CA2069213A1 - Multigrain snack food - Google Patents
Multigrain snack foodInfo
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- CA2069213A1 CA2069213A1 CA002069213A CA2069213A CA2069213A1 CA 2069213 A1 CA2069213 A1 CA 2069213A1 CA 002069213 A CA002069213 A CA 002069213A CA 2069213 A CA2069213 A CA 2069213A CA 2069213 A1 CA2069213 A1 CA 2069213A1
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Abstract
R.I.F.-2245A.A 11-11-91 ABSTRACT OF THE DISCLOSURE
There is disclosed an unpuffed cereal grain dough suitable for manufacture of fried snack foods, said dough comprising a total moisture content of about 20% to 35%, about 3% to 8% of added vegetable oil and nonionic emulsifier with the remainder being principally cooked ground grain and optionally pieces of cooked unground whole red wheat and dried fruit visibly discernible in the dough due to color differences. The product is preferably a multigrain composition.
There is disclosed an unpuffed cereal grain dough suitable for manufacture of fried snack foods, said dough comprising a total moisture content of about 20% to 35%, about 3% to 8% of added vegetable oil and nonionic emulsifier with the remainder being principally cooked ground grain and optionally pieces of cooked unground whole red wheat and dried fruit visibly discernible in the dough due to color differences. The product is preferably a multigrain composition.
Description
BACKGROU D OF THE INVENTION
Field of the Inventlon This invention relates to a food composition in the form of a snack food. In particular, this invention relates to a non-puffed, cereal grain dough extrudate which can be further processed such as for the manufacture of an oil-fried snack, particularly a multigrain snack.
Backqround Art Snack food products have long been prepared from wheat or corn by mi~ing the respective flour with water to form an extrudate which is then fried. Alternatively, potatoes have been thinly sliced and deep-fat fried to produce snack foods. Snack foods can thus include chip products, crackers, puffed dough articles and cookies.
Fried snacks have included, for example, the snack foods produced by the method of Willard in U.S. Patents 4,769,253 of ~ s~s~
E~.l.F.-2245A.~, 11-11-91 Sept. 6, 1988 and ~,770,B~1 of Sept. 13, 19~8. Th~se patents relate to e~:panded fried snacks prepared from vario~s extruded cereals.
U.S. Patent 4,517,204 of May 14, 1985 to Mottur et al.
relates to a puffed snack product. The puffed snack contains microcrystalline cellulose. In order to improve the te~ture and incr~ase the expansion of the batter upon extrusion due to the presence of the cellulose, about 0.5% to 4% by weight of edible oil is added to the batter. The products of the Mottur et al. patent are preferably baked. About 0.1% to 1% of nonionic emulsifiers can also be added to the oil in order to improve e~pansion of the product.
~ ommercial product which is a relatively low calorie version o~ se Doodles~ of Borden Inc., includes corn meal and bran in its composition and additionally contains about 1% of vegetable oil. This product is baked.
Frito-Lay, Inc. has manufactured a ~ultigrain snack, marketed ac Sunchips~, which is made from whole wheat, corn and other natural ingredients. The Sunchips~ product is corn-based having appro~ ,ately 50% by weight corn meal and about 25% by weight wheat on a before frying basis.
~ anderveer et al. U.S.Patent 4,777,045 of Oct. 11, 1988 .. ..
R.I.F.-2245A.A l1~ 91 relates to a brand containing snack of various cereal grains which are e~truded fro~ a twin screw cooker extruder. The extruded pieces are coated with from 1% to 10% of vegetable oil and a powdered flavorant is applied over the oil wherein the oil allegedly improves adhesion of the flavor particles, enhances flavor a_ceptability and improves mouth feel organoleptically.
Irvin et al. U.S.Patent 4,985,269 of Jan. 15, l991 relates to use of twin screw extruders for making corn dough masa which is further processed for the production of tortilla chips. This reference also discloses the use of about 0.1% to 0.6% of a nonionic emulsifier which can be added to the corn feed prior to extrusion.
Lewis et al. U.S. Patent 4,384,009 of May 17, 1983 relates to snacks of dehydrated meat products containing vegetable materials such as whole or nearly whole grains and additives such as fats, oils, seasonings, flavors, preservatives, and emulsifiers.
A. Howard U.S. Patent 4,526,800 of July 2, 1985 relates to an e~:panded snac~ food comprising cooked portions of dough containing gelatinized starch, including 10% to 70% by weight of bran and 5 to 35~ by weight of oil or fat.
.I.F.-2245A.A 11-11-91 AR~' OF THE INVENTION
This invention is directed to the formation of a fried snack food and its dough composition precursor. The food products of this invention are low in cholesterol and fat, possess a unique grain flavor, and exhibit improved texture and mouth feel.
It has been found that the addition of about 3~ to ~% of a plasticizer, e.g. vegetable oil, in the preparation of the dough compositions comprising a~out 20% to 35% total moisture, and about 45% to ,7% of grain such as ground grain with or without smaller quantitles of pieces of whole red wheat or dried fruit, minimizes the pic~ up of oil on frying as compared to such compositions without the added oil. Purthermore the fried snack can contain less plasticizer , e.g. vegetable oil, as compared to the fried product which does not contain the added plasticizer. This is the case when the quantity of added plasticizer is from about 3.5% or 4% to about 7% by weight of the dough composition. Also, about 3%
to ~O of plasticizer improves the mouth feel or texture of the fried snac~ product.
In one embodiment of the invention there is disclosed dough co~positions as described above suitable for making fried snacXs, as well as snack products produced from such compositions which contain one or a va iety of cereal grains.
~ ln ancther embodiment of the invention there is disclosed ~ 3 R.l.F.-2295A.A 11-11-gl cooked dough compositions and snack products which have visually discernible pieces of grain or fruit in the product.
In still another embodiment the dough composition is sheeted, shaped and cut into pieces which are dried to prepare pellets or half products which are then packaged for cooking by the consumer, e.g., by baking, frying or ~icrowaving. The drying can be accomplished by conventional means such as by merely permitting the pieces to air dry overnight, e.g. to about 10% to 14% of moisture.
Although there are a number of different embodiments in this invention, one of the embodiments, referred to as the First Embodiment, uses a cooker extruder to cook the ground grain and form the dough with or without the addition of pregelatinized unground whole red wheat or pieces of dried fruit. Another embodiment, referred to as the Second Embodiment, does not cook the dough in the extruder but instead part of the ground grain is gelatinized and enters the extruder together with unground gelatinized whole red wheat. In the Second Embodiment the extruder is maintained at a temperature of no higher than about 70 F in formation of the dough .
BR~EF_DEC,ÇR~lPTION 0 ~ E DRAWING
Fig. l is a process flow diagram of the present invention.
~ ~ $ ~3 ~
.I.F.-2245A.A 11-11-91 ~ig. 2 is a schematic side elevation of a twin screw eY~trUSion apparatus which ~an be used in this invention.
Fig.3 is a schematic view of the extruder barrel and twin screws taken along line 3-3 of Fig.2.
DETA LED DESCRIPTION OF THE INVENTION
Fig. 1 is a process flow diagram of an embodiment of the present invention wherein the extrudate is prepared by the First Embodiment. Ground grain from the ribbon blender, is metered into the main feed opening of the extruder. Also fed to the main feed opening of the extruder are metered amounts of oil and water, although the oil and water can be premixed with the ground grain prior to being fed to the main feed opening. The ingredients which are introduced through the main feed area of the extruder are referred to herein as the base feed. The base feed is cooked in the extruder.
Optionally, in the First Embodiment, cooked and gelatinized unground whole red wheat which has water added thereto and cooked and gelatinized in a steamer is added to the base feed which is coo~ed in the extruder. However, such addition is made through a secondary feed opening which ls near the extruder eY.it or die head.
There is some mixing of the gelatinized unground whole red wheat ~ith the previously coo~ed and ground base feed in the extruder.
~7~ 3 R.I.F.-22~5A.A 11-11-91 The mixing of the gelatinized unground whole red wheat is not vigorous and does not completely blend the unground whole red wheat in the mixture so that after extrusion, whole red wheat pieces are ~isually discernible in the dough. In some cases such as when pieces of dried nuts, e.g. roasted nuts, are added to the base feed through the secondary feed opening, the nuts are added without going through the steaming step. Alternatively, the base feed which is cooked in the extruder can pass through the extruder without addition of the unground whole red wheat or dried fruit pieces for subse~uent processing, e.g. frying.
In both the First and Second Embodiments, various dies such as sheeting dies can be mounted on the exit end of the extruder. After extrusion, the extrudate can go into a forming machine where it is sized and cut into appropriate sized and shaped pieces and then placed on a conveyer belt for transfer to the optional toaster or directly into the fryer. Alternatively, the dough co~position can be extruded through narrow die slits, cut at the extruder and go directly into the toaster or fryer. The toaster is an open flame gas oven where the cut pieces are placed for about 15 to 20 seconds at about 600 F to 650 F to remove surface moisture and help equilibrate the moisture content of the cut pieces. The cut pieces then, either from the cutting operation or the oven, are placed in a fryer maintained at conventional temperatures for conventional periods of time such as a temperature of 325 F to 410 F for about 1 to 3 minutes so that the moisture content of the R.I.F.-7245A.A 11-11-~1 final product will be about 1% to 3% by weight.
In both the First and Second ~mbodiments, the fried pieces are optionally conveyed through a coater where some vegetable oil can be sprayed on to the surfaces of the fried pieces at a level of about 3~ to 5% by weight of the finished product or the pieces can pass through a rotary tumbler,not shown, where salt or other flavorant is applied by dusting on to the pieces such as at a quantity of about 1% to 10% by weight of the finished product.
The product is then transported to the packaging machines on conveyors.
Fig.2 is a schematic side elevation view of a twin screw coo~ extruder apparatus which can be used in the First E- , ant. The apparatus 1 includes a twin screw extruder 2, a die mou ng block 3, a die head 5,and a main feed opening or funnel 7, for receiving the base feed ingredients although liquids such as added moisture (water) or plasticizer can also be received into the extruder through conduit 9. The extruder has a first, second, and third section. Each of these sections is further divided into two parts, not shown. The first section is principally a blending section, the second is a cooking section and the third a cooling section.
The apparatus 1 also has means 11. 11, and 11 for measuring temperature in each section of the extruder barrel, and element 13
Field of the Inventlon This invention relates to a food composition in the form of a snack food. In particular, this invention relates to a non-puffed, cereal grain dough extrudate which can be further processed such as for the manufacture of an oil-fried snack, particularly a multigrain snack.
Backqround Art Snack food products have long been prepared from wheat or corn by mi~ing the respective flour with water to form an extrudate which is then fried. Alternatively, potatoes have been thinly sliced and deep-fat fried to produce snack foods. Snack foods can thus include chip products, crackers, puffed dough articles and cookies.
Fried snacks have included, for example, the snack foods produced by the method of Willard in U.S. Patents 4,769,253 of ~ s~s~
E~.l.F.-2245A.~, 11-11-91 Sept. 6, 1988 and ~,770,B~1 of Sept. 13, 19~8. Th~se patents relate to e~:panded fried snacks prepared from vario~s extruded cereals.
U.S. Patent 4,517,204 of May 14, 1985 to Mottur et al.
relates to a puffed snack product. The puffed snack contains microcrystalline cellulose. In order to improve the te~ture and incr~ase the expansion of the batter upon extrusion due to the presence of the cellulose, about 0.5% to 4% by weight of edible oil is added to the batter. The products of the Mottur et al. patent are preferably baked. About 0.1% to 1% of nonionic emulsifiers can also be added to the oil in order to improve e~pansion of the product.
