CH621689A5 - Process for producing a semi-manufactured product of a food product and conversion of the semi-manufactured product into a food product - Google Patents

Description

The invention relates to a method for producing a semi-product of a food product and the conversion of the semi-product thus produced into the corresponding food product by cooking, baking or roasting.

DE-OS 2 449 283 describes a process for producing a simulated dough snack product or a semi-product therefor, which comprises the following steps: (a) Forming a dough by mixing a dry mixture of 20 to 80% of a dewatered potato product in which the Starch cells are essentially unbroken, 20 to 80% ungelatinized starch (as defined there) and less than 3.5% of a non-toxic ionic salt with water; (b) passing this dough through an extruder under pressure and temperature conditions which cause the starch contained in the dough to partially gelatinize to produce an extruded semi-translucent product; (c) cutting the extruded product into pieces of a predetermined shape or texture immediately or shortly after extrusion; (d) Drying the cut pieces at a temperature of up to 60 ° C to a moisture content of 9 to 13% to form a semi-product and optionally cooking or baking or frying this semi-product.

It has now been found that the dewatered potato product and / or the ungelatinized starch used in the dough mix of the process of said DE-OS can be replaced by one or more other starch types or starch containing materials (as described below) To give food products that have the desired taste and structure properties. Indeed, by using various starch containing materials and additional ingredients, snack foods and other food products with a wide range of different flavors and structures can be obtained.

The invention therefore relates to a method for producing a semi-product of a food product, which is characterized in that it comprises the following stages:

a) extruding a dough formed by mixing a dough mixture of one or more edible starch or starch containing materials together with less than 3.5%, based on the dry weight of the dough mixture, of a non-toxic ionic salt with water, the total starch content of the dough and the amount of free gelatinized starch are selected such that a partially gelatinized product with semi-translucent appearance is formed after the extrusion, the dough mixture consisting of a dry dough mixture of 20 to 80% of a dehydrated potato product in which the starch cells are essentially unbroken is 20 to 80% of an ungelatinized starch and less than 3.5% of a non-toxic ionic salt;

b) cutting the extruded product into pieces of predetermined shape or nature immediately or shortly after extrusion; and c) drying the pieces at a temperature up to 60 ° C to a moisture content of 9 to 13% to form a semi-product.

By cooking, baking or roasting, the corresponding food product is obtained from the semi-product thus produced.

The semi-product obtained by the method according to the invention can be used in particular for the production of snack products, in particular on simulated dough snack products. However, it can also be used to make other food products, e.g. B. for the production of breakfast cereals can be used.

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The percentages used here relate to the amounts of the various components in the dough mixture with reference to the dry weight of the dough mixture.

In the present case, the expression “free gelatinized starch” is understood to mean a starch which has been freed from starch cells of the material from which it is derived.

The term “product with a semi-translucent appearance” as used in the present case is intended to define a product which in its appearance represents an intermediate product between an opaque product, which is an indication that the extruded product has an insufficient amount of free contains gelatinized starch and a translucent product, which is an indication that the extruded product contains an excess amount of free gelatinized starch. It is possible to objectively determine whether a product has a “semi-translucent appearance” by comparing it directly with other products that have been made from the same dough mixture and that have opaque or translucent appearances.

An extruded product is considered to have a translucent appearance (as opposed to a semi-translucent appearance) if the amount of light transmitted does not increase if the amount of free gelatinized starch in the product is further increased, i. H. when its light transmission is maximum. It can be seen that the amount of light transmitted by the extruded products with semi-translucent and translucent appearance varies according to the components of the dough mixture used in their manufacture, and thus that the semi-translucent appearance of a specific extruded product by comparison with opaque and translucent products extruded products made from the same dough mixture must be determined.

It is necessary to carefully select the ingredient (s) of the batter mix to ensure that the extrudate contains the desired amount of free gelatinized starch after extrusion. If the amount of free gelatinized starch in the extrudate is too low, a hard dense food product is obtained after cooking or baking or frying the semi-product. On the other hand, if the amount of free gelatinized starch in the extrudate is too high, the cooked food is too low in density. In order to form an extrudate which meets the above conditions, it is generally preferred to use a dough mixture containing from 2 to 25% and advantageously from 3 to 10% of free gelatinized starch and the extrusion under such conditions in terms of temperature and pressurize that the extrudate contains from 3 to 30%, and preferably from 5 to 15%, of free gelatinized starch. It has been found that up to 30% of the ungelatinized starch originally present in the dough mixture can be gelatinized in the extruder by using suitable temperatures and suitable pressures. The preferred level of free gelatinized starch in the extrudate can generally vary within the above range depending on the particular ingredients used in the batter mix. However, the appropriate content can be quickly selected by referring to the appearance of the extrudate in the manner described above.

