CA2226766A1 - Filled cereal product - Google Patents
Filled cereal product Download PDFInfo
- Publication number
- CA2226766A1 CA2226766A1 CA002226766A CA2226766A CA2226766A1 CA 2226766 A1 CA2226766 A1 CA 2226766A1 CA 002226766 A CA002226766 A CA 002226766A CA 2226766 A CA2226766 A CA 2226766A CA 2226766 A1 CA2226766 A1 CA 2226766A1
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- Canada
- Prior art keywords
- cereal
- dough
- farinaceous
- product
- filled
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
- A23L7/10—Cereal-derived products
- A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
- A23L7/122—Coated, filled, multilayered or hollow ready-to-eat cereals
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
- A23L7/10—Cereal-derived products
- A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
- A23L7/135—Individual or non-extruded flakes, granules or shapes having similar size, e.g. breakfast cereals
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
- A23P20/10—Coating with edible coatings, e.g. with oils or fats
- A23P20/105—Coating with compositions containing vegetable or microbial fermentation gums, e.g. cellulose or derivatives; Coating with edible polymers, e.g. polyvinyalcohol
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
- A23P20/20—Making of laminated, multi-layered, stuffed or hollow foodstuffs, e.g. by wrapping in preformed edible dough sheets or in edible food containers
Abstract
The invention provides a farinaceous dough filled cereal product having a shelf-stable plurality of tastes and textures. In a preferred embodiment, a first plurality of net-like sheets of cereal shred are continuously laminated, followed by continuous depositing of at least one dough rope filling upon the first plurality of net-like sheets. A
second plurality of net-like sheets is continuously laminated upon the dough rope to provide a sandwiched matrix. Each of the net-like sheets has a plurality of generally parallel longitudinal strands and a plurality of cross-hatchings which are generally perpendicular to the longitudinal strands. The filled laminate is cut to wrap the filling and the product is baked.
second plurality of net-like sheets is continuously laminated upon the dough rope to provide a sandwiched matrix. Each of the net-like sheets has a plurality of generally parallel longitudinal strands and a plurality of cross-hatchings which are generally perpendicular to the longitudinal strands. The filled laminate is cut to wrap the filling and the product is baked.
Description
FILLED CEREAL PRODUCT
FIELD OF THE INVENTION
The instant invention generally relates to a cerea! product having a plurality of 5 tastes, sweetness and textures and more specifically to a dough-filled, shelf-stable, ready-to-eat cereal product having a plurality of tastes, sweetness and textures and method for making the same.
BACKGROUND OF THE INVENTION
With the demise of the traditional "bacon and eggs" breakfast, hot or cold cereal probably represents the most favored alternative repast. Given its popularity, and the increased competition for "market share", cold cereals have undergone a marked change from cornflakes and puffed wheat, rice or corn, and shredded wheat biscuits to various colored and flavored cereal bits. Cartoon and whimsical characters have been 15 coupled with cereals to add to their appeal to children. Still others advertise vitamin or fiber content. Given the myriad number of cereals available to, and the inherent fickle nature of the consumer, manufacturers constantly strive to produce a cereal product that will be the "next favorite".
It should also be noted that cereals have transcended the breakfast table to 20 become snack food. Therefore, when offered as a snack, the cereal product must stand on its own without the further accouterments of sugar or milk.
In addition, one can clearly ascertain the trends in flavoring of cereals. The trend spans the gulf from plain and sugar coated to fruit, chocolate and combinations of flavors. Texture has also endured both subtle and overt changes. Variations from25 bland to crispy texture has given way to dual-textures within the same cereal bit. By example, cereals with soft fruit interiors or cereal combined with fruit and nut pieces offer the consumer further texture and taste choices.
Notwithstanding the advances in cereal technology relating to taste and texture,cereal products must display certain physical qualities. The cereal must retain its flavor 30 over time, resist sogginess when exposed to milk and provide the consumer with a unique taste and texture. Taste and texture are the most difficult parameters to I
~ achieve Hence there is a longstanding need to provide the consumer with a cereal product with unique texture and taste.
One approach in striving to provide the consumer with a unique texture has been to employ conventional shredding systems in new ways. Conventional shredding 5 systems used in the production of shredded wheat are disclosed in U.S. Pat. Nos.
502,378; 2,008,024; 2,013,003, 2,693,419; 4,004,035; and Canadian Pat. No. 674,046.
A conventional shredding mill comprises a pair of closely spaced rolls or rollers that rotate in opposite directions, with at least one of the rolls having circumferential grooves. Upon passing between the rolls, the wheat is deformed into long individual 10 strings or shreds. The circumferentially grooved roll can also be grooved transversely to the circumferential grooves for the production of net-like sheets. A conventional 6 inch diameter roller for producing net-like sheets has 60 transverse grooves equally spaced about the circumference which produce cross-hatchings in the netted product.
When the rollers are held to roll in mutual contact, the shreds or filaments will be fairly 15 separate from each other, though more or less contacting, but when the rollers are sprung slightly apart, under pressure, the adjacent filaments may be united to each other by very thin translucent, almost transparent, webs or fins between them.
The shredding mills are typically arranged in a linear series along a common conveyor, with the shreds running longitudinally or in parallel with the direction of 20 movement of the conveyor. The sheets or layers of filaments are deposited on the convey~r in super-imposed position, with their filaments running in the same direction.
A typical biscuit, for example, may contain up to 21 individual layers of shreds. Upon obtaining the requisite thickness, the multiple layer web can be cut transversely and longitudinally into multiple lines of biscuits in known manner.
U.S. Patents Nos. 4,696,825 and 4,795,647 issued to Leibfred report shelf-stablepaste-filled shredded cereal biscuits. The paste may be a fruit paste filling (including a fruit dough filling which comprises a fruit paste and glycerin), a meat filling, a cheese filling or the like.
U.S. Patent No. 4,588,596 issued to Bone et a/. describes a ready-to-eat cereal produced from a cookie dough. A fatty acid or fatty acid salt is added to the cookie dough formulation to improve the bowl life of the cereal.
U.S. Patent No. 5,093,146 issued to Calandro et a/. describes a ready-to-eat 5 cereal prepared from a cookie formulation. The cereal may optionally be coated with a sugar-like glaze. The purpose of this invention is to provide a cookie-like cereal having an improved bowl life.
It is an object of the present invention to provide a new cereal bit.
Another object of the present invention is to provide a means of adding nut 10 pieces and /or fruit pieces to a shredded cereal bit.
Some embodiments of the present invention provide a continuous process for the production of multi-tex~ured dough-filled shredded wheat biscuits using shredding mills which are arranged in the conventional linear fashion wherein each shred layer is produced from a separate pair of shredding rollers. The variation enhances the textural 15 contrast of a crisp biscuit and an essentially dry, rich tasting, crumbly solid center that in some embodiments also includes a chewy character such as that found when the dough filling of the present invention also includes a significant portion of fruit such as apples. The multiple tastes and textures of the inventive cereal bit are shelf stable for extended periods of time.
SUMMARY OF THE INVENTION
The present invention provides a process for the continuous production of a shelf-stable farinaceous dough-filled cereal product having a plurality of tastes and textures. The cereal product of the present invention has a farinaceous central matrix 25 that is wrapped by an outer cereal portion. The farinaceous central matrix can contain other materials such as nut pieces, fruit pieces, or conventional pastes such as cheese or meat pastes.
In a preferred embodiment, a first plurality of disparate cereal shred layers are continuously laminated, followed by continuous addition of at least one dough filling 30 rope upon the first plurality of shredded layers. A second plurality of shredded cereal shred layers is continuously laminated upon the dough filling rope to obtain a sandwiched matrix. Each of the layers typically has a plurality of generally parallel longitudinal strands and a piurality of cross-hatchings which are generally perpendicular to the longitudinal strands. The cross-hatchings and the longitudinal strands form an integral net-like sheet. The longitudinal strands of each layer and the dough filling ropes are generally arrayed in a parallel conflguration. The sandwiched matrix is cut to wrap the filling and the product is baked.
The filling is a farinaceous dough that can be prepared by creaming a sugar component, dough conditioner, an emulsifler and a portion of the flour with a fat or shortening. Water and an optional liquid sweetener, such as honey or high fructose corn syrup, are added and blended to homogeneity. The remaining portion of the flour along with any leavening agent is then added and blended with the other ingredients to form a uniform cookie or other farinaceous dough. While some of the preferred embodiments of the present invention use a "cookie" dough, other embodiments uselS other types of conventional doughs such as yeast and quick bread doughs. In the practice of the present invention, the dough should substantially not run after it is placed on the first cereal layer. Thus, flowable batter should be avoided. The cookie dough may be allowed to set for a sufficient period of time under controlled conditions to proof the dough and develop the proper texture for shaping and machining.
The cookie dough contains at least one flour component in the amount of about 30% to 55% by weight of the dough and preferably about 35% to 50% by weight of the dough. In a preferred embodiment of the invention, the cookie dough contains a mixture of pastry and bread flour. The dough typically also includes at least one type of fat or shortening in the amount of about 5% to 25% by weight of the dough and preferably about 10% to 18%.
Process compatible ingredients can be included to adjust the texture of the product produced by the process of the present invention. For example, at least one solid, crystalline, or granulated sugar, such as sucrose, may be used in the farinaceous dough. In addition to solid or granulated sugars, liquid sweeteners may also be used.
Sweetening agents like liquid brown sugar, high fructose corn syrup and honey may be operatively substituted in the practice of the present invention. In embodiments of the invention, the sugar component may be added in an amount to provide, for example, from about 10% to 40% by weight, and preferably from about 15% to 30% by weight total sugar solids, based on the total weight of the farinaceous dough.
The farinaceous dough of the present invention preferably contains sufficient water to obtain a texture or consistency suitable for extruding the dough into the desired size. Generally, the total water content ranges from about 10% to 25%, by weight, and more preferably about 14% to 20%.
An optional dough conditioner and/or an optional emulsifier may be added to enhance machinability of the dough.