~ ommercial product which is a relatively low calorie version o~ se Doodles~ of Borden Inc., includes corn meal and bran in its composition and additionally contains about 1% of vegetable oil. This product is baked.
Frito-Lay, Inc. has manufactured a ~ultigrain snack, marketed ac Sunchips~, which is made from whole wheat, corn and other natural ingredients. The Sunchips~ product is corn-based having appro~ ,ately 50% by weight corn meal and about 25% by weight wheat on a before frying basis.
~ anderveer et al. U.S.Patent 4,777,045 of Oct. 11, 1988 .. ..
R.I.F.-2245A.A l1~ 91 relates to a brand containing snack of various cereal grains which are e~truded fro~ a twin screw cooker extruder. The extruded pieces are coated with from 1% to 10% of vegetable oil and a powdered flavorant is applied over the oil wherein the oil allegedly improves adhesion of the flavor particles, enhances flavor a_ceptability and improves mouth feel organoleptically.
Irvin et al. U.S.Patent 4,985,269 of Jan. 15, l991 relates to use of twin screw extruders for making corn dough masa which is further processed for the production of tortilla chips. This reference also discloses the use of about 0.1% to 0.6% of a nonionic emulsifier which can be added to the corn feed prior to extrusion.
Lewis et al. U.S. Patent 4,384,009 of May 17, 1983 relates to snacks of dehydrated meat products containing vegetable materials such as whole or nearly whole grains and additives such as fats, oils, seasonings, flavors, preservatives, and emulsifiers.
A. Howard U.S. Patent 4,526,800 of July 2, 1985 relates to an e~:panded snac~ food comprising cooked portions of dough containing gelatinized starch, including 10% to 70% by weight of bran and 5 to 35~ by weight of oil or fat.
.I.F.-2245A.A 11-11-91 AR~' OF THE INVENTION
This invention is directed to the formation of a fried snack food and its dough composition precursor. The food products of this invention are low in cholesterol and fat, possess a unique grain flavor, and exhibit improved texture and mouth feel.
It has been found that the addition of about 3~ to ~% of a plasticizer, e.g. vegetable oil, in the preparation of the dough compositions comprising a~out 20% to 35% total moisture, and about 45% to ,7% of grain such as ground grain with or without smaller quantitles of pieces of whole red wheat or dried fruit, minimizes the pic~ up of oil on frying as compared to such compositions without the added oil. Purthermore the fried snack can contain less plasticizer , e.g. vegetable oil, as compared to the fried product which does not contain the added plasticizer. This is the case when the quantity of added plasticizer is from about 3.5% or 4% to about 7% by weight of the dough composition. Also, about 3%
to ~O of plasticizer improves the mouth feel or texture of the fried snac~ product.
In one embodiment of the invention there is disclosed dough co~positions as described above suitable for making fried snacXs, as well as snack products produced from such compositions which contain one or a va iety of cereal grains.
~ ln ancther embodiment of the invention there is disclosed ~ 3 R.l.F.-2295A.A 11-11-gl cooked dough compositions and snack products which have visually discernible pieces of grain or fruit in the product.
In still another embodiment the dough composition is sheeted, shaped and cut into pieces which are dried to prepare pellets or half products which are then packaged for cooking by the consumer, e.g., by baking, frying or ~icrowaving. The drying can be accomplished by conventional means such as by merely permitting the pieces to air dry overnight, e.g. to about 10% to 14% of moisture.
Although there are a number of different embodiments in this invention, one of the embodiments, referred to as the First Embodiment, uses a cooker extruder to cook the ground grain and form the dough with or without the addition of pregelatinized unground whole red wheat or pieces of dried fruit. Another embodiment, referred to as the Second Embodiment, does not cook the dough in the extruder but instead part of the ground grain is gelatinized and enters the extruder together with unground gelatinized whole red wheat. In the Second Embodiment the extruder is maintained at a temperature of no higher than about 70 F in formation of the dough .
BR~EF_DEC,ÇR~lPTION 0 ~ E DRAWING
Fig. l is a process flow diagram of the present invention.
~ ~ $ ~3 ~
.I.F.-2245A.A 11-11-91 ~ig. 2 is a schematic side elevation of a twin screw eY~trUSion apparatus which ~an be used in this invention.
Fig.3 is a schematic view of the extruder barrel and twin screws taken along line 3-3 of Fig.2.
DETA LED DESCRIPTION OF THE INVENTION
Fig. 1 is a process flow diagram of an embodiment of the present invention wherein the extrudate is prepared by the First Embodiment. Ground grain from the ribbon blender, is metered into the main feed opening of the extruder. Also fed to the main feed opening of the extruder are metered amounts of oil and water, although the oil and water can be premixed with the ground grain prior to being fed to the main feed opening. The ingredients which are introduced through the main feed area of the extruder are referred to herein as the base feed. The base feed is cooked in the extruder.
Optionally, in the First Embodiment, cooked and gelatinized unground whole red wheat which has water added thereto and cooked and gelatinized in a steamer is added to the base feed which is coo~ed in the extruder. However, such addition is made through a secondary feed opening which ls near the extruder eY.it or die head.
There is some mixing of the gelatinized unground whole red wheat ~ith the previously coo~ed and ground base feed in the extruder.
~7~ 3 R.I.F.-22~5A.A 11-11-91 The mixing of the gelatinized unground whole red wheat is not vigorous and does not completely blend the unground whole red wheat in the mixture so that after extrusion, whole red wheat pieces are ~isually discernible in the dough. In some cases such as when pieces of dried nuts, e.g. roasted nuts, are added to the base feed through the secondary feed opening, the nuts are added without going through the steaming step. Alternatively, the base feed which is cooked in the extruder can pass through the extruder without addition of the unground whole red wheat or dried fruit pieces for subse~uent processing, e.g. frying.
In both the First and Second Embodiments, various dies such as sheeting dies can be mounted on the exit end of the extruder. After extrusion, the extrudate can go into a forming machine where it is sized and cut into appropriate sized and shaped pieces and then placed on a conveyer belt for transfer to the optional toaster or directly into the fryer. Alternatively, the dough co~position can be extruded through narrow die slits, cut at the extruder and go directly into the toaster or fryer. The toaster is an open flame gas oven where the cut pieces are placed for about 15 to 20 seconds at about 600 F to 650 F to remove surface moisture and help equilibrate the moisture content of the cut pieces. The cut pieces then, either from the cutting operation or the oven, are placed in a fryer maintained at conventional temperatures for conventional periods of time such as a temperature of 325 F to 410 F for about 1 to 3 minutes so that the moisture content of the R.I.F.-7245A.A 11-11-~1 final product will be about 1% to 3% by weight.
In both the First and Second ~mbodiments, the fried pieces are optionally conveyed through a coater where some vegetable oil can be sprayed on to the surfaces of the fried pieces at a level of about 3~ to 5% by weight of the finished product or the pieces can pass through a rotary tumbler,not shown, where salt or other flavorant is applied by dusting on to the pieces such as at a quantity of about 1% to 10% by weight of the finished product.
The product is then transported to the packaging machines on conveyors.
Fig.2 is a schematic side elevation view of a twin screw coo~ extruder apparatus which can be used in the First E- , ant. The apparatus 1 includes a twin screw extruder 2, a die mou ng block 3, a die head 5,and a main feed opening or funnel 7, for receiving the base feed ingredients although liquids such as added moisture (water) or plasticizer can also be received into the extruder through conduit 9. The extruder has a first, second, and third section. Each of these sections is further divided into two parts, not shown. The first section is principally a blending section, the second is a cooking section and the third a cooling section.
The apparatus 1 also has means 11. 11, and 11 for measuring temperature in each section of the extruder barrel, and element 13
2 ~ ~, R.I.F.-224~A.A 11-11-91 for heating the extruder barrel of the second section, and cooling water inlet ports 15 ls~and 15, to each section if needed, although water is used for cooling in the third section. A motor driven shaft 17 which through gearing means not shown drives the e~truder screws l9 19 in the same direction (co-rotating) within e~truder barrel 21 as more fully shown in Fig.3. A secondary feed funnel 24 can receive pieces of food directly into the cooling zone, namely the third section of the extruder 1-Fig. 3 is a view taken along line 3-3 of Fig 2 and shows a cross-section of extruder barrel 21 and co-rotating screws 19 19.
The cooker extruders used in this invention can be single screw coo~er e~truders but are preferably twin screw e~truders. The single screw extruders give a more erratic rate of feed due to the low friction between the screw and base feed occasioned by the relatively high oil content of the feed. Lack of steady feed rate causes sputtering on extrusion as well as changes in the composition of the extrudate, particularly when gelatini~ed unground whole red wheat or pieces of dried fruit are added to the base feed through funnel 24 of Fig. 2. The twin screw e~truders can have screws which are co-rotating or counter-rotating. The rotation of the screws convey the product from the inlet to the outlet while applying a mixing action as well as various amounts of shearing force to the mi~:ture or dough. Heat is generated by higher shearing forces, principally in the second (coo~ing) section ~ ~ $ ~ 3 R.l.F.-22~A.A ll-ll-gl of the extruder. The extruder outlet is equipped with a die or shaped orifice for forming or shaping of the dough, e.g. in the form of a sheet, as it is extruded.
The cooker extruders used in this invention have three main functional sections although each section can be further subdivided, generally into two subsections. The three main sections are: first, the mixing and blending section; second, the cooking section; and third, the cooling section. The first section contains a conveying screw or screws which mix the base feed and form a dough while moving the dough to the second section. The first section exerts low shear and low compression forces of the ingredients. The dough is then conveyed by the screws to the cooking section where some external heat is generally added, such as by thermostatically controlled induction heaters, e.g. 13 in Fig 2, although some of the heat is generated from the shear of the screws within the extruder barrel working against the dough. The cooker section has the Peak Te~perature, i.e. the hiahest temperature attained in the extruder. Most of the cooking and qelatinization of the dough takes place in this second section of the extruder.
The dough is conveyed by the screws from the second sectior tc the third section where the dough is cooled prior to discharge from the e~:truder. Also, secondary feed 24 as shown in Fig 2 can provide pieces of food directly into the moving dough of the base feed in .
R.I.F.-22~5A.A ]1-ll-gl the third section. The third section is one of low shear.
Preferably, the screw configuration at the area of the secondary feed does not produce much pressure on the dough such as by the use of a reverse screw configuration. This facilitates any addition of feed thro~gh the secondary feed 2~. The discharge from the extruder is generally through a die, such as a sheeting die. Cooling of the barrel in this third section is generally accomplished by tap water circulation about the extruder barrel.
The dough composition of this invention is not puffed as it exits the extruder. Puffed products are ~ade in extruders under puff extrusion cooking conditions which are well known in the art, and generally include temperatures at or above the boiling point of water and pressures of from about 2,000 to 4,000 pounds per square inch at the outlet of the extruder. In contrast to ~Ipuff conditions'l, applicants' dough composition, at the outlet of the extruder. is extruded, in the First Embodiment, at a te~perature belo~ about 165 F and preferably below about 155 E and at a pressure below about 550 pounds per square inch so that there is no puffing of the extrudate.
Although the preferred process for making the dough composition is by use of extruders such as cooking extruders in the First Embodiment or cooled press extruders in the Second Embodi~ent, other equipment for cooking all or a portion of the base feed, or mixing and preparing the dough composition can be used, e.g., the use of a Hamilton type kettle or a Stephan cooker-.
R.I.F.-2245A.A 11-11-g mixer.
~ nless otherwise indicated, the percentages of the various ingredients set forth herein are by weight and based on the total weiqht of either the feed, dough composition, or the fried snack, as appropriate. Furthermore, all ingredients except water (moisture) are on a moisture free (dry) basis. By the terms "dough composition" or "cooked dough composition" we mean the appropriate composition before cutting or sizing, e.g. the extrudate which is used to make the snack product.