The total starch content of the dough mixture is preferably 30 to 95% by weight of the mixture.

As regards in particular the constituents of the dough mixture, it was found that, for example, the dewatering used in the aforementioned DE-OS 2 449 283

Potato product can be replaced, at least in part, by one or more other starch-containing materials which are derived from edible vegetable products, provided that the dough mixture thus obtained has the desired content of free gelatinized starch. As with the dewatered potato product, these other starch containing materials are advantageously materials in which the starch cells are essentially unbroken. The term "herbal product" is used here in its broadest sense to refer to any product of plant origin as opposed to a product of animal origin. Such vegetable products include cereals such as rice, wheat, rye, barley and oats, as well as tubers such as tapioca. The vegetable products can be used in the dough mixture in the form of flours or fine powders, such as. B. wheat flour, rye flour, tapioca flour, oatmeal, semolina or semolina flour, barley flour, rice flour and various types of bean flour. Other pre-made cereal-based materials, such as bread crumbs or breadcrumbs and toasted wheat flakes, can also be used. The batter mix can e.g. Contain 20 to 80% by weight of the aforementioned materials, which, if desired, can partially include the dewatered potato product used in the aforementioned DE-OS 2 449 283.

If desired, the dough mixture can also contain non-latified starch, as described in the aforementioned DE-OS 2 449 283, which has been obtained from natural products such as potatoes, rice, wheat, corn, rye, oats and beans. A mixture of two or more such types of starch can also be used if desired. The presence of such ungelatinized starch can have a significant effect on the structure of the end product, in addition to achieving a particular taste conferred by the use of special starch containing materials. The dough mixture can thus contain, for example, a total of 20 to 80% by weight of ungelatinized starch.

Similarly, the dough mixture can also contain a proportion of pregelatinized starch, as described in the aforementioned DE-OS 2 449 283, which is derived from natural products such as potatoes, rice, wheat, corn, rye, oats and the like. If desired, a mixture of two or more pregelatinized starches can be used, the dough mixture containing, for example, a total of 2 to 20, preferably 4 to 15,% by weight of pregelatinized starch. The amount of pregelatinized starch used can be suitably selected within the above limits, taking into account the amount of free gelatinized starch in the other ingredients of the batter mix to provide the desired amount of free gelatinized starch in the batter mix as a whole, thereby a product of the desired quality is obtained according to the invention. Thus, for example, if the batter mix contains a pre-made cereal-based material, such as bread crumbs or toasted wheat flakes, which in turn has a relatively high content of free gelatinized starch, the amount of pre-gelatinized starch added can be adjusted accordingly.

The incorporation of sodium chloride or other non-toxic ionic salt such as potassium chloride, potassium bromide, sodium acetate or sodium ci-step into the dry mixture was found to be less than 3.5% and preferably more than 0.5% has a significant and desired effect on the nature of the end product. The choice of the stated amounts of ionic salt is therefore an important feature of the present invention.

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Sodium chloride can be used when a tasty product is desired, while on the other hand, when a sweetened product is desired, another non-toxic ionic salt can be used that does not interfere with the sweetening effect of the present sweetening agents. The amount of ionic salt in the batter mix can also be used to control oil absorption when the semi-product is baked in oil to achieve baking.

The batter mix is formulated with water to give a batter of the desired consistency. The dough preferably has a moisture content of up to 45% and not less than 25% at a temperature of e.g. 20 to 30 ° C.

The dough is then passed through an extruder where it is subjected to temperature and pressure conditions such that a partially gelatinized product as described above is obtained. The temperature to which the dough is subjected in the extruder is preferably below 90 ° C, with a temperature range of 50 to 75 ° C being particularly preferred. The temperature of the dough during extrusion should preferably be kept below 90 ° C to avoid excessive expansion. Generally, a pressure of 70 to 160 kg / cm2, preferably 90 to 115 kg / cm2 is used in the extruder.

The extruder used for the method according to the invention can expediently be a conventional screw-type dough press. Standard dough forms can be used in the extrusion head to give the extrudate the desired shape or texture, e.g. B. Vierek-ke, tubes, rods, spirals, rotated shapes (spins), gratings, etc.

