HRP20140463A2 - Method for producing a food product or semifinished food product - Google Patents

Abstract

Process for the production of finished food or semi-finished products characterized by the immersion of the grain and not completed before reaching the moment when the compressive force required for plastic deformation of the grain is not more than 107.91 N but not less than 1.47 N and the temperature in the immersion process does not exceed 45 ° C, the grinding being carried out at a temperature of mass exiting the grinding device not exceeding 60 ° C.

Description

This invention relates to the food industry, more precisely to the production of food products that contain cereals as components, and can be widely used in the production of bread and pastries, in the confectionery industry, in the production of pasta, pizza, snacks, pancakes, pelmen pasta, dry breakfast and other products.

Within the framework of the technological process presented in this invention, the procedure of germination of grain immersed in water to the initial stage (bioactivation of cereal grains) is carried out. The final product, which is obtained by using the cereal mass from sprouted grain, is different from the traditional one produced from flour; it is several times richer in the content of complex vitamins of group B, PP and other microelements (zinc, potassium, iron and others), which on average gives 20-40% more compared to traditional finished products. Regarding the content of vitamin E found in the germ of grains, the products produced in this way contain up to 10 times more vitamin E than those produced from flour. Modern research proves the important function of nutritional fibers for the human body, which ensure satiety, act as sorbents, binding cholesterol, carcinogenic substances, radionuclides, salts of heavy metals found in food, removing them from the body and lowering their content in the blood.

According to the results of research in the product (cereal bread from sprouted grain) obtained by the process in the invention presented here, the content of nutritional fibers (soluble and insoluble) is up to 22% of the total weight of the product. 200 g of sprouted grain bread is enough to meet the daily needs for nutritional fiber for the human body.

The final product obtained by using grain mass from germinated grain is characterized by an increased nutritional biological value, which is characterized by:

- Balanced amino acid composition of proteins;

- By the presence of micronutrients in a biologically adopted form;

- Synthesis of vitamins and antioxidants that are created in the process of grain germination;

- Increased amounts of nutritious fibers, a large part of which is soluble, which have the ability to be absorbed into the human blood, and to clean the blood vessels.

There is a well-known way of producing bread from cereals, in which the grain is hulled (the grain is peeled) until 50-80% of the fruit coat, which is in the grain, is removed, while preserving the germ of the aleurone layer. The grain is immersed in water, at a temperature of 8-40 °C, for 5-24 hours, until the moisture content of the grain is 30-50%, after which the chopped grain mass is mixed with other components, according to the recipe. Products are formed from the dough thus obtained, which are then subjected to control and baking (SU 1214054 A1, 1986).

As a disadvantage of the mentioned method, there is a large dispersion of the characteristic parameters of the grain preparation process, which complicates the control of the technological process and does not provide a stable quality of production, there are no criteria for the preparation of raw materials, for moving to the next stage of the technological process.

Another well-known way of preparing bread from grains, includes grinding (peeling the grain), moistening it, crushing it on dispersers, mixing the dough with the use of crushed grain and components provided for in the recipe, its fermentation, the formation of dough products, their control and baking. Wheat grain with autolytic activity of 170-365 s, glassiness of 40-70%, natural weight of 770-800 g/l is used, peeling is done until the fruit membranes are removed in the amount of 3-7% of the total weight of the grain, moistening it is carried out in the course of 20-30 h using water at a temperature of 8-40 °C, in an amount not less than 50% of the total weight of the grain. Grain crushing is done on a disperser/mill that contains sediment, and the apparatus has the following parts: a knife with three blades, a die with a diameter of 4 mm, a knife with 12 blades, a die with a diameter of 3 mm, a knife with 12 blades and a die with a diameter of 3 mm . The dough is mixed for 10-20 minutes until it reaches a consistency of 620-650 units according to the Farinograph, the dough rises for 60-120 minutes at a temperature of 30-40°C, and before baking, the dough products are subjected to rising in in the intended chamber, the baking of semi-finished dough is carried out on the floor or in molds at a temperature of 200-250 °C, for 15-60 minutes. (RU 22161175 from 18.10.2000)

The disadvantage of the mentioned method is the complexity of the device for controlling the technological process, the limitations of raw material parameters, and the large dispersion of parameters in grain preparation, which overall makes this method of production difficult to apply in practice.