Tlle coo~ed dough composition of the First Embodi~ent will co~prise a ~ixture of: from about 20~ to 35% of total moisture, from about 3% to 8% of a plasticizer, and from about 45% to 77% of grain wherein at least 45% is cooked ground grain, up to 32% is pieces of food which are visually discernible in the composition due to color differences of the food pieces from the base feed;
about 0~ to 10% of sugar ; and about 0% to 2% of flavorants such as malted barley. The pieces of food are in the form of whole or pieces of grain, e.g., whole red wheat or another food e.g.
such as fla~ed, chopped, or shredded nuts, which can withstand the further processing of the dou~h composition after it exits from tlle extruder, e.g. frying, baking, etc. The pieces of food, although visually discernable, will generally have their shape altered by going through the e~truder die and ~ixing in the extruàer cooling zone. Thus, in the case of coo~ed whole red wheat, 2 ~ ~
R.l.F.-22~5A.A 11~11-91 the pieces will often resemble flakes. Apart from the whole red wheat, the food pieces can be made up of dried fruit, partlcularly nuts.
In all instances, the plasticizer is a vegetable oil which is in addition to any oil inherent in the grain and mi~tures of vegetable oil with a nonionic emulsifier wherein the quantity of emulsifier is not more than about 2~ and preferably not more than 0.5%, based on the weight of the dough composition. The plasticizer is intimately admi~ed with the ground grain as part of the base feed. The plasticizer needs to be present when the mixture is worked, i.e,, in formation of the dough, in order to obtain the beneficial effects of this invention since such effects are not obtained simply by coating the extrudate with the same quantity of plasticizer.
The quantity of plasticizer used in the dough compositions of this in~ention can vary from about 3% to 8%, based on the weight of the dough composition. A preferred amount of plasticizer in the dough composition is from 3.5% or 4% to 7% and particularly from about 5'0 to 7% by weight of the dough composition. At about the
The cooker extruders used in this invention can be single screw coo~er e~truders but are preferably twin screw e~truders. The single screw extruders give a more erratic rate of feed due to the low friction between the screw and base feed occasioned by the relatively high oil content of the feed. Lack of steady feed rate causes sputtering on extrusion as well as changes in the composition of the extrudate, particularly when gelatini~ed unground whole red wheat or pieces of dried fruit are added to the base feed through funnel 24 of Fig. 2. The twin screw e~truders can have screws which are co-rotating or counter-rotating. The rotation of the screws convey the product from the inlet to the outlet while applying a mixing action as well as various amounts of shearing force to the mi~:ture or dough. Heat is generated by higher shearing forces, principally in the second (coo~ing) section ~ ~ $ ~ 3 R.l.F.-22~A.A ll-ll-gl of the extruder. The extruder outlet is equipped with a die or shaped orifice for forming or shaping of the dough, e.g. in the form of a sheet, as it is extruded.
The cooker extruders used in this invention have three main functional sections although each section can be further subdivided, generally into two subsections. The three main sections are: first, the mixing and blending section; second, the cooking section; and third, the cooling section. The first section contains a conveying screw or screws which mix the base feed and form a dough while moving the dough to the second section. The first section exerts low shear and low compression forces of the ingredients. The dough is then conveyed by the screws to the cooking section where some external heat is generally added, such as by thermostatically controlled induction heaters, e.g. 13 in Fig 2, although some of the heat is generated from the shear of the screws within the extruder barrel working against the dough. The cooker section has the Peak Te~perature, i.e. the hiahest temperature attained in the extruder. Most of the cooking and qelatinization of the dough takes place in this second section of the extruder.
The dough is conveyed by the screws from the second sectior tc the third section where the dough is cooled prior to discharge from the e~:truder. Also, secondary feed 24 as shown in Fig 2 can provide pieces of food directly into the moving dough of the base feed in .
R.I.F.-22~5A.A ]1-ll-gl the third section. The third section is one of low shear.
Preferably, the screw configuration at the area of the secondary feed does not produce much pressure on the dough such as by the use of a reverse screw configuration. This facilitates any addition of feed thro~gh the secondary feed 2~. The discharge from the extruder is generally through a die, such as a sheeting die. Cooling of the barrel in this third section is generally accomplished by tap water circulation about the extruder barrel.
The dough composition of this invention is not puffed as it exits the extruder. Puffed products are ~ade in extruders under puff extrusion cooking conditions which are well known in the art, and generally include temperatures at or above the boiling point of water and pressures of from about 2,000 to 4,000 pounds per square inch at the outlet of the extruder. In contrast to ~Ipuff conditions'l, applicants' dough composition, at the outlet of the extruder. is extruded, in the First Embodiment, at a te~perature belo~ about 165 F and preferably below about 155 E and at a pressure below about 550 pounds per square inch so that there is no puffing of the extrudate.
Although the preferred process for making the dough composition is by use of extruders such as cooking extruders in the First Embodiment or cooled press extruders in the Second Embodi~ent, other equipment for cooking all or a portion of the base feed, or mixing and preparing the dough composition can be used, e.g., the use of a Hamilton type kettle or a Stephan cooker-.
R.I.F.-2245A.A 11-11-g mixer.
~ nless otherwise indicated, the percentages of the various ingredients set forth herein are by weight and based on the total weiqht of either the feed, dough composition, or the fried snack, as appropriate. Furthermore, all ingredients except water (moisture) are on a moisture free (dry) basis. By the terms "dough composition" or "cooked dough composition" we mean the appropriate composition before cutting or sizing, e.g. the extrudate which is used to make the snack product.
Tlle coo~ed dough composition of the First Embodi~ent will co~prise a ~ixture of: from about 20~ to 35% of total moisture, from about 3% to 8% of a plasticizer, and from about 45% to 77% of grain wherein at least 45% is cooked ground grain, up to 32% is pieces of food which are visually discernible in the composition due to color differences of the food pieces from the base feed;
about 0~ to 10% of sugar ; and about 0% to 2% of flavorants such as malted barley. The pieces of food are in the form of whole or pieces of grain, e.g., whole red wheat or another food e.g.
such as fla~ed, chopped, or shredded nuts, which can withstand the further processing of the dou~h composition after it exits from tlle extruder, e.g. frying, baking, etc. The pieces of food, although visually discernable, will generally have their shape altered by going through the e~truder die and ~ixing in the extruàer cooling zone. Thus, in the case of coo~ed whole red wheat, 2 ~ ~
R.l.F.-22~5A.A 11~11-91 the pieces will often resemble flakes. Apart from the whole red wheat, the food pieces can be made up of dried fruit, partlcularly nuts.
In all instances, the plasticizer is a vegetable oil which is in addition to any oil inherent in the grain and mi~tures of vegetable oil with a nonionic emulsifier wherein the quantity of emulsifier is not more than about 2~ and preferably not more than 0.5%, based on the weight of the dough composition. The plasticizer is intimately admi~ed with the ground grain as part of the base feed. The plasticizer needs to be present when the mixture is worked, i.e,, in formation of the dough, in order to obtain the beneficial effects of this invention since such effects are not obtained simply by coating the extrudate with the same quantity of plasticizer.
The quantity of plasticizer used in the dough compositions of this in~ention can vary from about 3% to 8%, based on the weight of the dough composition. A preferred amount of plasticizer in the dough composition is from 3.5% or 4% to 7% and particularly from about 5'0 to 7% by weight of the dough composition. At about the
3.5% or 4% to 7% level of plasticizer addition, it has been found that the fried product contains less oil than when the dough composition is fried without the addition of plasticizer.
Furthermore, at less than about 4% of plasticizer in the dough compocition of the First Fmbodiment, particularly at less than ~ 3 R.I.F.-2245ti.A 11-11-91 about 3-O of plasticizer, the fried snack product is too light in te~:ture. In the Second Embodiment, the fried product is unduly hard at a plasticizer content of ~ess than about 3%. Additionally, when the dough composition contains at least 10% of unhulled grain or bran equivalent to the amount found in about 10% of unhulled grain, the fried product has a gummy mouthfeel when the quantity of plasticizer is less than about 3~. At about 8% and particularly above lO~ of plasticizer in the dough composition containing the above quantity of bran, the fried snack becomes mealy and falls apart in one's mouth.
Vegetable oils which are preferred for incorporation into the dough of the present invention as plasticizers include corn oil, sunrl-wer oil, canola oil, coconut oil, their hydrogenated or p~ , ly hydrogenated derivatives and mixtures thereof. Corn oil an~ ola oil or mi~ture thereof are particularly preferred.
The nonionic emulsifiers which can be used with the vegetable oil are those having an HLB of about 3.2 to 5.0, The emulsifier is preferably an ester of a polyol and a long chaln fatty acid such as that having from about 12 to 20 carbon atoms. Illustrative of suitable polyols there can be mentioned those of glycerin, ethylene o~ide, sorbitol, and glycols. The polyol will preferably have from 2 to 6 hydro~yl groups. Preferred emu]sifiers are those of mono-and di-glycerides such as that of glycerol monostearate, glycerol dlstearate, glycerol dioleate, glycerol monopalmitate, and the R.l.F.-22"5A.A 11 ll-gl li~e.
The total ~ois~ure, as recited in this invention, is the sum of moisture (water) in the dough composition such as that which may be added with the base ingredients, pieces of food or otherwise to the composition as well as the inherent moisture of the grain and other ingredients in the dough composition. The total amount of moisture can generally be calculated from a knowledge of the inherent moisture content of the various ingredients plus any added water. Also the total moisture can be determined by the analytical method found in the Fifteenth Edition of the AOAC, Method A in part 926.07 which is by the vacuum oven moisture technique. The quantity of all ingredients, apart from the water, e.g.grain,pieces of food and plasticizer are on a dry or moisture free basis, e.g. in the case of grain it is the weight of the grain less it's inherent moisture content.
In the First Embodiment, water is added to the ground grain prior to cooking. Thus, about 5% to 15% of water based on the weight of the finished dough composition is normally added to the ground grain and plasticizer prior to cooking when gelatinized whole red wheat is added through the secondary feed. When aàditions are not made to the dough through the secondary feed, the entire amount of added water is mixed with the ingredients prior to addition or at the time of addition to the extruder. Such quantity of water can vary from about 5% to 20 % by weight of the dough R.I.F.-2245A.A 11~ 91 composition.
In the First Embodiment, the dough compositions contain from about 20% to 35% of total moisture, preferably about 25% to 32 total moisture based on the weight of the dough composition. It is preferred that the ~oisture content not exceed about 30% since it has been found that increased water content causes increased oil pick~up in the frying step.
In the case when all of the ingredients are cooked in the extruder, all of the grain, e.g. 52% to 71% of the composition, is ground and such e~bodiment does not provide for discernible pieces of differently colored food in the composition. In such case, the added moisture which is provided with the base feed is that which will provide a total moisture content in the dough composition of from 20% to 35%, such as by the addition of from about 10% to 25%
moisture based on the base feed.
When a portion of the ground grain is substituted with gelatinized unground whole red wheat or pieces of fruit in the First Embodiment, the quantity of such pieces can vary from about 10% to 32% by weight of the dough composition, and preferably from about 15'~ tc 30~ on a dry, moisture free basis, based on the weight of the clough composition.
The term "gelatinized" as used herein applies to completely 3'~
R.1.~ 22q5A.A 11-11-91 gelatinized food as well as food which is substantially gelatinized such as that re~uired to eliminate white streaks on extrusion of the unground whole red wheat in preparation of the dough in this invention, e.g., extrusion through a die having a slit opening of about two inches long and about 0.022 inches wide, and wherein there is partial "gelatinization" or cooking of all the starch in the unground whole red wheat.
