CA2004149A1 - Process for making creamy instant agglomerated cereal - Google Patents
Process for making creamy instant agglomerated cerealInfo
- Publication number
- CA2004149A1 CA2004149A1 CA002004149A CA2004149A CA2004149A1 CA 2004149 A1 CA2004149 A1 CA 2004149A1 CA 002004149 A CA002004149 A CA 002004149A CA 2004149 A CA2004149 A CA 2004149A CA 2004149 A1 CA2004149 A1 CA 2004149A1
- Authority
- CA
- Canada
- Prior art keywords
- cereal
- blend
- extruder
- cereal blend
- moisture content
- 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.)
- Abandoned
Links
- 235000013339 cereals Nutrition 0.000 title claims abstract description 75
- 238000000034 method Methods 0.000 title claims abstract description 43
- 230000008569 process Effects 0.000 title claims abstract description 34
- 239000000203 mixture Substances 0.000 claims abstract description 58
- 239000008187 granular material Substances 0.000 claims abstract description 17
- 239000007788 liquid Substances 0.000 claims abstract description 17
- 239000004615 ingredient Substances 0.000 claims abstract description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 11
- 238000001035 drying Methods 0.000 claims description 7
- 238000000227 grinding Methods 0.000 claims description 5
- 240000007594 Oryza sativa Species 0.000 claims description 4
- 235000007164 Oryza sativa Nutrition 0.000 claims description 4
- 238000010411 cooking Methods 0.000 claims description 4
- 235000009566 rice Nutrition 0.000 claims description 4
- 235000013312 flour Nutrition 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000004806 packaging method and process Methods 0.000 abstract description 3
- 230000008901 benefit Effects 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 29
- 235000011868 grain product Nutrition 0.000 description 7
- 235000012438 extruded product Nutrition 0.000 description 5
- 239000002245 particle Substances 0.000 description 5
- 238000005054 agglomeration Methods 0.000 description 3
- 230000002776 aggregation Effects 0.000 description 3
- 229910052500 inorganic mineral Inorganic materials 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000011707 mineral Substances 0.000 description 3
- 235000010755 mineral Nutrition 0.000 description 3
- 235000013343 vitamin Nutrition 0.000 description 3
- 239000011782 vitamin Substances 0.000 description 3
- 229940088594 vitamin Drugs 0.000 description 3
- 229930003231 vitamin Natural products 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 2
- 239000013067 intermediate product Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 235000013336 milk Nutrition 0.000 description 2
- 239000008267 milk Substances 0.000 description 2
- 210000004080 milk Anatomy 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 235000019198 oils Nutrition 0.000 description 2
- 102000004169 proteins and genes Human genes 0.000 description 2
- 108090000623 proteins and genes Proteins 0.000 description 2
- 235000007319 Avena orientalis Nutrition 0.000 description 1
- 241000209763 Avena sativa Species 0.000 description 1
- 235000007558 Avena sp Nutrition 0.000 description 1
- 239000004278 EU approved seasoning Substances 0.000 description 1
- 240000005979 Hordeum vulgare Species 0.000 description 1
- 235000007340 Hordeum vulgare Nutrition 0.000 description 1
- 239000004940 MPF-50 Substances 0.000 description 1
- 241000982035 Sparattosyce Species 0.000 description 1
- 241000209140 Triticum Species 0.000 description 1
- 235000021307 Triticum Nutrition 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 239000001506 calcium phosphate Substances 0.000 description 1
- 235000011010 calcium phosphates Nutrition 0.000 description 1
- 239000004464 cereal grain Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000002036 drum drying Methods 0.000 description 1
- 235000013399 edible fruits Nutrition 0.000 description 1
- 239000000796 flavoring agent Substances 0.000 description 1
- 235000019634 flavors Nutrition 0.000 description 1
- 235000011194 food seasoning agent Nutrition 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 235000016709 nutrition Nutrition 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000005549 size reduction Methods 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 235000000346 sugar Nutrition 0.000 description 1
- 150000008163 sugars Chemical class 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical class [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- 229940104267 tripleflex Drugs 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
- A23L7/10—Cereal-derived products
- A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
- A23L7/135—Individual or non-extruded flakes, granules or shapes having similar size, e.g. breakfast cereals
Abstract
PROCESS FOR MAKING CREAMY INSTANT AGGLOMERATED CEREAL
ABSTRACT OF THE DISCLOSURE
The present invention relates to novel processes for producing pre-cooked instant agglomerated cereal capable of being readily dissolved in liquid to yield a cereal with a creamy consistency and to products produced by those processes. The starting dry cereal blend is moistened and cooked in an extruder which extrudes the cereal blend in an expanded form. The cereal blend is then ground through a mill with a screen having openings of about 0.093 inches in diameter or smaller, and agglomerates are thereafter formed by metering the ground cereal blend into an agglomerator.
The agglomerates or granules are then dried to a moisture content of about 4% to about 7%, at which time they are ready for packaging or for combining with a desired liquid.
The processes of the present invention have the additional advantage that heat-sensitive ingredients may be blended into the product after the cereal blend is extruded and before the cereal blend is metered into the agglomerator.