The dough formulation may further contain flavorings such as powdered cocoa, chocolate liquor, vanilla extracts, almond extract, nuts or seeds (including whole, pieces, diced or meal) such as almonds, Brazil, cashews, hazelnuts, pecans, and walnuts, peanuts, sunflower seeds, poppy seeds, fruit flavors, fruit pieces such as fruit granules, pastes, powders and dices from, for example, apples, pears, oranges and dates, raisins, peaches, blueberries and cranberries, spices such as cinnamon and nutmeg, and other flavoring agents. The amount of flavoring added is determined by the intensity of the flavoring agent, the desired intensitv of the flavor and any textural attribute contributed by the flavoring.
The method according to the present invention produces a ready-to-eat breakfast cereal having a sweet, dual textured taste and which remains crispy in milk for an extended period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a side view of a roller having a channel groove;
Fig. 2 is a top view of a roller having a channel groove; and Fig. 3 is a side view of a roller combined with a cleaning knife.
~ ( CA 02226766 1998-01-13 DETAILED DESCRIPTION OF THE INVENTION
The ready-to-eat farinaceous dough-filled cereal products of the present invention are shelf-stable and possess a plurality of textures. The dough filling is wrapped in a cereal layer which provides a textural contrast thereto. Typically, the outer cereal layer has a crisp dry texture and is generally compressible, whereas the central matrix has an essentially dry, crumbly texture, being preferably solid, being typically rigid and fracturing when bitten.
Moreover, the cereal product of the present invention exhibits a mouth feel thatdiffers from conventional cereals. For example, when the outer portion is a plurality of cereal shreds, the outer portion shreds are dry, bland, crisp and filamentous, while the central matrix is rich, solid and crumbly when the consumer chews the cereal morsel.
Both the shred layer and the central matrix have a water content of from about 1 to 8.5%.
As used herein the term "wrapped" does not require a complete covering, although such is preferred. Desirably, the covering is at least substantially complete along each cut edge of the biscuit and complete across the major dimensions of the biscuit. Accordingly, a filling is considered to be wrapped by a cereal layer where the filling is exposed along portions of one or more cut edges.
A shredded layer embodiment typically uses a plurality of layers, each of which has a plurality of generally parallel longitudinal strands and a plurality of cross-hatchings generally perpendicular to the longitudinal strands. The cross-hatchings and the longitudinal strands form an integral net-like sheet. The use of an open space within the area formed by the longitudinal strands and the cross-hatchings in the outer layers provides a more attractive product.
In preparing a shredded filled biscuit embodiment of the present invention, the cereal grains are cooked and tempered in a known manner to obtain particles which are suitable for shredding on shredding rolls. Suitable moisture contents of the cereal grains for shredding range from about 28% to 50%, more typically from about 42% to 46% by weight, based upon the weight of the cereal grains. The cooked and tempered cereal grains are transferred, suitably by means of belt conveyors to a hopper which feeds a screw conveyor. The latter transfers the cereal grain to a series of shredding rolls or mills via flow tubes or hoppers.
The shredding mills, to form the shreds, may comprise a pair of rolls that rotate in opposite directions. While the rolls typically have circumferential grooves, desirably S at least one of the rolls has both circumferential and cross-hatching grooves which are transverse to the circumferential grooves for the production of an integral net-like sheet.
Upon passing between the roll, the cereal grain is deformed into the circumferential grooves and the cross-hatching grooves. Each pair of rolls produces a cereal shred layer having a plurality of generally parallel longitudinal strands and a plurality of cross-hatchings generally perpendicular to the strands. The longitudinal strands are produced by the circumferential grooves and run in parallel with the direction of movement of an underlying conveyor. The cross-hatchings of the shred layer are produced by the cross-hatching grooves and run generally perpendicular to the direction of movement of the conveyor.
By arranging the shredding mills in a linear series along a common underlying conveyor, the shreds may be positioned as desired. Each of the shredded shred layers or sheets are deposited on the conveyor in super-imposed position, with their longitudinal strands running in the same direction. The shred formed thereby form a series of positioned laminae (individaul laminate layers) A first plurality of shredded cereal shred layers are continuously laminated. Atleast one dough filling is then continuously deposited upon the first plurality of shred layers. Each dough rope is typically deposited generally parallel to, or in the same direction as, the longitudinal strands. A second plurality of shred layers is then continuously deposited on the one or more dough rope fillings in super-imposed position to the first plurality of shred layers to obtain a sandwiched matrix of shred over-wrapping the central matrix.
The number of shredded cereal layers or net-like shredded sheets in the first plurality of shred layers may be the same or different from the number in the second plurality of shred layers. It is generally preferable to provide about the same total -CA 02226766 1998-01-l3 n~lmber of shredded shred layers in the first plurality as in the second plurality so as to provide a pleasing symmetrical appearance.
In other embodiments of the present invention, other conventional cereal layers are substituted for one or more shredded cereal layers described above.
The dough filling is deposited by means of an apparatus placed between adjacent pairs of shredding rolls. The dough filling is suitably applied by extrusion through a nozle so as to form an dough rope which is continuously deposited upon the first plurality of shred layers. The apparatus should have a means for controlling and directing the flow of the filling so as to provide a straight and uniform dough upon a substrate which moves at substantially the same linear rate as the dough rope.
Alternatively, the dough filling can be deposited using a channel roll such as shown in FlGs 1, 2 and 3. Cylindrical roller 10 has one or more grooves 230 running about its circumference. Typically, groove 230 has a semi-circular cross-section with a diameter between about 1/8 to 3/8 of an inch. Cylindrical roller 10 with its groove (or grooves) is combined with a smooth cylindrical roller, each of which rotates in the opposite direction. The dough filling is fed in via the nip above where the two rollers abut and the dough filling exits the rollers as rope at the bottom of the rollers. The dough filling rope is then laid upon the cereal wrapping. Desirably, a wire is employed to peel the dough out of the channel roller groove after the dough passes throùgh the nip.
Instead of using a wire to peel the dough out of the channel roller groove, a knife blade 5 such as shown in Fig. 3, can be used to remove the dough. Knife blade 5 is mounted in blade holder 3 through blade insertion slot 4 by mounting means 7 and 8, in this illustration, screws, and the blade holder 3 is in turn mounted to the roller apparatus via connect means 2 and mounting means 9.
A further alternate means of placing the dough filling on the cereal wrapping isvia a conventional wire cut dough extrusion device.
The number of ropes which are deposited generally ranges from about one to five or more, depending upon the width of the shredding roll and the desired biscuit ~0 size. A conventional 6 inch diameter shredding roll typically has a width of between about 5 to 6 inches. Typically, about 5 spoon size or bite size biscuits may be produced within this width thereby calling for the deposition of five dough ropes.
The mass flow rate of the dough rope from the apparatus forming the rope should be sufficient to provide typically at least about 15% by weight filling in the biscuit, S based upon the weight of the final product. Preferably, the products contains between about 18 and 36 % filing or central matrix.
The sandwiched matrix is cut transversely and longitudinally to the direction offlow of the product into multiple lines of filled biscuit preforms using known cutting devices. The sandwiched matrix is suitably first cut transversely and then longitudinally lO with respect to the longitudinal strands of each shredded shred layer. In producing rectangularly shaped biscuits, it is preferable to cut the biscuit so that its longest dimension is transverse to the longitudinal strands and the dough rope. This provides greater tolerance for cutting between the dough rope without cutting through the dough rope. The longitudinal cuts are suitably made about midpoint between adjacent dough 1 S ropes.
As a result of cutting completely through the sandwiched matrix one forms individual biscuit shapes prior to baking. However, cutting partially through the sandwiched matrix to form biscuit shapes, followed by baking and separating the baked partially cut laminate into individual biscuits in a known manner is preferred. This 20 procedure provides easier control of the orientation of a cut product as it passes through the oven.
The cutting edges of the transverse and longitudinal cutters should preferably be blunt so as to form at least substantially integral seam along each edge of the biscuit preform. The cutting should be such so as to at least substantially prevent the '5 appearance of the dough filling in the baked, final product.
Baking the shred covered matrix forms a mechanical structure that has a strong bond between the two layers. The resulting structure also retards the entry of milk into the cereal thereby delaying sogginess.
The fillings used in the filled shredded biscuits of the present invention may be a ;0 cookie-like formulation which is incorporated into a shredded cereal matrix that is baked to produce a ready-to-eat cereal. The combination is formed into pieces and baked preferably in an oven to leaven the cereal pieces and to produce a leavened cookie-like - crumb structure in part of the cereal piece. The resulting cereal pieces have a sufhciently low moisture to be shelf stable.
S In alternative embodiments of the present invention, the layers of shreds are replaced with any other conventional sheet of cooked cereal material. For example an extruded sheet of an oat based formulation could form the first layer upon which a filling is deposited. Thereafter, a sheet of a corn based formulation could be layered over the filling. Such a product would then typically be cut and baked in a conventional manner.
Such a product could be in the form of a sandwich, a puff, a pillow, a biscuit or the like.
In alternate embodiments of the invention, a cookie or other farinaceous dough formulation is prepared by first creaming sugar and a portion of the flour with the fat or shortening, a dough conditioner and an optional emulsifier. Liquid components, such as liquid sweeteners, flavors and water, are then blended into the creamed ingredients.
All the remaining dry ingredients, such as any remaining flour, leavening agents and the bowl-life extending ingredients are blended to form a homogeneous dough. The dough is optionally allowed to stand and proof for a period of time to develop proper texture.
The cookie dough is then added to a wrapping and the combination is baked. The baked pieces generally have a final moisture content of about 2% to 5.5% by weight.
An optional sugar glaze may be applied to the baked pieces to provide added sweetness and a glossy appearance. The optional sugar glaze may also alter the mouth-feel of the cereal product of the present invention.
The cookie or farinaceous dough contains at least one flour component in the amount of about 30% to 70% by weight of the dough and preferably about 30% to 55%
by weight of the dough. In a preferred embodiment of the invention, the cookie dough contains about 10% to 25% pastry flour based on the total weight of the dough.