It is preferred that the dough compositions of this invention contain ground grains wherein at least 5%, such as from about 10% to 30% based on the weight of the dough is unhulled. Such unhulled grains include t~e whole red ~heat when it is used. By "unhulled" we mean grain which contains its bran. Also, by the term "whole" as it relates to grain we again mean unhulled grain wherein its hull has not beeh removed. The dough is preferably a multigrain composition such as one containing about 20% to 60% of wheat; 10 to 60 % corn ; 5% to 30% rice; and 5% to 15% oats. However, minor quantities, e.g., not more than about 15% of other grains such as sorghum, soya, rye, and barley can also ~e used. Generally the extrudate of this invention ~ill contain up to 10% of sugar such as white cane sugar, white beet sugar brown sugar , and the like~ It is preferred that the level of reducing sugars be kept low because these tend to fo.m caramelized and burnt flavors and also dar~en the color of the food composition produced. Also, the amylopectin to amylose ratio of the food ingredients is preferably kept to a ratio of 4Q~ to about 60%
and particularly about 50~.
R.~.F.-22~5A.A 11~ gl The grains used in this invention can be in various forms.
Thus, the ground rice can be that of various rice flours such as that of brown or white rice. Rice is also lighter in color than wheat such as hulled wheat or corn flours and can therefore be added to achieve a desired color lightness in the fried snack product. This facilitates the color contrast with pieces of whole red wheat and dried fruit in the dough and in the fried product.
The ground wheat in the present invention can be various fractions of the wheat kernel. Soft wheat, in both the spring or winter wheat varieties, are particularly useful in the present invention.
Any of the different varieties of corn can be used in this invention such as yellow corn, e.g., yellow dent corn, white corn, or mixtures thereof.
The ground grain (flour) used in this invention is generally ground so that 100% thereof passes through a U.S. Series No.lO
sieve. Preferably, hard horny grains are milled to a size wherein 100% passes through a No.16 sieve and less than 20 remains on a No. 20 sieve. Examples of hard horny grains include certain dent corns, brown rice, and popcorn. Preferably, soft grains are milled to a size wherein 100% pass through a No. lO sieve and less than 20% remain on a No. 20 sieve. Examples of soft grains include red wheat, oats, various varieties of corn, and white wheat.
R.I.F.-~45A.A 11-11-91 Although the grains used in this invention contain some oil, the quantity of such inherent oil is not sufficient to significantly affect the properties of the fried snacks. Thus, oats contain substantial quantities of fat (oil), namely, about 10% in whole dried oats, but the quantity of oats is li~ited in this invention to not more than about 15~ of the dough. Furthermore, there is little or no oil in corn meal, about 4% in whole dried corn, about 2~ oil in whole dried wheat, and less than 1%, generally, less than 0.5% in whole dried brown rice.
The unground whole red wheat used in this invention is cooked in an excess of water under conditions sufficient to cause the wheat to imbibe or absorb up to about 35% to 55% by weight of water based on the dry weight of the whole red wheat. The cooking of the whole red wheat can be, for example, by exposure to steam or by soa~ing in boiling water. During cooking it is preferred that partial gelatinization of all the starch in the wheat takes place.
In the First Embodiment the hydrated, whole cooked red wheat lS
preferably chilled to below 60 F and more preferably to about qO F
before being placed in the extruder. It has been found that if the cooked and hydrated wheat is cold (e.g., 40 F) when added to the other cooked grains, a significant reduction in expansion of the ~xtrudate at the die is achieved.
Still another reason for partially gelatinizing all of the starch in the unground whole red wheat before blending with the ~J' ~ ',t ~ ~t R.I.F.-2245A.A 11~11-91 other grains in either the First or the Second Embodiment, is that when there is no partial gelatinization of al], of the starch in the whole red wheat, the subsequent break up of the grains on e~trusion leaves undesirable white streaks on the extrudate as ~ell as on the fried product from the raw starch in the wheat.
The pieces of whole red wheat or dried fruit such as nuts are substantially larger than the ground grain or flour so that the difference in coloration of the large pieces is easily discernible.
The pieces of food become macerated in the extruder and particularly on extrusion through the narrow slit dies so that the pieces may resemble flakes, The size of such pieces varies greatly but, as mentioned before, are much larger than the ground (flour) grain even though such pieces may be broken even before being pl '~n the extruder. Generally, such pieces of food have at let a dimension which is at least about one-thirty-second (1/32) of an inch (about 0.03) inches.
The dough composition of this invention can also contain fillers such as potatoes or other starchy foods.
In a preferred formulation of the First Embodiment, the quantity of the various ingredients is: from about 4~ to 7% of added plasticizer; from about 25% to 32% of total ~oisture; about 19~ to 26% of fine corn meal; about 15% to 21% of gelatinized unground whole red wheat; about 8% to 12% of whole brown rice flour; about 4% to 6% of ground white wheat flour; about 4~ to 6%
~ .I.F.-22~5~.A 11~ 91 of ground white oat flour; about ~% to 6% Or powdered brown sugar;
and from about 0.5% to 1% of malted barley. In all embodi~ents, the malted barley should have any remaining enzyme activity neutralized or substantially neutralized since the enzyme adversely affects the texture and organoleptic properties of the product.
In another embodiment, the cut pieces of the dough composition ,e.g. the extrudate, are allowed to air dry overnight and are then fried. The drying can take place by other means in order to limit the moisture content ,e.g. to about 10% to 14% of the dough composition. Such cut pieces which have been dried are known as pellets or half products. Alternatively, the half products can be packaged for frying, baking, or microwave cooking by the consumer.
The low moisture content prevents the half product from spoiling.
The half products, fried as described above, can then be topically seasoned by methods and ingredients well known in the art.
The product produced from the frying step of this invention is a slightly expanded, cooked, oil-fried, snack food. The product exhibits no cholesterol and has a fat content dictated only by the frying conditions utilized. The oil or fat pick-up is minimized by the incorporation of the plasticizer into the formulation of the dough. After frying, the product is drained of excess frying oil and optionally topically flavored such as with salt. The resulting snack food product exhibits a unique texture and mouthfeel, particularly when a blend of grains is used. The pieces of whole 2 ~ ?~
R.I.E.-2245A.A 11~ 91 red wheat, when used, provide darker spots on the fried product.
Illustratively, the fried product, as well as the dough, will generally be tan or light brown in color with the whole red wheat pieces providing darker spots dispersed throughout the product.
The fried snack products of this invention will generally contain less than about 32% of total plasticizer (oil plus any emulsifier), by weight of the snack product, and preferably less than 28~ such as from 22% or from 25% to 27% of plasticizer. This is a relatively small quantity of oil for a fried snack which generally contain above 30% or 35% of plastici~er and at times at least 50% of plasticizer. Of course much of this plasticizer content is oil which is picked up in the frying step.
In order that tho5e skilled in the art may more fully understand the invention presented herein, the following examples, tables and procedures are set forth. In the examples, as well as elsewhere in this application, all percentages are by weight and unless otherwise indicated, the percentages of grains or pieces of food are on a dry ( moisture free ) basis in relation to the dough composition, e.g.extrudate, or fried snack, as appropriate.
P~R~OCEDl~RE U ~D IN THE EXAMPLES
Several examples of a multigrain snack food product were prepared according to the present invention. Table I provides the composition for 17 examples prepared by use of a twin screw cooker R.l.F.-2245A.A 11-11-gl e~truder, e~cept for added water and added plasticizer in the base feed. The a~ount of water added to the base feed was about 10~, based on the weight of the final dough composition. The quantity of added plasticizer in the dough co~position, which was part of the base feed, based on the weight of the extrudate, for some of the e~amples is shown in Table 2.
In the case where the pieces of whole red wheat were used, e~g. E~amples 2-6 and 11-15 the process was as follows: The e~trudates were prepared by pre-blending the ground grains in a mixer until the moisture was of uniform consistency and homo~eneity. To this mixture was added with further blending sugar (white cane), oil, and/or glycerol monostearate (GMS) as indicated in Table I. Water, 5% to 25% by weight based on the weight of the base feed was then added to the mixture with blending until uniEorm. Each mixture was then fed into a Clextral BC 45 twin screw e~truder at a rate of from 180 to 1000 grams per minute.
Ungrouild whole red wheat was cooked by adding the wheat and enough water to achieve 50% solids in a swept surface kettle. The wheat was cooked on medium heat for about 30 minutes covered, then the heat t~as turned up to high for about 15 minutes. The cover was then re~o~-ed fro~ the kettle and cooking was continued (about 15 minutes) until a ~oisture content in the wheat of about 40% weight was attained.
~ .I.Y. 22~A.A ll-11-sl The whole cooked red wheat was fed into the extruder containing the mixture of ground grains. The addition to the e~truder was made at the secondary feed 24 near the discharge end of the extruder at a rate of about 26% of the pre-blended grain feed rate. The mixture was then extruded at a thickness of about 0.08 inches and sheeted using either a standard pasta-type or a snack chip-t~pe die. The peak barrel temperature during extrusion was 200-350 F and the screw speed was varied from 25 to 300 revolutions per minute. Examples which use dried fruit were run in much the same way except that the fruit was added in a relatively dry state, after being roasted.
The extrudate from the above processing was then put through sizing rolls to reduce its thickness to a thickness of between about 0.02 and 0.050 inches. The sheet was then cut into desired shapes, often called pellets. In one embodiment, the pellets were immediately fried in a vegetable oil at, for example 3500F for about ~0 seconds.
Specific parameters used for the manufacture of the dough composition prepared in Example 11 of Table 1 by the use of a Clextral BC 45 Twin screw extruder with a low shear screw were as follows: screw speed of 100 rpm; motor amps of 17; feed rate for the base feed of 230 grams/minute ; cooled whole red wheat feed rate of lO0 grams/min.; thrust bearing pressure of 50~ psi; die head pressure of 420 psi; die head temperature of 13~F ; and ~ 3 R.I.F.-2245A.A 11 ll-gl extrudate te~perature of 150 F. Each of the three sections of the extruder are subdivided into two zones with zones 1-2 being part of section l; zones 3-~ being part of section 2 and zones 5-6 being part of section 3 ( the cooling zone). The barrel temperatures in the various zones were as follows; zone 1 of 150 F; zone 2 of 300 F; zone 3 of 300 F; zone 4 of 300 F; zone 5 of 61 F and zone 6 of 119 F. The extrudate of Example 11 was sheeted to 0.025 inches thic~ness, cut to round shape and subsequently fried at 350 F for 60 seconds.
3 ",3J ~ ~3 ~ .,~ ~ ~5"...~
L~ ~ ~ ~~ L~- ~ ' ~ I
t ~ L
il ~ ~L~
~ : t h 16 ~ 517ZZ -~
R . I . P .--22~15A .A 11 -ll-gl TABLE: 1 ( CONTINUED ) H 0% SQ On Dry Basis Example 14 15 16 17 Unground, Whole Red Wheat (Cooked) 40 27.3 25.7 26.0 25.9 ~hole White Wheat Flour 12.8 7.7 7.3 9.2 7.2 Whole Oat Flour 11.5 7.4 7.0 6.9 6.9 Corn Meal 11.8 34.0 32.1 34.9 31.9 Whole Xernel Corn Flour 12.0 --- --- --- ---Whole Brown Rice Flour 11.7 15.4 14.5 9.2 14.5 Malted Barley Flakes 9.0 1.0 0.9 1.0 1.0 BrOWJ1 Sugar --- 7.2 6.8 6.9 6.8 Popped Popcorn 5.5 --- --- --- ---GMS --- --_ ___ ___ ___ Corn Or Canola Oil --- --- 5.7 6.2 6.1 The added plasticizer in the extrudates for some of the e~amples from Table 1 were compared with the total amount of plasticizer in the fried snack after frying. The results are shown in Table 2. It can be seen fro~ Table 2 that the use of about 3%
to about 85o of added plasticizer inhibited the amount of oil picked up from the frying step. The plasticizer in all cases is measured on a moisture free basis for the extrudate. The abbreviation of G~.S
R.l.F.-2245A.A 11~ 91 in the table as well as the previous Tabl.e 1 refers to glycerol monostearate which was used at the 1.9% level in the e~trudate whereas the remaining examples were with corn oil or canola oil as the plasticizer. The frying mediu~ was either corn oil or canola oil and the procedures for preparing the extrudate and frying of the product is that which has been set forth hereinbefore.