ABSTRACT OF THE DISCLOSURE
The present invention relates to novel processes for producing pre-cooked instant agglomerated cereal capable of being readily dissolved in liquid to yield a cereal with a creamy consistency and to products produced by those processes. The starting dry cereal blend is moistened and cooked in an extruder which extrudes the cereal blend in an expanded form. The cereal blend is then ground through a mill with a screen having openings of about 0.093 inches in diameter or smaller, and agglomerates are thereafter formed by metering the ground cereal blend into an agglomerator.
The agglomerates or granules are then dried to a moisture content of about 4% to about 7%, at which time they are ready for packaging or for combining with a desired liquid.
The processes of the present invention have the additional advantage that heat-sensitive ingredients may be blended into the product after the cereal blend is extruded and before the cereal blend is metered into the agglomerator.
Description
~ - ....
PROCESS FOR MAKING CREAMY INSTANT_AGG OMERATED CEREAL
BACKGROUND OF THE INVENTION ~-~
Field of the Invention This invention relates to processes for making pre- ' cooked instant cereal products, and more particularly to processes involving the steps of extrusion, size reduction ` ~-and agglomeration of a dry cereal blend to provide instant cereals capable of rapidly dispersing in liquids to form a - -creamy product for consumption.
Prior methods for preparing cereal products have ~:
been described whereby dry cereal ingredients are moistened and heated through the use of extruders or drum drying techniques and then dried before packaging such as described in U.S. Patent No. 4,044,159. Other methods have been described for production of cereal-type products that can readily be dispersed in liquids (see, for example, U.S.
Patent Nos. 3,615,674 and 4,016,337).
None of these methods, however, teaches the process of the present invention that produces a pre-cooked instant cereal product of high quality consistency and taste which may be readily dissolved in liquids without forming lumps in less than 60 seconds, and more typically in less than 30 seconds. The novel processes of this invention are further ~ -~
advantageous because they use the efficient heat-transfer method of an extrusion process and allow for the intermediate addition of heat-sensitive ingredients to the 30 cereal. The resulting novel products are capable of -yielding a high quality cereal of creamy consistency upon ;~
mixing with liquid such as milk or waterj particularly suited for the feeding of infants. Further, the products are capable of rapidly and instantly dissolving in liquids ~s that allow for quick and easy preparation of a creamy appealing product for consumption.
' '..:.'~. ' ',' ''' ~i''"
SUMMARY OF THE INVENTION
The present invention relates to novel processes for ;~ r producing pre-cooked instant agglomerated cereal capable of being readily dissolved in liquid to give a creamy -5 consistency. The starting dry cereal blend is moistened and -cooked in an extruder which extrudes the cereal blend in an ~ ~ ;
expanded form. The cereal blend is then ground through a -~
mill equipped with a screen having openings of about 0.093 inches in diameter or smaller. Granules are formed by metering the ground cereal blend into an agglomerator. The granules are then dried to a moisture content of about 4 to about 7%, at which time they are ready for packaging or for combining with a desired liquid. Preferably, the cereal blend is extruded from the extruder at a moisture content of about 14 to about 16% and at a temperature of about 220F to about 260F. Further, it is preerred that the cereal blend i8 extruded from the extruder in a rope and sliced with a blade into about 1/2 inch to about 3/4 inch in diameter puffs which after drying have a density of about 21 g/100 ml of product. Typically, the extruder has a diehead opening of about 1/8 inch in diameter to about 1/4 inch in diameter.
In the agglomerating step it is preferred that the moisture content of the extruded product be adjusted to about 14%.
The processes of the present invention have the further advantage that heat-sensitive ingredients may be blended into the product after the cereal blend is extruded and before the cereal blend is metered into the agglomerator.
DETAILED DESCRIPTION
Though processes of the present invention are particularly suited for use as infant cereals, they may be used to produce any pre-cooked cereal-type product where quick and easy dispersability of a cereal product into liquid is desired. In addition, through use of the processes of the present invention a product is produced efficiently because intermediate products have a low moisture content which minimizes the amount of drying time : :,' . : ' . ',' ' ~'-: '. i. ;,-' .
3 -~
required and provides an intermediate product which is easier to grind. For the purposes of this invention, what is intended to be defined by creamy instant cereal, is a~ ~-cereal capable of being readily dissolved in liquid in less than 60 seconds without leaving or forming lumps, and more typically in less than 30 seconds with only minimal stirring.
The starting dry cereal blend for the production of -an instant cereal as detailed by the methods of the present invention may include cereal grains or blends which are capable of expanding in an extruder such as rice, wheat, oat, corn, barley or the like, as well as mixtures thereof and special composites such as hi-protein formulas.
Additional ingredients can include calcium phosphates, -various proteins, various conventional minerals, vitamins, oils and seasonings.
The dry cereal blend ingredients are first moistened and cooked in an extruder where water or another suitable wetting agent is added to evenly adjust the moisture content 20 of the dry cereal blend to about 14% to about 22%, ;~ ;
preferably to about 16% to about 20%, and most preferably to about 18% to about 20%. If desired, the cereal blend may be moistened to the moisture contents described above prior to its entry into an extruder, but adjusting the moisture content through the use of an extruder is the preferred method. It has been found to be particularly advantageous to utilize a twin screw type of extruder having a plurality of jacketed zones that can be either heated (or cooled) individually.
