CN103607896B - 健康分层曲奇 - Google Patents

健康分层曲奇 Download PDF

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CN103607896B
CN103607896B CN201280030318.3A CN201280030318A CN103607896B CN 103607896 B CN103607896 B CN 103607896B CN 201280030318 A CN201280030318 A CN 201280030318A CN 103607896 B CN103607896 B CN 103607896B
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L·朗凡
A·韦雷尔
A·阿洛提
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Abstract

本公开涉及用于生产包含至少一块饼干和夹心的分层曲奇的方法，所述分层曲奇包含10wt%－25wt%的脂肪和15wt%－40wt%的糖，其中所述分层曲奇的可缓慢消化的淀粉占总可利用淀粉的比例为至少31%，该方法包括：形成料团，其包含谷类面粉、脂肪、糖和相对于料团总重至多8wt%的添加的水；将所述料团模制成饼干的形状；烘焙所述饼干；和用夹心装配所述饼干以形成分层曲奇；其中所述谷类面粉包含精制谷类面粉，其含量占所述料团总重的至少21wt%，其中吸水率如通过所测定的为55%以下。

Description

健康分层曲奇
本发明涉及曲奇。更具体地，本公开涉及可即食的包含连续饼干和夹心层的可即食的分层曲奇，例如夹心在饼干上的曲奇或三明治曲奇。
消费者对其食物的健康益处且特别是其营养模式的关注正在逐渐增加。分层曲奇作为零食被食用以提供除常规膳食外的能量补给。这种烘焙产品中主要的能量来源以淀粉的形式贮存。对可以在较长时间内提供能量的分层曲奇存在需求，且这种曲奇的能量供给比例与其淀粉内含物的消化相关。与可缓慢消化的淀粉(SDS)相比，可快速消化的淀粉(RDS)提供更短时间的能量。在烘焙前，用于形成分层曲奇的料团包含大量可缓慢消化的淀粉。然而，在烘焙过程中，可缓慢消化的淀粉的这种量减少。这归因于烘焙过程中的淀粉糊化。
糊化因料团混合物中存在水而发生。糊化是指淀粉的结晶区域部分熔化，导致可消化性增加。在湿料团热处理的过程中，淀粉颗粒首先膨胀，然后逐步释放其结晶结构，直到它们爆裂为止，导致颗粒(直链淀粉和支链淀粉)中包含的多糖类浸出。在高度浓缩的系统例如饼干料团中，这一系列事件可能受到受限的含水量限制，但结晶区域逐步熔化仍然会发生。
将理解在下文中“长效能量”将指使用Englyst方法(Englyst,1996)通过终产品的缓慢可利用的葡萄糖(SAG)测量的可缓慢消化的淀粉的量高于15.0g/100g分层曲奇。
制造健康分层曲奇且尤其是具有高水平可缓慢消化的淀粉的一个问题在于可以降低可缓慢消化的淀粉含量的夹心部分的贡献。分层曲奇通常包含占分层曲奇总重10wt%－40wt%的夹心。
用于增加可缓慢消化淀粉含量的一种解决方案在于向夹心组合物中加入天然淀粉。然而，可以加入的天然淀粉的量受到终产品的感官特性的限制。过高的淀粉含量将提供令人不愉快的口感。
另一种解决方案将是增加分层曲奇饼干部分的料团组合物中的淀粉含量(SAG来源)。然而，这将引起为了能够加工料团所需的混合过程中加水量的增加。增加所添加的水对SAG的负面影响(其增加淀粉糊化)超过了加入更多淀粉的正面效应。
分层曲奇的另一个问题在于夹心部分所提供的脂肪和/或糖的含量。为了维持饼干作为整体的良好营养特性，因而有必要减少分层曲奇饼干部分的脂肪和/或糖含量。然而，脂肪和糖都是料团增塑剂。因此，用于包括减少量的脂肪和或糖的饼干部分的料团组合物显示受损的可加工性，并且这在工业化生产线中特别是个问题。
为了处理料团的差的可加工性，当然可以向料团中加入水。然而，水在饼干烘焙过程中触发淀粉糊化且这导致烘焙的饼干部分中不希望地低的可缓慢消化的淀粉含量。因此，长效能量特性可能丧失。
WO2005/34635公开了用于加工仅包含7.0wt%添加的水的三明治曲奇料团的解决方案。在这种解决方案中，使用线-切割曲奇(depositor)沉积器形成了料团。然而，这种加工方法阻止具有锐边和尖锐(sharp)设计的饼干形成。
另一种解决方案获知于EP0372596，其涉及夹心曲奇(三明治曲奇被视为一种类型的夹心曲奇)。该文件的目的在于提供包含瓜尔豆胶的夹心曲奇。通常，瓜尔豆胶以粉末形式被用于面包房中且其强力地结合水。因此，瓜尔豆胶的使用使得有必要增加料团的含水量并且这导致淀粉的进一步糊化(产品中SDS更少)。EP0372596仅涉及其中饼干部分包含瓜尔豆胶的分层曲奇。
因此，对改进的饼干存在需求，它解决至少某些与现有技术相关的问题，或至少为其提供了商业上有用的替代方案。
特别地，对生产包含10wt%－25wt%的脂肪和15wt%－40wt%的糖的分层曲奇的方法存在需求，其中分层曲奇的可缓慢消化的淀粉占总可利用淀粉的比例为至少31wt%。
因此，在第一个方面中，本公开提供了用于生产包含至少一块饼干和夹心的分层曲奇的方法，所述分层曲奇包含10wt%－25wt%的脂肪和15wt%－40wt%的糖，其中所述分层曲奇的可缓慢消化的淀粉占总可利用淀粉的比例为至少31%，该方法包括：
形成料团，其包含谷类面粉、脂肪、糖和相对于料团总重至多8wt%的添加的水；
