ng a screen size of o.a60 lnch to an a~tating heater at a temperature of about 210 F and ~eld for about 15 minutes. The slurry was then removed and approxl~matel~ 2/3, by weight thereof, transferred to a holding tank and the temperature adjusted to about 90 F.
After about 17 minutes at this temperature, the slurry containing hydrolyzed starch ~as recombined with the portion containing gelatinized starch and fed to a conventional double drum dryer, each drum operating at an interval pressure of 80 p.s.i.g. The drums were rotated at 5 revolutions per minute and the dried sheet easily removed with doctor blades. The resulting sheet was non-plastic, cont~nuous and had a film thickness of about 5 mil. Similar tests were conducted with corn, barley, wheat and oat and mixtures thereof.
., ,", '.
~ ~ EXAMPLE II
.
Using the slurry formulation of Example I, a quantity of slurry was divided into 2 portions in about a 2 to 1 weight -~
- 20 ratio. The larger portion was subjected to gelatinization as in Example I, at 170 F. Thereafter, the remaining ungelatinized slurry, still at room temperature, was added thereto, lowering ~;
the temperature to about 120 F. Hydrolysis was allowed to occur for about 20 minutes. The resulting slurry was again drum dried and the dehydrated sheet easily removed from the drum surfaces. ;
.
. .
:~' ' -`11-` ~".;
..
.
104~ii891V :
~ I~n each~of E,xa~ples ~ nd I~I! th~,,res,ultin~ ce~e,a,l ~as found to have'excellent ~econ~ti~tut~on cha~acte~s.t~cs and a hi~ghIy~ appeti`zing taste.
Although.the foregoing invent~on has been described in some detail ~y way of ~llustrat~on an~ example for purposes of clarity of understanding, ~t wi~ll Be apparent to one skilled in the art that certain chan~es and mod;~f~cations may be practiced within the spirit of the invention as limited only by the scope of the appended cla-`ms.
.
, ~12-.
~-
1045~30 close control of processing variables such as enzyme concentration, concentration of the solids in the cereal slurry, reaction temper-ature, reaction time and ultimate dryer speed when dehydrating the slurry into a continuous cereal sheet. Furthermore, in such ;~ conventional processing it has been shown that the salt in the formula does more than merely enhance the flavor; lt also aids in the drying operation, particularly for rice cereal. However, since evidence has recently been presented which tends to show that excessive salt in the diet may cause hypertension, it has been desirable to investigate cereal formulas with both reduced and completely eliminated salt content. Attempts to eliminate salt from the slurry have heretofore resulted in completely unsatis-factory moisture evaporation rates for the cereal slurry.
It has now been found that the salt concentration of the grain cereal slurry can be substantially reduced or actually entirely eliminated, without adversely affecting the ultimate product quality or overall efficiency of product dehydration, by completely hydrolyzing a portion, e.g., from about 30% to 70%, ,' by weight, of the total starch in the slurry composition.
Furthermore, it has been found that improved results are obtained whether the remaining non-hydrolyzed starch is separated prior to lnitial gelatinization and then returned to the slurry in an ungelatinized form prior to enzyme hydrolysis, or separated after total gelatinization from the slurry portion to be hydrolyzed and thereafter re-added to the hydrolyzed portion of the slurry when enzyme conversion has been completed. With either procedure, the resulting slurry is readily dried and exhibits highly desirable reconstitution characteristics including an appetizing flavor.
Grain starch granules are formed of two basic types of starch molecule, i.e., the linear maltose polymer-amylose and the branched maltose polymer-amylopectin. The size of the maltose .
~ - 3 -104589[) polymer and the amount of each type of the polymer that is present in the starch granule determine the specific properties of the individual starch. Both types are normally synthesized by and are present in plants. Most starch granules, as produced by nature, contain approximately 20 to 30% of the amylose-type molecule, with the balance being amylopectin-type molecules.