The extruder is further advantageously equipped with a cutting device, pressure-sensing gauge and a thermocouple. ~ -The pressure gauge and thermocouple are placed immediately preceding the die so that the processing pressure and -temperature can be readily ascertained. The jacketed -35 heating zones provide heat to the product by conduction and ~ ~
further heat is imputed to the product by the friction ~-developed with the rotating screw. The heat imputed from :
:
---` 20041~9 - ~
the extruder surfaces to the product and accomplishes the desired cooking.
The extruder is advantageously provided with a cutter blade for attachment and controlled periodic rotation along the outer surface of the extruder head to cut the extruded material into short segments as it leaves the extruder such that the segments may be readily dried and fitted into a mill for grinding. ~;
Any configuration of shaped opening can be provided -~
in the extruder die with openings ranging from about 1/16 inch to about 3/4 inch in diameter, the desired size depending upon the composition of the dry cereal blend used since the expansion of different grains varies as they are extruded. For a blend which contains primarily rice flour, for instance, an opening of about 1/8 inch to about l/4 inch in diameter is preferred, a diameter of 5/32 inch is most preferred. The cereal blend thus preferably exits the ~' extruder in a rope of about 1/2 inch to about 3/4 inch in diameter and pieces are cut to yield puffs with such diameters.
The cereal product should be processed through the extruder so that the moisture content of the extruded product is about 12% to about 20%, preferably about 14% to about 16%, and most preferably about 15%. The temperature ~-of the product being extruded should be 160F to 340F, preferably about 200F to about 340F, most preferably about i~
220F to about 260F.
The extruded cereal product is then allowed to dry to a total product moisture content of between about 7% to ~ `~
30 about 10%, preferably to about 7% by any of the conventional -methods well-known in the art. The dried product is then ,~
ground to give a fine powder-like particle size. Typically it is ground in a mill with a screen having openings of about 0.093 inches in diameter or smaller, preferably about ~ `
0.093 inches to about 0.033 inches in diameter, most ~-~
preferably 0.050 inches in diameter.
~ ,.: . .: .
:~
~.,',' ;,''.::'~
: -~.- ::::
.: .: .
Z~`04~
Once the extruded cereal product has been ground to a smaller particle size, it may be blended with other ingredients if desired, particularly heat sensitive ingredients whose taste, color, nutritional value etc. would be decreased through the heat process of the extruder.
Examples of products which could be added include milk -products and other protein sources, flavors, minerals, fruit, sugars, and vitamins or the like.
The dried extruded product (including any additional :
blended ingredients, if desired) is then passed through an agglomerator (an apparatus well-known in the field), which ~ ;
evenly applies moisture to the dried product to bring the .-moisture content of the product up to about 14% while i~
creating small granules of the product. This agglomerating process should allow some binding of the particles together to create granules which, once dried, will more readily mix with liquid. This may be advantageously accomplished by using a disc pelletizer type of agglomerator (Teledyne ;~
Readco, York, PA; Sprout-Bauer, Muncie, PA). The pan onto ' which the extruded product is dropped is angled at, for instance, about a 50 angle. The pan is rotated at a speed to allow the dried particles to pass through a spray of water and as the particles bind due to the addition of the ~`
water they drop off the pan as small wet agglomerates or granule8. Granule size can be ad~usted by controlling the di8c speed, disc angle, total feed rate, position of the water and dry cereal in relation to the face of the disc. ~ ;i ;
Other agglomerators such as a fluidized bed-type agglomerator (Glatt, West Germany) or high-speed mixer agglomerator (Bepex s Tripleflex Vertical Agglomerator, Bepex, Minneapolis, MN) may also be used.
Once the wet agglomeration process is completed, the wet granules are dried in any one of the many driers, such as fluidized bed driers or vibrating bed ovens, which are - ~'~
typically used in the field in connection with agglomerators. The wet granules are dried briefly at low heat, for example, about 180F until the moisture content is i~ ~
'~: - . ' :- : :. ...
200~
-:
reduced to about 7% by total weight or until the dried product has a density of about 19 g to about 24 g/100 ml of product, preferably about 19 g to about 21 g/100 ml of product, most preferably 21 g/100 ml of product. The 5 agglomerates are screened to remove oversized material. ~ ~
Undersized material may be recycled back to the ~;
agglomeration step. The preferred product is that which is capable of passing through an 8 mesh sieve but not capable of passing through a 20 mesh sieve, although a broader range 10 is also useful. All mesh sizes referred to herein are ~-according to the U.S. Bureau of Standards. ;~`
To further illustrate the invention, the following example is provided. It should be understood that the particular details of the example are not to be regarded as ~ . -limitations as they may be varied as will be understood by one skilled in this art. `
': : :~ " "~:
Example~
The following components were mixed to create a dry cereal blend~
. : .~ ~'.