In both the wrapping layer and in the filling, any cereal grain or mixture thereof may be used. Exemplary cereal grains are wheat, corn, oat, barley. rye, rice, and mixtures thereof In the filling, the cereal grain includes a flour which may be bleached or unbleached. Wheat fi'our, and in particular bread flour and/or pastry flour, and mixtures of wheat flour with other grain flours are generally preferred.
Corn bran, wheat bran, oat bran, rice bran, and mixtures thereof may be used to S replace the flour in whole or in part to produce a fiber-enriched product, to enhance color, or to affect texture. The bran may be included, for example, in amounts of up to about 20% by weight, based upon the weight of the dough. Generally the bran component will be included in amounts of about 1% to 10% by weight, and preferably from about 2% to 5% by weight, based upon the weight of the dough.
The preferred fat or shortening in the present invention may be any food grade fat or shortening suitable for baking applications. The fats which may be used generally include vegetable fats, lard, tallow and mixtures thereof. The fat may be fractionated, partially hydrogenated, and/or inter-esterified. Edible reduced- or low-calorie, or non-digestible fats, fat substitutes, or synthetic fats, such as sucrose polyesters which are 15 process compatible, may also be used. The shortenings or fats may be solid or semi-solid at room temperature of about 75~F to 90~F. The use of fats which are solid or semi-solid at room temperature is generally preferred over liquid oils to reduce oil separation from the finished product during storage.
The fat or shortening is generally included in amounts of about 0% to 25% by 20 weight, based on the total weight of the ingredients. Preferably, the fat or shortening is included in amounts of about 10% to 18% by weight.
Exemplary emulsifiers which can be used include lecithin, sorbitan monostearate, mono- and/or di-glycerides and polyoxyethylene sorbitan fatty acidesters, such as polysorbates (e.g., polyoxyethylene (20) sorbitan monostearate).25 Emulsifiers are often added to cookie doughs to enhance the formation of the emulsion with the fat component and to reduce the amount of mixing required. Generally, emulsifiers are included in cookie doughs to reduce the amount of work needed to form the emulsion.
A dough conditioner and/or emulsifier such as sodium stearoyl lactylate, non-fat30 milk, whole eggs, lecithin and salt may be added to the dough formulation. For example, a dough conditioner can be used to produce a machinable dough consistency for extended periods of time. When used, a dough conditioner and/or emulsifier is generally included in the dough in the amount of about 0.05% to 3% by weight.
The ready-to-eat cereal of the present invention may also contain process-S compatible ingredients to modify the texture of the products, such as sucrose, fructose,lactose, dextrose, galactose, maltodextrins, corn syrup solids, hydrogenated starch hydrolysates, protein hydrolysates and mixtures thereof. Reducing sugars, such as fructose, maltose, lactose, and dextrose or mixtures of reducing sugars may be used to promote browning during the baking stage. Fructose is the preferred reducing sugar, lO because of its ready availability and its generally more enhanced browning effect. The source of fructose may include invert syrup, corn syrup, high fructose corn syrup, molasses, brown sugar, maple syrup and mixtures thereof. The sugar may be admixed with other ingredients in either solid form or crystalline form.
Crystalline or granulated sucrose alone or with other sugars is preferred in thelS present invention. The sucrose content may, for example, be at least about 80% by weight, based upon the total sugar solids content of the dough. The balance of the sugar solids may comprise, for example fructose, dextrose, lactose, or mixtures thereof.
In embodiments of the present invention, the total sugar solids content of the farinaceous dough of the present invention is, for example, at least about 10% by 20 weight, and may, for example, go up to about 40% by weight, based upon the total weight of the cookie dough. The sugar solids content preferably ranges from about 15% to 40%, by weight, based upon the weight of the cookie dough.
The total moisture content of the farinaceous dough is generally in the range ofabout 10% to 25% by weight. The preferred moisture content is from about 14% to 25 20% by weight. The amount of added water is generally in the amount of about 5% to 17% by weight. The amount of moisture in the farinaceous dough should be sufficient to provide the desired consistency to enable proper processing of the dough. The total moisture content of the dough will include any water added as a separate ingredient, as well as the moisture from the flour, which is usually 10% to 14% by weight of the flour 30 and the moisture from other ingredients, including, for example, high fructose corn syrups, honey, invert syrups, or liquid humectants. Generally, the amount of water present in the farinaceous dough is sufficient to produce a consistency which can be extruded using conventional equipment. If the water content is too low, the dough may be too stiff and cannot be machined. The addition of too much water may cause the S dough to become sticky and too soft to hold its shape.
The formulation of the present invention may contain up to about 3% by weight of a yeast or chemical leavening system, based on the total weight of the farinaceous dough. The amount of the leavening agent used is selected to control the rise and spread of the dough and to adjust the pH of the finished cereal. Exemplary optional chemical leavening agents include sodium bicarbonate, ammonium bicarbonate, sodium phosphate, cream of tartar (also known as potassium bitartrate) and mixtures thereof. In the preferred embodiments of the invention, the leavening agent is provided in amounts of about 0.2% to 1% by weight based on the weight of the dough.
In embodiments of the invention, a dry multi-vitamin premix may be included in the farinaceous dough. Dry vitamin compositions are preferred to avoid the addition of the carrier liquid to the farinaceous dough. Dry multi-vitamin premixes suitable for the invention may, for example, be such as those supplied by Hoffman LaRoche Company.
In one form of the invention, the vitamin premix is dry blended with the sugar component before admixing with the remaining ingredients.
A vitamin premix may be included in an amount of up to about 0.5% by weight, based on the total weight of the farinaceous dough. The preferred range for the vitamin premix may be about 0.05% to 0.3% by weight, based on the total weight of the farinaceous dough. The amount of vitamin premix used can be altered to meet any level of vitamin concentration desired.
An exemplary multi-vitamin premix that may be used in this invention includes one or more vitamins, such as vitamin E, biotin, vitamin A, vitamin D, niacin, vitamin B6, vitamin B2, folic acid and minerals, such as calcium, iron, and zinc.
Alternatively, the optional vitamin premix may be added as a coating in any conventional cereal coating.
The farinaceous dough preferably contains at least one flavoring component.
Suitable flavorings include, for example, powdered cocoa, chocolate liquor, vanilla extract, nuts or seeds (including whole, pieces, diced or meal) such as almonds, Brazil, cashews, hazelnuts, pecans, and walnuts, peanuts, sunflower seeds, poppy seeds, fruit S flavors, fruit pieces such as fruit granules, pastes, powders and dices from, for example, apples, pears, oranges and dates, raisins, peaches, blueberries and cranberries, spices such as cinnamon ancl nutmeg, and other flavoring agents. The amount of the flavoring added is determined by the intensity of the flavoring agent, the desired intensity of the flavor and any textural attribute contributed by the flavoring.
10 Generally, the amount of flavoring included in the dough formulation is less than about 70% and preferably between about 1% to 50%, by weight. Typically, a nut containing farinaceous dough used in the present invention contains between about 0% and 50%
nuts whereas a fruit containing farinaceous dough used in the present invention contains between about 0% and 50% fruit pieces. Moreover, a farinaceous dough used 15 in the present invention typically contains between about 0 and 15% of other flavoring material. It is preferred that a nut containing farinaceous dough used in the present invention contains between about 0 and 35% nuts, a fruit containing farinaceous dough used in the present invention contains between about 0% and 35% fruit pieces, and that the farinaceous dough used in the present invention contains less than about 5%
20 of other flavoring material.
In a preferred process of the present invention, the ingredients of the farinaceous dough are selected to produce a leavened, cookie-like filling. The ingredients generally comprise at least one flour, sugar, fat or shortening, a dough conditioner, emulsifier, leavening and a flavoring. The flour, sugar, dough conditioner, 25 emulsifier and fat or shortening are preferably creamed in a suitable mixing device, such as a Hobart mixer. The ingredients are blended for a sufficient period of time to form a uniform mixture. The mixing time may vary, depending on temperature conditions, mixing speed, and the proportions of the respective ingredients. Mixing is generally carried out at room temperature or slightly above room temperature. The mixing speed is preferably set at a low speed for about three minutes to ten minutes. A
uniform mixture is generally achieved in about five minutes.
After the flour, sugar and fat or shortening are blended, the liquid ingredients, such as liquid sweeteners. water, aqueous leavening systems, and flavors are mixed 5 for about one to five minutes, generally about two minutes, to uniformly disperse the ingredients and form a homogeneous mixture. The remaining dry ingredients are then added and blended for about two minutes.
Desirably, the homogeneous mixture is optionally allowed to set for about thirtyto ninety minutes before extruding into a cereal wrapping.
The cereal grains which are used in preparing the outer cereal portion may be wheat, oats, rice, corn, barley, rye, combinations thereof, and the like.
The cut, filled product may be dried, baked and toasted in conventional equipment. Suitable ovens for drying, baking and toasting the cut filled product include Proctor & Schwartz, Werner-Lehara, Wolverine and Spooner ovens containing forced15 air and gàs fired burners and a conveyor.
Temperature profiles used in the oven for drying, baking and toasting of the biscuit preforms are generally within the range of about 200 ~F to 600 ~F. The total time for drying, baking and toasting should be such so as to produce light to moderate browning. It depends upon the number of shred layers, the size of the shredded 20 product, the filling, and the type of oven. In a continuous system, the typical total time for drying, baking and toasting typically ranges from about 5 minutes to 15 minutes whereas in a batch oven system, the typical total time for drying, baking and toasting typically ranges from about 10 to 20 minutes.
In a preferred form of the invention, a confectionery glazing solution is applied 25 over the cereal pieces to provide a sweet taste. The glaze is generally a sugar solution which is heated to completely disperse the sugar. A suitable sugar may be, for example, about 85% by weight sucrose and about 15% by weight high fructose corn syrup or invert sugar. The sugar is dissolved in water at about 180 ~F and mixed to form a homogeneous cloudy mixture. The glaze is held at a temperature of between~0 about 155 ~F to 165 ~F and applied. The glaze is preferably applied by spraying. The glaze is preferably applied as a coating comprising about 10% to 15% by weight, based on the total weight of the cereal pieces.
