CA1189739A - Method of making food coatings, fillers and pellets - Google Patents

Method of making food coatings, fillers and pellets

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Publication number
CA1189739A
CA1189739A CA000432456A CA432456A CA1189739A CA 1189739 A CA1189739 A CA 1189739A CA 000432456 A CA000432456 A CA 000432456A CA 432456 A CA432456 A CA 432456A CA 1189739 A CA1189739 A CA 1189739A
Authority
CA
Canada
Prior art keywords
ingredients
extruder
full fat
soya flour
fat soya
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
Application number
CA000432456A
Other languages
French (fr)
Inventor
William D.D. Cameron
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
D & S Manufacturing Pty Ltd
Original Assignee
D & S Manufacturing Pty Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by D & S Manufacturing Pty Ltd filed Critical D & S Manufacturing Pty Ltd
Priority to CA000432456A priority Critical patent/CA1189739A/en
Application granted granted Critical
Publication of CA1189739A publication Critical patent/CA1189739A/en
Expired legal-status Critical Current

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Abstract

ABSTRACT OF THE DISCLOSURE

The invention relates to a less costly and quicker way to make food coatings, filler and pellets by using ingredients such as grains and/or pulses with an average moisture content of less than 12% then directly extruding the gelatinised elastic-like mass with such a low moisture content that drying is not required.

Description

3~
This invention relates to a method for manufacturing a dry coating used in such products as crurnbed fish fingers, chicken pieces, etc., fillers used in smallgoods, such as sausa~es, and food ingredients, such as a component of rnuesli and food pellets.
Breadcrumbs used domestically are usually manufactured from reprccessed, stale bread and vaLy widely in terms of colour, flavour, grain size, hardness, absorption, moisture content and general properties which affect their ability to adhere to the basic food item comprising poultry, fish or meat.
When crumbs are applied commercially it is necessary to control the above factors within critical tolerances.
Specification of cereal products used as binders or fillers in smallgoods is also critical - particularly in relation to water absorption ability. For both coating crumbs and fillers the specification calls for a moisture content of less than 10~.
The conventional method for manufacturing coating crumbs involves the following operations - making dough (moisture content approximately 30%), fermentation, baking a loaf (moisture content approximately 18-20%), slicing, drying to 7-10~ moisture, milling and screeningO
A particular type of filler, commonly referred to as yeastless rusk, is made from lean biscuit dough having a moisture content over 18~ which is not fermented but normally aerated using a combination of sodium bicarbonate and acid phosphate and~o~ ammonium bicarbonate.
After baking, the biscuit is subject to controlled drying which reduces the moisture to approximately 2% without
- 2 ~ ~