InaredientsWeiqht(lbs) ~ ~
rice flour 133.00 ; ~ - , ~oy oil 2.67 vitamins & minerals 2.71 The cereal blend was metered at a uniform rate to a twin screw MPF-50 extruder manufactured by Baker Perkins (Grand Rapids, MI) which adjusted the moisture content of the cereal blend with water so that when entering the barrel of the extruder the cereal blend had a moisture content of ;~
about 18%. The extruder was equipped and set with the -following screw profile: ~ -. ., -.,~,...
' ;': ", ~: .
2004~'19 1/4" spacer 9" feedscrew -6 - 30 degree forward paddles 3ll feedscrew 2" single pitch (S.P.) feedscrew 1 paddle 6" single lead ~;
PROCESS FOR MAKING CREAMY INSTANT_AGG OMERATED CEREAL
BACKGROUND OF THE INVENTION ~-~
Field of the Invention This invention relates to processes for making pre- ' cooked instant cereal products, and more particularly to processes involving the steps of extrusion, size reduction ` ~-and agglomeration of a dry cereal blend to provide instant cereals capable of rapidly dispersing in liquids to form a - -creamy product for consumption.
Prior methods for preparing cereal products have ~:
been described whereby dry cereal ingredients are moistened and heated through the use of extruders or drum drying techniques and then dried before packaging such as described in U.S. Patent No. 4,044,159. Other methods have been described for production of cereal-type products that can readily be dispersed in liquids (see, for example, U.S.
Patent Nos. 3,615,674 and 4,016,337).
None of these methods, however, teaches the process of the present invention that produces a pre-cooked instant cereal product of high quality consistency and taste which may be readily dissolved in liquids without forming lumps in less than 60 seconds, and more typically in less than 30 seconds. The novel processes of this invention are further ~ -~
advantageous because they use the efficient heat-transfer method of an extrusion process and allow for the intermediate addition of heat-sensitive ingredients to the 30 cereal. The resulting novel products are capable of -yielding a high quality cereal of creamy consistency upon ;~
mixing with liquid such as milk or waterj particularly suited for the feeding of infants. Further, the products are capable of rapidly and instantly dissolving in liquids ~s that allow for quick and easy preparation of a creamy appealing product for consumption.
' '..:.'~. ' ',' ''' ~i''"
SUMMARY OF THE INVENTION
The present invention relates to novel processes for ;~ r producing pre-cooked instant agglomerated cereal capable of being readily dissolved in liquid to give a creamy -5 consistency. The starting dry cereal blend is moistened and -cooked in an extruder which extrudes the cereal blend in an ~ ~ ;
expanded form. The cereal blend is then ground through a -~
mill equipped with a screen having openings of about 0.093 inches in diameter or smaller. Granules are formed by metering the ground cereal blend into an agglomerator. The granules are then dried to a moisture content of about 4 to about 7%, at which time they are ready for packaging or for combining with a desired liquid. Preferably, the cereal blend is extruded from the extruder at a moisture content of about 14 to about 16% and at a temperature of about 220F to about 260F. Further, it is preerred that the cereal blend i8 extruded from the extruder in a rope and sliced with a blade into about 1/2 inch to about 3/4 inch in diameter puffs which after drying have a density of about 21 g/100 ml of product. Typically, the extruder has a diehead opening of about 1/8 inch in diameter to about 1/4 inch in diameter.
In the agglomerating step it is preferred that the moisture content of the extruded product be adjusted to about 14%.
The processes of the present invention have the further advantage that heat-sensitive ingredients may be blended into the product after the cereal blend is extruded and before the cereal blend is metered into the agglomerator.
DETAILED DESCRIPTION
Though processes of the present invention are particularly suited for use as infant cereals, they may be used to produce any pre-cooked cereal-type product where quick and easy dispersability of a cereal product into liquid is desired. In addition, through use of the processes of the present invention a product is produced efficiently because intermediate products have a low moisture content which minimizes the amount of drying time : :,' . : ' . ',' ' ~'-: '. i. ;,-' .
3 -~
required and provides an intermediate product which is easier to grind. For the purposes of this invention, what is intended to be defined by creamy instant cereal, is a~ ~-cereal capable of being readily dissolved in liquid in less than 60 seconds without leaving or forming lumps, and more typically in less than 30 seconds with only minimal stirring.
The starting dry cereal blend for the production of -an instant cereal as detailed by the methods of the present invention may include cereal grains or blends which are capable of expanding in an extruder such as rice, wheat, oat, corn, barley or the like, as well as mixtures thereof and special composites such as hi-protein formulas.
Additional ingredients can include calcium phosphates, -various proteins, various conventional minerals, vitamins, oils and seasonings.
The dry cereal blend ingredients are first moistened and cooked in an extruder where water or another suitable wetting agent is added to evenly adjust the moisture content 20 of the dry cereal blend to about 14% to about 22%, ;~ ;
preferably to about 16% to about 20%, and most preferably to about 18% to about 20%. If desired, the cereal blend may be moistened to the moisture contents described above prior to its entry into an extruder, but adjusting the moisture content through the use of an extruder is the preferred method. It has been found to be particularly advantageous to utilize a twin screw type of extruder having a plurality of jacketed zones that can be either heated (or cooled) individually.