The starch granules are formed by attractive forces between these large carbohydrate molecules, i.e., the linear portions of the molecule tend to associate together into micelles which bind the various molecules together into a crystalline-like structure. Such a structure is fairly rigid and insoluble in cold water. However, when the temperature of a suspension of starch in water is increased to or above a critical point, called the gelatinization temperature, water penetrates the granules, causing them to swell and produce a vis-cous mass. Gelatinization temperatures vary from about 140-167 F
depending upon the particular type of starch involved. By increas-ing the temperature above that required for gelatinization, i.e., to about 220 F, adequate gelatinization of the cereal grain is thus insured.
Treatment of gelatinized starches with an enzyme such as amylase converts the starch, i.e., hydrolyzes it, to produce lower viscosity types of molecules such as dextrins and maltose.
Ultimate enzyme conversion with an enzyme such as amylase results in the starch molecule being depolymerized to maltose and, de-pending upon the structure of the starch, various higher sugars such as maltotriose, maltotetrose, etc. The present novel pro-cess involves conventional gelatinization and subsequent hydrolysis, but in a manner whereby the ultimate portion reduced to dextrin and maltose is readily controlled within the concen-tration required to obtain satisfactory slurry properties and reconstitution characteristics, even in the absence of conventional 1~45890 concentrations of salt. The susceptibility of the ultimate packaged cereal product to cakin~ when subjected to storage humidities in excess of 70% relative humidity is directly related to the maltose content. sy employing the present process, maltose concentration is readily controlled at the optimum concentration of about 14o of the packaged product, i.e., 14%
of the solids in the slurry. Thus, when the enzyme is allowed to react on previously gelatinized starch molecules, cooled to a temperature in the range of normal enzyme activity, the time of reaction, the enzyme concentration and the temperature of the reaction do not require the precise control that was heretofore mandatory in conventional gelatinization/hydrolysis cereal processes.
Although the present invention is not intended to be limited to any specific theoretical concept, it appears that enzyme hydrolysis is limited to that portion of the cereal slurry starch that has previously been gelatinized. Furthermore, ~ -by heating the starch slurry to a temperature significantly above the gelatinization temperature of the starch, i.e., in about the range of 160-220 F, not only will all the starch present be gelatinized, but any naturally occurring enzymes will be in part permanently inactivated or destroyed. The process of this invention is particularly useful where the grain requires high temperature gelatinization, higher than the inactivation temperature of most diastatic enzyme systems. Thus grains such as long grain rice can now be utilized more readily in cereal preparation.
As a result, subsequent quantity control of the amount of gelatinized starch that is allowed to be subjected to enzyme conversion, will enable the hydrolysis to be conducted without stringent process conditions, i.e., hydrolysis of the gelatinized starch can go to completion. The ultimate effect of such uniformly complete hydrolysis appears to be that the de~Ytrins are more com-1045890 - ~-pletely hydrolyzed. Therefore, de~ydration is not dependent on ~h~ presence of salt as an aid thereto.
Thus, the invention contemplates a process for preparing a precooked, dehydratecl product which comprises adjust-ing the temperature of a slurry of gelatinized starch into the range of activity exhibited by an amylase enzyme, contacting sufficient of the amylase enzyme with the slurry to substantially hydrolyze the gelatinized starch, combining a quantity of a slurry of non-hydrolyzed starch with a quantity of a slurry of the substantially hydrolyzed starch wherein the combined quantities of ingredients create a maltose concentration of about 14% based on total weight of slurry solids, and drying the combined slurry to provide the dehydrated product.
The invention also contemplates the gelatinized starch being completely hydrolyzed by the amylase.
As mentioned above, the enzyme amylase is such a ` cereal grain enzyme that converts to starch.
; .
Turning now to the process in more detail, two alter-native procedures have been found to be satisfactory. The first ` 20 involves dividing a slurry of ungelatinized starch into a first and second stream in a ratio of about 3-7:7-3, and preferably ~ about 30-45 to 70-55. The second stream is independently subjected ; to high temperature gelatinization. Thereafter, the hot gelatin-ized starch slurry is cooled by incorporating therewith the first stream of unheated ungelatinized starch. The combined starch slurry is then contacted with an enzyme and the gelatinized r-portion converted to the hydrolyzed product. Finally, the converted starch-containing slurry is subjected to conventional dehydration - such as on a drum dryer.