charring or serious disco]ouration. The rusk is thern milled and screened to a range oE particle sizes dependant on application and end use.
In recent years a new process has been developed which avoids production of a baked loaf or biscuit by employing a steam extrusion process. Finely ground wheat flour is mixed with water and/or st2am to make a dough containing 18-30% moisture, which is extruded under high pressure in dies. The dough is then cut into smaller pieces through a mill using rotating blades, dried to less than 10 moisture, ground and screened.
There is another process which is employed in the manufacture of extruded snack foods. Directly expanded snacks are extruded from a starch base to which moisture has been added to bring the level up to about 18~. This mixture is then extruded through an orifice to give a product of a specific final shape - considerably expanded to approximately 15 times its original volume. The product is then dried to a moisture content of approximately 1~ prior to being flavoured - 20 with an application of oil, seasoning, etc.
This invention differs from the above processes in a number of ways:-(i) There i~ no formulation of dough~
(ii~ No additional water is added forpre-conditioning.
(iii) No post extrusion drying required.
(iv) Controlled expansion of extrudate is possible and hence control of ultimate nature of finished product.
~ (v) ~ Ingredients are mixed in dry state with conseq-lent improvement in uniforrnity and texture of the product.
(vi) It is possible to develop more satisfactory methods for the control of colour of the finished product.
A particular feature of the new invention is that ingredient materials are mixed in a dry state with a moisture content of less than about ~ and then directly extruded, thus avoiding the necessity to make a dough or to remove moisture after extrusion. Following extrusion, the product has only to be ground and screened into appropriate sizes for use as coating crumbs or fillers with a finished moisture c~b~lt4~9~o content of ~HU~.
A further advantage of the new process is that a wide range of crumb textures can be produced which satisfy varying specifications of products - e.g. fish fingers which must be cooked, frozen, thawed and then reheated require a harder crumb than does a product which is crumbed and cooked for immediate eating.
The new process handles a wide range of ingredient materials, such as semolina, whole grains such as wheat, peas, lentils, as distinct from the other process for manufacturing crumbs which traditionally use wheaten flour.
This facilitates blending of materials to achieve finished products with desired characteristics of hardness, textures, flavours, water absorbency, etc. The term ingredients used in this specification and claims is deined as whole grains, pulses and the like and derivatives thereof.
This invention in one broad form comprises a method 30~ of manufacturing food coa~ings, fillers or pellets comprising -the steps of feeding the ingredients in-to an extruder, said ingredien-ts having an average moisture content of about 8-12%, processing the ingredients through the extruder at a temperature and pressure which cause the starches present to gelatinise to form a dense elastic-like mass and extruding this mass having about 4-9% residual moisture.
Though it is not necessary, the ingredients may be preground to obtain even size which improves even distribution of the ingredients and their characteristics, such as colour, taste, etc. The ingredients are mixed or blended to obtain a uniform consistency either in a ground or whole form.
The invention will now be described with reference to the drawings in which;
Figure 1 is a sectional view of part of the extruder, Figure 2 is a view along section line Il-II of Figure 1.
The ingredients are mixed in a dry sta-te according -to the formulation which will produce the desired end product.
The ingredients are then fed into the extxuder 1 and the auger or screw 2 applies friction and shear as the ingredients are forced towards the die 3. The length to diameter ratio of the auger can be 2:1 to 4;1. The internal wall of the extruder may take the form of a female auger 4 whose spiral curves in the opposi.te direction to the spiral on the male auger 2. This gives improved friction and shear.
A number of combinations of extruder design, speed of auger and residence time can produce a satisfactory product. As a guide barrel temperature of 200 C, auger speeds of ~' 7~S~

350-~00 RPM, internal temperature at the end of the extruder of 170C to 230C and residence time of 8 seconds have been found to give satisfactory results. Internal pressures in front of the die-plate of 2000-2500 psi have been noted under these conditions.
Operation includes the ability to control the auger speed and to control temperature along the length of the extruder.
Initial startup of the extruder requires pre-heating of the barrel, but thereafter a balance of internal pressure within the extruder determines the properties of the extruded mass. For adequate control of the shear-induced exotherm, control of barrel temperature, internal pressure, auger speed and residence time is desirable.
To obtain the above conditions, it is necessary to design the appropriate combination of auger, barrel and dle configuration. In combination with auger design, appropriate internal pressures can be controlled by means of a breaker plate 5 similar in design to normal plastic extruders and/or by means of a restricting gap 6 between the breaker plate 5 and a spacer ring 7. Further pressure regulating can be obtained by a further gap 8 adjacent the die orifices 9 and between the spacer ring 7 and the die 3. The face of the breaker plate 5 may have radial grooves 10 to improve the grinding effect and to help move the ingredients towards the die 3.
Research has shown that some variation in the design ` of the extruder is possible. ~y suitably increasing the .~ ..

hardness and wear resistance of the material in the screw and barrel and experimenting with various design parameters of the extruder, after pre-heating the barrel there was produced the amazing result of ordinary dry whole grain being fed into the extruder and being gelatinised into an extrudable material that could be directly ground into granules without an expensive heat drying step. A basic configuration that will produce the desired results i5 as follows: a screw of 75mm diameter with a two-start semi-circular groove of 32mm pitch over a length oE
150mm; the screw operates in a mating barrel having rifling of counter pitch bllt of similar configuration to the screw; nominal speed of the screw is 400 rpm; the die may have 16 holes of 6mm diameter in a circle of lOOmm diameter.
The extrudate undergoes comminution to provide products of the required size range. These are then separated by screening. Because of the low moisture content there is no appreciable expansion of the extrudate.