Alternatively, or in addition, any other conventional cereal coating such as a frosting, an icing, tack-ons. a fondant or other su~ar, flavoring or spray oil may be S applied to the cereal pieces at conventional levels in a conventional manner.
The coated cereal pieces are then dried to about 3% to 4% by weight moisture and packaged.
The hnal product suitably has an average moisture content of about 1.5% to 6.5%, more preferably from about 2.5% to 5.5% by weight, based upon the weight of lO the final product, as determined by a vacuum oven moisture analysis.
Desirably, the baked product of the present invention has a water activity of less than about 0.74 and more desirably less than about 0.45. The Decagon CX-1 water activity monitor is a useful way to determine the water activities of the products of the present invention. Preferredly, if the product after baking has a water activity of more 15 than about 0.45, it is dried. A useful method of drying the product is by putting the product in a 250~F oven for about 20 minutes.
The color of the hnal baked product desirably is a substantially uniform off-white to light golden tan color.
The cereal shreds may contain one or more additives at the usual levels of 20 concentration.' Exemplary thereof is a sugar such as sucrose, salt, malt, flavoring, food colorant, emulsifier such as a blend of distilled monoglycerides, vitamins and/or minerals.
The present invention is further illustrated in the following examples. All percentages, parts, and proportions are by weight and all temperatures are in ~F, 25 unless indicated otherwise:
Typically the ratio of dry solids in the dough filling to the dry solids in the wrapping material is between about 1:1 and 1:7, although it is preferred that the ratio is - between about 1:2 and 1:5 and it is more preferred that the ratio dry solids in the filling to the dry solids in the wrapping material is between about 1:2.5 to 1:4.
EXAMPLE I
Using a conventional shredded wheat production system, four layers of conventional wheat shreds were laid down. A web layer was placed on top of the four layers of shreds and a 3/16" strip of Pillsbury Refrigerated Sugar Cookie Dough was S extruded on the web layer. A second web layer was placed on top of the cookie dough and three more layers of shreds were laid on the second web layer.
Next, the seven layers of shreds, the two web layers and the cookie dough were flattened with a large stainless steel sheet so as to slightly compact the plurality of layers. The plurality of layers was then cut into biscuits of about 28/32" by 30/~~ and baked at about 450~F for about fifteen and a half minutes. After baking, the product was dried in a 250~F oven for about twenty minutes.
COMPARATIVE EXAMPLE I
Example I was repeated, except that no filling was added to the layers of wheat shreds. These biscuits were baked for about ten minutes at 450~F.
EXAMPLE ll Example I was repeated, except that before the second web layer was placed on the cookie dough, pecan meal or pecan pieces were sprinkled on the cookie dough.Additionally, the biscuits were baked for about fourteen minutes.
EXAMPLE lll Example I was repeated, except that before the second web layer was placed on the cookie dough, either a small or a large nut mixture was sprinkled on the cookie dough.
The small nut mixture consisted of an equal mass of each of walnut fluff, fine diced almonds and pecan meal whereas the large nut mixture consisted of an equalmass of each of 3/16" walnut pieces, small diced almonds and midget cut pecan pieces. The biscuits were baked for about fourteen minutes.
COMPARATIVE EXAMPLE ll Apple granola granules were placed in the center of a shredded wheat matrix at a level of about 20% of the total product. This combination was baked, however, it lacked structural integrity and fell apart upon removal from the oven.
'~ ! CA 02226766 1998-01-13 EXAMPLE IV
Example I was repeated, except that before the second web layer was placed on the cookie dough, 12 mesh apple granules were sprinkled on the cookie dough, and in some instances, cinnamon was sprinkled on the apple granules. These biscuits were 5 baked for about fourteen minutes.
The products of Examples I - IV and Comparative Example I were evaluated as follows:
Example Qrganoleptic Evaluation Comparative Example I Crisp biscuit, good wheat taste Example I Crisp texture, sweet flavor with dual texture (crispouter layer and crumbly inner layer) Example ll - pecan pieces Sweet with nuts and dual texture Example ll - pecan meal Crisp with dual texture, sweet with a nutty taste Example lll - small nut pieces Dual textured, sweet with nuts lS Example lll - large nut pieces Dual textured, sweet with nuts Example IV - apple granules Dual textured, very slight apple flavor Example IV - apple granules with cinnamon Dual textured with an apple cinnamon flavor Each of the products of the present invention was able to maintain a structural 20integrity.
EXAMPLE V
Example I was repeated, except that a mixture of 3 parts, by weight, cookie dough combined with 4 parts, by weight, 12 mesh apple granules was used instead of the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
25In addition to the crisp, crumbly texture, the apple granules also provided the product with a chewy texture.
EXAMPLE Vl Example I was repeated, except that a mixture of 5 parts, by weight, cookie dough combined with 2 parts, by weight, 12 mesh apple granules was used instead of 30the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
~I CA 02226766 l998-0l-l3 EXAMPLE Vll Example I was repeated. except that a mixture of 3 parts, by weight, cookie dough combined with 4 parts, by weight, pecan meal was used instead of the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
E>~AMPLE Vlll Example I was repeated, except that a mixture of 5 parts, by weight, cookie dough combined with 2 parts, by weight, pecan meal was used instead of the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
E)CAMPLE IX
Separately, a conventional cooked wheat berries, a conventional cookie dough, a conventional cereal coating and a conventional cereal frosting were prepared. The cookie dough consisted about 32 % wheat flour, about 21 % sugar, about 10 % of an all purpose partially hydrogenated cotton seed and soybean oil shortening, about 0.2%
sodium bicarbonate, about 0.2% cream of tartar, about 0.4 % salt, about 0.8 %
cinnamon, about 24% 1/8" chopped evaporated apple pieces, about 0.8% non-fat drymilk, about 0.8% lecithin, about 0.2% of a dry vitamin and mineral blend and natural and artificial flavors. The cereal coating was a mixture of sugar and corn syrup and had about 77 % solids. The cereal frosting was a white fondant of about 79% sugar, about-1.6 % of an partially hydrogenated cotton seed and soybean oil shortening in a hard fat flake form, and about 0.5% gelatin, the frosting had about 80 % solids, the balance being water.
Using an about 6 inch wide conventional shredded wheat production system, four layers of conventional wheat shreds were laid down. Five approximately 3/16"
strips of cookie dough, at between about 45 and 85~F, were deposited using a channel roll on top of the four layers of shreds, each strip was spaced about an inch from any neighboring cookie dough strips. Three additional layers of shreds were laid on the five strips of cookie dough. The sandwiched cookie dough was partially cut into approximately rectangular shapes prior to baking.
The shred layers with the sandwiched cookie dough was baked in a pilot plant Wolverine continuous multi-zone dryer with a first zone temperature of about 480~F
and an exit zone temperature of about 330~F for about 9 minutes. After exiting the oven, the edges were trimmed off and the sheets were broken into individual biscuits.
Any fines were removed by screening.
Next, using a pilot plant batch reel, the baked biscuits were coated with the 5 conventional cereal coating and dried at about 225~F. Again, any fines present were removed by screening.
The dried, coated biscuits were then arranged in a monolayer in a large tray andiced with the conventional icing. The icing is pumped through a tube with holes so as to coat the dried, coated biscuits with the icing. The iced biscuits were stored at room 10 temperature at least until the icing started to turn white. Thereafter, the biscuits were packaged and stored.
The finished product was roughly 53% shreds, 20% cookie dough filling, 13 %
coating and 14 % icing and had a moisture content of between 5 and 5.5 %.
Before packaging, any fines present were again removed by screening. The I S biscuits were then packaged, desirably in an odor barrier material that is an effective to retain the flavors in the packaging.
FIELD OF THE INVENTION
The instant invention generally relates to a cerea! product having a plurality of 5 tastes, sweetness and textures and more specifically to a dough-filled, shelf-stable, ready-to-eat cereal product having a plurality of tastes, sweetness and textures and method for making the same.
BACKGROUND OF THE INVENTION
With the demise of the traditional "bacon and eggs" breakfast, hot or cold cereal probably represents the most favored alternative repast. Given its popularity, and the increased competition for "market share", cold cereals have undergone a marked change from cornflakes and puffed wheat, rice or corn, and shredded wheat biscuits to various colored and flavored cereal bits. Cartoon and whimsical characters have been 15 coupled with cereals to add to their appeal to children. Still others advertise vitamin or fiber content. Given the myriad number of cereals available to, and the inherent fickle nature of the consumer, manufacturers constantly strive to produce a cereal product that will be the "next favorite".
It should also be noted that cereals have transcended the breakfast table to 20 become snack food. Therefore, when offered as a snack, the cereal product must stand on its own without the further accouterments of sugar or milk.
In addition, one can clearly ascertain the trends in flavoring of cereals. The trend spans the gulf from plain and sugar coated to fruit, chocolate and combinations of flavors. Texture has also endured both subtle and overt changes. Variations from25 bland to crispy texture has given way to dual-textures within the same cereal bit. By example, cereals with soft fruit interiors or cereal combined with fruit and nut pieces offer the consumer further texture and taste choices.
Notwithstanding the advances in cereal technology relating to taste and texture,cereal products must display certain physical qualities. The cereal must retain its flavor 30 over time, resist sogginess when exposed to milk and provide the consumer with a unique taste and texture. Taste and texture are the most difficult parameters to I
~ achieve Hence there is a longstanding need to provide the consumer with a cereal product with unique texture and taste.
One approach in striving to provide the consumer with a unique texture has been to employ conventional shredding systems in new ways. Conventional shredding 5 systems used in the production of shredded wheat are disclosed in U.S. Pat. Nos.
502,378; 2,008,024; 2,013,003, 2,693,419; 4,004,035; and Canadian Pat. No. 674,046.