The dough extrudate is preferably cut into pieces immediately after leaving the extrusion while it is still in a plastic state. In some cases, however, it may be desirable to delay cutting the extrudate until it has migrated up to 50 cm, for example from the extrusion head, to ensure that it is in a suitable shape for cutting into well-defined shapes. For example, with certain extrudates, e.g. As those in the form of tubes, the ends of the cut pieces may be compressed as a result of the cutting process if the cutting process is too close to the head, which may be undesirable in appearance. The cutting of the extrudate can be carried out in a conventional manner, e.g. B. by means of a cutter for long articles or similar devices.

The cut pieces are then dried under carefully controlled conditions. The drying temperature should not exceed 60 ° C to avoid the formation of a hard coating on the surface of the pieces. The drying temperature is preferably in the range from 30 to 50 ° C. The drying is generally carried out in a drying drum or a drying cylinder for a period of 5 to 20 hours, advantageously 6 to 10 hours. However, the above drying times can be reduced by using an electric heater or a microwave heater. The drying is preferably carried out at a relative humidity of at least 50% (in order to avoid the formation of a hard coating on the surface of these pieces) and not above 80%.

The semi-product formed by drying the extrudate is in the form of hard, brittle pieces. which, if desired, can be stored in closed containers for a long time.

The semi-product can, for example, by a roasting or. Baking or puffing process is cooked or baked to give the cooked or baked product. In order to produce a bloated or expanded (expanded) snack product, the baking process can advantageously be carried out by quickly baking or frying the pieces in edible oil, e.g. B. vegetable oil, at a temperature of 175 to 220 ° C, preferably 185 to 205 ° C, the oil content in the end product is preferably less than 20%.

The puffing operation can advantageously include a salt, hot air or gas puffing operation. As an alternative to the above baking or swelling steps, the semi-product can be boiled in boiling water.

After cooking, the semi-finished product can be salted, sweetened or seasoned in another way before packaging.

However, to ensure the taste or nutritional value of the final product, numerous additional ingredients can also be added to the original dough. Examples of such ingredients include flavor enhancers such as monosodium glutamate, antioxidants such as butylated hydroxyanisole, butylated hydroxytoluene and propyl gallate, homogenizers, sweeteners such as sugar, saccharin and sorbitol and foods such as protein materials, especially soy protein, minerals and vitamins. 25 The following examples explain the effect of varying the composition of the dough mixture compared to that described in the examples of DE-OS 2 449 283. For the sake of convenience, the ingredients of the latter dough mixture are designated as follows:

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Formulation according to DE-OS 2 449 283

Code components

%

35 A potato starch (ungelatinized) 45

B Potato granules (partially gelatinized) 45

C Pregelatinized potato starch 7

D salt 3

E other additives

40

In the following examples, the process for producing a snack product was carried out within the following parameters:

Moisture content of the dough 25 to 45%

45 Dough temperature <90 ° C

Temperature in the extruder <75 ° C

Pressure in the extruder 70 to 160 kg / cm2

Dryer temperature 30 to 60 ° C

Drying time 5 to 20 hours

so relative humidity in the dryers 50 to 80% moisture content of the semi-finished product 9 to 13% temperature in the baking device 175 to 220 ° C.

example 1

55 a) The potato granulate component of the mixture (B) was partially replaced by other cereal flours. The other ingredients were kept at the percentages of the above formulation.

Dough composition 60 A potato starch 45%

B potato granules 5%

Wheat flour 40%

or

Rye flour 40%

65 or

Tepioca flour 40%

or

Oatmeal 40%

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C pre-gelatinized potato starch 7%

D salt 3%

Snack products were made by a method according to the invention which was carried out within the above parameters. After baking, the products obtained had an interesting texture and taste.

b) The potato granulate component of the mixture (B) was completely replaced by other cereal flours. The other ingredients were kept at percentages of the above formulation.

Dough composition

Potato starch

45%

Semolina or semolina flour

45%

or

Rye flour

45%

or

Barley flour

45%

or

wheat flour

45%

or

Tapioca flour

45%

or

Rice flour

45%

or

Bread crumbs

45%

or

Horse bean flour

45%

or

toasted wheat flakes

45%

pre-gelatinized potato flour

7%

salt

3%

Snack products were produced by the method according to the invention within the above parameters. After baking, the products obtained had an interesting texture and taste. However, products made using semolina flour, barley and oats or oat types showed less expansion, which resulted in a harder texture.

c) lb) was repeated, maintaining the same ratio between A and B and increasing the proportion of pregelatinized potato starch C in order to achieve greater expansion.