The extruder is further advantageously equipped with a cutting device, pressure-sensing gauge and a thermocouple. ~ -The pressure gauge and thermocouple are placed immediately preceding the die so that the processing pressure and -temperature can be readily ascertained. The jacketed -35 heating zones provide heat to the product by conduction and ~ ~
further heat is imputed to the product by the friction ~-developed with the rotating screw. The heat imputed from :
:
---` 20041~9 - ~
the extruder surfaces to the product and accomplishes the desired cooking.
The extruder is advantageously provided with a cutter blade for attachment and controlled periodic rotation along the outer surface of the extruder head to cut the extruded material into short segments as it leaves the extruder such that the segments may be readily dried and fitted into a mill for grinding. ~;
Any configuration of shaped opening can be provided -~
in the extruder die with openings ranging from about 1/16 inch to about 3/4 inch in diameter, the desired size depending upon the composition of the dry cereal blend used since the expansion of different grains varies as they are extruded. For a blend which contains primarily rice flour, for instance, an opening of about 1/8 inch to about l/4 inch in diameter is preferred, a diameter of 5/32 inch is most preferred. The cereal blend thus preferably exits the ~' extruder in a rope of about 1/2 inch to about 3/4 inch in diameter and pieces are cut to yield puffs with such diameters.
The cereal product should be processed through the extruder so that the moisture content of the extruded product is about 12% to about 20%, preferably about 14% to about 16%, and most preferably about 15%. The temperature ~-of the product being extruded should be 160F to 340F, preferably about 200F to about 340F, most preferably about i~
220F to about 260F.
The extruded cereal product is then allowed to dry to a total product moisture content of between about 7% to ~ `~
30 about 10%, preferably to about 7% by any of the conventional -methods well-known in the art. The dried product is then ,~
ground to give a fine powder-like particle size. Typically it is ground in a mill with a screen having openings of about 0.093 inches in diameter or smaller, preferably about ~ `
0.093 inches to about 0.033 inches in diameter, most ~-~
preferably 0.050 inches in diameter.
~ ,.: . .: .
:~
~.,',' ;,''.::'~
: -~.- ::::
.: .: .
Z~`04~
Once the extruded cereal product has been ground to a smaller particle size, it may be blended with other ingredients if desired, particularly heat sensitive ingredients whose taste, color, nutritional value etc. would be decreased through the heat process of the extruder.
Examples of products which could be added include milk -products and other protein sources, flavors, minerals, fruit, sugars, and vitamins or the like.
The dried extruded product (including any additional :
blended ingredients, if desired) is then passed through an agglomerator (an apparatus well-known in the field), which ~ ;
evenly applies moisture to the dried product to bring the .-moisture content of the product up to about 14% while i~
creating small granules of the product. This agglomerating process should allow some binding of the particles together to create granules which, once dried, will more readily mix with liquid. This may be advantageously accomplished by using a disc pelletizer type of agglomerator (Teledyne ;~
Readco, York, PA; Sprout-Bauer, Muncie, PA). The pan onto ' which the extruded product is dropped is angled at, for instance, about a 50 angle. The pan is rotated at a speed to allow the dried particles to pass through a spray of water and as the particles bind due to the addition of the ~`
water they drop off the pan as small wet agglomerates or granule8. Granule size can be ad~usted by controlling the di8c speed, disc angle, total feed rate, position of the water and dry cereal in relation to the face of the disc. ~ ;i ;
Other agglomerators such as a fluidized bed-type agglomerator (Glatt, West Germany) or high-speed mixer agglomerator (Bepex s Tripleflex Vertical Agglomerator, Bepex, Minneapolis, MN) may also be used.
Once the wet agglomeration process is completed, the wet granules are dried in any one of the many driers, such as fluidized bed driers or vibrating bed ovens, which are - ~'~
typically used in the field in connection with agglomerators. The wet granules are dried briefly at low heat, for example, about 180F until the moisture content is i~ ~
'~: - . ' :- : :. ...
200~
-:
reduced to about 7% by total weight or until the dried product has a density of about 19 g to about 24 g/100 ml of product, preferably about 19 g to about 21 g/100 ml of product, most preferably 21 g/100 ml of product. The 5 agglomerates are screened to remove oversized material. ~ ~
Undersized material may be recycled back to the ~;
agglomeration step. The preferred product is that which is capable of passing through an 8 mesh sieve but not capable of passing through a 20 mesh sieve, although a broader range 10 is also useful. All mesh sizes referred to herein are ~-according to the U.S. Bureau of Standards. ;~`
To further illustrate the invention, the following example is provided. It should be understood that the particular details of the example are not to be regarded as ~ . -limitations as they may be varied as will be understood by one skilled in this art. `
': : :~ " "~:
Example~
The following components were mixed to create a dry cereal blend~
. : .~ ~'.
InaredientsWeiqht(lbs) ~ ~
rice flour 133.00 ; ~ - , ~oy oil 2.67 vitamins & minerals 2.71 The cereal blend was metered at a uniform rate to a twin screw MPF-50 extruder manufactured by Baker Perkins (Grand Rapids, MI) which adjusted the moisture content of the cereal blend with water so that when entering the barrel of the extruder the cereal blend had a moisture content of ;~
about 18%. The extruder was equipped and set with the -following screw profile: ~ -. ., -.,~,...