A conventional shredding mill comprises a pair of closely spaced rolls or rollers that rotate in opposite directions, with at least one of the rolls having circumferential grooves. Upon passing between the rolls, the wheat is deformed into long individual 10 strings or shreds. The circumferentially grooved roll can also be grooved transversely to the circumferential grooves for the production of net-like sheets. A conventional 6 inch diameter roller for producing net-like sheets has 60 transverse grooves equally spaced about the circumference which produce cross-hatchings in the netted product.
When the rollers are held to roll in mutual contact, the shreds or filaments will be fairly 15 separate from each other, though more or less contacting, but when the rollers are sprung slightly apart, under pressure, the adjacent filaments may be united to each other by very thin translucent, almost transparent, webs or fins between them.
The shredding mills are typically arranged in a linear series along a common conveyor, with the shreds running longitudinally or in parallel with the direction of 20 movement of the conveyor. The sheets or layers of filaments are deposited on the convey~r in super-imposed position, with their filaments running in the same direction.
A typical biscuit, for example, may contain up to 21 individual layers of shreds. Upon obtaining the requisite thickness, the multiple layer web can be cut transversely and longitudinally into multiple lines of biscuits in known manner.
U.S. Patents Nos. 4,696,825 and 4,795,647 issued to Leibfred report shelf-stablepaste-filled shredded cereal biscuits. The paste may be a fruit paste filling (including a fruit dough filling which comprises a fruit paste and glycerin), a meat filling, a cheese filling or the like.
U.S. Patent No. 4,588,596 issued to Bone et a/. describes a ready-to-eat cereal produced from a cookie dough. A fatty acid or fatty acid salt is added to the cookie dough formulation to improve the bowl life of the cereal.
U.S. Patent No. 5,093,146 issued to Calandro et a/. describes a ready-to-eat 5 cereal prepared from a cookie formulation. The cereal may optionally be coated with a sugar-like glaze. The purpose of this invention is to provide a cookie-like cereal having an improved bowl life.
It is an object of the present invention to provide a new cereal bit.
Another object of the present invention is to provide a means of adding nut 10 pieces and /or fruit pieces to a shredded cereal bit.
Some embodiments of the present invention provide a continuous process for the production of multi-tex~ured dough-filled shredded wheat biscuits using shredding mills which are arranged in the conventional linear fashion wherein each shred layer is produced from a separate pair of shredding rollers. The variation enhances the textural 15 contrast of a crisp biscuit and an essentially dry, rich tasting, crumbly solid center that in some embodiments also includes a chewy character such as that found when the dough filling of the present invention also includes a significant portion of fruit such as apples. The multiple tastes and textures of the inventive cereal bit are shelf stable for extended periods of time.
SUMMARY OF THE INVENTION
The present invention provides a process for the continuous production of a shelf-stable farinaceous dough-filled cereal product having a plurality of tastes and textures. The cereal product of the present invention has a farinaceous central matrix 25 that is wrapped by an outer cereal portion. The farinaceous central matrix can contain other materials such as nut pieces, fruit pieces, or conventional pastes such as cheese or meat pastes.
In a preferred embodiment, a first plurality of disparate cereal shred layers are continuously laminated, followed by continuous addition of at least one dough filling 30 rope upon the first plurality of shredded layers. A second plurality of shredded cereal shred layers is continuously laminated upon the dough filling rope to obtain a sandwiched matrix. Each of the layers typically has a plurality of generally parallel longitudinal strands and a piurality of cross-hatchings which are generally perpendicular to the longitudinal strands. The cross-hatchings and the longitudinal strands form an integral net-like sheet. The longitudinal strands of each layer and the dough filling ropes are generally arrayed in a parallel conflguration. The sandwiched matrix is cut to wrap the filling and the product is baked.
The filling is a farinaceous dough that can be prepared by creaming a sugar component, dough conditioner, an emulsifler and a portion of the flour with a fat or shortening. Water and an optional liquid sweetener, such as honey or high fructose corn syrup, are added and blended to homogeneity. The remaining portion of the flour along with any leavening agent is then added and blended with the other ingredients to form a uniform cookie or other farinaceous dough. While some of the preferred embodiments of the present invention use a "cookie" dough, other embodiments uselS other types of conventional doughs such as yeast and quick bread doughs. In the practice of the present invention, the dough should substantially not run after it is placed on the first cereal layer. Thus, flowable batter should be avoided. The cookie dough may be allowed to set for a sufficient period of time under controlled conditions to proof the dough and develop the proper texture for shaping and machining.
The cookie dough contains at least one flour component in the amount of about 30% to 55% by weight of the dough and preferably about 35% to 50% by weight of the dough. In a preferred embodiment of the invention, the cookie dough contains a mixture of pastry and bread flour. The dough typically also includes at least one type of fat or shortening in the amount of about 5% to 25% by weight of the dough and preferably about 10% to 18%.
Process compatible ingredients can be included to adjust the texture of the product produced by the process of the present invention. For example, at least one solid, crystalline, or granulated sugar, such as sucrose, may be used in the farinaceous dough. In addition to solid or granulated sugars, liquid sweeteners may also be used.
Sweetening agents like liquid brown sugar, high fructose corn syrup and honey may be operatively substituted in the practice of the present invention. In embodiments of the invention, the sugar component may be added in an amount to provide, for example, from about 10% to 40% by weight, and preferably from about 15% to 30% by weight total sugar solids, based on the total weight of the farinaceous dough.
The farinaceous dough of the present invention preferably contains sufficient water to obtain a texture or consistency suitable for extruding the dough into the desired size. Generally, the total water content ranges from about 10% to 25%, by weight, and more preferably about 14% to 20%.
An optional dough conditioner and/or an optional emulsifier may be added to enhance machinability of the dough.
The dough formulation may further contain flavorings such as powdered cocoa, chocolate liquor, vanilla extracts, almond extract, nuts or seeds (including whole, pieces, diced or meal) such as almonds, Brazil, cashews, hazelnuts, pecans, and walnuts, peanuts, sunflower seeds, poppy seeds, fruit flavors, fruit pieces such as fruit granules, pastes, powders and dices from, for example, apples, pears, oranges and dates, raisins, peaches, blueberries and cranberries, spices such as cinnamon and nutmeg, and other flavoring agents. The amount of flavoring added is determined by the intensity of the flavoring agent, the desired intensitv of the flavor and any textural attribute contributed by the flavoring.
The method according to the present invention produces a ready-to-eat breakfast cereal having a sweet, dual textured taste and which remains crispy in milk for an extended period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a side view of a roller having a channel groove;
Fig. 2 is a top view of a roller having a channel groove; and Fig. 3 is a side view of a roller combined with a cleaning knife.
~ ( CA 02226766 1998-01-13 DETAILED DESCRIPTION OF THE INVENTION
The ready-to-eat farinaceous dough-filled cereal products of the present invention are shelf-stable and possess a plurality of textures. The dough filling is wrapped in a cereal layer which provides a textural contrast thereto. Typically, the outer cereal layer has a crisp dry texture and is generally compressible, whereas the central matrix has an essentially dry, crumbly texture, being preferably solid, being typically rigid and fracturing when bitten.
Moreover, the cereal product of the present invention exhibits a mouth feel thatdiffers from conventional cereals. For example, when the outer portion is a plurality of cereal shreds, the outer portion shreds are dry, bland, crisp and filamentous, while the central matrix is rich, solid and crumbly when the consumer chews the cereal morsel.
Both the shred layer and the central matrix have a water content of from about 1 to 8.5%.
As used herein the term "wrapped" does not require a complete covering, although such is preferred. Desirably, the covering is at least substantially complete along each cut edge of the biscuit and complete across the major dimensions of the biscuit. Accordingly, a filling is considered to be wrapped by a cereal layer where the filling is exposed along portions of one or more cut edges.
A shredded layer embodiment typically uses a plurality of layers, each of which has a plurality of generally parallel longitudinal strands and a plurality of cross-hatchings generally perpendicular to the longitudinal strands. The cross-hatchings and the longitudinal strands form an integral net-like sheet. The use of an open space within the area formed by the longitudinal strands and the cross-hatchings in the outer layers provides a more attractive product.
In preparing a shredded filled biscuit embodiment of the present invention, the cereal grains are cooked and tempered in a known manner to obtain particles which are suitable for shredding on shredding rolls. Suitable moisture contents of the cereal grains for shredding range from about 28% to 50%, more typically from about 42% to 46% by weight, based upon the weight of the cereal grains. The cooked and tempered cereal grains are transferred, suitably by means of belt conveyors to a hopper which feeds a screw conveyor. The latter transfers the cereal grain to a series of shredding rolls or mills via flow tubes or hoppers.
The shredding mills, to form the shreds, may comprise a pair of rolls that rotate in opposite directions. While the rolls typically have circumferential grooves, desirably S at least one of the rolls has both circumferential and cross-hatching grooves which are transverse to the circumferential grooves for the production of an integral net-like sheet.
Upon passing between the roll, the cereal grain is deformed into the circumferential grooves and the cross-hatching grooves. Each pair of rolls produces a cereal shred layer having a plurality of generally parallel longitudinal strands and a plurality of cross-hatchings generally perpendicular to the strands. The longitudinal strands are produced by the circumferential grooves and run in parallel with the direction of movement of an underlying conveyor. The cross-hatchings of the shred layer are produced by the cross-hatching grooves and run generally perpendicular to the direction of movement of the conveyor.
By arranging the shredding mills in a linear series along a common underlying conveyor, the shreds may be positioned as desired. Each of the shredded shred layers or sheets are deposited on the conveyor in super-imposed position, with their longitudinal strands running in the same direction. The shred formed thereby form a series of positioned laminae (individaul laminate layers) A first plurality of shredded cereal shred layers are continuously laminated. Atleast one dough filling is then continuously deposited upon the first plurality of shred layers. Each dough rope is typically deposited generally parallel to, or in the same direction as, the longitudinal strands. A second plurality of shred layers is then continuously deposited on the one or more dough rope fillings in super-imposed position to the first plurality of shred layers to obtain a sandwiched matrix of shred over-wrapping the central matrix.