将所述料团模制成饼干的形状；
烘焙所述饼干；和
用夹心装配所述饼干以形成分层曲奇；
其中所述谷类面粉包含精制谷类面粉，其含量占所述料团总重的至少21wt%，其中吸水率如通过所测定的为55%以下。
现在将进一步描述本公开。在如下段落中，更详细地定义本公开的不同方面。除非有清楚地相反地指示，如此定义的每个方面都可以与任何其它方面相结合。特别地，显示为优选或有利的任何特征都可以与显示为优选或有利的任何其它特征相组合。
饼干是烘焙的可食用的基于谷类的产品。它们通常具有低湿度和松脆的质地。它们通常是小的，并且用泡打粉、小苏打或有时用酵母发酵。它们通常是甜的。它们可以含有内含物和夹心。
如本文所定义的，“分层曲奇”应被理解为由交替和连续的饼干和夹心层制成的曲奇。最简单的分层曲奇是具有单一基底饼干41的曲奇4，在所述单一基底饼干41上沉积了夹心43，如图3中所示。另一种类型的分层曲奇是三明治曲奇5，其在两层饼干51、52之间包含夹心层53，如图4中所示。
本公开的目的在于提供符合提供长效能量和为健康点心的标准的分层曲奇。因此，本公开提供了用于生产包含具有至少一块饼干和夹心部分的饼干的分层曲奇的方法，所述分层曲奇包含10wt%－25wt%的脂肪和15wt%－40wt%的糖。
用于形成饼干的料团包含谷类面粉、脂肪、糖和相对于料团总重至多8wt%的添加的水。所述谷类面粉包含精制谷类面粉，其含量占料团总重的至少21wt%，其中如通过所测定的吸水率在55%以下。
术语“脂肪”是指可以食用并且可以用于制造分层曲奇的任何脂质来源，植物或动物来源。这种脂肪的实例是棕榈油、菜籽油以及其它植物油、来自动物来源的黄油。优选地，可即食的分层曲奇具有10wt%－25wt%的脂肪，更优选11wt%－23wt%脂肪，甚至更优选12wt%－20wt%，更优选15wt%－20wt%。更具体地，分层曲奇的饼干部分包含占饼干部分总重5wt%－30wt%的脂肪，优选6wt%－22wt%，更优选7wt%－15wt%。
如本文所定义的“糖”或“糖类”是指任何单糖类和二糖类的干物质，无论其是何种来源且还扩展至葡萄糖糖浆（也称作葡萄糖-果糖糖浆或果糖-葡萄糖糖浆）的所有干物质。在单糖类中有果糖、半乳糖、葡萄糖、甘露糖及其混合物。在二糖类中有蔗糖，但蔗糖可以部分或全部被另一种二糖替代，例如乳糖或麦芽糖。葡萄糖糖浆包含单糖类和二糖类，也包含一些更长链的聚合葡萄糖。为避免疑虑，当考虑加入到混合物中的葡萄糖糖浆或其它糖混悬液形式的糖的量时，仅应考虑糖的干重。糖浆或混悬液的含水量应被认为是如本文所述的添加的水的一部分。
可使用本公开的方法得到的分层曲奇(即包括夹心)包含占分层曲奇总重15wt%－40wt%的糖，优选18wt%－36wt%，更优选20wt%－32wt%，仍然更优选25wt%－30wt%。
更具体地，所述饼干部分包含占饼干部分总重10wt%－25wt%的糖，优选11wt%－22wt%,更优选12wt%－20wt%，甚至更优选12wt%－15wt%。存在于饼干配方（即不包括夹心）中的最优选的糖量为至少12wt%。这是为了感官影响和技术原因。不希望受到理论约束，推断低于12wt%的糖类影响料团的机械性能。一般而言，在料团中，通过富含能够溶解的可溶性成分的添加的水形成连续相。因为糖能够溶于水，它有效地增加存在的水的有效容积(1g糖溶于1ml水得到1.6ml总体积)。因此，存在至少12wt%的糖类减少了包括另外添加的水的需求，且由此通过允许更少的水，增加最终饼干的SDS值。更高的糖量使得更难以满足健康饼干的要求。
所述健康分层曲奇优选包含占终产品总卡路里值至多27.5%的糖、占终产品总卡路里值至多38.0%的脂肪和占终产品总卡路里值至少55.0%的可利用碳水化合物。
可即食的分层曲奇具有的可缓慢消化的淀粉占总可利用淀粉的比例(SDS/(SDS+RDS))为至少31wt%，优选至少35wt%，更优选至少38wt%，仍然更优选至少40wt%。为了可消化性，最高比例将优选为至多80wt%。总可利用淀粉包含可缓慢消化的淀粉(SDS)和可快速消化的淀粉(RDS)。总可利用淀粉与总淀粉之间的差别在于总可利用淀粉不含不能被消化（即在小肠中逃离消化）的抗性淀粉。
与可快速消化的淀粉相比，认为可缓慢消化的淀粉提供更高的健康益处。的确，可快速消化的淀粉在消化过程中快速地分解成葡萄糖，由此可被身体快速地利用。因此，血糖水平快速升高。这可以触发导致在脂肪组织中的一定储存的胰岛素递送。因此，能量可仅被较短时间地提供。相反，可缓慢消化的淀粉缓慢地被身体吸收。因此，能量可被更长时间地提供。
SDS或可缓慢利用的葡萄糖(SAG)可以通过用Englyst方法得到的可缓慢利用的葡萄糖(SAG)测量值来表征(“RapidlyAvailableGlucoseinFoods:anInVitroMeasurementthatReflectstheGlycaemicResponse”,Englyst等人,Am.J.Clin.Nutr.,1996(3),69(3),448-454;“GlycaemicIndexofCerealProductsExplainedbyTheirContentofRapidlyandSlowlyAvailableGlucose”,Englyst等人,Br.J.Nutr.,2003(3),89(3),329-340;“MeasurementofRapidlyAvailableGlucose(RAG)inPlantFoods:aPotentialInVitroPredictoroftheGlycaemicResponse”,Englyst等人,Br.J.Nutr.,1996(3),75(3),327-337)。SAG是指可能被用于在人小肠中缓慢吸收的葡萄糖的量(来自糖和淀粉，包括麦芽糖糊精)。在本公开的情形中，SDS含量等于SAG含量，因为没有除淀粉（即SDS）之外的其它SAG来源。可快速利用的葡萄糖(RAG)是指很可能被用于在人小肠中快速吸收的葡萄糖的量。