The alternative procedure which has been found to be similarly effective in overcoming the shortcomings of prior art processes involves the initial high temperature gelatinization in the total cereal slurry. Thereafter, the gelatinized starch is divided into a first and second stream, the second stream cooled, for example, in conventional heat exchange equipment such B ::
., . . ............ . ...... . ...... ~ .
.. ~ .. ~ . ~ .. ..
10458~90 a5 a line heat exchanger to a temperature of approximately 90F.
The cooled stream is then subjected to enzyme conversion. Upon completion of enzyme hydrolysis, the streams are recombined and subjected to conventional dehydration such as on a drum dryer.
Where hydrolysis can be carried out at temperatures of 80 F or lower, satisfactory results have been obtained without dividing the gelatinized starch into a first and second stream, but in allowing hydrolysis to occur upon the total slurry.
Conventional drum drying involves the application of lQ a liquid material in the form of a solution or slurry to a revolv-ing heated metal drum that conducts heat to the wet material during a partial revolution of the drum to reduce the water content there-of by evaporation. The dried material is thereafter scraped from the surface of the drum by a stationary knife (doctor blade) spaced around the drum periphery from the point of application by an arc-uate distance corresponding to that desired to allow for drying.
In this manner, the product is exposed to heat during the brief time r required for the drum to rotate around this arc between the point of application and the fixed location of the knife. -In the fluid cereal slurry industry, the drying is usually accomplished with atmospheric double drum dryers, i.e., a pair of closely spaced cylindrical drying surfaces that are heated internally such as by steam. Drums are conventionally employed that have the same radius and are in parallel alignment with their axes of rotation on the same level.
The cereal slurry to be dried is disposed as a "puddle'l or pool in the space (trough) formed between the upper ad-jacent surfaces of the two drums. The puddle, normally in direct contact with the upper adjacent surfaces of both drums, provides a thin film that is deposited on the drums as they rotate down-'; ~
:
-.... ~ .
1~45890 wardly toward the nip ~ormed between their adjacent outer surfaces.
Drying of the film continues throughout the aforementioned arcuate interval while the sheet is in contact with the heated drum sur- _~
face prior to being scraped from each drum by respective stationary ~ -blades Flaking is either accomplished s-i~ultaneously with the scraping or is produced subsequently with separate apparatus.
It is advantageous for the dehydrated sheet to have a thickness of about 4-7 mils. However, the film thickness will obviously be dependent upon the space provided between the drums drier. In addition, the film thickness can be varied by modifica-tions in drum speed and/or steam pressure within the drum. With respect to the steam pressure, conventional equipment advantageously utilizes steam in the range of 30-90 p.s.i.g. Tension or draw-off rollers may be employed to assist in the removal of the sheet from the drum surface.
The resulting dry cereal sheet can be prepared for packaging and ultimate consumption by flaking into various sizes depending, of course, on the re-hydration characteristics desired.
The flaking can be accomplished on standard equipment such as a 10-mesh U.S. sieve series screen (0.030 inch wire).
The present invention is useful with any cereal grain flour normally modified with enzymatic hydrolysis. Typical examples, in addition to rice, include oat, wheat, corn, barley and the like, and mixtures thereof, in an amount of about 5-25%, and preferably 10-15% by weight of the total weight of slurry formulation.
589(~
Any enzyme th~t hyd~ol~zes gelatinized grain starch can be employed l~n amounts up to about 1.0% ~ total weight of slurry formulat~on. Although ~l~gher amounts can also be used w-ith no adverse affects, amounts in the ~ange of 0.25-0.75% by weight are espec~ally ad~antageous. The enzyme can be introduced ~nto the cereal slurry e~ther prior to gelation ~with the result that a portion of the enzyme is inact~vated by the high temperature) or subsequent to gelatinization. Holding times for enzyme conversion have been varied from 10-25 minutes with satisfactory results.
- The rate and completeness of hydrolysis of the gelatinized slurry is dependent upon temperature conditions as well as time of conversion (digestion). Although it is preferred to accomplish the conversion at about 120 F, the temperature can be varied, depending upon the amount of starch that has been gelatinized. For example, when only 30% of the starch is gelatinized, it is desirable to maintain a temperature of about 120 F. Conversely, when the gelatinized portion approaches or exceeds 50%, a lower temperature down to about 90 F can be advantageously employed.
