IE43588B1

IE43588B1 - Manufacture of food products

Info

Publication number: IE43588B1
Application number: IE1768/76A
Authority: IE
Original assignee: Gen Mills Inc
Priority date: 1975-08-27
Filing date: 1976-08-10
Publication date: 1981-04-08
Also published as: CH617069A5; LU75668A1; SE7609496L; BE845556A; FR2321850B1; IE43588L; JPS5228962A; ATA596976A; NL7609391A; GR60859B; GB1552200A; DK388576A; ZA764365B; FR2321850A1; IT1069665B; JPS6040815B2; DE2637820A1; ES451008A1; NO762936L; AT350884B

Abstract

Snacks (savouries) are prepared, such as potato crisps, puffs and biscuits, by cooking a hydrated floury type substance under pressure; a gelatinised paste is formed which is extruded through a die of the desired cross-section, the extruded element is compressed between two compression surfaces and is cut into segments of the required length.

Description

This invention is concerned with improvements in or relating to the manufacture of snack food products by extrusion puffing.

The food products which are sold in the general 5 category of snack items are many and varied, typically including such items as chips (e.g., potato chips and corn chips), puffs (e.g. corn puffs) and crackers (e.g., cheese flavored crackers). Generally, snack items are eaten apart from a regular meal; however, on occasion, they may LO be part of such a meal. Often, a variety of snack items are served at the same time.

People generally regard snacks in a discriminating manner. A person, for example, may try various snacks in a leisurely manner centering his choice on those snacks which have some sort of special appeal. A considerable amount of work has been undertaken in developing refinements in snack products. Also, a good deal of creative effort has been directed towards making new snack products which are distinctive in some regard.

The present invention relates to a method for producing a new puffed type snack product. In the past, puffedtype snack products have typically been prepared by processing of a farinaceous material in a screw extruder where elevated pressure and temperature are developed.

As the material leaves the extruder, substantial expansion takes place. 3 3 8 8 - 3 We have now discovered that farinaceous material maybe processed to yield a product having a desirable balance of crunch and texture if, shortly after extrusion puffing, the material is partially compressed while it is still in a pliable condition.

In carrying out the method according to the invention farinaceous material is mixed with water and possibly various other materials to form a hydrated particulate material.

The hydrated particulate material is then fed to a suitable extruder such as a collet Extruder and extruded under substantial temperature and pressure. The temperature and pressure should be sufficient to cook the material and provide adequate expansion upon extrusion. The expanded extrudate may then be passed between a pair of compression surfaces such as a pair of rolls; thereby, compressing the expanded material. The compressed extrudate may then be cut into pieces of a desired size.

According to the present invention therefore there is provided a method of manufacturing a food product which comprises (a) cooking a hydrated farinaceous material having a moisture content in the range 13.0% to 25.0% by weight in a pressurized chamber at an elevated temperature to form a substantially gelatinized dough, (b) extruding said farinaceous material through a die opening to form an extrudate having a desired cross section, the moisture content of said extrudate being reduced relative to the moisture content of said hydrated material so that it is in the range 5.0 to 12.0% by weight, and the volume of said extrudate being increased 3 to 7 fold relative to the volume of said hydrated material, (c) compressing at least a portion of said extrudate between a pair of surfaces while said extrudate remains pliable, the distance between said S3 8 _ 4 surfaces being such that the thickness of at least portions of the extrudate is substantially reduced, and (d) cutting the extrudate into segments of predetermined length.

The cut segments of extrudate obtained in the process according to the invention may be toasted and enrobed with an oil and/or seasoning. Alternatively, the pieces may be deep fat fried. The compressed extrudate may be processed in other ways. For example, the surface may be colored to resemble fat and lean portions of bacon.

The present invention may be carried out using any of a variety of cereal grains or other starch containing material. Typical materials that may be utilized are rice, wheat, oats, corn, barley and potato material. If desired, a combination of such materials may be utilized. The farinaceous material may be in the form of a finely ground flour or if desired, the particle size granulation may be somewhat larger such as a meal.