在Englyst方法中，通过手工和粗磨一种或多种饼干制备饼干样品。然后使饼干样品在标准化条件下、在转化酶、胰腺α淀粉酶和淀粉葡糖苷酶的存在下经受酶促消化。调整参数例如pH、温度(37℃)、粘度和机械混合以模拟胃肠条件。在20min的酶促消化时间后，测量了葡萄糖，并标记为RAG。在120min的酶促消化时间后，再次测量葡萄糖，并标记为可利用的葡萄糖(AG)。通过从AG中减去RAG得到SAG(SAG=AG-RAG)，因此，SAG相应于第20分钟至第120分钟之间释放的葡萄糖部分。通过单独的分析获得了游离的葡萄糖(FG)，包括从蔗糖中释放的葡萄糖。然后从RAG中减去FG得到了RDS(RDS=RAG-FG)。
优选地，可即食的三明治曲奇具有至少16.5g/100g三明治曲奇的SAG含量，更优选至少18.0g/100g三明治曲奇，仍然更优选至少21.0g/100g三明治曲奇。最高的SAG优选至多为50.0g/100g。
所述饼干还可以包含多元醇类或短链可溶性纤维。它们以与糖类似的方式在下述中起作用：改善料团的机械性能而不增加存在于饼干中的淀粉的水解。使用多元醇类或短链可溶性纤维允许提供不含糖的或糖减少的饼干。优选地，所述成分包含低于20%、优选低于10wt%、优选低于5%的多元醇类或短链可溶性纤维，这是为了胃肠耐受问题和用于清楚的标记。与糖类类似，仅应考虑多元醇类或短链可溶性纤维的干重。如果饼干包含10wt%以上的多元醇类，则它被认为具有轻泻特性且因此必须相应地标记。在一个实施方案中，所述饼干包含至少0.1wt%的多元醇类或短链可溶性纤维。更优选地，所述成分不含多元醇类或短链可溶性纤维。在一个实施方案中，所述成分不含瓜尔豆胶或其它粘性可溶性纤维，例如果胶、黄原胶、车前草或葡甘露聚糖
料团包含谷类面粉，其含有含量占料团总重的至少21wt%的精制谷类面粉，其中该料团具有的如通过所测定的吸水率在55%以下。优选地，所述谷类面粉包含至少41wt%的含量的精制谷类面粉。优选地，如通过根据NF-ISO-5530-1标准所测定的吸水率为52%以下。所述精制谷类面粉优选至多占料团的60wt%且更优选至多50wt%。
通过的测量在NF-ISO-5530-1下被标准化。在该标准中将吸水率定义为为了获得具有500UF的最大稠度的料团所需的、14wt%水含量时每100g面粉中的水量。稠度是以任意单位(调粉性记录单位UF)表示的、料团在标准中指定的恒定速度下在内被捏揉的过程中的抗性。首先，测量了面粉的含水量。然后将水加入到面粉中，计算水量使得料团的稠度接近500UF(480UF－520UF)。将面粉和水彼此揉合，对于两个料团槽记录了测量值。根据这些测量值和为形成料团而加入到面粉中的水的体积，得到了吸水率。
使用这种类型的面粉提供了下列优势：需要更少的水来形成料团并由此限制了淀粉的糊化。因此，获得了健康的曲奇。
用于测量含水量的技术是本领域中熟知的。可以使用AAC44-15.02国际方法(水份-空气烘箱法)（1999修订的）测量面粉、料团和最终饼干中的含水量。
所述精制谷类面粉优选是选自下述的精制小麦面粉：软质小麦面粉、具有低受损淀粉的小麦面粉和经热处理的小麦面粉，及其混合物。使用这些类型的面粉，有可能限制烘焙过程中的淀粉糊化并且增加终产品中的SDS。的确，与精制小麦面粉相比，在这些面粉中淀粉受损更少。淀粉糊化使得淀粉能够更易于消化且由此减少终产品中可缓慢消化的淀粉含量。
软质小麦面粉和硬质小麦面粉均为由小麦(Triticumaestivum)生产的小麦面粉类型。软质小麦面粉不应与仅由小麦生产的面粉混淆，且硬质小麦面粉不应与由硬粒小麦(Triticumdurum)生产的面粉混淆。术语“软质”和“硬质”是指用于制造面粉的小麦谷粒的硬度，而不是指小麦的品种。谷粒的硬度归因于胚乳细胞的密度。软质小麦胚乳具有较低的密度，其对应于较弱的淀粉和蛋白质键。因此，可以将软质小麦谷粒破碎成比硬质小麦谷粒更细的颗粒并且得到更少的受损淀粉。
谷粒的硬度归因于胚乳细胞的密度。软质小麦胚乳具有较低的密度，其对应于较弱的淀粉和蛋白质键。因此，可以将软质小麦谷粒破碎成比硬质小麦谷粒更细的颗粒并且得到更少的受损淀粉。
软质小麦面粉可以从研磨软质小麦得到，例如在Crousty,Alteo,Epson(均来自Syngenta)或Arkeos(来自Limagrain)等名称下商业化的那些。使用吸收更少水的更软的面粉允许使用比对于更硬的面粉更宽范围的添加的水。即，即使使用直至8wt%的水，面粉一般吸收更少的水且淀粉含量因此在烘焙过程中更少糊化。此外，由于吸收了更少的水，有更多的自由水可用于润滑料团且可用甚至减少量的添加的水(约3-4wt%)生产可加工的料团。在一个实施方案中，当使用软质面粉时，料团可以包含直至10wt%添加的水。
具有低受损淀粉的小麦面粉是指面粉具有的受损淀粉的含量低于面粉重量的5.5%。受损的淀粉含量是在研磨操作过程中被物理地损伤的淀粉粒的百分比。它是通过AACC76-31.01方法测量的。
经热处理的小麦面粉的实例是用许多加热和冷却循环处理或经退火的小麦面粉。退火是通过改善晶体生长和通过促进淀粉链之间的相互作用而改变淀粉的理化特性的热液处理。