- 6a -
3~73t~

In order to achieve control over density and tenderness of certain crumbs it is pre~erable to include in the ingredients products which include fat and emulsifiers.
This can be achieved by incorporating approximately 2-5% of full fat soya flour which contributes fat and lecithin in the required proportions.
A typical formulation for a tender crumb by this process i5:-Whole wheat - 48.23 Semolina - 47.5%
Full fat soya flour - 2.5%
Salt - 1.5~
Dextrose - 0.3%
The new process can be used to produce a broad range of products:
(1) Crumbs - These cannot be truly described as "bread crumbs" because at no time in the process is bread made.
Texture, f]avour and colour is varied according to requirements of the end product.
~2) Rusk - Conventional rusk is made from a yeastless biscuit so that it has longer shelf-life and is dried to minimum moisture level to enhance moisture absorbency as well as improving shelf-life.
The new process faciLitates production of hard, low moisture granules which retain their individuality when incorporated with sausage mixes, etc. and have very high ; water absorbency - over 3:1 compared with flour of, say, less than 1:1 and conventional rusk of say, 2.5:1.
(3) Flavoured/Coloured Coatings - The new process facilitates production of different flavours and colours due to the ease o~ varying ~ormulae, the low moisture content during the process and the short processing time which has rninimal effect on losing or distorting added flavour and colour.
Thus it is possible to extend the market applications either by addition o~ artificial or natural flavours or by using different basic ingredients.
For example, by using whole wheat it has been shown that crumb with a decided nutty flavour results which can be enhanced by addition of a nut flavour to the grain being fed into the system. The resulting product can be marketed as a nut replacer or extender for application to the outside of ice cream, in cake recipes, sweet confectionery~ etc.
Similarly, split peas and soya beans can be extruded to give characteristic flavoured coatings.
(4) Croutons - The new process will extrude shapes simulating conventional croutons - a coating of fat and/or flavour being applied by continuous spray onto the hot extrudate.
Apart from quality advantages arising from use of the new process, theee are substantial savings in energy consumption both in the extrusion operation and in the absence of drying equipment. Capital expenditure and floor space requirements are also considerably lower than for the peeviously accepted processes.
The flexibility of the new process facilitates production of a high density crumb when required. This r~sults in a thinner layer of crumbs on the outside of a finished product for the same weight a~plication - often allowing the manufacturer to apply crumbs with a single 3~

enrobiny process, compared with the double operation necessary when crumbs of lower density are applied.
The process facilitates production of a crumb with particularly high water absorbency properties. Consequently, smallgoods can be manufactured with a higher meat/cereal ratio than wlth a conventional rusk type binder.

Claims (22)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of manufacturing food coatings, fillers or pellets comprising the steps of feeding the food ingredients into an extruder, said ingredients having an average moisture content of about 8-12%, processing the ingredients through the extruder at a temperature and pressure which causes the starches present to gelatinize to form a dense elastic-like mass and extruding this mass having about 4-9% residual moisture.
2. A method as claimed in claim 1, wherein the mass extruded is ground to the required particle size.
3. A method as claimed in claim 1, wherein the extruder is preheated to a barrel temperature of about 200°C, auger speeds are 350 to 400 r.p.m., residence time of the ingredients in the extruder is about 8 seconds and internal pressures are 2000 to 2500 p.s.i.
4. A method as claimed in claim 2, wherein the extruder is preheated to a barrel temperature of about 200°C, auger speeds are 350 to 400 r.p.m., residence time of the ingredients in the extruder is about 8 seconds and internal pressures are 2000 to 2500 p.s.i.