It can be seen from Table 2 that at levels of about 4% to about 7%, the added plasticizer in the base feed provides a fried product with less total plasticizer than frying of the product without the added plasticizer. However, even below about 3% and ~bove about 7% of added plasticizer the total quantity of plasticizer ( generally vegetable oil) in the fried product is less than that which is calculated by adding the added plasticizer to the amount picked up on frying without the added plasticizer. It has also been discovered that at levels above about ~% or 10% of added oil the final product becornes unacceptably ~ushy and falls apart in the consumer's mouth. Thus, while conventional oil frying of snack foods typi.cally results in an oil( plasticizer~ content in the snac~ food of 30% to 35% by weight and often 50% by weight or higher, the present invention can produce a fried snack food with less than about 30% by weight total oil, and preferably less than ~S~ by weight.
~$~
1~ . I . F . -Z245A .A 11-11-91 COMPARISON OF AMOUNT OF PLASTICIZER ADDED TO DOUGH WITH AMOUNT OF
Example Plasticizer Added Total Oil 14 ~% 3~.3 1 1.9% 31%
13 2% 31%
3.4% 30.3%
9 4.8% 27.7%
5.7% 26.~%
16 6.2% 25%
17 6.1% 25%
11 6.5% 29.4%
12 8% 33.3%
In the Second Embodiment a portion of the flour, such as 40% to 60% of the flour on a dry basis, is pregelatinized and then mixed wlth the remaining flour and unground whole red wheat which is also pregelatinized. This mixture is fed.through an extruder which does not further cook the ingredients. After the dough is extruded, the process is substantially the same for both the First Embodiment and the Second Embodiment.
~ J~ 3 I~.I.F.-2245A.A 11-11-91 The Second Embodiment is particularly preferred. In the Second Embodiment the feed to the extruder comprises from about 25~
to 35% of total moisture and preferably from 28% to 32% of total moisture; about 50% to 70% of grain on a moisture free basis, wherein about 30% to 40% is ground grain (flour) and preferably 32%
to 38% is flour and 20% to 30%, preferably 22% to 28% is unground gelatinized whole red wheat. From about 40% to 60% of the flour in the Second Embodiment is gelatinized before entering the extruder.
Preferably about 45% to 55% of the flour is gelatinized before entering the extruder. In the Second embodiment, the plasticizer and the quantities thereof are the same as in the First Emb~diment.
Optionally, the composition can contain additional vegetable or dried fruit ingredients as in the First Embodiment.
In the process for making the dougn of the Second Embodiment, the flours, including the pregelatinized flours are blended and mixed in the appropriate proportions with the unground and gelatinized whole red wheat as well as the plasticizer and any other feed ingredients. This mixture then enters into an extruder which is maintained at a temperature not above 70 F, such as that of about 50 to 70 F
A suitable extruder for the Second Embodiment is a tubular press with a compression screw such as a conventional pasta press, e.g., a Mapampianti pasta press. In this process the press is not 2 ~ s ~ .I.F.-22~A.A 11~11-91 heated but heat builds up during the friction and extrusion of the feed mi~ture. The heat is removed and the temperature is maintained at about 50 ~ to 70 F. This is achieved by circulation of tap or cold water through the hollow screw and the jacketed barrel of the press. This is in contrast to the temperatures normally employed in such presses such as in the ~anufacture of pasta wherein the temperature is generally above 100 ~ or 110 F.
The reason for maintaining the lower te~perature is that better friction is developed between the feed material the extruder screw and inside surface of the barrel.
The problems in the use of the single screw cooker extruders are overcome in the Second Embodiment by: having a higher total moisture content in the initial feed; pregelatinizing a portion of the flour feed; and keeping a low temperature in the extruder.
Preferably, in the Second E~bodiment, the mixture is extruded through a die having a narrow opening such as a die having an opening of about 0.022 inches wide and about two inches long. Such die can have a straight or wavy slit opening so as to produce the corresponding dough configuration. The extrudate emerging from such die is then face cut at the die, preferably directly into a ~ryer. l`he cut pieces of dough with the above mention die, will thus have a thickness of about 0.022 inches, a length of about 2 inches and can be face cut to have various widths such as a width of about one and a half inches.
9 ~ 1 ?3 R.I.F.-2245~ gl In the following preferred formulation of the Second Embodiment, about 90% of the rice was gelatinized and 50% to 60% of the total guantity of corn was gelatinized prior to entry in the extruder. A suitable pregelatinized rice for the following ~ ~>~e ~r 5,~
formulation is Pre Gel Waxy Flour RF-G80~0 of the ~4~ Company whereas a suitable pregelatinized corn flour is Pre Gel Corn Flour , from the ConAgra Company.
R.l.F.-2245A.A 11-11-91 A preferred formula~ion for making the dough of the Second Embodiment is as follows:
% AS IS ~ OF MOISTURE
AND DRY BASIS
Moisture 30.56 Corn Flour (89% ts^) 16.89 15.04 Pre gel corn Flour (91.5% ts)10.09 9.23 Pre Gel Waxy Rice Flour (91.2% ts) 6.60 6.02 Whole Oat Flour (89.8% ts) 5.12 4.60 Powdered Brown Sugar 5.56 5.56 Malted Barley fla~es (91.0% ts) 0.58 0.53 ~nground, Boiled, Soft Red Whole Wheat (48% ts)51.3424.64 Canola Oil 3.80 3.80 Lecithin 0.02 0.02 TnTALS 100.00 100.00 're~ers -to total solids.
The f`ollowing procedure can be used for producing the dough of the above formulation by use of a single screw pasta extruder with a 2,000 pound per hour feed rate. Pre-blended flour, including the pregelatinized flour, is placed into a metering feeder. The feed rate is adjusted to 905.2 pounds per hour and the feeder is 224~A.A ll--11-91 started. An oil spray, at the beginning of the ~i~ing chamber preceding the extrusion barrel, is adjusted to 75.8 pounds per hour. I~owever, the oil may be added instead to the pieces of gelatinized whole red wheat. The unground gelatinized whole red wheat feed is adjusted to 1019 pounds per hour. These ingredien~s are mi~:ed and the mixture is extruded while the barrel and screw temperatures are maintained at about 60F. A die having a wavy opening is at the exit end of the extruder. The extrudate is cut at the die. Frying of the cut dough is at 350 F for about one minute.
The fried chips are then removed from the fryer and placed in a seasoning tumbler and then sent to a packaging machine.
A typical analysis of the fried product of the above formula and process of the Second Embodiment has a total oil content of about 26%, a moisture content of 1.5%, and the seasoning is fine flour salt at 1%. All of the percentages herein being on a weight basis and apart from the moisture or water being on a dr~ or solids basis.
A preferred feed formulation of the Second Embodiment comprises: about 25% to 35% of total moisture; about 5% to l5G~ of pregeled corn flour; about 15% to 25% of corn flour which has not been gelatinized; about 4% to 8% of pregeled rice flour; about 2%
to 6% of whole oat flour which has not been gelatinized; about 65 to 10o of brown sugar; about 4% to 7% of vegetable oil as ~ ~f ~
R~l~F~-Z245A.A ~ -sl plasticizer; and about 20% to 30~ of the unground, gelatinized whole red wheat.
Broadly, a dough composition of this invention which includes both the First Embodiment and the Second Embodiment comprises:
A. about 3% to 8% of a plasticizer, preferably 3.5~ or 4% to 7%;
B. about 20% to 35~ of total moisture, preferably 25% to 32% of total moisture;
C. A total quantity of edible plant material food, e.g., vege~able and fruit, of from about 50% to 77% and preferably 60% to 77%, on a dry basis, wherein the quantity of grain, both flour and gelatinized whole red wheat pieces as well as any pieces of dried fruit is from about 50% to 77%, wherein at least 45% of the dough is flour and at least 40% of the flour is gelatinized, and up to 32% of the dough is gelatinized whole red wheat pieces or dried fruit which have a different coloration from the flour and are visibly discernible in the dough and subsequent fried product.
The composition can contain additional ingredients as described hereinbefore.
Furthermore, at less than about 4% of plasticizer in the dough compocition of the First Fmbodiment, particularly at less than ~ 3 R.I.F.-2245ti.A 11-11-91 about 3-O of plasticizer, the fried snack product is too light in te~:ture. In the Second Embodiment, the fried product is unduly hard at a plasticizer content of ~ess than about 3%. Additionally, when the dough composition contains at least 10% of unhulled grain or bran equivalent to the amount found in about 10% of unhulled grain, the fried product has a gummy mouthfeel when the quantity of plasticizer is less than about 3~. At about 8% and particularly above lO~ of plasticizer in the dough composition containing the above quantity of bran, the fried snack becomes mealy and falls apart in one's mouth.
Vegetable oils which are preferred for incorporation into the dough of the present invention as plasticizers include corn oil, sunrl-wer oil, canola oil, coconut oil, their hydrogenated or p~ , ly hydrogenated derivatives and mixtures thereof. Corn oil an~ ola oil or mi~ture thereof are particularly preferred.
The nonionic emulsifiers which can be used with the vegetable oil are those having an HLB of about 3.2 to 5.0, The emulsifier is preferably an ester of a polyol and a long chaln fatty acid such as that having from about 12 to 20 carbon atoms. Illustrative of suitable polyols there can be mentioned those of glycerin, ethylene o~ide, sorbitol, and glycols. The polyol will preferably have from 2 to 6 hydro~yl groups. Preferred emu]sifiers are those of mono-and di-glycerides such as that of glycerol monostearate, glycerol dlstearate, glycerol dioleate, glycerol monopalmitate, and the R.l.F.-22"5A.A 11 ll-gl li~e.
The total ~ois~ure, as recited in this invention, is the sum of moisture (water) in the dough composition such as that which may be added with the base ingredients, pieces of food or otherwise to the composition as well as the inherent moisture of the grain and other ingredients in the dough composition. The total amount of moisture can generally be calculated from a knowledge of the inherent moisture content of the various ingredients plus any added water. Also the total moisture can be determined by the analytical method found in the Fifteenth Edition of the AOAC, Method A in part 926.07 which is by the vacuum oven moisture technique. The quantity of all ingredients, apart from the water, e.g.grain,pieces of food and plasticizer are on a dry or moisture free basis, e.g. in the case of grain it is the weight of the grain less it's inherent moisture content.
In the First Embodiment, water is added to the ground grain prior to cooking. Thus, about 5% to 15% of water based on the weight of the finished dough composition is normally added to the ground grain and plasticizer prior to cooking when gelatinized whole red wheat is added through the secondary feed. When aàditions are not made to the dough through the secondary feed, the entire amount of added water is mixed with the ingredients prior to addition or at the time of addition to the extruder. Such quantity of water can vary from about 5% to 20 % by weight of the dough R.I.F.-2245A.A 11~ 91 composition.