精制小麦面粉仍可由特别选择的研磨部分制成，从而该面粉具有如通过根据NF-ISO-5530-1标准所测定的55%以下的非常低的吸水率。优选地，选择的研磨部分具有小粒度，即低于40μm的细颗粒的百分比为50%以上。可以通过在研磨过程中的粒度测量(通过激光粒度测量或筛目直径)分析辅助选择研磨部分。
所述谷类面粉可以包含全粒谷类面粉。
“全粒谷类面粉”是指直接或间接由包含胚乳、麸皮和胚芽的全粒谷物生产的面粉。全粒面粉还可以优选由单独的面粉重构，所述单独的面粉由胚乳、麸皮和胚芽分别以下述比例制成：所述比例使重构的全粒面粉与直接由仍然保留麸皮和胚芽的谷类生产的全粒面粉具有相同的组成。
“全粒谷类面粉”应区别于指仅由谷类胚乳制成的面粉的“精制谷类面粉”。能通过本公开的方法获得的分层曲奇的饼干部分的饼干包含至少29wt%、优选至少30wt%、更优选至少31wt%的全粒谷类面粉。优选地，所述饼干包含至多70wt%、更优选至多60wt%、仍然更优选至多50wt%的全粒谷类面粉。这些含量是根据最终饼干部分重量中全粒谷类面粉的总重计算的。当全粒谷类面粉的量超过70wt%时，加工料团变得非常困难。
全粒谷类面粉优选选自全粒小麦面粉、全粒大麦粉、全粒黑麦粉、全粒斯佩耳特小麦粉、全粒燕麦粉、全粒稻米粉、全粒玉米面粉、全粒粟面粉、全粒高粱面粉、全粒画眉草面粉、全粒黑小麦面粉和假谷类面粉例如苋菜粉和藜粉，以及它们的混合物。优选地，全粒谷类面粉选自全粒小麦面粉、全粒大麦粉、全粒黑麦粉、全粒斯佩耳特小麦粉、全粒燕麦粉，及它们的混合物。更优选地，其选自全粒小麦面粉、全粒大麦粉、全粒黑麦粉、全粒斯佩耳特小麦粉及它们的混合物。
优选地，全粒谷类面粉包含至少两种不同类型的全粒谷类面粉。在一个实施方案中，全粒谷类面粉包含全粒小麦面粉。全粒小麦面粉可以是重构的、获自精制小麦面粉、麦麸粉和麦胚粉的混合物的全粒小麦面粉。优选地，所述精制小麦面粉与用于此方法中的具有低于55%的吸水率（如通过所测量的）的精制小麦面粉相同。在此后一种情形中，这种精制小麦面粉的一部分被用于重构全粒小麦面粉，然而，该部分将被包括在料团的精制小麦面粉含量中并同时被包括在全粒谷类面粉含量的一部分中。因此，它将被包括在为了具有可加工的料团所必需的精制小麦面粉的至少14.5wt%、优选至少29wt%中。优选地，其它全粒谷类面粉选自全粒大麦粉、全粒黑麦粉、全粒斯佩耳特小麦粉及其混合物。
在一个优选的实施方案中，全粒谷类面粉包含占全粒谷类面粉总重至多80wt%的全粒小麦面粉，优选至多60wt%，更优选至多50wt%，更优选至多32wt%。
在一个优选的实施方案中，全粒谷类面粉包含四种不同类型的全粒谷类面粉：全粒大麦粉、全粒黑麦粉、全粒斯佩耳特小麦粉和全粒小麦面粉。
优选地，全粒谷类面粉是多谷类面粉，即至少20wt%的全粒谷类面粉不是全粒小麦面粉，优选至少40wt%，更优选至少50wt%，仍然更优选至少68wt%。
当使用除全粒小麦面粉外的全粒谷类面粉类型时，甚至更难以得到具有超过31wt%的足够SDS/(SDS+RDS)值的最终的分层曲奇，因为与全粒小麦面粉相比，某些类型的全粒谷类面粉（例如燕麦、大麦和斯佩耳特小麦）包含更少的SDS。
所述料团包含相对于料团总重至多8wt%的量的水。即在烘焙前添加的水构成总料团的8wt%。所述水在烘焙过程中基本上从饼干中被除去。添加的水不包括已经存在于某些成分中的水(例如约12wt%的谷类面粉为水)。至少某些存在于这些成分中的水在烘焙过程中也从饼干中被除去。因此，料团和最终的饼干中谷类面粉的wt%因这种水份的丧失而基本上相同。与料团相比，饼干的无含水量的成分(例如脂肪)将形成更大的wt%。。
所述料团包含至多8wt%添加的水，优选3－8wt%，更优选4－7wt%，最优选5－6wt%。如上所述，术语“添加的水”是指除其它成分外添加的水。因此，“添加的水”不包括包含在任意其它成分中的水，所述其它成分例如谷类面粉(通常为约10-15wt%)、薄片或麸皮和胚芽。对于糖的糖浆、短链可溶性纤维、多元醇类等，存在于糖浆中的水被视为添加的水的一部分。
本文所讨论的且具有3－8wt%含水量的饼干料团的流变性为相当有特征性的。料团通常不具有“连续的”结构，如面包/比萨料团，而是更像分离颗粒的集合。当料团具有低于3wt%的含水量时，不能形成料团。在这种低水化水平下，料团表现得更像颗粒材料(类似于砂子)。这种料团的质地类似于酥饼或酥面团并且显示出非常有限的内聚性。这种料团在压制后也比更为湿润的料团硬得多。因此，料团的可加工性降低且不能通过旋转模制加工。在添加的水的量高于8wt%时，料团的机械性能增加，而在烘焙时淀粉水解的程度增加且SDS减少。
由于烘焙时天然存在于谷类面粉中的水的水丧失，所以料团的谷类含量的wt%值基本上与最终的饼干的wt%值相同。
所述饼干还可以包含约19－约50wt%的其它成分，包括全粒谷物薄片、未精制的非-全粒面粉和另外的成分，例如乳化剂、膨发剂、维生素、矿物、盐、调味剂和乳或乳品成分，及其组合。这些另外的成分在下文中更详细地讨论。
所述饼干还可以包含至多34.5wt%的全粒谷物薄片，优选至多19wt%，优选至多16wt%，更优选至多11wt%，仍然更优选至多9wt%，例如全粒燕麦薄片或麦芽全粒黑麦薄片。过量的薄片（即超过19wt%）将为饼干提供预料之外的外观，即可以阻挠潜在消费者的颗粒样饼干和更致密的产品的外观。当薄片存在时，优选它们占饼干的至少约0.9wt%，因为更少的量在终产品中可以是不可辨别的。