The number of shredded cereal layers or net-like shredded sheets in the first plurality of shred layers may be the same or different from the number in the second plurality of shred layers. It is generally preferable to provide about the same total -CA 02226766 1998-01-l3 n~lmber of shredded shred layers in the first plurality as in the second plurality so as to provide a pleasing symmetrical appearance.
In other embodiments of the present invention, other conventional cereal layers are substituted for one or more shredded cereal layers described above.
The dough filling is deposited by means of an apparatus placed between adjacent pairs of shredding rolls. The dough filling is suitably applied by extrusion through a nozle so as to form an dough rope which is continuously deposited upon the first plurality of shred layers. The apparatus should have a means for controlling and directing the flow of the filling so as to provide a straight and uniform dough upon a substrate which moves at substantially the same linear rate as the dough rope.
Alternatively, the dough filling can be deposited using a channel roll such as shown in FlGs 1, 2 and 3. Cylindrical roller 10 has one or more grooves 230 running about its circumference. Typically, groove 230 has a semi-circular cross-section with a diameter between about 1/8 to 3/8 of an inch. Cylindrical roller 10 with its groove (or grooves) is combined with a smooth cylindrical roller, each of which rotates in the opposite direction. The dough filling is fed in via the nip above where the two rollers abut and the dough filling exits the rollers as rope at the bottom of the rollers. The dough filling rope is then laid upon the cereal wrapping. Desirably, a wire is employed to peel the dough out of the channel roller groove after the dough passes throùgh the nip.
Instead of using a wire to peel the dough out of the channel roller groove, a knife blade 5 such as shown in Fig. 3, can be used to remove the dough. Knife blade 5 is mounted in blade holder 3 through blade insertion slot 4 by mounting means 7 and 8, in this illustration, screws, and the blade holder 3 is in turn mounted to the roller apparatus via connect means 2 and mounting means 9.
A further alternate means of placing the dough filling on the cereal wrapping isvia a conventional wire cut dough extrusion device.
The number of ropes which are deposited generally ranges from about one to five or more, depending upon the width of the shredding roll and the desired biscuit ~0 size. A conventional 6 inch diameter shredding roll typically has a width of between about 5 to 6 inches. Typically, about 5 spoon size or bite size biscuits may be produced within this width thereby calling for the deposition of five dough ropes.
The mass flow rate of the dough rope from the apparatus forming the rope should be sufficient to provide typically at least about 15% by weight filling in the biscuit, S based upon the weight of the final product. Preferably, the products contains between about 18 and 36 % filing or central matrix.
The sandwiched matrix is cut transversely and longitudinally to the direction offlow of the product into multiple lines of filled biscuit preforms using known cutting devices. The sandwiched matrix is suitably first cut transversely and then longitudinally lO with respect to the longitudinal strands of each shredded shred layer. In producing rectangularly shaped biscuits, it is preferable to cut the biscuit so that its longest dimension is transverse to the longitudinal strands and the dough rope. This provides greater tolerance for cutting between the dough rope without cutting through the dough rope. The longitudinal cuts are suitably made about midpoint between adjacent dough 1 S ropes.
As a result of cutting completely through the sandwiched matrix one forms individual biscuit shapes prior to baking. However, cutting partially through the sandwiched matrix to form biscuit shapes, followed by baking and separating the baked partially cut laminate into individual biscuits in a known manner is preferred. This 20 procedure provides easier control of the orientation of a cut product as it passes through the oven.
The cutting edges of the transverse and longitudinal cutters should preferably be blunt so as to form at least substantially integral seam along each edge of the biscuit preform. The cutting should be such so as to at least substantially prevent the '5 appearance of the dough filling in the baked, final product.
Baking the shred covered matrix forms a mechanical structure that has a strong bond between the two layers. The resulting structure also retards the entry of milk into the cereal thereby delaying sogginess.
The fillings used in the filled shredded biscuits of the present invention may be a ;0 cookie-like formulation which is incorporated into a shredded cereal matrix that is baked to produce a ready-to-eat cereal. The combination is formed into pieces and baked preferably in an oven to leaven the cereal pieces and to produce a leavened cookie-like - crumb structure in part of the cereal piece. The resulting cereal pieces have a sufhciently low moisture to be shelf stable.
S In alternative embodiments of the present invention, the layers of shreds are replaced with any other conventional sheet of cooked cereal material. For example an extruded sheet of an oat based formulation could form the first layer upon which a filling is deposited. Thereafter, a sheet of a corn based formulation could be layered over the filling. Such a product would then typically be cut and baked in a conventional manner.
Such a product could be in the form of a sandwich, a puff, a pillow, a biscuit or the like.
In alternate embodiments of the invention, a cookie or other farinaceous dough formulation is prepared by first creaming sugar and a portion of the flour with the fat or shortening, a dough conditioner and an optional emulsifier. Liquid components, such as liquid sweeteners, flavors and water, are then blended into the creamed ingredients.
All the remaining dry ingredients, such as any remaining flour, leavening agents and the bowl-life extending ingredients are blended to form a homogeneous dough. The dough is optionally allowed to stand and proof for a period of time to develop proper texture.
The cookie dough is then added to a wrapping and the combination is baked. The baked pieces generally have a final moisture content of about 2% to 5.5% by weight.
An optional sugar glaze may be applied to the baked pieces to provide added sweetness and a glossy appearance. The optional sugar glaze may also alter the mouth-feel of the cereal product of the present invention.
The cookie or farinaceous dough contains at least one flour component in the amount of about 30% to 70% by weight of the dough and preferably about 30% to 55%
by weight of the dough. In a preferred embodiment of the invention, the cookie dough contains about 10% to 25% pastry flour based on the total weight of the dough.
In both the wrapping layer and in the filling, any cereal grain or mixture thereof may be used. Exemplary cereal grains are wheat, corn, oat, barley. rye, rice, and mixtures thereof In the filling, the cereal grain includes a flour which may be bleached or unbleached. Wheat fi'our, and in particular bread flour and/or pastry flour, and mixtures of wheat flour with other grain flours are generally preferred.
Corn bran, wheat bran, oat bran, rice bran, and mixtures thereof may be used to S replace the flour in whole or in part to produce a fiber-enriched product, to enhance color, or to affect texture. The bran may be included, for example, in amounts of up to about 20% by weight, based upon the weight of the dough. Generally the bran component will be included in amounts of about 1% to 10% by weight, and preferably from about 2% to 5% by weight, based upon the weight of the dough.
The preferred fat or shortening in the present invention may be any food grade fat or shortening suitable for baking applications. The fats which may be used generally include vegetable fats, lard, tallow and mixtures thereof. The fat may be fractionated, partially hydrogenated, and/or inter-esterified. Edible reduced- or low-calorie, or non-digestible fats, fat substitutes, or synthetic fats, such as sucrose polyesters which are 15 process compatible, may also be used. The shortenings or fats may be solid or semi-solid at room temperature of about 75~F to 90~F. The use of fats which are solid or semi-solid at room temperature is generally preferred over liquid oils to reduce oil separation from the finished product during storage.
The fat or shortening is generally included in amounts of about 0% to 25% by 20 weight, based on the total weight of the ingredients. Preferably, the fat or shortening is included in amounts of about 10% to 18% by weight.
Exemplary emulsifiers which can be used include lecithin, sorbitan monostearate, mono- and/or di-glycerides and polyoxyethylene sorbitan fatty acidesters, such as polysorbates (e.g., polyoxyethylene (20) sorbitan monostearate).25 Emulsifiers are often added to cookie doughs to enhance the formation of the emulsion with the fat component and to reduce the amount of mixing required. Generally, emulsifiers are included in cookie doughs to reduce the amount of work needed to form the emulsion.
A dough conditioner and/or emulsifier such as sodium stearoyl lactylate, non-fat30 milk, whole eggs, lecithin and salt may be added to the dough formulation. For example, a dough conditioner can be used to produce a machinable dough consistency for extended periods of time. When used, a dough conditioner and/or emulsifier is generally included in the dough in the amount of about 0.05% to 3% by weight.
The ready-to-eat cereal of the present invention may also contain process-S compatible ingredients to modify the texture of the products, such as sucrose, fructose,lactose, dextrose, galactose, maltodextrins, corn syrup solids, hydrogenated starch hydrolysates, protein hydrolysates and mixtures thereof. Reducing sugars, such as fructose, maltose, lactose, and dextrose or mixtures of reducing sugars may be used to promote browning during the baking stage. Fructose is the preferred reducing sugar, lO because of its ready availability and its generally more enhanced browning effect. The source of fructose may include invert syrup, corn syrup, high fructose corn syrup, molasses, brown sugar, maple syrup and mixtures thereof. The sugar may be admixed with other ingredients in either solid form or crystalline form.
Crystalline or granulated sucrose alone or with other sugars is preferred in thelS present invention. The sucrose content may, for example, be at least about 80% by weight, based upon the total sugar solids content of the dough. The balance of the sugar solids may comprise, for example fructose, dextrose, lactose, or mixtures thereof.
In embodiments of the present invention, the total sugar solids content of the farinaceous dough of the present invention is, for example, at least about 10% by 20 weight, and may, for example, go up to about 40% by weight, based upon the total weight of the cookie dough. The sugar solids content preferably ranges from about 15% to 40%, by weight, based upon the weight of the cookie dough.
The total moisture content of the farinaceous dough is generally in the range ofabout 10% to 25% by weight. The preferred moisture content is from about 14% to 25 20% by weight. The amount of added water is generally in the amount of about 5% to 17% by weight. The amount of moisture in the farinaceous dough should be sufficient to provide the desired consistency to enable proper processing of the dough. The total moisture content of the dough will include any water added as a separate ingredient, as well as the moisture from the flour, which is usually 10% to 14% by weight of the flour 30 and the moisture from other ingredients, including, for example, high fructose corn syrups, honey, invert syrups, or liquid humectants. Generally, the amount of water present in the farinaceous dough is sufficient to produce a consistency which can be extruded using conventional equipment. If the water content is too low, the dough may be too stiff and cannot be machined. The addition of too much water may cause the S dough to become sticky and too soft to hold its shape.