The most similar to the proposed procedure is the process of obtaining a nutritious product from cereals, which provides processing of plant raw materials until the appearance of sprouts and subsequent processing to the finished product, which is characterized by the fact that the whole grain is used, at least from two cereal crops, and the processing of the fruits of cereal crops until the appearance of sprouts is realized in water. This mode is a prototype. (RU 2083116 of 14.02.1996).

The basic difference of the prototype from the above-mentioned analogies is the use of the characteristics of the state of the grain for the processing of the composition of the grain itself, which consists in the appearance of sprouts, and not the internal parameters of preparation, such as the time and temperature of immersion.

However, the given criterion is subjective enough and does not have a quantitative assessment, which does not allow an objective assessment of the condition of the grain during the technological process and which would ensure the stability of the properties of the final product. Post-processing is also described in general terms.

The invention presented here relates to obtaining a complex technical result: providing a technological control facility, applying scientifically based regimes of technological processes and obtaining stable production properties with increased biological value of the final product.

The mentioned technical result is achieved by the immersion process of the grain, which ends when the pressure force, which leads to the plastic deformation of the grain, is less than 107.91 N, but greater than 1.47 N, and the temperature of the immersion process does not exceed 45°C. grain grinding is achieved at the output temperature of the ground mass which does not exceed 60°C.

An important moment in the production of products from biologically activated grain occurs at the beginning of biological processes, which lead to the appearance of germs or their "germination". The beginning of the biological processes of germination has a "trigger" character and begins with a threshold humidity of 20% of the grain in relation to the raw substance. Therefore, the moisture content of the biologically activated grain cannot be lower than this specified value.

However, when the grain humidity increases to 52-55% in the raw substance, procatalytic processes begin, which leads to the hydrolysis of grain proteins: gliadin, gordein, gluten, avenin, leucosin and others, which significantly lowers the rheological properties of the dough mass, which is obtained from the grain such a degree of humidity, if the protein sequence participates in the formation of the gluten skeleton of the final nutritional product. For this reason, the stated humidity must be considered as the limiting limiting factor on the other side of the interval.

When choosing the humidity of the grain, its structural and mechanical properties change. Figure 1 shows the dependence of the grain deformation on the pressing force at different moisture levels of the raw material. It is obvious that with increasing humidity, the modulus of elasticity of the grain decreases and, at higher values of humidity, the grain loses its properties as a solid body and the character of the dependence of the deformation of the grain on the pressing force changes, a horizontal part appears on it, which appears as a confirmation of plastic deformation (Fig. 2.) and this force of pressing the grain, which leads to its plastic deformation, becomes determining for the amount of energy that needs to be spent on grinding the soaked grain. If the pressing force necessary for the plastic deformation of the grain is large, then the energy spent on grinding the grain, which is transferred to the mass of the grain, leads to its overheating. Figure 3 shows the dependence of the pressing force, necessary for the plastic deformation of the grains, in relation to the humidity of the grains. Figure 4 shows the dependence of the degree of additional heating of the grain mass during grinding on grain moisture. The dependencies presented in Figures 2-5 were obtained experimentally during work within the framework of this technical solution for class 3 wheat grains, for other grains the dependencies presented have an analogous character. The plastic deformation of the grain is characterized by the loss of the previous shape, the grain becomes flatter, and at high humidity values, the plastic deformation of the grain is performed by extruding the endosperm through the grain envelope.