' ;': ", ~: .
2004~'19 1/4" spacer 9" feedscrew -6 - 30 degree forward paddles 3ll feedscrew 2" single pitch (S.P.) feedscrew 1 paddle 6" single lead ~;
3" feedscrew 3" single lead : `` ~
The diehead was a twin hole die of 5/32 inches. The barrel ~ ~ -length had a ratio of 15:1 (length/diameter of. screw). The feed rate was 200 lb/hr, the pump setting was 5.9 and the motor had a screw speed of 400 rpm. The meter load was 70%. :
15 Steam introduction into 5 heating zones of the extruder was such that zone 1 was 60F, zone 2 was 125F, zones 3,4 and 5 ~ -~
were 180F. The moist blend was forced out of the die under a pressure of 1450 lbs/in2, at a temperature of 237F and a moisture content of 15%. ~ ~ ;
The extruded product was found to have expanded, on an average to about 1/2 to 3/4 inches in diameter with a ~-~
moisture content of about 15%. The product was cut into puffs and allowed to cool. The puffs were dried in ambient air to a crisp ball. The dried product was then milled 25 through a Fitzpatrick Model D comminuting lB (0.050 inch) ;~
~creen (Fitzpatrick Company, Chicago, IL) at slow speed.
Density of the ground cereal was 31 g/100 ml. At this point the moisture content of the product was 7%.
The milled cereal was then agglomerated with a 30 Sprout-Bauer 16 inch disc pelletizer. The disc was operated at a feed rate of 60 lbs/hr, a disc speed of 3.5 rpm, and a ban angle of 50. Water was sprayed onto the disc and the -cereal. Small spherical granules were formed as the cereal was brought to a moisture content of about 14%.
The wet agglomerates or granules were dried in a hot laboratory air upflow tray drier oven at 180F for 15 minutes. The dried product had a density of 21 g/100 ml.
: . . .
;~004149 : ~
It was passed through a series of sieves for sizing as follows:
~, .,`~ '',' Sieve Size (U.S. Std.) y~ Retention of Granules 10 mesh 3 14 mesh 5 20 mesh 32 - ~
30 mesh 35 ~ ;
on pan 24 The cereal retained by the 20 mesh sieve and larger pore `
size sieves was collected for use as the instant cereal.
The resulting cereal mixed instantly in water in less than 30 seconds without lumping. Water adsorption was 100 ml/20 g cereal.
Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be appreciated that certain changes and modifications may be practiced within the ~cope of the invention as limited only by the scope of the appended claims.
,, .",, ,.; .,, i '`'' " ~ '''"", ''~, ' '.'``..,' ,, : , ... . .
,., ., ,,,-:..
: ",,.~, .
.,"-' ",',,.,' ~ .' ''
The diehead was a twin hole die of 5/32 inches. The barrel ~ ~ -length had a ratio of 15:1 (length/diameter of. screw). The feed rate was 200 lb/hr, the pump setting was 5.9 and the motor had a screw speed of 400 rpm. The meter load was 70%. :
15 Steam introduction into 5 heating zones of the extruder was such that zone 1 was 60F, zone 2 was 125F, zones 3,4 and 5 ~ -~
were 180F. The moist blend was forced out of the die under a pressure of 1450 lbs/in2, at a temperature of 237F and a moisture content of 15%. ~ ~ ;
The extruded product was found to have expanded, on an average to about 1/2 to 3/4 inches in diameter with a ~-~
moisture content of about 15%. The product was cut into puffs and allowed to cool. The puffs were dried in ambient air to a crisp ball. The dried product was then milled 25 through a Fitzpatrick Model D comminuting lB (0.050 inch) ;~
~creen (Fitzpatrick Company, Chicago, IL) at slow speed.
Density of the ground cereal was 31 g/100 ml. At this point the moisture content of the product was 7%.
The milled cereal was then agglomerated with a 30 Sprout-Bauer 16 inch disc pelletizer. The disc was operated at a feed rate of 60 lbs/hr, a disc speed of 3.5 rpm, and a ban angle of 50. Water was sprayed onto the disc and the -cereal. Small spherical granules were formed as the cereal was brought to a moisture content of about 14%.
The wet agglomerates or granules were dried in a hot laboratory air upflow tray drier oven at 180F for 15 minutes. The dried product had a density of 21 g/100 ml.
: . . .
;~004149 : ~
It was passed through a series of sieves for sizing as follows:
~, .,`~ '',' Sieve Size (U.S. Std.) y~ Retention of Granules 10 mesh 3 14 mesh 5 20 mesh 32 - ~
30 mesh 35 ~ ;
on pan 24 The cereal retained by the 20 mesh sieve and larger pore `
size sieves was collected for use as the instant cereal.
The resulting cereal mixed instantly in water in less than 30 seconds without lumping. Water adsorption was 100 ml/20 g cereal.
Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be appreciated that certain changes and modifications may be practiced within the ~cope of the invention as limited only by the scope of the appended claims.
,, .",, ,.; .,, i '`'' " ~ '''"", ''~, ' '.'``..,' ,, : , ... . .