The farinaceous material may be mixed with water to raise the moisture content preferably to within range of 13-25 percent, preferably 16 to 22 percent. The terms percent11, and parts as used herein, will mean by weight unless otherwise indicated. Any suitable mixer may be used, for example, the present invention has been carried out using a 'Hobart1 mixer (the word 'Hobart' is a Trade Mark). It has been found advantageous to permit the mixed farinaceous material to temper for a period of time, such as 2 hours or more; thereby, assuring equilibration of the moisture throughout the farinaceous material.

A Collet Extruder is suitable for use in the present invention. A typical Collet Extruder is shown and described in U.S. Patent No. 3,358,582. Suitable 4558 8 - 5 temperatures of the extrudate at the die face are in the range of 235° to 35O°F. Suitable pressures are in the range of 500 to 1,500 p.s.i.g. (pounds per square inch gauge). The Collet Extruder may be used either with or without cooling jackets and may have a screw length to diameter ratio in the range of 1 : 1 to 3 : 1.

The farinaceous material typically will expand about 3 to 7 times upon extrusion and at this point, will be interspersed with many small voids or bubbles. A substantial amount of the moisture flashes off during the expansion or puffing. For example, the moisture content of the material may be 13 to 25 percent immediately before extrusion and 5 to 12 percent immediately following extrusion.

The compression step is carried out while the extruded material remains in the pliable condition and prior to cooling to a rigid solid. The extrusion remains soft and pliable for a short time following extrusion usually 2 to 15 seconds. The compression step may be carried out using a pair of stainless steel rolls. Alternatively, the compression step may be carried out between a pair of reciprocating plates or between a pair of endless belts. If desired, the surface of one or both ’ of the rolls, plates or belts may be provided with design which would ultimately be impressed into the extrudate during compression. The compressed thickness may, for example, be between 50 and 5 percent of the original thickness and will typically be 1/64 to 1/4 inch in thickness.

The extrudate may be cut before or after compression.

Although various modifications may be made without departing from the scope of the present invention, the following examples illustrate the present invention. 3 8 8 - 6 Example I A potato based snack was prepared according to the present invention by blending 75 parts potato granules and 25 parts corn meal in a 'Hobart' mixer. Sufficient water was added during blending to adjust the total moisture content to about 18 percent. The mixture was then held for 2 hours to assure equilibration of the moisture. The hydrated mixture was then fed to a Collet Extruder which was operated at 400 r.p.m. The extruder was equipped with a die having five orifices, each being 1 inch by 0.016 inch slits. The temperature of the extrudate at the face of the die was about 285°P. The extruded ribbon was about 1/4 inch in thickness. Immediately following extrusion and while the puffed extrudate was still soft and pliable, the extrudate was compressed between a set of rolls having a waffle pattern. The waffle grids were about 1/4 inch square. The areas compressed to the greatest extent were about 1/64 inch thick and the remainder of the ribbon was of a thickness of 1/4 inch. The compressed strands were then cut into pieces about 1-1/4 inches in length. The cut pieces were toasted at 35O°P, for 3 minutes and then enrobed with oil and salt. The compressed snack possessed a crunch and a harder texture quite different from the uncompressed potato based Collet extrusion.

Example II A corn snack was prepared by blending with a 'Hobart' mixer, 80 parts corn meal, 20 parts defatted corn germ, 0.25 parts calcium hydroxide with sufficient water added to adjust the moisture content to 18 percent. The blended material was permitted to steep for 2 hours. The material was fed to a Collet Extruder operating at 300 r.p.m. The Collet Extruder was equipped with a die having 3 orifices.

Each orifice was a slit 0.75 inches by 0.016 inches. The temperature of the extrudate at the die face was 285°P.

The soft strands were immediately compressed between two rolls having matching concave oval impressions. The rolls compressed certain portions of the strands but left a substantial portion of the strand uncompressed. After cutting and toasting, the pieces were enrobed with oil and salt. The pieces had a flavor and texture similar to a brittle corn chip which is quite different from the usual corn product prepared from a Collet.