The formulation of the present invention may contain up to about 3% by weight of a yeast or chemical leavening system, based on the total weight of the farinaceous dough. The amount of the leavening agent used is selected to control the rise and spread of the dough and to adjust the pH of the finished cereal. Exemplary optional chemical leavening agents include sodium bicarbonate, ammonium bicarbonate, sodium phosphate, cream of tartar (also known as potassium bitartrate) and mixtures thereof. In the preferred embodiments of the invention, the leavening agent is provided in amounts of about 0.2% to 1% by weight based on the weight of the dough.
In embodiments of the invention, a dry multi-vitamin premix may be included in the farinaceous dough. Dry vitamin compositions are preferred to avoid the addition of the carrier liquid to the farinaceous dough. Dry multi-vitamin premixes suitable for the invention may, for example, be such as those supplied by Hoffman LaRoche Company.
In one form of the invention, the vitamin premix is dry blended with the sugar component before admixing with the remaining ingredients.
A vitamin premix may be included in an amount of up to about 0.5% by weight, based on the total weight of the farinaceous dough. The preferred range for the vitamin premix may be about 0.05% to 0.3% by weight, based on the total weight of the farinaceous dough. The amount of vitamin premix used can be altered to meet any level of vitamin concentration desired.
An exemplary multi-vitamin premix that may be used in this invention includes one or more vitamins, such as vitamin E, biotin, vitamin A, vitamin D, niacin, vitamin B6, vitamin B2, folic acid and minerals, such as calcium, iron, and zinc.
Alternatively, the optional vitamin premix may be added as a coating in any conventional cereal coating.
The farinaceous dough preferably contains at least one flavoring component.
Suitable flavorings include, for example, powdered cocoa, chocolate liquor, vanilla extract, nuts or seeds (including whole, pieces, diced or meal) such as almonds, Brazil, cashews, hazelnuts, pecans, and walnuts, peanuts, sunflower seeds, poppy seeds, fruit S flavors, fruit pieces such as fruit granules, pastes, powders and dices from, for example, apples, pears, oranges and dates, raisins, peaches, blueberries and cranberries, spices such as cinnamon ancl nutmeg, and other flavoring agents. The amount of the flavoring added is determined by the intensity of the flavoring agent, the desired intensity of the flavor and any textural attribute contributed by the flavoring.
10 Generally, the amount of flavoring included in the dough formulation is less than about 70% and preferably between about 1% to 50%, by weight. Typically, a nut containing farinaceous dough used in the present invention contains between about 0% and 50%
nuts whereas a fruit containing farinaceous dough used in the present invention contains between about 0% and 50% fruit pieces. Moreover, a farinaceous dough used 15 in the present invention typically contains between about 0 and 15% of other flavoring material. It is preferred that a nut containing farinaceous dough used in the present invention contains between about 0 and 35% nuts, a fruit containing farinaceous dough used in the present invention contains between about 0% and 35% fruit pieces, and that the farinaceous dough used in the present invention contains less than about 5%
20 of other flavoring material.
In a preferred process of the present invention, the ingredients of the farinaceous dough are selected to produce a leavened, cookie-like filling. The ingredients generally comprise at least one flour, sugar, fat or shortening, a dough conditioner, emulsifier, leavening and a flavoring. The flour, sugar, dough conditioner, 25 emulsifier and fat or shortening are preferably creamed in a suitable mixing device, such as a Hobart mixer. The ingredients are blended for a sufficient period of time to form a uniform mixture. The mixing time may vary, depending on temperature conditions, mixing speed, and the proportions of the respective ingredients. Mixing is generally carried out at room temperature or slightly above room temperature. The mixing speed is preferably set at a low speed for about three minutes to ten minutes. A
uniform mixture is generally achieved in about five minutes.
After the flour, sugar and fat or shortening are blended, the liquid ingredients, such as liquid sweeteners. water, aqueous leavening systems, and flavors are mixed 5 for about one to five minutes, generally about two minutes, to uniformly disperse the ingredients and form a homogeneous mixture. The remaining dry ingredients are then added and blended for about two minutes.
Desirably, the homogeneous mixture is optionally allowed to set for about thirtyto ninety minutes before extruding into a cereal wrapping.
The cereal grains which are used in preparing the outer cereal portion may be wheat, oats, rice, corn, barley, rye, combinations thereof, and the like.
The cut, filled product may be dried, baked and toasted in conventional equipment. Suitable ovens for drying, baking and toasting the cut filled product include Proctor & Schwartz, Werner-Lehara, Wolverine and Spooner ovens containing forced15 air and gàs fired burners and a conveyor.
Temperature profiles used in the oven for drying, baking and toasting of the biscuit preforms are generally within the range of about 200 ~F to 600 ~F. The total time for drying, baking and toasting should be such so as to produce light to moderate browning. It depends upon the number of shred layers, the size of the shredded 20 product, the filling, and the type of oven. In a continuous system, the typical total time for drying, baking and toasting typically ranges from about 5 minutes to 15 minutes whereas in a batch oven system, the typical total time for drying, baking and toasting typically ranges from about 10 to 20 minutes.
In a preferred form of the invention, a confectionery glazing solution is applied 25 over the cereal pieces to provide a sweet taste. The glaze is generally a sugar solution which is heated to completely disperse the sugar. A suitable sugar may be, for example, about 85% by weight sucrose and about 15% by weight high fructose corn syrup or invert sugar. The sugar is dissolved in water at about 180 ~F and mixed to form a homogeneous cloudy mixture. The glaze is held at a temperature of between~0 about 155 ~F to 165 ~F and applied. The glaze is preferably applied by spraying. The glaze is preferably applied as a coating comprising about 10% to 15% by weight, based on the total weight of the cereal pieces.
Alternatively, or in addition, any other conventional cereal coating such as a frosting, an icing, tack-ons. a fondant or other su~ar, flavoring or spray oil may be S applied to the cereal pieces at conventional levels in a conventional manner.
The coated cereal pieces are then dried to about 3% to 4% by weight moisture and packaged.
The hnal product suitably has an average moisture content of about 1.5% to 6.5%, more preferably from about 2.5% to 5.5% by weight, based upon the weight of lO the final product, as determined by a vacuum oven moisture analysis.
Desirably, the baked product of the present invention has a water activity of less than about 0.74 and more desirably less than about 0.45. The Decagon CX-1 water activity monitor is a useful way to determine the water activities of the products of the present invention. Preferredly, if the product after baking has a water activity of more 15 than about 0.45, it is dried. A useful method of drying the product is by putting the product in a 250~F oven for about 20 minutes.
The color of the hnal baked product desirably is a substantially uniform off-white to light golden tan color.
The cereal shreds may contain one or more additives at the usual levels of 20 concentration.' Exemplary thereof is a sugar such as sucrose, salt, malt, flavoring, food colorant, emulsifier such as a blend of distilled monoglycerides, vitamins and/or minerals.
The present invention is further illustrated in the following examples. All percentages, parts, and proportions are by weight and all temperatures are in ~F, 25 unless indicated otherwise:
Typically the ratio of dry solids in the dough filling to the dry solids in the wrapping material is between about 1:1 and 1:7, although it is preferred that the ratio is - between about 1:2 and 1:5 and it is more preferred that the ratio dry solids in the filling to the dry solids in the wrapping material is between about 1:2.5 to 1:4.
EXAMPLE I
Using a conventional shredded wheat production system, four layers of conventional wheat shreds were laid down. A web layer was placed on top of the four layers of shreds and a 3/16" strip of Pillsbury Refrigerated Sugar Cookie Dough was S extruded on the web layer. A second web layer was placed on top of the cookie dough and three more layers of shreds were laid on the second web layer.
Next, the seven layers of shreds, the two web layers and the cookie dough were flattened with a large stainless steel sheet so as to slightly compact the plurality of layers. The plurality of layers was then cut into biscuits of about 28/32" by 30/~~ and baked at about 450~F for about fifteen and a half minutes. After baking, the product was dried in a 250~F oven for about twenty minutes.
COMPARATIVE EXAMPLE I
Example I was repeated, except that no filling was added to the layers of wheat shreds. These biscuits were baked for about ten minutes at 450~F.
EXAMPLE ll Example I was repeated, except that before the second web layer was placed on the cookie dough, pecan meal or pecan pieces were sprinkled on the cookie dough.Additionally, the biscuits were baked for about fourteen minutes.
EXAMPLE lll Example I was repeated, except that before the second web layer was placed on the cookie dough, either a small or a large nut mixture was sprinkled on the cookie dough.
The small nut mixture consisted of an equal mass of each of walnut fluff, fine diced almonds and pecan meal whereas the large nut mixture consisted of an equalmass of each of 3/16" walnut pieces, small diced almonds and midget cut pecan pieces. The biscuits were baked for about fourteen minutes.
COMPARATIVE EXAMPLE ll Apple granola granules were placed in the center of a shredded wheat matrix at a level of about 20% of the total product. This combination was baked, however, it lacked structural integrity and fell apart upon removal from the oven.
'~ ! CA 02226766 1998-01-13 EXAMPLE IV
Example I was repeated, except that before the second web layer was placed on the cookie dough, 12 mesh apple granules were sprinkled on the cookie dough, and in some instances, cinnamon was sprinkled on the apple granules. These biscuits were 5 baked for about fourteen minutes.
The products of Examples I - IV and Comparative Example I were evaluated as follows:
Example Qrganoleptic Evaluation Comparative Example I Crisp biscuit, good wheat taste Example I Crisp texture, sweet flavor with dual texture (crispouter layer and crumbly inner layer) Example ll - pecan pieces Sweet with nuts and dual texture Example ll - pecan meal Crisp with dual texture, sweet with a nutty taste Example lll - small nut pieces Dual textured, sweet with nuts lS Example lll - large nut pieces Dual textured, sweet with nuts Example IV - apple granules Dual textured, very slight apple flavor Example IV - apple granules with cinnamon Dual textured with an apple cinnamon flavor Each of the products of the present invention was able to maintain a structural 20integrity.