The use of fluid milk, and preferably whole milk or non-fat dry milk powder in amounts up to 25~, and particularly from about 5 to about 15~, by weight of the slurry, can also be employed to significantly improve and enhance the natural flavor of the product.
Vegetable oils, such as soya oil, lecithin, sesame oil, rice oil and the like, may also be desirable ingredients when employed in amounts of about 1 to 3% by weight of the slurry.
The ~egetable oil also aids in release of the dried sheet, improves the general character of the sheet, and results in a more desirable flake.
1~45890 The o~ject of dehxdrating is~ to remove ~s much o~
the watex present ~n the pur~e a~ possl~ble w~ithout detri~entally affect~ng ~ts q~uality~. Theref~rer the final products en~isioned b~ this invent~on u~uall~ conta~n at least qO% solids and preferably from 95 to ~8~ sol~ds.
To further ~llus*rate the novel process of this invention, the follo~ing examples are prov~ded. It should be understood that the details thereof are not to be regarded as limitations as they may be varied as will be understood by one skilled in this art. The percentages included throughout this disclosure are based on the total weight of the formulation prior to cooking, unless otherwise indicated.
, EXAMPLE I
A formulation was prepared in the following proportions:
Quantity percent Ingredient by weight*
.
Rice Flour 70.0 Rice Polish 25.0 Dicalcium Phosphate2.6 Sodium Iron Pyrophosphate .8 Rice Oil .7 Vitamin Mix .2 Malt 7 100.0 *Solids content only ~10--.
' `
104S8gO
Suffici~ent ~ater ~a~ added to xeduce the oye~all sol~ds content to about 22.6%. The s~lui~ry~at about room temperature, ~as pumpea t~rous~ a l~ne stra~ner hav~ng a screen size of o.a60 lnch to an a~tating heater at a temperature of about 210 F and ~eld for about 15 minutes. The slurry was then removed and approxl~matel~ 2/3, by weight thereof, transferred to a holding tank and the temperature adjusted to about 90 F.
After about 17 minutes at this temperature, the slurry containing hydrolyzed starch ~as recombined with the portion containing gelatinized starch and fed to a conventional double drum dryer, each drum operating at an interval pressure of 80 p.s.i.g. The drums were rotated at 5 revolutions per minute and the dried sheet easily removed with doctor blades. The resulting sheet was non-plastic, cont~nuous and had a film thickness of about 5 mil. Similar tests were conducted with corn, barley, wheat and oat and mixtures thereof.
., ,", '.
~ ~ EXAMPLE II
.
Using the slurry formulation of Example I, a quantity of slurry was divided into 2 portions in about a 2 to 1 weight -~
- 20 ratio. The larger portion was subjected to gelatinization as in Example I, at 170 F. Thereafter, the remaining ungelatinized slurry, still at room temperature, was added thereto, lowering ~;
the temperature to about 120 F. Hydrolysis was allowed to occur for about 20 minutes. The resulting slurry was again drum dried and the dehydrated sheet easily removed from the drum surfaces. ;
.
. .
:~' ' -`11-` ~".;
..
.
104~ii891V :
~ I~n each~of E,xa~ples ~ nd I~I! th~,,res,ultin~ ce~e,a,l ~as found to have'excellent ~econ~ti~tut~on cha~acte~s.t~cs and a hi~ghIy~ appeti`zing taste.
Although.the foregoing invent~on has been described in some detail ~y way of ~llustrat~on an~ example for purposes of clarity of understanding, ~t wi~ll Be apparent to one skilled in the art that certain chan~es and mod;~f~cations may be practiced within the spirit of the invention as limited only by the scope of the appended cla-`ms.
.
, ~12-.
~-
Claims (9)
1. A process for preparing a precooked, dehydrated product comprising: adjusting the temperature of a slurry of gelatinized starch into the range of activity exhibited by an amylase enzyme; contacting sufficient of said amylase enzyme with said slurry to substantially hydrolyze said gelatinized starch; combining a quantity of a slurry of non-hydrolyzed starch with a quantity of a slurry of said hydrolyzed starch wherein the combined quantities of ingredients create a maltose concentration of about 14% based on total weight of slurry solids;
and drying said combined slurry to provide said dehydrated product.
and drying said combined slurry to provide said dehydrated product.