Example III A cracker-like rice product was prepared from ground polished rice by adjusting the moisture content to about 20 percent. The hydrated rice was steeped for 3 hours and extruded through a Collet Extruder operating at 300 r.p.m.

The Collet Extruder was provided with a die having 3 orifices. Each orifice was a slit 1-3/8 inches by 0.062 inches. The temperature of the extrudate at the face of the die was 285°F. The extruded strands were about 3/16 inches thick and were compressed while soft and pliable between 2 smooth rolls to a thickness of about 1/8 inch. The resulting strips were cut into pieces and toasted. A glaze was applied to the pieces. The product had the crisp texture of a cooked rice cracker.

Example IV Example I was repeated except the extruded ribbon was compressed to a uniform thickness of about 1/16 inch and then deep fat fried at 375°F.

Example V A snack was prepared by blending in a 'Hobart' mixer, parts ground whole rice, 25 percent ground whole wheat. - 8 25 percent corn cones, 20 percent tapioca granules, and 2 percent sugar. The moisture content was adjusted to 19 percent. The hydrated mixture was extruded through a die at 285°F. and puffed to a thickness of about 3/16 inches. The extrudate was passed between a pair of compression rolls having a waffle pattern of ridges. The product was toasted and enrobed with a maple flavored glaze.

Claims

1. A method of manufacturing a food product which comprises (a) cooking a hydrated farinaceous material having a moisture content in the range 13.0 to 25.0% by weight in a pressurized chamber at an elevated temperature to form a substantially gelatinized dough, (b) extruding said farinaceous material through a die opening to form an extrudate having a desired cross section, the moisture content of said extrudate being reduced relative to the moisture content of said hydrated material so that it is in the range 5.0 to 12.0% by weight, and the volume of said extrudate being increased 3 to 7 fold relative to the volume of said hydrated material, (c) compressing at least a portion of said extrudate between a pair of surfaces while said extrudate remains pliable, the distance between said surfaces being such that the thickness of at least portions of the extrudate is substantially reduced, and (d) cutting the extrudate into segments of predetermined length.

2. A method as claimed in claim 1 wherein the hydrated farinaceous material is prepared by adding and uniformly mixing sufficient water in farinaceous material to raise the moisture level of the mixture to within the range 13.0 to 25.0 percent by weight.

3. A method as claimed in claim 2 wherein said moisture level is from 16.0 to 22.0 percent by weight.

4. A method as claimed in any of the preceding claims wherein said elevated temperature is from 235° to 35O°F., and the pressure within the chamber is from 500 to 1,500 p.s.i.g. 5. A method as claimed in any of the preceding claims wherein the farinaceous material comprises a mixture of corn, rice and potatoes. 6. A method as claimed in any of the preceding claims wherein the hydrated farinaceous material is in admixture with at least one flavoring ingredient. 5 7. A method as claimed in any of the preceding claims wherein the mixture of ingredients is tempered for a period of time sufficient to provide equilibration of the moisture throughout the farinaceous material before the mixture is introduced into the pressurized chamber for LO cooking. 8. A method as claimed in any of the preceding claims wherein at least one of the compression surfaces is provided with a surface pattern whereby at least one of the surfaces of the extrudate when compressed has an L5 irregular surface, and the thickness of said compressed extrudate varies. 9. A method as claimed in claim 8 in which both surfaces are provided with a pattern thereon. 10. A method of manufacturing a food product which !0 comprises extrusion puffing of cooked hydrated farinaceous material followed by partial compression of the extruded ' material while it is still in a pliable condition substantially as described herein. 11. A method of manufacturing a food product which

5. Comprises extrusion puffing of cooked hydrated farinaceous material followed by partial compression of the extruded material while it is still in a pliable condition substantially as described herein with reference to any one of the Examples. 0 12. Food products whenever manufactured by a method as claimed in any of the preceding claims.