- Page 1 of Claims -
5. A method as claimed in claim 1, wherein the internal pressure is regulated by varying the gap between a breaker plate and spacer ring situated between the auger and the die of the extruder.
6. A method as claimed in claim 2, wherein the internal pressure is regulated by varying the gap between a breaker plate and spacer ring situated between the auger and the die of the extruder.
7. A method as claimed in claim 3, wherein the internal pressure is regulated by varying the gap between a breaker plate and spacer ring situated between the auger and the die of the extruder.
8. A method as claimed in claim 3, wherein the internal pressure is regulated by varying the gap between a breaker plate and spacer ring situated between the auger and the die of the extruder.
9. A method as claimed in claim 1, wherein about 2 to 5 of full fat soya flour is added to the ingredients.
10. A method as claimed in claim 2, wherein about 2 to 5%
of full fat soya flour is added to the ingredients.

- Page 2 of Claims -
11. A method as claimed in claim 3, wherein about 2 to 5%
of full fat soya flour is added to the ingredients.
12. A method as claimed in claim 4, wherein about 2 to 5%
of full fat soya flour is added to the ingredients.
13. A method as claimed in claim 5, wherein about 2 to 5%
of full fat soya flour is added to the ingredients.
14. A method as claimed in claim 6, wherein about 2 to 5 of full fat soya flour is added to the ingredients.
15. A method as claimed in claim 7, wherein about 2 to 5%
of full fat soya flour is added to the ingredients.
16. A method as claimed in claim 8, wherein about 2 to 5%
of full fat soya flour is added to the ingredients.
17. A method as claimed in claims 1, 2 or 3, wherein the ingredients are whole wheat about 48.2%, semolina about 47.5%, full fat soya flour about 2.5%, salt about 1.5% and dextrose about 0.3%.
18. A method as claimed in claims 4, 5 or 6, wherein the ingredients are whole wheat about 48.2%, semolina about 47.5%, full fat soya flour about 2.5%, salt about 1.5% and dextrose about 0.3%.

- Page 3 of Claims -
19. A method as claimed in claims 7, 8 or 9, wherein the ingredients are whole wheat about 48.2%, semolina about 47.5%, full fat soya flour about 2.5%, salt about 1.5% and dextrose about 0.3%.
20. A method as claimed in claims 10, 11 or 12, wherein the ingredients are whole wheat about 48.2%, semolina about 47.5%, full fat soya flour about 2.5%, salt about 1.5% and dextrose about 0.3%.
21. A method as claimed in claims 13, 14, or 15, wherein the ingredients are whole wheat about 48.2%, semolina about 47,5%, full fat soya flour about 2.5%, salt about 1.5% and dextrose about 0.3%.
22. A method as claimed in claim 16, wherein the ingredients are whole wheat about 48.2%, semolina about 47.5%, full fat soya flour about 2.5%, salt about 1.5% and dextrose about 0.3%.

- Page 4 of Claims -
CA000432456A 1983-07-14 1983-07-14 Method of making food coatings, fillers and pellets Expired CA1189739A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000432456A CA1189739A (en) 1983-07-14 1983-07-14 Method of making food coatings, fillers and pellets

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000432456A CA1189739A (en) 1983-07-14 1983-07-14 Method of making food coatings, fillers and pellets

Publications (1)

Publication Number Publication Date
CA1189739A true CA1189739A (en) 1985-07-02

Family

ID=4125666

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000432456A Expired CA1189739A (en) 1983-07-14 1983-07-14 Method of making food coatings, fillers and pellets

Country Status (1)

Country Link
CA (1) CA1189739A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11102998B1 (en) 2017-08-25 2021-08-31 The Hershey Company Binders and methods of making and using the same

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11102998B1 (en) 2017-08-25 2021-08-31 The Hershey Company Binders and methods of making and using the same

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