In laboratory conditions, the force applied to the grain was realized by means of a lever mechanism. The grains were passed between the static part - the base of the mechanism and the sponge, which was located on the lever closer to the axis of rotation. The end of the lever was connected to the dynamometer. The force was measured using a dynamometer, connected to the end of the lever at the moment of plastic deformation or grain destruction. Knowing the length of the lever and its distance from the axis of rotation to the sponge with the pressed grain, the obtained force on the dynamometer was converted into the force of pressing the grain between the sponge. In production conditions, in order to determine the pressing force necessary for the plastic deformation of the grain, a simple method can be used: place the grain on the plate of an electric scale and, pressing the grain from the top with a flat and hard object, read on the indicator of the scale the value at which the endosperm is pushed out of the grain. or if it flattens.

The acceptable value of the pressure (crushing force), which is necessary for the plastic deformation of the grain, is at most 107.91 N, if at high deformation forces the degree of additional heating of the mass of the grain during grinding starts to rise sharply and starts to exceed the value of 30°C. The specified degree of heating of the grain mass becomes critical for some applications, especially for the production of bread and pastry products, if the cooling of the grain before grinding is carried out in practice with cold water, the average temperature of which is 12°C.

The final temperature of the dough mass is 37°C, which is the maximum technological interval for dough used for the production of bread and pastry products. In addition, the operation of mills (for example, dispersers) on grains with high pressure force values, necessary for plastic deformation, leads to irrational energy loss and rapid wear of the working part. However, for the production of other products, the grinding temperature of the grain mass does not have to be a critical parameter, and then the heating of the grain mass above 60°C appears as a limitation. Temperatures above the specified value in combination with the acidity of the environment, between pH 4.3-4.6, cause the inactivation of the enzymes α-amylase and β-amylase, which is achieved by the hydrolysis of starch into dextrins and simple sugars (saccharides) and determines such important dough parameters as which are the ability to produce sugar and gas, as well as the biochemical composition of the product. During short-term exposure to temperatures above 60°C, partial destruction of the tertiary and quaternary structure of proteins also begins, which is a phenomenon of biological degradation of the raw material. When immersing grains, an analogous unwanted effect is achieved when the ambient temperature is over 45°C for a long time, which leads to the blocking of the biological processes of grain germination. The mentioned criterion for limiting the temperature applies, however, only to healthy food products in which the manufacturer tries to preserve vitamins and other micronutrients in their natural form as much as possible.

Therefore, the establishment of the limit value of the pressure force of the grain, which leads to its plastic deformation, which does not exceed 107.91 N, and which is achieved when the moisture content of the grain is more than 20% in relation to the raw substance, meets the conditions of the "trigger" mechanism of the beginning of sprout formation and ensures acceptable structural-mechanical properties of the grain from the point of view of its further processing. Grains, even from the same group, differ from each other, and because of this, it has been experimentally determined that at least 80% of the grains of a certain group being processed must reach the limit force of deformation. In doing so, of course, it is not necessary for the entire batch to undergo control, it is sufficient to take 10-15 grains each from the lower, middle and upper part of the immersion container.

High grain moisture values (more than 50%) correspond to a pressure force that leads to a plastic deformation of the grain of less than 1.47 N, which corresponds to the force of destruction of the grain envelope, which contains the creamy endosperm, which no longer shows mechanical resistance to grain compression. A further increase in grain moisture practically does not occur. For this reason, the grain soaking phase must end when the specified grain condition is reached. High humidity values are necessary for some practical applications of this method.

The parameter "pressure force, necessary for the plastic deformation of grains" allows an integral assessment of the results of the grain soaking phase, which depends on a large number of parameters: temperature, time, grain varieties, the degree of its cleaning, the application of the stratification method, as well as other factors, which significantly simplifies the process technological controls and makes it more objective. There is a certain dependence between the pressure (compression force) necessary for the plastic deformation of the grain and its humidity, the character of that curve changes depending on the type of grain, temperature, immersion conditions. Figure 3 shows two curves of the dependence of pressure force, necessary for plastic deformation of grains, on grain moisture of two types: wheat of soft varieties and wheat of hard varieties. The latter is characterized by significantly better transparency and crystallinity of the grain structure. Since in the given method, the grinding operation is followed after immersion, the structural-mechanical properties of the grains become determining for the grinding work and as a criterion for the readiness of the grains for grinding after immersion, the pressure force, necessary for the plastic deformation of the grains, is used as the most significant and informative factor.