EXAMPLE V
Example I was repeated, except that a mixture of 3 parts, by weight, cookie dough combined with 4 parts, by weight, 12 mesh apple granules was used instead of the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
25In addition to the crisp, crumbly texture, the apple granules also provided the product with a chewy texture.
EXAMPLE Vl Example I was repeated, except that a mixture of 5 parts, by weight, cookie dough combined with 2 parts, by weight, 12 mesh apple granules was used instead of 30the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
~I CA 02226766 l998-0l-l3 EXAMPLE Vll Example I was repeated. except that a mixture of 3 parts, by weight, cookie dough combined with 4 parts, by weight, pecan meal was used instead of the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
E>~AMPLE Vlll Example I was repeated, except that a mixture of 5 parts, by weight, cookie dough combined with 2 parts, by weight, pecan meal was used instead of the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
E)CAMPLE IX
Separately, a conventional cooked wheat berries, a conventional cookie dough, a conventional cereal coating and a conventional cereal frosting were prepared. The cookie dough consisted about 32 % wheat flour, about 21 % sugar, about 10 % of an all purpose partially hydrogenated cotton seed and soybean oil shortening, about 0.2%
sodium bicarbonate, about 0.2% cream of tartar, about 0.4 % salt, about 0.8 %
cinnamon, about 24% 1/8" chopped evaporated apple pieces, about 0.8% non-fat drymilk, about 0.8% lecithin, about 0.2% of a dry vitamin and mineral blend and natural and artificial flavors. The cereal coating was a mixture of sugar and corn syrup and had about 77 % solids. The cereal frosting was a white fondant of about 79% sugar, about-1.6 % of an partially hydrogenated cotton seed and soybean oil shortening in a hard fat flake form, and about 0.5% gelatin, the frosting had about 80 % solids, the balance being water.
Using an about 6 inch wide conventional shredded wheat production system, four layers of conventional wheat shreds were laid down. Five approximately 3/16"
strips of cookie dough, at between about 45 and 85~F, were deposited using a channel roll on top of the four layers of shreds, each strip was spaced about an inch from any neighboring cookie dough strips. Three additional layers of shreds were laid on the five strips of cookie dough. The sandwiched cookie dough was partially cut into approximately rectangular shapes prior to baking.
The shred layers with the sandwiched cookie dough was baked in a pilot plant Wolverine continuous multi-zone dryer with a first zone temperature of about 480~F
and an exit zone temperature of about 330~F for about 9 minutes. After exiting the oven, the edges were trimmed off and the sheets were broken into individual biscuits.
Any fines were removed by screening.
Next, using a pilot plant batch reel, the baked biscuits were coated with the 5 conventional cereal coating and dried at about 225~F. Again, any fines present were removed by screening.
The dried, coated biscuits were then arranged in a monolayer in a large tray andiced with the conventional icing. The icing is pumped through a tube with holes so as to coat the dried, coated biscuits with the icing. The iced biscuits were stored at room 10 temperature at least until the icing started to turn white. Thereafter, the biscuits were packaged and stored.
The finished product was roughly 53% shreds, 20% cookie dough filling, 13 %
coating and 14 % icing and had a moisture content of between 5 and 5.5 %.
Before packaging, any fines present were again removed by screening. The I S biscuits were then packaged, desirably in an odor barrier material that is an effective to retain the flavors in the packaging.
Claims (22)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A ready-to-eat cereal product comprising:
(a) a farinaceous central matrix; and (b) an outer shredded cereal layer.
(a) a farinaceous central matrix; and (b) an outer shredded cereal layer.
2. The cereal product as claimed in claim 1 wherein said outer shredded cereal layer comprises a plurality of generally parallel longitudinal strands and a plurality of cross-hatchings generally perpendicular to said strands, said cross-hatchings and said longitudinal strands forming an integral net-like sheet.
3. The cereal product as claimed in claim 1 wherein said farinaceous central matrix is a baked cookie dough
4. The cereal product as claimed in claim 1 wherein the water activity of the filled product is less than about 0.74.
5. The cereal product as claimed in claim 4 wherein said farinaceous central matrix constitutes at least about 15 percent, by weight based upon the total weight, of the cereal product.
6. The cereal product as claimed in claim 5 wherein at least about 30% of said outer shredded cereal layer is at least one member selected from the group consisting of wheat, corn, oat, barley, rye and rice.
7. The cereal product as claimed in claim 6 further comprising a particulate layer, said particulate layer having at least one member of the group consisting of sugar, nut meal, small nut pieces, fruit granules and small fruit pieces.
8. The cereal product as claimed in claim 6 wherein the farinaceous central matrix is a cookie dough.
9. The cereal product as claimed in claim 8 wherein the farinaceous central matrix further comprises apple pieces.
10. The cereal product as claimed in claim 8 wherein the farinaceous central matrix further comprises nut pieces.
11. The cereal product as claimed in claim 4 the water activity of the filled biscuit is less than about 0.45.
12. A farinaceous dough-filled cereal preform comprising:
(a) a farinaceous dough matrix; and (b) a shredded cereal wrapping.
(a) a farinaceous dough matrix; and (b) a shredded cereal wrapping.
13. The farinaceous dough-filled cereal preform of claim 12 wherein said cereal wrapping comprises a shredded wheat.
14. The farinaceous dough-filled cereal preform of claim 13 in which said farinaceous dough filling is at least about 15 percent by weight based upon the total weight of the preform.
15. The farinaceous dough-filled cereal preform of claim 14 wherein said farinaceous dough is a cookie dough.
16. The farinaceous dough-filled cereal preform of claim 15 in which said farinaceous dough filling comprises:
(a) between about 0 and 25% fat or shortening;
(b) between about 0 and 50% nuts;
(c) between about 0 and 50% fruit pieces; and (d) at least about 10% sugar.
(a) between about 0 and 25% fat or shortening;
(b) between about 0 and 50% nuts;
(c) between about 0 and 50% fruit pieces; and (d) at least about 10% sugar.
17. The farinaceous dough-filled cereal preform of claim 16 which comprises at least about 4% nuts.
18. The farinaceous dough-filled cereal preform of claim 16 which comprises at least about 4% fruit pieces.
19. The farinaceous dough-filled cereal preform of claim 18 which further comprises at least about 4% nuts.
20. The farinaceous dough-filled cereal preform of claim 17 in which between about 10 and 18% of the filling is fat or shortening.
21. A ready-to-eat cereal product having a farinaceous central matrix and a shelf stable plurality of tastes and textures comprising:
(a) a farinaceous central matrix, said farinaceous central matrix comprising:
i) between about 30 and 55% of a flour component;
ii) between about 8 and 25% fat or shortening;
iii) between about 0 and 50% nuts;
iv) between about 0 and 50% fruit pieces; and v) at least about 10% sugar; and (b) a shredded cereal wrapping said product having a water activity of about 0.45 or less.
(a) a farinaceous central matrix, said farinaceous central matrix comprising:
i) between about 30 and 55% of a flour component;
ii) between about 8 and 25% fat or shortening;
iii) between about 0 and 50% nuts;
iv) between about 0 and 50% fruit pieces; and v) at least about 10% sugar; and (b) a shredded cereal wrapping said product having a water activity of about 0.45 or less.
22. A process for preparing a cereal product with a farinaceous central matrix comprising the steps of:
(a) preparing a cooked cereal based wrapping;
(b) forming a first sheet of said cooked cereal based wrapping;
(c) preparing a farinaceous dough;
(d) depositing said dough on a portion of said first sheet of cooked cereal based wrapping;
(e) forming a second sheet of said cooked cereal based wrapping;
(f) layering said second sheet on said first sheet with said farinaceous dough deposits to form a layered cereal preform;
(g) cutting said layered cereal preform; and (h) baking the dough and wrapping combination.
(a) preparing a cooked cereal based wrapping;
(b) forming a first sheet of said cooked cereal based wrapping;
(c) preparing a farinaceous dough;
(d) depositing said dough on a portion of said first sheet of cooked cereal based wrapping;
(e) forming a second sheet of said cooked cereal based wrapping;
(f) layering said second sheet on said first sheet with said farinaceous dough deposits to form a layered cereal preform;
(g) cutting said layered cereal preform; and (h) baking the dough and wrapping combination.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US79906797A | 1997-02-10 | 1997-02-10 | |
| US799,067 | 1997-02-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2226766A1 true CA2226766A1 (en) | 1998-08-10 |
Family
ID=25174962
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002226766A Abandoned CA2226766A1 (en) | 1997-02-10 | 1998-01-13 | Filled cereal product |
Country Status (2)
| Country | Link |
|---|---|
| KR (1) | KR19980071200A (en) |
| CA (1) | CA2226766A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101415548B1 (en) * | 2012-04-23 | 2014-07-04 | 전라북도 정읍시 | Manufacturing method of cereal bar comprising rice |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4539211A (en) * | 1983-08-11 | 1985-09-03 | The Quaker Oats Company | Process for manufacturing cavity-filled cereal pieces |
| US4696825A (en) * | 1985-01-25 | 1987-09-29 | Nabisco Brands, Inc. | Continuous production of shelf-stable multi-textured shredded cereal biscuits having a paste filling |
| US4961943A (en) * | 1990-01-22 | 1990-10-09 | Nabisco Brands, Inc. | Process of preparing cereal-coated dried fruit |
-
1998
- 1998-01-13 CA CA002226766A patent/CA2226766A1/en not_active Abandoned
- 1998-02-09 KR KR1019980003694A patent/KR19980071200A/en not_active Application Discontinuation
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| Publication number | Publication date |
|---|---|
| KR19980071200A (en) | 1998-10-26 |
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