,., ., ,,,-:..
: ",,.~, .
.,"-' ",',,.,' ~ .' ''
Claims (18)
1. A process for producing a pre-cooked instant agglomerated cereal capable of being readily dissolved in liquid comprising the following steps:
(a) cooking a moistened cereal blend in an extruder;
(b) grinding the cereal blend through a mill equipped with a screen having about 0.093 inches in diameter or smaller openings;
(c) forming granules by metering the cereal blend through an agglomerator; and (d) drying the granules to a moisture content of about 4% to about 7%.
(a) cooking a moistened cereal blend in an extruder;
(b) grinding the cereal blend through a mill equipped with a screen having about 0.093 inches in diameter or smaller openings;
(c) forming granules by metering the cereal blend through an agglomerator; and (d) drying the granules to a moisture content of about 4% to about 7%.
2. The process of claim 1, wherein the cereal blend is extruded from the extruder at a moisture content of about 14% to about 16%.
3. The process of claim 1, wherein the cereal blend is extruded from the extruder at a temperature of about 220°F to about 260°F.
4. The process of claim 1, wherein the cereal blend is extruded from the extruder in a rope and sliced with a blade into about 1/2 inch to about 3/4 inch in diameter puffs.
5. The process of claim 1, wherein additional ingredients are blended into the cereal blend after the cereal blend is extruded and before the cereal blend is metered into the agglomerator.
6. The process of claim 1, wherein the moisture content of the granules is adjusted to about 14% by the agglomerator.
7. The process of claim 1, wherein the granules after drying have a density of about 21 g/100 ml.
8. The process of claim 1, wherein the extruder has a diehead opening of about 1/8 inch in diameter to about 1/4 inch in diameter.
9. The process of claim 1, wherein the cereal blend contains more than 50% rice flour.
10. The process of claim 1, wherein the mill is equipped with a screen having about 0.050 inches in diameter openings.
11. The composition produced by the method of claim 1 which is not capable of passing through a 20 mesh sieve.
12. The composition produced by the method of claim 2 which is capable of readily dissolving in liquid in less than 30 seconds.
13. A process for producing a pre-cooked instant agglomerated cereal capable of being readily dissolved in liquid comprising the following steps:
(a) heating a moistened dry cereal blend in an extruder;
(b) grinding the cereal blend through a screen having openings of about 0.093 inches in diameter or smaller;
(c) agglomerating the cereal blend by adding water until its moisture content reaches about 14%; and (d) drying the cereal blend so that it has a density of about 19 to about 24 g/100 ml.
(a) heating a moistened dry cereal blend in an extruder;
(b) grinding the cereal blend through a screen having openings of about 0.093 inches in diameter or smaller;
(c) agglomerating the cereal blend by adding water until its moisture content reaches about 14%; and (d) drying the cereal blend so that it has a density of about 19 to about 24 g/100 ml.
14. The process of claim 13, wherein the cereal blend is extruded from the extruder at a temperature of about 220°F to about 260°F.
15. A process for producing a pre-cooked instant agglomerated cereal capable of being readily dissolved in liquid comprising cooking a moistened dry cereal blend to a temperature of about 220°F to about 260°F in an extruder having a diehead opening of about 1/8 inch in diameter to about 1/4 inch in diameter; grinding the cereal blend; and moistening the cereal blend with an agglomerator until the cereal blend reaches a moisture content of about 14% and then drying the blend to a moisture content of about 4% to about 7%.
16. A process for producing an instant agglomerated cereal capable of being readily dissolved in liquid comprising cooking a moistened dry cereal blend in an extruder to a temperature of about 220°F to about 260°F;
grinding the cereal blend; agglomerating the cereal blend with water to form granules; and drying the granules to a moisture content of about 4% to about 7%.
grinding the cereal blend; agglomerating the cereal blend with water to form granules; and drying the granules to a moisture content of about 4% to about 7%.