2. A process for preparing a precooked, dehydrated product comprising: adjusting the temperature of a slurry of gelatinized starch into the range of activity exhibited by amylase; contacting sufficient of said-amylase with said slurry to completely hydrolyze said gelatinized starch; combining a quantity of a slurry of non-hydrolyzed starch with a quantity of a slurry of said completely hydrolyzed starch wherein the combined quantities of ingredients create a maltose concentr-ation of about 14% based on total weight of slurry solids; and drying said combined slurry to provide said dehydrated product.
3. A process in accordance with Claim l or Claim 2 wherein the ratio of said non-hydrolyzed starch to said gelatinized starch is about 1:2 by weight.
4. A process in accordance with Claim 1 wherein said slurry of gelatinized starch is obtained by heating a slurry of ungelatinized starch to a temperature of at least about 160° F for a period of time sufficient to produce substantially complete gelatinization.
5. A process in acco-rdance with Claim 2 wherein said slurry of gelatinized starch is obtained by heating a slurry of ungelatinized starch to a temperature of at least about 160°F
for a period of time sufficient to produce substantially complete gelatinization.
for a period of time sufficient to produce substantially complete gelatinization.
6. A process in accordance with Claim 1 or Claim 2 wherein said non-hydrolyzed starch comprises non-gelatinized starch.
7. A process in accordance with Claim 2, Claim 4 or Claim 5 wherein said non-gelatinized starch is combined with said temperature adjusted gelatinized starch prior to said enzyme contact.
8. A process in accordance with Claim 4 wherein said non-hydrolyzed starch slurry is gelatinized simultaneously with said gelatinized starch slurry, but separated therefrom prior to said temperature adjustment and said enzyme contact.
9. A process in accordance with Claim 5 wherein said non-hydrolyzed starch slurry is gelatinized simultaneously with said gelatinized starch slurry, but separated therefrom prior to said temperature adjustment and said contacting with said slurry.
10. A process in accordance with Claim 4 or Claim 5 wherein said heating is sufficient to completely inactivate the natural enzymes in said cereal starch.
11. A process in accordance with Claim 1 or Claim 2 wherein the cereal grain of said starch slurry is selected from rice, oat, barley, corn, wheat and mixtures thereof.
12. A cereal grain starch slurry comprising a major portion of gelatinized non-hydrolyzed cereal grain starch and a minor portion of gelatinized, hydrolyzed cereal grain starch when produced by the process of Claim 1, Claim 2 or Claim 4.
13. A cereal grain starch slurry comprising a major portion of gelatinized non-hydrolyzed cereal grain starch and a minor portion of gelatinized, hydrolyzed cereal grain starch when produced by the process of Claim 5, Claim 8 or Claim 9.
14. A starch slurry wherein the ratio of non-gelatinized starch to gelatinized starch is about 1:2 by weight when produced by the process of Claim 1, Claim 2 or Claim 4.
15. A starch slurry wherein the ratio of non-gelatinized starch to gelatinized starch is about 1:2 by weight when produced by the process of Claim 5, Claim 8 or
9. A process in accordance with Claim 5 wherein said non-hydrolyzed starch slurry is gelatinized simultaneously with said gelatinized starch slurry, but separated therefrom prior to said temperature adjustment and said contacting with said slurry.
10. A process in accordance with Claim 4 or Claim 5 wherein said heating is sufficient to completely inactivate the natural enzymes in said cereal starch.
11. A process in accordance with Claim 1 or Claim 2 wherein the cereal grain of said starch slurry is selected from rice, oat, barley, corn, wheat and mixtures thereof.
12. A cereal grain starch slurry comprising a major portion of gelatinized non-hydrolyzed cereal grain starch and a minor portion of gelatinized, hydrolyzed cereal grain starch when produced by the process of Claim 1, Claim 2 or Claim 4.
13. A cereal grain starch slurry comprising a major portion of gelatinized non-hydrolyzed cereal grain starch and a minor portion of gelatinized, hydrolyzed cereal grain starch when produced by the process of Claim 5, Claim 8 or Claim 9.