In the process of experimental testing of the given patent, an unexpected dependence between grain moisture and its mechanical strength was observed, which shows that at the initial stage of moisture selection, the grain loses its strength due to the softening of the coating, then, for some time, the pressure force necessary for plastic deformation grain is at a level higher than 107.91 N, which is associated with the slow penetration of moisture between the starch crystals, and then leads to a sudden decrease in the mechanical strength of the grain, which is associated with internal structural changes, which is manifested in the fact that did the water to a sufficient degree create a medium for the movement of the starch grains, in relation to each other. It is precisely this qualitative change in grain properties, when grain starch changes from a crystalline to an amorphous form, that is the basis of the choice of the above meaning "pressure force, necessary for the plastic deformation of grains" which is 107.91 N. The given change in grain properties can be clearly shown graphically in Figure 3, where the horizontal part of the curve corresponds to the process of slow passage of moisture between starch grains. If the initial part of the curve for wheat grains of soft and hard varieties is different, then after the transition of starch to the amorphous form, the mechanical properties of grains of different varieties become similar. The change in grain properties is also confirmed in Figure 5, where the dependence of the pressure force necessary for the plastic deformation of the wheat grain on the time it is kept in water is presented.

For each specific application of the given method, the pressure force required for the plastic deformation of the grain is chosen for technological reasons, which is then used as a control during the production technological process.

The regime of germination and grain processing under these conditions ensures an increase in the content of vitamins and other biological substances, partial hydrolysis of starch until the beginning of the stage of intense gluten reduction.

Description of images

Figure 1 shows the graphic dependence of the grain deformation on the pressure force at different raw material humidity, curve 1 - for humidity 15%, curve 2 - for humidity 15.8% and curve 3 - for humidity 16.7%, at a glassiness of 50 %.

Figure 2 shows the dependence curve of grain deformation on pressure force with the proportion of plastic deformation at humidity up to 40%. On the vertical axis is the force in kgs, and on the horizontal axis is the deformation in mm.

Figure 3 shows the dependence of the pressure force required for the plastic deformation of the grains on the humidity of the grains. The lower curve is for wheat grain of soft varieties, and the upper curve is for wheat grain of hard varieties.

Figure 4 shows the dependence of the degree of additional heating of the grain mass during grinding on grain moisture. The vertical axis shows the temperature in degrees Celsius, and the horizontal axis shows the humidity in % in dry grain.

Figure 5 shows the dependence of the pressure force, necessary for the plastic deformation of the grain, on the time it remains in the water.

The figures show the values in kgs units, they are converted into the Newton(N) unit by multiplying them by a factor of 9.81.

The ways of realizing the invention can be illustrated through several examples:

Example 1. Production of whole grain bread from a mixture of wheat and rye. For the production of this food product, basic raw materials are used, which consists entirely of grain as a component, which is prepared from wheat and rye, in a ratio of 4:1. Cleaned of external impurities, the grains are washed on the MMZ-300 grain washing device and immersed in water with a temperature of 35 °C. No thermostatic regime is required. It is possible to add other cereal crops: whole-grain oats, barley, up to 10% of the total weight of dry grain. Next, the grain is washed every 12 hours, watered with fresh water at a temperature of 25 °C. The amount of water (weight) twice greater than the amount of grain is taken. Immersion is carried out until the moment when no less than 80% of the grain is subjected to plastic deformation at a compressive force of 39.24 N to 49.05 N. Then the grain is washed in cold water at a temperature of 14-16°C and ground on a disperser LZ-15, controlling the temperature of the dough mass at the exit from the disperser, which must not exceed the temperature of the grain that is charged into the disperser by more than 15°C, that is, the final temperature of the grinding of the grain mass must not exceed 30°C. When the dough mass is heated more, the worn-out cutting device must be replaced with a new one. Salt is added to the obtained dough mass in the following ratio: 1.8% (in relation to the mass of dry grain), pressed baker's yeast in a ratio of 4% of the mass of dry grain, water as needed. The mixture is fed to the mixing device L4+HTV or to a similar device.