Dough composition

A

Potato starch

43.5%

B

Semolina or semolina flour

43.5%

or

Barley flour

43.5%

or

Oatmeal

43.5%

C.

pre-gelatinized potato starch

10.0%

D

salt

3%

Snack products were produced by the process according to the invention within the above parameters. After baking, the product obtained had a satisfactory degree of expansion and retained the interesting basic taste of the grain used.

Example 2

Potato starch A was replaced with various other starches and potato granules B were replaced with other types of flour.

Dough composition a) A wheat starch 45%

B

Semolina or semolina flour

45%

or

Rye flour

45%

or

Barley flour

45%

or

wheat flour

45%

or

Tapioca flour

45%

or

Bread crumbs

45%

or

Horse bean flour

45%

or

toasted wheat flakes

45%

C.

pre-gelatinized potato starch

7%

D

salt

3%

A

Cornstarch

45%

B

Semolina or semolina flour

45%

or

Rye flour

45%

or

Barley flour

45%

or

Oatmeal

45%

or

Tapioca flour

45%

or

Bread crumbs

45%

or

Horse bean flour

45%

or

toasted wheat flakes

45%

C.

pre-gelatinized potato starch

7%

D

salt

3%

A

tapioca

45%

B

Semolina or semolina flour

45%

or

Rye flour

45%

or

Barley flour

45%

or

Oatmeal

45%

or

Tapioca flour

45%

or

Bread crumbs

45%

or

Horse bean flour

45%

or

toasted wheat flakes

45%

C.

pre-gelatinized potato starch

7%

D

salt

3%

Each of the dough compositions a), b) and c) were converted into a snack product according to the inventive method within the above parameters.

In all of the three cases, the baked products had an interesting texture and an interesting taste, especially those made from a dough that contained semolina or semolina flour, rye flour, bread crumbs, horse bean flour and roasted wheat flakes. In some cases, however, the products showed a harder texture and it is believed that softer textures can be obtained if desired by increasing the proportion of pregelatinized potato starch in the batter composition used.

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Example 3

The pre-gelatinized potato starch C was replaced by other pre-gelatinized starch types in order to determine whether changes in the texture can be achieved.

T composition

A

Wheat starch

45%

B

wheat flour

45%

or

Rye flour

45%

or

Bread crumbs

45%

or

Horse bean flour

45%

or

toasted wheat flakes

45%

C.

pre-gelatinized wheat starch

7%

D

salt

3%

A

Cornstarch

45%

B

wheat flour

45%

or

Rye flour

45%

or

Bread crumbs

45%

or

Horse bean flour

45%

or

toasted wheat flakes

45%

C.

pre-gelatinized corn starch

7%

D

salt

3%

Snack products were produced by the process according to the invention within the above parameters. The baked products showed very similar properties compared to those made with pregelatinized potato starch.

Example 4

Changes were made to the formulation, replacing A and B either with one component or with more than two components.

Dough composition

FROM

Bread crumbs

92%

C.

pre-gelatinized potato starch

5%

D

salt

3%

A

Potato starch

28.5%

B

Potato granules

28.5%

Tapioca flour

28.5%

C.

pre-gelatinized potato starch

7%

D

salt

3%

E

Soy flour

4.5%

Snack products were produced by the process according to the invention within the above parameters. In both cases, snack products with an interesting texture and taste were obtained.

The following five attempts are given with more attention to detail.

Example 5

The following ingredients were mixed intimately according to the formulation below:

Corn starch 45%

Semolina or semolina flour 45%

pre-gelatinized potato starch 7%

Salt 3%

The ingredients were mixed in a vertical mixer for 10 minutes, the moisture content of the resulting mixture being 12%. The dry mixture was placed in a conventional dough press where the moisture content was adjusted to 32% and further intimate mixing took place prior to extrusion. After mixing, the dough material was compressed using a auger-type auger-type screw, extruded through a mold and cut flat to short lengths. The pressure cylinder had a hot water jacket that reached average temperatures of 50 to 60 ° C, and the mixture was compressed at pressures of 90 to 115 kg / cm2.

A common dough form was used which formed tubular pieces approximately 30 mm long and 15.0 mm in outer diameter with a wall thickness of approximately 0.9 mm. The extrudate had a white translucent appearance and was stretchy. After extrusion, the semi-product was slowly dried in a batch dryer under conditions similar to a continuous dryer. The final moisture content of the semi-product obtained was 10.5 to 12%. The product had a hard and brittle nature and could be stored in closed containers for a longer period.