更一般地，可即食的分层曲奇的饼干部分可以包含可见的全粒谷物的块。优选的薄片是燕麦薄片和麦芽黑麦薄片，这归因于对消费者的感官影响。这还有助于增加料团配方中的全粒含量而不损害最终饼干的适口性。最优选的薄片是婴儿燕麦薄片，因为其外观对于消费者是有利的且它们为饼干贡献额外的、在烘焙过程中较不易于被水解的SDS。它们在加工过程中保持比大薄片更为完整。
作为实例，一些不同薄片的含量范围在下表中举出：
成分类型 饼干配方中的最小% 饼干配方中的最大%
小麦薄片 0.9 9
麦芽燕麦薄片 0.9 19
婴儿燕麦薄片 3 18
燕麦薄片 3 9
大麦薄片 0.9 3
可即食的分层曲奇的饼干部分仍然可以包含另外的谷类麸皮和/或谷类胚芽。在存在另外的谷类麸皮和谷类胚芽的情况中，麸皮和胚芽来自选自如下的不同谷类：小麦、大麦、黑麦、斯佩耳特小麦(spelt)、燕麦或其混合物。
可以与谷类面粉和水混合用于形成料团的其它成分是：乳化剂、膨发剂。
乳化剂可以是大豆卵磷脂、单甘油酯的二乙酰基酒石酸酯、硬脂酰乳酸钠。
膨发剂可以是碳酸氢铵、碳酸氢钠、焦磷酸钠或其混合物。
其它成分还可以是维生素或矿物，例如维生素B1、维生素、维生素PP、铁和镁，及其混合物。
其它成分可以是盐、调味剂、可可粉、固体块、乳和乳品衍生物、蜂蜜和钙补充剂。
调味剂可以是粉末形式或液体形式。
固体块可以是巧克力颗粒(drop)、水果块、坚果如榛子(优选榛子块)、挤出的谷类等。固体块不包括谷类薄片。固体块带来质地和风味而不增加SAG含量。所述三明治饼干优选包含2wt%－15wt%固体块，优选4wt%－10wt%。
巧克力颗粒是固体巧克力块。“巧克力”应理解为指“黑巧克力”、“乳巧克力”或“白巧克力”。优选地，巧克力颗粒是黑巧克力块，其包含至少35wt%的可可液块(US法规)，更优选35wt%可可固体(欧盟法规)，更优选至少40wt%。。
在本公开的范围内，“水果块”是指类似于水果的植物的任何甜的可食用部分的块，例如葡萄干、无花果、梅干、橙、蔓越莓、蓝莓、覆盆子、草莓、杏、黑醋栗、红醋栗、桃、梨、猕猴桃、香蕉、苹果、柠檬、菠萝、蕃茄。这些水果的块是干燥的或经加工的。此用语不包括坚果。
所述夹心部分是在冷却后具有从粘性(对于果酱)到固体(对于无水脂肪夹心)范围的稠度的夹心。所述夹心可以是基于水的或基于脂肪的。
优选地，在40℃下，夹心具有0.5Pa.s－500Pa.s的Casson屈服应力和0.1Pa－1000Pa的屈服应力。Casson屈服应力可以根据IOCCC10/1973:2000方法测量。这依赖于使用以PC为界面并且装配有共轴测量装置(TEZ150-PC)和共轴滚筒式测量系统(CC27)的高性能流变仪MCR300(AntonPaarPhysica)。
优选地，夹心部分贡献了分层曲奇的10wt%－40wt%，优选15wt%－32wt%，更优选25wt%－30wt%。
夹心部分可以包含至少一种如下成分：脂肪、糖、水、淀粉、乳和乳品衍生物、调味剂、果粉、水果块、可可粉、巧克力糖果、种子。
当夹心部分包含未糊化的加入的淀粉时，未糊化加入的淀粉占夹心部分的2.0wt%－40.0wt%，优选占夹心部分的7.0－22.0wt%。
乳化剂可以是如下的至少一种：大豆卵磷脂、单甘油酯的二乙酰基酒石酸酯、硬脂酰乳酸钠。
乳和乳品衍生物可以是乳清粉、酸奶粉(具有活酵素)、鲜乳、奶粉、甜乳清粉、乳蛋白、乳清蛋白。
调味剂可以是固体或液体形式。
果粉是干燥的粉碎的水果，例如草莓、覆盆子、葡萄干、无花果、梅干、橙、蔓越莓、蓝莓、杏、黑醋栗、红醋栗、桃、梨、猕猴桃、香蕉、苹果、柠檬、菠萝、蕃茄。
在一个实施方案中，用于生产根据本公开的分层曲奇的方法(如图1中所示)包括：
-将谷类面粉、脂肪、糖和其余成分与相对于料团总重至多8wt%的添加的水混合E1，用于形成料团2；
-将料团2旋转模制E3，用于使饼干部分的饼干3成形；
-烘焙E5饼干部分的饼干；
-由至少一块饼干和夹心形成E7-E8分层曲奇；
其中所述谷类面粉包含精制谷类面粉，优选精制小麦面粉，所述精制谷类面粉占料团的至少21wt%，优选至少41wt%，其中如通过根据NF-ISO-5530-1标准所测量的吸水率在55%以下，优选低于52%。
料团的混合优选使用具有双夹层的卧式搅拌器进行。调整混合时期，使得水量受控。优选地，在混合过程中料团温度为15℃－35℃，更优选15℃－30℃。
使用常规的旋转模制设备，难以且有时不可能加工这样的颗粒料团。因此，设计了新的特定旋转模制机用于旋转模制步骤。然而，可以使用其它模制技术，但是为较不优选的。
这种特定的旋转模制机1(如图2中所示)包含：
-用于使料团2成形为饼干3的模制滚筒11和槽纹滚筒12；和任选地
-有助于给模制和槽纹滚筒11、12进料的起漏斗作用的料斗13；和/或
-用于使饼干3脱模的脱模带14。
模制滚筒11具有用于接收料团2的模腔。该模腔将给予料团2饼干部分的饼干3的形状。槽纹滚筒12优选包含5－15mm、优选10mm±50%的槽以允许料团有充分的粘性，而没有破碎的固体块如薄片，并且在操作过程中压制在模制滚筒11模腔内部接收的料团2，使得料团完全充满模腔并取得其形状。槽纹滚筒12被安装在水平轴上且可在其上被调节以改变施加于料团2的压制力。应使用高度挤压，因为料团2缺乏连续性，因此，粘着的料团块将为可脱模的并且可从脱模带14上转移至烘箱带上，所述烘箱带驱动未烹制的饼干3进入用于烘焙的烘箱。