17. The process of claim 16, wherein the cereal blend is agglomerated with water to a moisture content of about 14%.
18. The process of claim 17, wherein the cereal blend is extruded from the extruder at a moisture content of about 14% to about 16%.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US28528088A | 1988-12-16 | 1988-12-16 | |
| US285,280 | 1988-12-16 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2004149A1 true CA2004149A1 (en) | 1990-06-16 |
Family
ID=23093564
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002004149A Abandoned CA2004149A1 (en) | 1988-12-16 | 1989-11-29 | Process for making creamy instant agglomerated cereal |
Country Status (6)
| Country | Link |
|---|---|
| JP (1) | JPH02227038A (en) |
| AU (1) | AU4591389A (en) |
| CA (1) | CA2004149A1 (en) |
| FR (1) | FR2640472A1 (en) |
| IT (1) | IT1237433B (en) |
| ZA (1) | ZA898938B (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5385746A (en) * | 1991-07-20 | 1995-01-31 | Nestec S.A. | Preparation of cereal foods by extrusion cooking |
| US5451423A (en) * | 1993-01-09 | 1995-09-19 | Nestec S.A. | Preparation of a cooked cereal product |
| EP0772980A1 (en) | 1995-11-07 | 1997-05-14 | Societe Des Produits Nestle S.A. | Enzyme treated amylaceous product |
Families Citing this family (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| IN181843B (en) | 1995-04-28 | 1998-10-03 | Nestle Sa | |
| US8828432B2 (en) | 1996-10-28 | 2014-09-09 | General Mills, Inc. | Embedding and encapsulation of sensitive components into a matrix to obtain discrete controlled release particles |
| US7201923B1 (en) | 1998-03-23 | 2007-04-10 | General Mills, Inc. | Encapsulation of sensitive liquid components into a matrix to obtain discrete shelf-stable particles |
| EP1900283A3 (en) | 1998-03-23 | 2010-02-10 | General Mills, Inc. | Encapsulation of components into edible products |
| US6146682A (en) * | 1998-05-26 | 2000-11-14 | Bestfoods | Wet toasted pasta having improved hot water pour-over rehydration properties and method of manufacture |
| US6500463B1 (en) | 1999-10-01 | 2002-12-31 | General Mills, Inc. | Encapsulation of sensitive components into a matrix to obtain discrete shelf-stable particles |
| US6558718B1 (en) | 2000-06-19 | 2003-05-06 | General Mills, Inc. | Nutrient clusters for food products and methods of preparation |
| DE10214644A1 (en) * | 2002-04-02 | 2003-10-16 | Buehler Ag | Instant modified flours |
| US7803413B2 (en) | 2005-10-31 | 2010-09-28 | General Mills Ip Holdings Ii, Llc. | Encapsulation of readily oxidizable components |
| US9622500B2 (en) | 2008-11-04 | 2017-04-18 | The Quaker Oats Company | Food products prepared with soluble whole grain oat flour |
| US10980244B2 (en) | 2008-11-04 | 2021-04-20 | The Quaker Oats Company | Whole grain composition comprising hydrolyzed starch |
| US10689678B2 (en) | 2008-11-04 | 2020-06-23 | The Quaker Oats Company | Method and composition comprising hydrolyzed starch |
| MY162821A (en) | 2009-06-14 | 2017-07-31 | Quaker Oats Co | Method of preparing highly dispersible whole grain flour |
| ES2567315T3 (en) | 2011-03-21 | 2016-04-21 | Pepsico, Inc. | Preparation procedure of acid-rich whole grain LPB beverages |
| BR112014002956A8 (en) | 2011-07-12 | 2022-09-06 | Pepsico Inc | METHOD OF PREPARING A MILK DRINK CONTAINING OATS |
| US11172695B2 (en) | 2016-03-22 | 2021-11-16 | The Quaker Oats Company | Method, apparatus, and product providing hydrolyzed starch and fiber |
| US20170275662A1 (en) | 2016-03-22 | 2017-09-28 | The Quaker Oats Company | Method and Apparatus for Controlled Hydrolysis |
| RU2649597C1 (en) * | 2017-03-16 | 2018-04-04 | Игорь Васильевич Рыбалко | Method of manufacture of quick-to-make cornmeal from corn flour |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4044159A (en) * | 1971-10-01 | 1977-08-23 | Gerber Products Company | Extruded cereal product and its preparation |
| US4103034A (en) * | 1974-10-18 | 1978-07-25 | Nabisco, Inc. | Process for production of textured protein flakes |
| US4032668A (en) * | 1975-01-30 | 1977-06-28 | The Jim Dandy Company | Expansion process for the production of instant grits |
| KR870005590A (en) * | 1985-12-02 | 1987-07-06 | 나탈리 엠. 워터맨 | Method of manufacturing extruded pseudo-grain products for quick cooking |
| JPS62208247A (en) * | 1986-03-07 | 1987-09-12 | Nippon Saitetsuku Kk | Production of gelatinized cereal |
-
1989
- 1989-11-23 ZA ZA898938A patent/ZA898938B/en unknown
- 1989-11-29 CA CA002004149A patent/CA2004149A1/en not_active Abandoned
- 1989-12-05 AU AU45913/89A patent/AU4591389A/en not_active Abandoned
- 1989-12-13 IT IT04865189A patent/IT1237433B/en active IP Right Grant
- 1989-12-15 JP JP1327073A patent/JPH02227038A/en active Pending
- 1989-12-15 FR FR8916659A patent/FR2640472A1/en not_active Withdrawn
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5385746A (en) * | 1991-07-20 | 1995-01-31 | Nestec S.A. | Preparation of cereal foods by extrusion cooking |
| US5451423A (en) * | 1993-01-09 | 1995-09-19 | Nestec S.A. | Preparation of a cooked cereal product |
| EP0772980A1 (en) | 1995-11-07 | 1997-05-14 | Societe Des Produits Nestle S.A. | Enzyme treated amylaceous product |
Also Published As
| Publication number | Publication date |
|---|---|
| ZA898938B (en) | 1990-08-29 |
| FR2640472A1 (en) | 1990-06-22 |
| JPH02227038A (en) | 1990-09-10 |
| AU4591389A (en) | 1990-06-21 |
| IT8948651A0 (en) | 1989-12-13 |
| IT1237433B (en) | 1993-06-04 |
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Legal Events
| Date | Code | Title | Description |
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| FZDE | Discontinued |