In the First Embodiment, the dough compositions contain from about 20% to 35% of total moisture, preferably about 25% to 32 total moisture based on the weight of the dough composition. It is preferred that the ~oisture content not exceed about 30% since it has been found that increased water content causes increased oil pick~up in the frying step.
In the case when all of the ingredients are cooked in the extruder, all of the grain, e.g. 52% to 71% of the composition, is ground and such e~bodiment does not provide for discernible pieces of differently colored food in the composition. In such case, the added moisture which is provided with the base feed is that which will provide a total moisture content in the dough composition of from 20% to 35%, such as by the addition of from about 10% to 25%
moisture based on the base feed.
When a portion of the ground grain is substituted with gelatinized unground whole red wheat or pieces of fruit in the First Embodiment, the quantity of such pieces can vary from about 10% to 32% by weight of the dough composition, and preferably from about 15'~ tc 30~ on a dry, moisture free basis, based on the weight of the clough composition.
The term "gelatinized" as used herein applies to completely 3'~
R.1.~ 22q5A.A 11-11-91 gelatinized food as well as food which is substantially gelatinized such as that re~uired to eliminate white streaks on extrusion of the unground whole red wheat in preparation of the dough in this invention, e.g., extrusion through a die having a slit opening of about two inches long and about 0.022 inches wide, and wherein there is partial "gelatinization" or cooking of all the starch in the unground whole red wheat.
It is preferred that the dough compositions of this invention contain ground grains wherein at least 5%, such as from about 10% to 30% based on the weight of the dough is unhulled. Such unhulled grains include t~e whole red ~heat when it is used. By "unhulled" we mean grain which contains its bran. Also, by the term "whole" as it relates to grain we again mean unhulled grain wherein its hull has not beeh removed. The dough is preferably a multigrain composition such as one containing about 20% to 60% of wheat; 10 to 60 % corn ; 5% to 30% rice; and 5% to 15% oats. However, minor quantities, e.g., not more than about 15% of other grains such as sorghum, soya, rye, and barley can also ~e used. Generally the extrudate of this invention ~ill contain up to 10% of sugar such as white cane sugar, white beet sugar brown sugar , and the like~ It is preferred that the level of reducing sugars be kept low because these tend to fo.m caramelized and burnt flavors and also dar~en the color of the food composition produced. Also, the amylopectin to amylose ratio of the food ingredients is preferably kept to a ratio of 4Q~ to about 60%
and particularly about 50~.
R.~.F.-22~5A.A 11~ gl The grains used in this invention can be in various forms.
Thus, the ground rice can be that of various rice flours such as that of brown or white rice. Rice is also lighter in color than wheat such as hulled wheat or corn flours and can therefore be added to achieve a desired color lightness in the fried snack product. This facilitates the color contrast with pieces of whole red wheat and dried fruit in the dough and in the fried product.
The ground wheat in the present invention can be various fractions of the wheat kernel. Soft wheat, in both the spring or winter wheat varieties, are particularly useful in the present invention.
Any of the different varieties of corn can be used in this invention such as yellow corn, e.g., yellow dent corn, white corn, or mixtures thereof.
The ground grain (flour) used in this invention is generally ground so that 100% thereof passes through a U.S. Series No.lO
sieve. Preferably, hard horny grains are milled to a size wherein 100% passes through a No.16 sieve and less than 20 remains on a No. 20 sieve. Examples of hard horny grains include certain dent corns, brown rice, and popcorn. Preferably, soft grains are milled to a size wherein 100% pass through a No. lO sieve and less than 20% remain on a No. 20 sieve. Examples of soft grains include red wheat, oats, various varieties of corn, and white wheat.
R.I.F.-~45A.A 11-11-91 Although the grains used in this invention contain some oil, the quantity of such inherent oil is not sufficient to significantly affect the properties of the fried snacks. Thus, oats contain substantial quantities of fat (oil), namely, about 10% in whole dried oats, but the quantity of oats is li~ited in this invention to not more than about 15~ of the dough. Furthermore, there is little or no oil in corn meal, about 4% in whole dried corn, about 2~ oil in whole dried wheat, and less than 1%, generally, less than 0.5% in whole dried brown rice.
The unground whole red wheat used in this invention is cooked in an excess of water under conditions sufficient to cause the wheat to imbibe or absorb up to about 35% to 55% by weight of water based on the dry weight of the whole red wheat. The cooking of the whole red wheat can be, for example, by exposure to steam or by soa~ing in boiling water. During cooking it is preferred that partial gelatinization of all the starch in the wheat takes place.
In the First Embodiment the hydrated, whole cooked red wheat lS
preferably chilled to below 60 F and more preferably to about qO F
before being placed in the extruder. It has been found that if the cooked and hydrated wheat is cold (e.g., 40 F) when added to the other cooked grains, a significant reduction in expansion of the ~xtrudate at the die is achieved.
Still another reason for partially gelatinizing all of the starch in the unground whole red wheat before blending with the ~J' ~ ',t ~ ~t R.I.F.-2245A.A 11~11-91 other grains in either the First or the Second Embodiment, is that when there is no partial gelatinization of al], of the starch in the whole red wheat, the subsequent break up of the grains on e~trusion leaves undesirable white streaks on the extrudate as ~ell as on the fried product from the raw starch in the wheat.
The pieces of whole red wheat or dried fruit such as nuts are substantially larger than the ground grain or flour so that the difference in coloration of the large pieces is easily discernible.
The pieces of food become macerated in the extruder and particularly on extrusion through the narrow slit dies so that the pieces may resemble flakes, The size of such pieces varies greatly but, as mentioned before, are much larger than the ground (flour) grain even though such pieces may be broken even before being pl '~n the extruder. Generally, such pieces of food have at let a dimension which is at least about one-thirty-second (1/32) of an inch (about 0.03) inches.
The dough composition of this invention can also contain fillers such as potatoes or other starchy foods.
In a preferred formulation of the First Embodiment, the quantity of the various ingredients is: from about 4~ to 7% of added plasticizer; from about 25% to 32% of total ~oisture; about 19~ to 26% of fine corn meal; about 15% to 21% of gelatinized unground whole red wheat; about 8% to 12% of whole brown rice flour; about 4% to 6% of ground white wheat flour; about 4~ to 6%
~ .I.F.-22~5~.A 11~ 91 of ground white oat flour; about ~% to 6% Or powdered brown sugar;
and from about 0.5% to 1% of malted barley. In all embodi~ents, the malted barley should have any remaining enzyme activity neutralized or substantially neutralized since the enzyme adversely affects the texture and organoleptic properties of the product.
In another embodiment, the cut pieces of the dough composition ,e.g. the extrudate, are allowed to air dry overnight and are then fried. The drying can take place by other means in order to limit the moisture content ,e.g. to about 10% to 14% of the dough composition. Such cut pieces which have been dried are known as pellets or half products. Alternatively, the half products can be packaged for frying, baking, or microwave cooking by the consumer.
The low moisture content prevents the half product from spoiling.
The half products, fried as described above, can then be topically seasoned by methods and ingredients well known in the art.
The product produced from the frying step of this invention is a slightly expanded, cooked, oil-fried, snack food. The product exhibits no cholesterol and has a fat content dictated only by the frying conditions utilized. The oil or fat pick-up is minimized by the incorporation of the plasticizer into the formulation of the dough. After frying, the product is drained of excess frying oil and optionally topically flavored such as with salt. The resulting snack food product exhibits a unique texture and mouthfeel, particularly when a blend of grains is used. The pieces of whole 2 ~ ?~
R.I.E.-2245A.A 11~ 91 red wheat, when used, provide darker spots on the fried product.
Illustratively, the fried product, as well as the dough, will generally be tan or light brown in color with the whole red wheat pieces providing darker spots dispersed throughout the product.
The fried snack products of this invention will generally contain less than about 32% of total plasticizer (oil plus any emulsifier), by weight of the snack product, and preferably less than 28~ such as from 22% or from 25% to 27% of plasticizer. This is a relatively small quantity of oil for a fried snack which generally contain above 30% or 35% of plastici~er and at times at least 50% of plasticizer. Of course much of this plasticizer content is oil which is picked up in the frying step.
In order that tho5e skilled in the art may more fully understand the invention presented herein, the following examples, tables and procedures are set forth. In the examples, as well as elsewhere in this application, all percentages are by weight and unless otherwise indicated, the percentages of grains or pieces of food are on a dry ( moisture free ) basis in relation to the dough composition, e.g.extrudate, or fried snack, as appropriate.
P~R~OCEDl~RE U ~D IN THE EXAMPLES
Several examples of a multigrain snack food product were prepared according to the present invention. Table I provides the composition for 17 examples prepared by use of a twin screw cooker R.l.F.-2245A.A 11-11-gl e~truder, e~cept for added water and added plasticizer in the base feed. The a~ount of water added to the base feed was about 10~, based on the weight of the final dough composition. The quantity of added plasticizer in the dough co~position, which was part of the base feed, based on the weight of the extrudate, for some of the e~amples is shown in Table 2.
In the case where the pieces of whole red wheat were used, e~g. E~amples 2-6 and 11-15 the process was as follows: The e~trudates were prepared by pre-blending the ground grains in a mixer until the moisture was of uniform consistency and homo~eneity. To this mixture was added with further blending sugar (white cane), oil, and/or glycerol monostearate (GMS) as indicated in Table I. Water, 5% to 25% by weight based on the weight of the base feed was then added to the mixture with blending until uniEorm. Each mixture was then fed into a Clextral BC 45 twin screw e~truder at a rate of from 180 to 1000 grams per minute.
Ungrouild whole red wheat was cooked by adding the wheat and enough water to achieve 50% solids in a swept surface kettle. The wheat was cooked on medium heat for about 30 minutes covered, then the heat t~as turned up to high for about 15 minutes. The cover was then re~o~-ed fro~ the kettle and cooking was continued (about 15 minutes) until a ~oisture content in the wheat of about 40% weight was attained.
~ .I.Y. 22~A.A ll-11-sl The whole cooked red wheat was fed into the extruder containing the mixture of ground grains. The addition to the e~truder was made at the secondary feed 24 near the discharge end of the extruder at a rate of about 26% of the pre-blended grain feed rate. The mixture was then extruded at a thickness of about 0.08 inches and sheeted using either a standard pasta-type or a snack chip-t~pe die. The peak barrel temperature during extrusion was 200-350 F and the screw speed was varied from 25 to 300 revolutions per minute. Examples which use dried fruit were run in much the same way except that the fruit was added in a relatively dry state, after being roasted.
The extrudate from the above processing was then put through sizing rolls to reduce its thickness to a thickness of between about 0.02 and 0.050 inches. The sheet was then cut into desired shapes, often called pellets. In one embodiment, the pellets were immediately fried in a vegetable oil at, for example 3500F for about ~0 seconds.
Specific parameters used for the manufacture of the dough composition prepared in Example 11 of Table 1 by the use of a Clextral BC 45 Twin screw extruder with a low shear screw were as follows: screw speed of 100 rpm; motor amps of 17; feed rate for the base feed of 230 grams/minute ; cooled whole red wheat feed rate of lO0 grams/min.; thrust bearing pressure of 50~ psi; die head pressure of 420 psi; die head temperature of 13~F ; and ~ 3 R.I.F.-2245A.A 11 ll-gl extrudate te~perature of 150 F. Each of the three sections of the extruder are subdivided into two zones with zones 1-2 being part of section l; zones 3-~ being part of section 2 and zones 5-6 being part of section 3 ( the cooling zone). The barrel temperatures in the various zones were as follows; zone 1 of 150 F; zone 2 of 300 F; zone 3 of 300 F; zone 4 of 300 F; zone 5 of 61 F and zone 6 of 119 F. The extrudate of Example 11 was sheeted to 0.025 inches thic~ness, cut to round shape and subsequently fried at 350 F for 60 seconds.