优选将槽纹滚筒12与模制滚筒11之间的速度差维持在低于10%，从而饼干3的形成不受损。的确，模制滚筒11与槽纹滚筒12转速之间的更高差异将引起对料团2的剪切应力，所述料团将不能被压制到模腔上，而是将在模制滚筒11与槽纹滚筒12的圆周面之间被铺展且被较少堆积。
可以优选地控制料斗13中料团2的水平，从而其是最小的，且模制和槽纹滚筒11、12几乎是可见的。目的在于防止料团2压实，从而确保模制滚筒11沿脱模带14的宽度规则地进料。料团2必须尽可能地少地被堆积。
切割器15(其尖端151位于模制和槽纹滚筒11、12的轴线AA之下)优选在模腔顶部切割料团2。切割器15确定保留在模腔内部的料团2的量并且使得能够调整其中料团块的重量。形成未烹制饼干的每个料团块优选重0.5克－40克，更优选1克－35克，仍然更优选1克－30克。
优选由棉花和/或聚酰胺制成的脱模带14具有用于提取比常规料团更干燥的料团块（即颗粒料团）的适合尺寸的织物。将脱模带14安装在至少两个滚筒16、17上，其中之一（一般为橡胶滚筒16）挤压模制滚筒11。在橡胶滚筒16对模制滚筒11的压力下，位于模腔内部的料团块附着至脱模带14并且朝着烘箱被输送以用于烘焙。
旋转模制机1还可以包含用于脱模带14的增湿器18，例如增湿器18是蒸汽设备或喷水设备。
静置步骤E2的静置时间应受到限制以避免料团2高度干燥，这将需要再添加水且由此将通过触发淀粉糊化而妨碍SAG含量。
在烘焙E5前，可以给饼干3挂糖衣(glaze)，使得它们获得有光泽的外观。因此，该方法可包括给成形的饼干3挂糖衣的可选的额外步骤E4。可以用优选包含奶粉和/或糖霜和/或缓冲剂例如碳酸氢钠、氢氧化钠的水性糖衣给饼干3挂糖衣。优选地，糖衣包含脱脂奶粉。仍优选地，糖衣包含淀粉糖霜，即蔗糖天然甜味剂，其特征在于其通过研磨冰糖得到的精细粒度测量并且加入了淀粉作为抗凝聚剂。
优选进行烘焙E5直至烘焙的饼干3(终产品)的含水量为0.5wt%－5.0wt%，例如通过轻柔地烘焙(即在烘焙的前三分之一时间（如果烘焙时间为6min，在2min中）中饼干内的烘焙温度低于110℃，优选低于100℃)。
烘焙后，将烘焙的饼干在开放带（即未覆盖的带）上冷却E6，优选不使用冷却隧道，因为在输入与输出之间存在过大的温度差，它引起饼干3龟裂(失败)。然后使夹心沉积E7在一块饼干上(对于夹心在饼干上的曲奇是在基底饼干上，或对于三明治曲奇是在两块饼干中的一块上)。
最终的饼干的含水量在烘焙后优选低于最终的饼干的3wt%且优选为最终的饼干的1－2wt%。
低含水量有助于提供长期货架稳定的产品。例如，可以将本发明的饼干和三明治饼干保存在20-25℃达1年，而仍是可食用的。已经进行了基于感官专家小组评估的存架期研究。发现取决于成分，完整的感官特征谱可被维持达7个月。然而，饼干的可食用性延长至少直至1年的标志。
在分层曲奇为三明治曲奇的情况中，然后通过在三明治的顶部装配E8第二块饼干制成三明治曲奇。
通过冷却隧道E9中的加压-空气冷却分层曲奇。然后包装E10分层曲奇，例如，将分层曲奇包装入包含50g分层曲奇的包装物中并且将包装物收集到小包中，所述小包被设计为包含5或6个包装物。优选地，可以将分层曲奇包装入包装物中，从而一个包装物包含一份，例如2块三明治曲奇。
本公开还涉及能通过上述方法得到的可即食的分层曲奇。优选地，所述分层曲奇还包含占分层曲奇总重至少18wt%的总淀粉。
现在结合作为非限制性实例提供的附图描述本公开，其中：
-图1是显示本公开的方法的优选实施方案的不同步骤的流程图；
-图2是作为用于本公开的方法的旋转模制机的图示；
-图3是可获自本公开的方法的夹心在饼干上的曲奇的图示；且
-图4是可获自本公开的方法的三明治曲奇的图示。
作为图1的图例：
E1:将成分混合成料团
E2:静置料团
E3:将料团旋转模制成饼干
E4:给饼干挂糖衣
E5:烘焙饼干
E6:冷却饼干
E7:使夹心沉积在一块饼干上
E8:装配分层曲奇
E9:冷却分层曲奇
E10:包装分层曲奇
现在将关于下列非限制性实施例描述本公开。
实施例1
所述三明治曲奇具有如下组成(以最终曲奇的百分比计)：
-料团成分87.12wt%
-糖衣成分3.02wt%
-夹心成分28.00wt%
-除去水-18.14wt%
-总计100wt%
更具体地，三明治曲奇的饼干由使用如下配方形成的料团生产：
(将含量表示为分别相对于最终的饼干和未烘焙料团的重量的百分比)
使用对实施例1中使用的精制软质小麦面粉测量的吸水率值为53-54%。
在卧式搅拌器中将料团成分混合在一起，直到料团得到均匀的稠度。然后使料团静置。静置后，将料团填料到旋转模制机的料斗用于形成饼干。将料团填料，使得旋转模制机的模制和槽纹滚筒几乎可见。使模制和槽纹滚筒的速度差异保持低于10%。然后用包含下述的糖衣给饼干挂糖衣(以最终的饼干的重量百分比计)：
-水2.68wt%
-脱脂奶粉0.27wt%
-精制糖粉0.07wt%
-总计3.02wt%。
在给饼干挂糖衣后，驱动它们至烘箱用于烘焙约6min。在烘焙过程中，使料团的温度保持低于160℃且含水量减少至达到1%。
当从烘箱内取出饼干时，允许它们在开放带上冷却至饼干温度低于33℃。
然后用夹心装配饼干，以形成三明治曲奇。所述夹心具有如下组成：
-糖14.26wt%
-小麦淀粉1.93wt%
-乳化剂0.08wt%
-调味剂0.04wt%
-可可粉4.31wt%
-脂肪7.38wt%
-总计28.00wt%。
所述三明治曲奇具有18.08wt%的脂肪和26.5wt%的糖。脂肪占所述三明治曲奇总卡路里值的35.7%，而碳水化合物占57%，更精确地，糖占23%。所述三明治曲奇具有的SDS/(RDS+SDS)比例为39.95%和16.5gSAG/100g三明治曲奇。