The dough is then divided into pieces by mass, which corresponds to the chosen shape in the bread and pastry industry, on any type of dough dividing machine or by hand, the dough is given a round shape, on any type of shaping device or by hand, and it is arranged on bread and pastry molds previously greased with vegetable oil.

Resting of the product takes place at a temperature of 40-45°C and humidity of 80% for 25-35 minutes, baking takes place at a temperature of 220-240°C, for a duration of 25-40 minutes, depending on the mass of the product and with the addition of steam at the beginning and end of the baking process. After baking, the finished products are removed from the mold, scraped and packed.

Example 2. pasta production. Grains of durum wheat, cleaned of external impurities, are washed on the MMZ-500 grain washing device and immersed by the entire volume, pouring water at a temperature of 45°C. A thermostatic regime is not required. Next, the grain is washed every 12 hours, fresh water at a temperature of 35°C is poured. The amount of water (by weight) is chosen to be twice the amount of grain. Immersion is carried out until the moment when no less than 80% of the grains are subjected to plastic deformation at a compressive force of 107.91 N. Then the grains are washed in cold water at a temperature of 14-16°C and ground on a dipergator (mill) MTPM-300 with supplementary knife-grid sections, controlling the temperature of the dough mass at the exit from the disperser, which must not exceed 60°C. At higher dough heating temperatures, the worn part of the cutting device must be replaced with a new one. The resulting grain component, in the form of a dough mass, is mixed with wheat semolina to make a pasta-type product according to GOST 12307 in a ratio of 1:1 in the necessary amount on a dough processing device TMM-60 or similar. In order to regulate the final humidity of the dough up to 32%, water is added to increase the humidity, or pasta semolina, if it is necessary to reduce the humidity. The obtained dough is batched in the "Mercury PM-50" pasta press, the pressed product goes through the "ear" type filter. The pasta is dried in a cabinet type dryer to a humidity of no more than 19%. Drying to a nominal humidity of 14-15% takes place in cardboard boxes on the packaging side in a natural environment. Pre-packaging is done on a vertical packaging device, or on any type of device.

Example 3. Crust (base) for pizza. The pizza crust consists entirely of a granular component, which is made from wheat grains. The grain of wheat, cleaned of external impurities, is washed on the washing device MMZ-500 (MM3-500), and soaked in water with its entire volume at a temperature of 35°C. A thermostatic regime is not required. Given the circumstances that shaping the volume of the product like bread is insignificant for the basis of pizza, the soaking phase is carried out until the moment when no less than 80% of the grain is subjected to plastic deformation at a pressure force of 1.47 N. The grain is washed and ground, as shown in example 1, after dividing the mass of the dough in order, they are dosed into the dispenser of the "ZANUSSI HPZF45" press, and baked until the structure of crumbs. The pizza crust is then shipped for filling or frozen and packaged as a semi-finished product for retail sale.

Claims (2)

1. The process of production of finished food products or semi-products, indicated by the fact that it ensures the introduction of a granular component into the composition of the product or semi-product, which is obtained by soaking in water at least one type of grain with subsequent grinding of the swollen grain, whereby the grinding is carried out in such a way that the output temperature mass from the grinding device does not exceed 60°C, and the soaking takes place at a water temperature of 0°C to 45°C until the swelling stage, where the compression force in the range of 1.47 N to 107.91 N leads to plastic deformation not less than 80% of the grain. 2. The process of producing finished food products or semi-finished products, according to patent claim 1, characterized by the fact that as a criterion for the capacity of the swollen grain for further processing, the values of the compression force necessary for the plastic deformation of the grain are used, and that the processing of the grain begins after reaching the pressure force necessary for plastic deformation no higher than the chosen specific value, which is determined by the type of product being produced.