3 ",3J ~ ~3 ~ .,~ ~ ~5"...~
L~ ~ ~ ~~ L~- ~ ' ~ I
t ~ L
il ~ ~L~
~ : t h 16 ~ 517ZZ -~
R . I . P .--22~15A .A 11 -ll-gl TABLE: 1 ( CONTINUED ) H 0% SQ On Dry Basis Example 14 15 16 17 Unground, Whole Red Wheat (Cooked) 40 27.3 25.7 26.0 25.9 ~hole White Wheat Flour 12.8 7.7 7.3 9.2 7.2 Whole Oat Flour 11.5 7.4 7.0 6.9 6.9 Corn Meal 11.8 34.0 32.1 34.9 31.9 Whole Xernel Corn Flour 12.0 --- --- --- ---Whole Brown Rice Flour 11.7 15.4 14.5 9.2 14.5 Malted Barley Flakes 9.0 1.0 0.9 1.0 1.0 BrOWJ1 Sugar --- 7.2 6.8 6.9 6.8 Popped Popcorn 5.5 --- --- --- ---GMS --- --_ ___ ___ ___ Corn Or Canola Oil --- --- 5.7 6.2 6.1 The added plasticizer in the extrudates for some of the e~amples from Table 1 were compared with the total amount of plasticizer in the fried snack after frying. The results are shown in Table 2. It can be seen fro~ Table 2 that the use of about 3%
to about 85o of added plasticizer inhibited the amount of oil picked up from the frying step. The plasticizer in all cases is measured on a moisture free basis for the extrudate. The abbreviation of G~.S
R.l.F.-2245A.A 11~ 91 in the table as well as the previous Tabl.e 1 refers to glycerol monostearate which was used at the 1.9% level in the e~trudate whereas the remaining examples were with corn oil or canola oil as the plasticizer. The frying mediu~ was either corn oil or canola oil and the procedures for preparing the extrudate and frying of the product is that which has been set forth hereinbefore.
It can be seen from Table 2 that at levels of about 4% to about 7%, the added plasticizer in the base feed provides a fried product with less total plasticizer than frying of the product without the added plasticizer. However, even below about 3% and ~bove about 7% of added plasticizer the total quantity of plasticizer ( generally vegetable oil) in the fried product is less than that which is calculated by adding the added plasticizer to the amount picked up on frying without the added plasticizer. It has also been discovered that at levels above about ~% or 10% of added oil the final product becornes unacceptably ~ushy and falls apart in the consumer's mouth. Thus, while conventional oil frying of snack foods typi.cally results in an oil( plasticizer~ content in the snac~ food of 30% to 35% by weight and often 50% by weight or higher, the present invention can produce a fried snack food with less than about 30% by weight total oil, and preferably less than ~S~ by weight.
~$~
1~ . I . F . -Z245A .A 11-11-91 COMPARISON OF AMOUNT OF PLASTICIZER ADDED TO DOUGH WITH AMOUNT OF
Example Plasticizer Added Total Oil 14 ~% 3~.3 1 1.9% 31%
13 2% 31%
3.4% 30.3%
9 4.8% 27.7%
5.7% 26.~%
16 6.2% 25%
17 6.1% 25%
11 6.5% 29.4%
12 8% 33.3%
In the Second Embodiment a portion of the flour, such as 40% to 60% of the flour on a dry basis, is pregelatinized and then mixed wlth the remaining flour and unground whole red wheat which is also pregelatinized. This mixture is fed.through an extruder which does not further cook the ingredients. After the dough is extruded, the process is substantially the same for both the First Embodiment and the Second Embodiment.
~ J~ 3 I~.I.F.-2245A.A 11-11-91 The Second Embodiment is particularly preferred. In the Second Embodiment the feed to the extruder comprises from about 25~
to 35% of total moisture and preferably from 28% to 32% of total moisture; about 50% to 70% of grain on a moisture free basis, wherein about 30% to 40% is ground grain (flour) and preferably 32%
to 38% is flour and 20% to 30%, preferably 22% to 28% is unground gelatinized whole red wheat. From about 40% to 60% of the flour in the Second Embodiment is gelatinized before entering the extruder.
Preferably about 45% to 55% of the flour is gelatinized before entering the extruder. In the Second embodiment, the plasticizer and the quantities thereof are the same as in the First Emb~diment.
Optionally, the composition can contain additional vegetable or dried fruit ingredients as in the First Embodiment.
In the process for making the dougn of the Second Embodiment, the flours, including the pregelatinized flours are blended and mixed in the appropriate proportions with the unground and gelatinized whole red wheat as well as the plasticizer and any other feed ingredients. This mixture then enters into an extruder which is maintained at a temperature not above 70 F, such as that of about 50 to 70 F
A suitable extruder for the Second Embodiment is a tubular press with a compression screw such as a conventional pasta press, e.g., a Mapampianti pasta press. In this process the press is not 2 ~ s ~ .I.F.-22~A.A 11~11-91 heated but heat builds up during the friction and extrusion of the feed mi~ture. The heat is removed and the temperature is maintained at about 50 ~ to 70 F. This is achieved by circulation of tap or cold water through the hollow screw and the jacketed barrel of the press. This is in contrast to the temperatures normally employed in such presses such as in the ~anufacture of pasta wherein the temperature is generally above 100 ~ or 110 F.
The reason for maintaining the lower te~perature is that better friction is developed between the feed material the extruder screw and inside surface of the barrel.
The problems in the use of the single screw cooker extruders are overcome in the Second Embodiment by: having a higher total moisture content in the initial feed; pregelatinizing a portion of the flour feed; and keeping a low temperature in the extruder.
Preferably, in the Second E~bodiment, the mixture is extruded through a die having a narrow opening such as a die having an opening of about 0.022 inches wide and about two inches long. Such die can have a straight or wavy slit opening so as to produce the corresponding dough configuration. The extrudate emerging from such die is then face cut at the die, preferably directly into a ~ryer. l`he cut pieces of dough with the above mention die, will thus have a thickness of about 0.022 inches, a length of about 2 inches and can be face cut to have various widths such as a width of about one and a half inches.
9 ~ 1 ?3 R.I.F.-2245~ gl In the following preferred formulation of the Second Embodiment, about 90% of the rice was gelatinized and 50% to 60% of the total guantity of corn was gelatinized prior to entry in the extruder. A suitable pregelatinized rice for the following ~ ~>~e ~r 5,~
formulation is Pre Gel Waxy Flour RF-G80~0 of the ~4~ Company whereas a suitable pregelatinized corn flour is Pre Gel Corn Flour , from the ConAgra Company.
R.l.F.-2245A.A 11-11-91 A preferred formula~ion for making the dough of the Second Embodiment is as follows:
% AS IS ~ OF MOISTURE
AND DRY BASIS
Moisture 30.56 Corn Flour (89% ts^) 16.89 15.04 Pre gel corn Flour (91.5% ts)10.09 9.23 Pre Gel Waxy Rice Flour (91.2% ts) 6.60 6.02 Whole Oat Flour (89.8% ts) 5.12 4.60 Powdered Brown Sugar 5.56 5.56 Malted Barley fla~es (91.0% ts) 0.58 0.53 ~nground, Boiled, Soft Red Whole Wheat (48% ts)51.3424.64 Canola Oil 3.80 3.80 Lecithin 0.02 0.02 TnTALS 100.00 100.00 're~ers -to total solids.
The f`ollowing procedure can be used for producing the dough of the above formulation by use of a single screw pasta extruder with a 2,000 pound per hour feed rate. Pre-blended flour, including the pregelatinized flour, is placed into a metering feeder. The feed rate is adjusted to 905.2 pounds per hour and the feeder is 224~A.A ll--11-91 started. An oil spray, at the beginning of the ~i~ing chamber preceding the extrusion barrel, is adjusted to 75.8 pounds per hour. I~owever, the oil may be added instead to the pieces of gelatinized whole red wheat. The unground gelatinized whole red wheat feed is adjusted to 1019 pounds per hour. These ingredien~s are mi~:ed and the mixture is extruded while the barrel and screw temperatures are maintained at about 60F. A die having a wavy opening is at the exit end of the extruder. The extrudate is cut at the die. Frying of the cut dough is at 350 F for about one minute.
The fried chips are then removed from the fryer and placed in a seasoning tumbler and then sent to a packaging machine.
A typical analysis of the fried product of the above formula and process of the Second Embodiment has a total oil content of about 26%, a moisture content of 1.5%, and the seasoning is fine flour salt at 1%. All of the percentages herein being on a weight basis and apart from the moisture or water being on a dr~ or solids basis.
A preferred feed formulation of the Second Embodiment comprises: about 25% to 35% of total moisture; about 5% to l5G~ of pregeled corn flour; about 15% to 25% of corn flour which has not been gelatinized; about 4% to 8% of pregeled rice flour; about 2%
to 6% of whole oat flour which has not been gelatinized; about 65 to 10o of brown sugar; about 4% to 7% of vegetable oil as ~ ~f ~
R~l~F~-Z245A.A ~ -sl plasticizer; and about 20% to 30~ of the unground, gelatinized whole red wheat.
Broadly, a dough composition of this invention which includes both the First Embodiment and the Second Embodiment comprises:
A. about 3% to 8% of a plasticizer, preferably 3.5~ or 4% to 7%;
B. about 20% to 35~ of total moisture, preferably 25% to 32% of total moisture;
C. A total quantity of edible plant material food, e.g., vege~able and fruit, of from about 50% to 77% and preferably 60% to 77%, on a dry basis, wherein the quantity of grain, both flour and gelatinized whole red wheat pieces as well as any pieces of dried fruit is from about 50% to 77%, wherein at least 45% of the dough is flour and at least 40% of the flour is gelatinized, and up to 32% of the dough is gelatinized whole red wheat pieces or dried fruit which have a different coloration from the flour and are visibly discernible in the dough and subsequent fried product.
The composition can contain additional ingredients as described hereinbefore.
Claims (28)
1. An unpuffed cooked dough composition suitable for making a fried snack food, said composition comprising a mixture of:
A. about 20% to 35% of total moisture;
B. about 45% to 77% of solid food on a moisture free basis, wherein:
a. at least 45% of said dough is cooked ground grain selected from the group consisting of wheat, rice, corn, not more than 15% of oats, and mixtures thereof; and b. 15% to 30% of said dough are pieces of food which have a different coloration from the cooked ground grain and are visually discernible in the composition, said pieces of food selected from the group consisting of gelatinized unground whole red wheat and dried fruit and;
C. about 4% to 7% of a plasticizer selected from the group consisting of a vegetable oil and a nonionic emulsifier intimately admixed with said ground grain, said oil being in addition to oil inherent in said grain and wherein the quantity of emulsifier does not exceed about 2%; all of the above percentages being based on the weight of the dough composition.
R.I.F.-2245A.A 11-11-91
A. about 20% to 35% of total moisture;
B. about 45% to 77% of solid food on a moisture free basis, wherein:
a. at least 45% of said dough is cooked ground grain selected from the group consisting of wheat, rice, corn, not more than 15% of oats, and mixtures thereof; and b. 15% to 30% of said dough are pieces of food which have a different coloration from the cooked ground grain and are visually discernible in the composition, said pieces of food selected from the group consisting of gelatinized unground whole red wheat and dried fruit and;
C. about 4% to 7% of a plasticizer selected from the group consisting of a vegetable oil and a nonionic emulsifier intimately admixed with said ground grain, said oil being in addition to oil inherent in said grain and wherein the quantity of emulsifier does not exceed about 2%; all of the above percentages being based on the weight of the dough composition.