对比例1
用于对比例1的三明治曲奇具有如下组成(以最终曲奇的百分比计)：
-料团成分87.30wt%
-糖衣成分3.02wt%
-夹心成分28.00wt%
-除去水-18.32wt%
-总计100wt%
更具体地，三明治曲奇的饼干由使用如下配方形成的料团生产：
(将含量表示为分别相对于最终的饼干和未烘焙料团的重量的百分比)
各种成分的量实际上与实施例1相同，仅在料团中加入了更多的水，由此改变了所有成分的百分比。另一个差别在于实施例1中使用精制小麦面粉，而在对比例1中，使用了常规的软质小麦面粉。这种软质小麦面粉具有的使用测定的吸水率值为58-59%。
在卧式搅拌器中将料团成分混合在一起，直到料团得到均匀的稠度。然后静置料团。静置后，将料团进料入普通旋转模制机的料斗用于形成饼干。使模制和槽纹滚筒的速度差异保持低于10%。然后用包含下述的糖衣给饼干挂糖衣(以最终的饼干的重量百分比计)：
-水2.68wt%
-脱脂奶粉0.27wt%
-精制糖粉0.07wt%
-总计3.02wt%。
在给饼干挂糖衣后，驱动它们至烘箱用于烘焙约6min。在烘焙过程中，使料团的温度保持低于160℃，且含水量降至达1%。
当从烘箱内取出饼干时，允许它们在开放带上冷却至饼干温度低于33℃。
然后用夹心装配饼干，以形成三明治曲奇。所述夹心具有如下组成：
-糖14.26wt%
-小麦淀粉1.93wt%
-乳化剂0.08wt%
-调味剂0.04wt%
-可可粉4.31wt%
-脂肪7.38wt%
-总计28.00wt%。
这种三明治曲奇具有29.7%的SDS/(RDS+SDS)和12.5g/100g三明治曲奇的SAG。因此，这种三明治曲奇的SAG含量远低于15g/100g三明治曲奇。这表明料团配方的改变和使用不同的旋转模制机使得三明治曲奇具有更好的SAG含量。
此外，在实施例1中使用精制小麦面粉使得能够将料团中加入的水含量降低至少于料团的8wt%。相信这使得能够更好地保护淀粉免于糊化且由此保持高量的SDS。
实施例2
所述三明治曲奇具有如下组成(以最终曲奇的百分比计)：
-料团成分87.60wt%
-糖衣成分3.01wt%
-夹心成分28.00wt%
-除去水-18.62wt%
-总计100wt%
更具体地，三明治曲奇的饼干由使用如下配方形成的料团生产：
(将含量表示为分别相对于最终的饼干和未烘焙料团的重量的百分比)
用于实施例2的精制软质小麦面粉具有如使用 测定的53-54%的吸水率。
在卧式搅拌器中将料团成分混合在一起，直到料团得到均匀的稠度。然后将料团静置。静置后，将料团填料到旋转模制机的料斗用于形成饼干。将料团填料，使得旋转模制机的模制和槽纹滚筒几乎可见。使模制和槽纹滚筒的速度差异保持低于10%。然后用包含下述的糖衣给饼干挂糖衣(以最终的饼干的重量百分比计)：
-水2.68wt%
-脱脂奶粉0.27wt%
-精制糖粉0.07wt%
-总计3.01wt%。
在给饼干挂糖衣后，驱动它们至烘箱用于烘焙约6min。在烘焙过程中，使料团的温度保持低于160℃，且含水量降至达1%。
当从烘箱内取出饼干时，允许它们在开放带上冷却至饼干温度低于33℃。
然后用夹心装配饼干，以形成三明治曲奇。所述夹心具有如下组成：
-乳品衍生物(乳清、酸奶)4.48wt%
-小麦淀粉5.60wt%
-糖10.07wt%
-乳化剂0.07wt%
-调味剂(酸奶)0.06wt%
-酸化剂0.02wt%
-脂肪7.70wt%
-总计28.00wt%。
所述三明治曲奇具有17.62wt%的脂肪和28.3wt%的糖。脂肪占所述三明治曲奇总卡路里值的34.8%，而碳水化合物占59%，更精确地，糖占25%。所述三明治曲奇具有的SDS/(RDS+SDS)比例为43.38%和19gSAG/100g三明治曲奇。
对比例2
用于对比例1的三明治曲奇具有如下组成(以最终曲奇的百分比计)：
-料团成分87.80wt%
-糖衣成分3.01wt%
-夹心成分28.00wt%
-除去水-18.81wt%
-总计100wt%
更具体地，三明治曲奇的饼干由使用如下配方形成的料团生产：
(将含量表示为分别相对于最终的饼干和未烘焙料团的重量的百分比)
各种成分的量实际上与实施例2相同，仅在料团中加入了更多的水，由此改变了所有成分的百分比。另一个差别在于实施例2中使用精制小麦面粉，而在对比例2中，使用了常规的软质小麦面粉。这种软质小麦面粉具有的使用测定的吸水率值为58-59%。
在卧式搅拌器中将料团成分混合在一起，直到料团得到均匀的稠度。然后静置料团。静置后，将料团进料入普通旋转模制机的料斗用于形成饼干。使模制和槽纹滚筒的速度差异保持低于10%。然后用包含下述的糖衣给饼干挂糖衣(以最终的饼干的重量百分比计)：
-水2.68wt%
-脱脂奶粉0.27wt%
-精制糖粉0.07wt%
-总计3.01wt%。
在给饼干挂糖衣后，驱动它们至烘箱用于烘焙约6min。在烘焙过程中，使料团的温度保持低于160℃，且含水量降至达1%。
当从烘箱内取出饼干时，允许它们在开放带上冷却至饼干温度低于33℃。
然后用夹心装配饼干，以形成三明治曲奇。所述夹心具有如下组成：
-乳品衍生物(乳清、酸奶)4.48wt%
-小麦淀粉5.60wt%
-糖10.07wt%
-乳化剂0.07wt%
-调味剂(酸奶)0.06wt%
-酸化剂0.02wt%
-脂肪7.70wt%
-总计28.00wt%。
这种三明治曲奇具有28.5%的SDS/(RDS+SDS)和12.3g/100g三明治曲奇的SAG。因此，这种三明治曲奇的SAG含量远低于15g/100g三明治曲奇。这表明料团配方的改变和使用不同的旋转模制机使得三明治曲奇具有更好的SAG含量。