The semi-product was baked in vegetable oil at a temperature of 205 ° C for about 14 seconds. The inflated material showed a 1.3 to 1.5 times expansion in diameter and the oil absorption was 14 to 18% based on the total weight. Finally, the bloated product was either salted or coated with flavoring agents. The product obtained was a high quality snack with a well defined shape and a golden brown color.

Example 6

The following ingredients were mixed intimately.

Corn starch 45%

Rye flour 45%

pre-gelatinized potato starch 7%

Salt 3%

The dough material was then processed as described in Example 5, but with the following changes:

Moisture content of the mixture 13.2%

Dough moisture content 32%

Extrudate length 30 mm

outer diameter 15.0 mm

Wall thickness 1.2 mm

Expansion of the end product in diameter = 1.4 to 1.6 times.

Appearance of the end product = dark brown and spotty.

Example 7

The following ingredients were mixed intimately.

Tapioca 45%

Bread crumbs 45%

pre-gelatinized potato starch 7%

Salt 3%

The dough material was then processed as described in Example 5, but with the following changes:

Moisture content of the mixture 10.3%

Moisture content of the dough 30.5%

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Extrudate - length of outer diameter wall thickness

30 mm 15.5 mm 2.1 mm

Expansion of the final product in diameter = 1.4 to 1.7 times.

Appearance of the final product = light brown. Example 8

The following ingredients were mixed intimately.

tapioca

Horse bean flour pregelatinized potato starch salt

45% 45% 7% 3%

Moisture content of the mixture Moisture content of the dough extrudate - length outer diameter wall thickness

9.8% 28% 30 mm 14.5 mm 1.4 mm

Expansion of the final product in diameter = 1.2 to 1.4 times.

Appearance of the final product = golden brown.

Example 9

The following ingredients were mixed intimately.

Wheat starch '• 45%

roasted wheat flakes 45%

pre-gelatinized potato starch 7%

Salt 3%

The dough material was then processed as described in Example 5, but with the following changes:

The dough material was then processed as described in Example 5, but with the following changes:

20th

Moisture content of the mixture Moisture content of the dough Extrudate - length of outer diameter Wall thickness

11.2% 31.8% 30 mm 15 mm 1.3 mm

Expansion of the end product in diameter = 1.4 to 1.6 times.

Appearance of the end product = brown, spotty.

Claims (11)

621 689 2nd PATENT CLAIMS 1. A process for producing a semi-product of a food product, characterized in that it comprises the following stages: a) extruding a dough formed by mixing a dough mixture of one or more edible starch or starch containing materials together with less than 3.5%, based on the dry weight of the dough mixture, of a non-toxic ionic salt with water, the total starch content of the dough and the amount of free gelatinized starch are selected such that a partially gelatinized product with semi-translucent appearance is formed after the extrusion, the dough mixture consisting of a dry dough mixture of 20 to 80% of a dehydrated potato product in which the starch cells are essentially unbroken is 20 to 80% of an ungelatinized starch and less than 3.5% of a non-toxic ionic salt; b) cutting the extruded product into pieces of predetermined shape or nature immediately or shortly after extrusion; and c) drying the pieces at a temperature up to 60 ° C to a moisture content of 9 to 13% to form a semi-product. 2. The method according to claim 1, characterized in that the mixture contains 3 to 10% of free gelatinized starch. 3. The method according to claim 1, characterized in that the extruded product contains 5 to 15% of free gelatinized starch. 4. The method according to claim 1, characterized in that the dough mixture contains 20 to 80 wt.% Of a starch-containing material in which the starch cells are essentially unbroken. 5. The method according to claim 1, characterized in that the mixture contains 20 to 80 wt.% Of an ungelatinized starch component. 6. The method according to claim 1, characterized in that the mixture contains 2 to 20% by weight of a pregelatinized starch component. 7. The method according to any one of the preceding claims, characterized in that the mixture contains more than 0.5%, but less than 3.5%, of a non-toxic ionic salt. 8. The method according to any one of the preceding claims, characterized in that the dough has a moisture content of 25 to 45%. 9. The method according to any one of the preceding claims, characterized in that the cut pieces are dried at a temperature of 30 to 50 ° C. 10. The method according to any one of the preceding claims, characterized in that the cut pieces are dried at a relative humidity of 50 to 80%. 11. Use of the semi-product, obtained by the process according to claim 1, for the production of a food product, characterized in that the semi-product is converted into the corresponding food product by cooking, baking or roasting.