R.I.F.-2245A.A 11-11-91
2. The composition of claim 1 wherein the quantity of the ground grain is at least 52% and the solid food consists of wheat, rice, corn, not more than 15% oats, dried fruit, up to 2% of flavorant, up to 10% of sugar, starchy food fillers and not more than 15% of other grains.
3 The composition of claim 2 wherein the pieces of food are that of unground whole red wheat.
4. The composition of claim 2 wherein the pieces of food are that of flaked, chopped, or shredded nuts.
5. The composition of claim 1 which includes about 4% to 6% of brown sugar and 0.5% to 1% of malted barley.
6. A snack food prepared by frying the composition of claim 1 and wherein the fried snack contains less than 32% of vegetable oil.
7. A half product prepared by cutting into predetermined sized pieces and then drying the dough of claim 1 to a moisture content of 10% to 14%.
8. A continuous process for making a dough extrudate suitable for a snack food which comprises the steps of:
A. providing to a cooker extruder having low shear, a main feed opening, a mixing zone adjacent the main feed opening, a R.I.F.-2245A.A 11-11-91 cooking zone adjacent the mixing zone and a cooling zone adjacent the cooking zone wherein the cooling zone has a secondary feed opening to the extruder, from about 3% to 8% of plasticizer selected from the group consisting of a vegetable oil and not more than 2% of a nonionic surfactant, from about 45% to 77% of ground grain on a dry basis, said grain selected from the group consisting of corn, wheat, rice, up to 15% of oats and mixtures thereof with at least 10% thereof being ground whole grain; and water; and B. mixing the water, plasticizer and ground grain in the mixing zone of the extruder to form a mixture;
C. cooking the mixture in the cooking zone of the extruder;
F. cooling the mixture in the cooling zone while adding and mixing therein from about 15% to 30%, on a dry basis, of pieces of a food selected from the group consisting of gelatinized unground whitened wheat and dried fruit, said pieces of food having a color which is different from the ground grain so that the pieces are visually discernible in the dough upon extrusion; and G. extruding the dough and pieces of food from the extruder to produce an extrudate having a total moisture content of from about 20% to 35%, the quantity of all of said ingredients being based on the weight of the extrudate.
A. providing to a cooker extruder having low shear, a main feed opening, a mixing zone adjacent the main feed opening, a R.I.F.-2245A.A 11-11-91 cooking zone adjacent the mixing zone and a cooling zone adjacent the cooking zone wherein the cooling zone has a secondary feed opening to the extruder, from about 3% to 8% of plasticizer selected from the group consisting of a vegetable oil and not more than 2% of a nonionic surfactant, from about 45% to 77% of ground grain on a dry basis, said grain selected from the group consisting of corn, wheat, rice, up to 15% of oats and mixtures thereof with at least 10% thereof being ground whole grain; and water; and B. mixing the water, plasticizer and ground grain in the mixing zone of the extruder to form a mixture;
C. cooking the mixture in the cooking zone of the extruder;
F. cooling the mixture in the cooling zone while adding and mixing therein from about 15% to 30%, on a dry basis, of pieces of a food selected from the group consisting of gelatinized unground whitened wheat and dried fruit, said pieces of food having a color which is different from the ground grain so that the pieces are visually discernible in the dough upon extrusion; and G. extruding the dough and pieces of food from the extruder to produce an extrudate having a total moisture content of from about 20% to 35%, the quantity of all of said ingredients being based on the weight of the extrudate.
9. The process of claim 8 wherein the pieces of food are that of cooked unground whole red wheat wherein all of the starch in the unground whole red wheat is partially gelatinized.
R.I.F.-2245A.A 11-11-91
R.I.F.-2245A.A 11-11-91
10. An unpuffed dough composition suitable for making a fried snack food, said composition comprising, by weight, a mixture of:
A. about 25% to 35% of moisture;
B. about 50% to 70% of grain on a moisture free basis, wherein, a. about 30% to 40% is flour selected from the group consisting of wheat, rice, corn, not more than 15% of oats, and mixtures thereof with from about 40% to 60% of said flour being gelatinized, and b. about 20% to 30% is pieces of gelatinized unground whole red wheat, C. about 3% to 8% of a plasticizer selected from the group consisting of a vegetable oil and a nonionic emulsifier intimately admixed therein, said oil being in addition to oil inherent in said grain and wherein the quantity of emulsifier does not exceed about 0.5%.
A. about 25% to 35% of moisture;
B. about 50% to 70% of grain on a moisture free basis, wherein, a. about 30% to 40% is flour selected from the group consisting of wheat, rice, corn, not more than 15% of oats, and mixtures thereof with from about 40% to 60% of said flour being gelatinized, and b. about 20% to 30% is pieces of gelatinized unground whole red wheat, C. about 3% to 8% of a plasticizer selected from the group consisting of a vegetable oil and a nonionic emulsifier intimately admixed therein, said oil being in addition to oil inherent in said grain and wherein the quantity of emulsifier does not exceed about 0.5%.
11. The composition of claim 10 wherein the plasticizer is vegetable oil in a quantity of 3.5% to 7%.
12. The composition of claim 11 wherein the quantity of grain is at least 60% and about 45% to 55% of the flour is gelatinized.
13. The composition of claim 11 wherein the dough contains about R.I.F.-2245A.A 11-11-91 4% to 8% of sugar.
14. The composition of claim 10 wherein: the flour comprises from about 20% to 30% of corn, 3% to 10% of rice and 2% to 10% of oats.
15. The composition of claim 14 wherein the rice is gelatinized and the composition includes from about 0.2% to 1% of malted barley substantially free of enzymatic activity.
16. A chip product prepared by cutting into predetermined sized pieces and then frying in vegetable oil the dough of claim 10 and wherein the fried chip product contains less than 28% of vegetable oil.
17. A process for making a dough extrudate suitable for a snack food which comprises the steps of:
A. providing to an extruder a feed which, by weight, comprises:
a. about 30% to 40% of grain flour on a moisture free basis, said flour selected from the group consisting of wheat, rice, corn, not more than 15% of oats, and mixtures thereof with about 40% to 60% of said flour being gelatinized;
b. about 20% to 30% on a moisture free basis of unground gelatinized whole red wheat; and c. about 3% to 8% of a plasticizer selected from the R.I.F.-2245A.A 11-11-91 group consisting of a vegetable oil and not more than 0.5% of a nonionic emulsifier said oil being in addition to oil inherent in said grain;
d. said feed containing 25% to 35% of total moisture;
and B. extruding said mixture while maintaining the screw and barrel of the extruder at a temperature of from about 50 F to 70 F to produce an extrudate wherein pieces of whole red wheat are dispersed throughout the extrudate and are visible therein due to the darker color of the whole red wheat.
A. providing to an extruder a feed which, by weight, comprises:
a. about 30% to 40% of grain flour on a moisture free basis, said flour selected from the group consisting of wheat, rice, corn, not more than 15% of oats, and mixtures thereof with about 40% to 60% of said flour being gelatinized;
b. about 20% to 30% on a moisture free basis of unground gelatinized whole red wheat; and c. about 3% to 8% of a plasticizer selected from the R.I.F.-2245A.A 11-11-91 group consisting of a vegetable oil and not more than 0.5% of a nonionic emulsifier said oil being in addition to oil inherent in said grain;
d. said feed containing 25% to 35% of total moisture;
and B. extruding said mixture while maintaining the screw and barrel of the extruder at a temperature of from about 50 F to 70 F to produce an extrudate wherein pieces of whole red wheat are dispersed throughout the extrudate and are visible therein due to the darker color of the whole red wheat.
18. The process of claim 17 wherein the plasticizer is from about 3.5% to 7% of a vegetable oil.
19. The process of claim 17 wherein the feed includes gelatinized rice flour.
20. The process of claim 17 wherein the feed includes from about 4% to 8% of sugar.
21. The process of claim 17 wherein: the plasticizer is vegetable oil in quantity of 3.5% to 7%; the flour is a mixture of grain flours which includes from about 3% to 10% of pregelatinized rice flour; the whole red wheat pieces have one dimension of at least R.I.F.-2245A.A 11-11-91 0.03 inches and all of the starch in the whole red wheat is partially gelatinized; and the temperature of the extruder barrel is maintained at 55 F to 65 F by cooling.
22. The process of claim 17 which includes the steps of cutting the extrudate into predetermined sized pieces and then frying the pieces in vegetable oil to produce a fried chip product containing less than 28% of vegetable oil.
23. An unpuffed dough composition suitable for making a fried snack food, said composition comprising, by weight, a mixture of:
A. about 20 to 35% of total moisture;
B. about 50% to 77% of a food selected from the group consisting of grain and dried fruit on a moisture free basis wherein:
a. at least 45% of said food is ground grain having a particle size wherein 100% thereof passes through a U.S. Series No.
10 sieve with at least 40% of said dough being gelatinized, said ground grain selected from the group consisting of wheat, rice, corn not more than 15% of oats, and mixtures thereof, and b. up to 32% of said food is pieces of food which have a different coloration from the ground grain and are visually discernible in the composition, said pieces of food selected from, the group consisting of pieces of gelatinized unground whole red wheat and dried fruit; and R.I.F.-2245A.A 11-11-91 C. about 3% to 8% of a plasticizer selected from the group consisting of a vegetable oil and a nonionic emulsifier intimately admixed in said composition, said oil being in addition to oil inherent in said grain and wherein the quantity of emulsifier does not exceed about 2%.
A. about 20 to 35% of total moisture;
B. about 50% to 77% of a food selected from the group consisting of grain and dried fruit on a moisture free basis wherein:
a. at least 45% of said food is ground grain having a particle size wherein 100% thereof passes through a U.S. Series No.
10 sieve with at least 40% of said dough being gelatinized, said ground grain selected from the group consisting of wheat, rice, corn not more than 15% of oats, and mixtures thereof, and b. up to 32% of said food is pieces of food which have a different coloration from the ground grain and are visually discernible in the composition, said pieces of food selected from, the group consisting of pieces of gelatinized unground whole red wheat and dried fruit; and R.I.F.-2245A.A 11-11-91 C. about 3% to 8% of a plasticizer selected from the group consisting of a vegetable oil and a nonionic emulsifier intimately admixed in said composition, said oil being in addition to oil inherent in said grain and wherein the quantity of emulsifier does not exceed about 2%.
24. The composition of claim 23 wherein the pieces of food are that of whole red wheat in a quantity of 10% to 32%.
25. The composition of claim 23 wherein the ground grain includes 5% to 30% of unhulled grain.
26. A chip product prepared by cutting into predetermined sized pieces and frying in vegetable oil the dough of claim 23 and wherein the chip product contains less than 28% of vegetable oil and nonionic emulsifier.
27. The composition of claim 22 wherein the vegetable oil is a member selected from the group consisting of corn oil, canola oil, coconut oil and partially hydrogenated derivatives thereof.
28. The composition of claim 27 wherein the oil is canola oil.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US79575891A | 1991-11-21 | 1991-11-21 | |
| US795,758 | 1991-11-21 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2069213A1 true CA2069213A1 (en) | 1993-05-22 |
Family
ID=25166370
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002069213A Abandoned CA2069213A1 (en) | 1991-11-21 | 1992-05-22 | Multigrain snack food |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA2069213A1 (en) |
| NZ (1) | NZ242702A (en) |
-
1992
- 1992-05-12 NZ NZ242702A patent/NZ242702A/en unknown
- 1992-05-22 CA CA002069213A patent/CA2069213A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| NZ242702A (en) | 1995-07-26 |
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Dead |