此外，在实施例1中使用精制小麦面粉使得能够将料团中加入的水含量降低至少于料团的8wt%。相信这使得能够更好地保护淀粉免于糊化且由此保持高量的SDS。
实施例3
所述三明治曲奇具有如下组成(以最终曲奇的百分比计)：
-料团成分90.39wt%
-糖衣成分1.90wt%
-夹心成分27.00wt%
-除去水-19.29wt%
-总计100wt%
更具体地，三明治曲奇的饼干由使用如下配方形成的料团生产：
(将含量表示为分别相对于最终的饼干和未烘焙料团的重量的百分比)
通过对精制小麦面粉测量的吸水率值为53-54%。
在卧式搅拌器中将料团成分混合在一起，直到料团得到均匀的稠度。然后静置料团。静置后，将料团填料到旋转模制机的料斗用于形成饼干。将料团填料，使得旋转模制机的模制和槽纹滚筒几乎可见。使模制和槽纹滚筒的速度差异保持低于10%。然后用包含下述的糖衣给饼干挂糖衣(以最终的饼干的重量百分比计)：
-水1.69wt%
-脱脂奶粉0.17wt%
-精制糖粉0.04wt%
-总计1.90wt%。
在给饼干挂糖衣后，驱动它们至烘箱用于烘焙约7min。在烘焙过程中，使料团的温度保持低于160℃，且含水量降至达1.1%。
当从烘箱内取出饼干时，允许它们在开放带上冷却至饼干温度低于33℃。
然后用夹心装配饼干以形成三明治曲奇。所述夹心具有如下组成：
-糖16.47wt%
-增湿剂6.75wt%
-植物脂肪1.62wt%
-果汁浓缩物1.35wt%
-树胶0.27wt%
-酸度调节剂0.38wt%
-乳化剂0.11wt%
-调味剂(混合的浆果)0.05wt%
-总计27.00wt%。
所述三明治曲奇具有12.05wt%的脂肪和29.3wt%的糖。脂肪占所述三明治曲奇的总卡路里值的26%，而碳水化合物占68%，更精确地，糖占27.7%。所述三明治曲奇具有SDS/(RDS+SDS)的比例为35.07%和15.5gSAG/100g三明治曲奇。
除非另有所述，否则本文引述的百分比值均按重量计，且适合时，按最终的饼干重量计。
尽管已经详细描述了本公开的优选实施方案，但是本领域技术人员将理解，可对它们进行变化而不偏离本公开或所附权利要求的范围。

Claims (19)

1.用于生产包含至少一块饼干和夹心的分层曲奇的方法，所述分层曲奇包含10wt％－25wt％的脂肪和15wt％－40wt％的糖，其中所述分层曲奇的可缓慢消化的淀粉占总可利用淀粉的比例为至少31％，该方法包括：
形成料团，其包含谷类面粉、脂肪、糖和相对于料团总重至多8wt％的添加的水；
将所述料团模制成饼干的形状；
烘焙所述饼干；和
用夹心装配所述饼干以形成分层曲奇；
其中所述谷类面粉包含精制谷类面粉，其含量占所述料团总重的至少21wt％，其中吸水率如通过所测定的为55％以下。
2.权利要求1的方法，其中所述分层曲奇是包含其它饼干的三明治曲奇且其中所述饼干夹住所述夹心。
3.权利要求1的方法，其中所述分层曲奇具有至少15.0g/100g的分层曲奇的可缓慢利用的葡萄糖值。
4.权利要求1－3中任一项的方法，其中所述精制谷类面粉包含精制小麦面粉。
5.权利要求4的方法，其中所述小麦面粉选自软质小麦面粉、具有低受损淀粉的小麦面粉和经热处理的小麦面粉，及其中两种或更多种的组合。
6.权利要求1的方法，其中所述模制是旋转模制。
7.权利要求6的方法，其中旋转模制使用旋转模制机进行，所述旋转模制机包含：
用于使料团成形为饼干的模制滚筒和槽纹滚筒，所述模制滚筒接收料团且具有5－15mm的凹槽的所述槽纹滚筒将所述模制滚筒内压制料团；和任选的
用于向模制和槽纹滚筒填料的起漏斗作用的料斗；和/或
用于使饼干脱模的脱模带。
8.权利要求7的方法，其中使槽纹滚筒与模制滚筒之间的速度差维持在低于10％。
9.权利要求7的方法，其中所述槽纹滚筒具有10mm的凹槽。
10.权利要求7-9中任一项的方法，其中所述旋转模制机还包含用于脱模带的增湿系统。
11.能通过权利要求1－10中任一项的方法获得的可即食的分层曲奇，其包含饼干和夹心，所述分层曲奇包含10wt％－25wt％的脂肪和15wt％－40wt％的糖，其中所述分层曲奇的可缓慢消化的淀粉占总可利用淀粉的比例为至少31wt％。
12.权利要求11的分层曲奇，其中该分层曲奇是包含其它饼干部分的三明治曲奇且其中所述饼干夹住所述夹心。
13.权利要求11的分层曲奇，还包含占该分层曲奇总重至少30wt％的总淀粉。
14.权利要求11－13中任一项的分层曲奇，其中该分层曲奇具有至少15.0g/100g分层曲奇的可缓慢利用的葡萄糖值。
15.权利要求11－13中任一项的分层曲奇，其包含12wt％－20wt％的脂肪和/或包含20wt％－32wt％的糖。
16.权利要求11－13中任一项的分层曲奇，其中所述饼干包含相对于饼干总重5wt％－30wt％的脂肪和/或相对于饼干总重10wt％－25wt％的糖。
17.权利要求11－13中任一项的分层曲奇，其中所述夹心贡献了所述分层曲奇的10wt％－40wt％。
18.权利要求11－13中任一项的分层曲奇，其中相对于夹心的重量，所述夹心具有2.0wt％－40.0wt％的非糊化的加入的淀粉。
19.权利要求11－13中任一项的分层曲奇，其包含占所述三明治曲奇总重2wt％－15wt的固体块，其中所述固体块不增加SAG含量。
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