14. A starch slurry wherein the ratio of non-gelatinized starch to gelatinized starch is about 1:2 by weight when produced by the process of Claim 1, Claim 2 or Claim 4.
15. A starch slurry wherein the ratio of non-gelatinized starch to gelatinized starch is about 1:2 by weight when produced by the process of Claim 5, Claim 8 or
Claim 9.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA235,414A CA1045890A (en) | 1975-09-15 | 1975-09-15 | Cereal process |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA235,414A CA1045890A (en) | 1975-09-15 | 1975-09-15 | Cereal process |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1045890A true CA1045890A (en) | 1979-01-09 |
Family
ID=4104037
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA235,414A Expired CA1045890A (en) | 1975-09-15 | 1975-09-15 | Cereal process |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1045890A (en) |
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2442661B1 (en) | 2009-06-14 | 2015-10-21 | The Quaker Oats Company | Method of preparing highly dispersible whole grain flour |
| US9504272B2 (en) | 2008-11-04 | 2016-11-29 | The Quaker Oats Company | Method of processing oats to achieve oats with an increased avenanthramide content |
| US9510614B2 (en) | 2008-11-04 | 2016-12-06 | The Quaker Oats Company | Food products prepared with soluble whole grain oat flour |
| US9622500B2 (en) | 2008-11-04 | 2017-04-18 | The Quaker Oats Company | Food products prepared with soluble whole grain oat flour |
| US10092016B2 (en) | 2011-07-12 | 2018-10-09 | Pepsico, Inc. | Method of preparing an oat-containing dairy beverage |
| US10426181B2 (en) | 2011-03-21 | 2019-10-01 | The Quaker Oats Company | Method for preparing high acid RTD whole grain beverages |
| US10689678B2 (en) | 2008-11-04 | 2020-06-23 | The Quaker Oats Company | Method and composition comprising hydrolyzed starch |
| US10913963B2 (en) | 2016-03-22 | 2021-02-09 | The Quaker Oats Company | Method and apparatus for controlled hydrolysis |
| US10980244B2 (en) | 2008-11-04 | 2021-04-20 | The Quaker Oats Company | Whole grain composition comprising hydrolyzed starch |
| US11172695B2 (en) | 2016-03-22 | 2021-11-16 | The Quaker Oats Company | Method, apparatus, and product providing hydrolyzed starch and fiber |
-
1975
- 1975-09-15 CA CA235,414A patent/CA1045890A/en not_active Expired
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9504272B2 (en) | 2008-11-04 | 2016-11-29 | The Quaker Oats Company | Method of processing oats to achieve oats with an increased avenanthramide content |
| US9510614B2 (en) | 2008-11-04 | 2016-12-06 | The Quaker Oats Company | Food products prepared with soluble whole grain oat flour |
| US9622500B2 (en) | 2008-11-04 | 2017-04-18 | The Quaker Oats Company | Food products prepared with soluble whole grain oat flour |
| US10689678B2 (en) | 2008-11-04 | 2020-06-23 | The Quaker Oats Company | Method and composition comprising hydrolyzed starch |
| US10975404B2 (en) | 2008-11-04 | 2021-04-13 | The Quaker Oats Company | Method and composition comprising hydrolyzed starch |
| US10980244B2 (en) | 2008-11-04 | 2021-04-20 | The Quaker Oats Company | Whole grain composition comprising hydrolyzed starch |
| EP2442661B1 (en) | 2009-06-14 | 2015-10-21 | The Quaker Oats Company | Method of preparing highly dispersible whole grain flour |
| US10426181B2 (en) | 2011-03-21 | 2019-10-01 | The Quaker Oats Company | Method for preparing high acid RTD whole grain beverages |
| US10092016B2 (en) | 2011-07-12 | 2018-10-09 | Pepsico, Inc. | Method of preparing an oat-containing dairy beverage |
| US10913963B2 (en) | 2016-03-22 | 2021-02-09 | The Quaker Oats Company | Method and apparatus for controlled hydrolysis |
| US11172695B2 (en) | 2016-03-22 | 2021-11-16 | The Quaker Oats Company | Method, apparatus, and product providing hydrolyzed starch and fiber |
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