NZ242702A - Dough, containing whole gelatinized red wheat and vegetable oil, extruded at 50-70 degrees f. - Google Patents

Description

242702 Priority Daic(c;.

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Publication Date: .4 W*. 1995 f» A .< N.Z. PATENT OFFICE 12 MAY 1992 RECEIVED Patents Form No. 5 Patents Act 1953 COMPLETE SPECIFICATION "Multlgraln Snack cood" WE, Borden, Inc. a corporation duly organized under the laws of the State of New Jersey. United States of America, of 180 East Broad Street, Columbus, Ohio 43215, United States of America hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which 1t Is to be performed, to be particularly described In and by the following statement: BJG/7991H 1 (followed by page 1(a)) 249702 B.I .F.-2245A.A 11-11-QI TITLE: MULTIGRAIN SNACK POOD BACKGROUND OF THE INVENTION Field of the Invention This invention relates to a food composition in the form of a snack food. In particular, this invention relates to a non-puffed, cereal grain dough extrudate which can be further processed such as for the manufacture of an oil-fried snack, particularly a multigrain snack.

Background Art Snack food products have long been prepared from wheat or corn by mixing the respective flour with water to form an extrudate which is then fried. Alternatively, potatoes have been thinly sliced and deep-fat fried to produce snack foods. Snack foods can thus include chip products, crackers, puffed dough articles and cookies.

• Fried snacks have included, for example, the snack foods produced by the method of Willard in U.S. Patents 4,769,253 of Sept. 6, 19B6 and 4,770,891 of Sept. 13, 1988. These patents relate to expanded fried snacks prepared from various extruded cereals.

U.S. Patent 4,517,204 of May 14, 1985 to Mottur et al. relates to a puffed snack product. The puffed snack contains r.icrocrystalline cellulose. In order to improve the texture and increase the expansion of the batter upon extrusion due to the presence of the cellulose, about 0.5% to 41 by weight of edible oil is added to the batter. The products of the Mottur et al. patent are preferably baked. About 0.1% to 1% of nonionic emulsifiers can also be added to the oil in order to improve expansion of the product.

A romnercial product which is a relatively low calorie version t of cheese Doodles'* of Borden Inc., includes corn neal and bran in its composition and additionally contains about 1% of vegetable oil. This product is baked.

Frito-Lay, Inc. has manufactured a nultigrain snack, marketed as Sunchips5, which is made from whole wheat, corn and other natural ingredients. The Sunchips* product is corn-based having approximately 50% by weight corn jneal and about 25% by weight wheat or. a before frying basis.

Vanderveer et al. U.S.Patent 4,777,045 of Oct. 11, .1988 ' \ ' 2 c 24 2 7 0 Z R.I iT* » 224&AiA 11-11-91 relates to a brand containing snack of various cereal grains which — are extruded from a twin screw cooker extruder. The extruded pieces are coated with from 1% to 10% of vegetable oil and a powdered flavorant is applied over the oil wherein the oil allegedly improves adhesion of the flavor particles, enhances flavor acceptability and improves mouth feel organoleptically.

Irvin et al. U.S.Patent 4,985,269 of Jan. 15, 1991 relates to use of twin screw extruders for making corn dough masa which is further processed for the production of tortilla chips. This reference also discloses the use of about 0.1% to 0.6% of a nonionic emulsifier which can be added to the corn feed prior to extrusion.

Lewis et al. U.S. Patent 4,384,009 of May 17, 1963 relates to snacks of dehydrated meat products containing vegetable materials such as whole or nearly whole grains and additives such as fats, oils, seasonings, flavors, preservatives, and emulsifiers.

A. Howard U.S. Patent 4,526,800 of July 2, 19E5 relates to an expanded snack food comprising cooked portions of dough containing gelatinized starch, including 10% to 70% by weight of bran and 5t to 35% by weight of oil or fat. 24 ? ' " L s.i.r.-aaisA.A li-n 01 SUMMARY OF THE INVENTION •• This invention is directed to the formation of a fried snack food and its dough composition precursor. The food products of this invention are low in cholesterol and fat, possess a unique grain flavor, and exhibit improved texture and mouth feel.

It has been found that the addition of about 3% to 8% of a plasticizer, e.g. vegetable oil, in the preparation of the dough compositions comprising about 20% to 35% total moisture; and about 4 5% to 77% of grain such as ground grain with or without smaller quantities of pieces of whole red wheat or dried fruit, minimizes the pick up of oil on frying as compared to such compositions without the added oil. Furthermore the fried snack can contain less plasticizer , e.g. vegetable oil, as compared to the fried product which does not contain the added plasticizer. This is the case when the quantity of added plasticizer is from about 3.5% or 4% to about 7% by weight of the dough composition. Also, about 3% to 8% of plasticizer improves the mouth feel or texture of the fried snack product. 24?702 H.1.F.-2245A.A 11-11-91 cooked dough compositions and snack products which have visually •• discernible pieces of grain or fruit in the product.

In another embodiment the dough composition is sheeted, shaped and cut into pieces which are dried to prepare pellets or half products which are then packaged for cooking by the consumer, e.g., by baking, frying or microwaving. The drying can be accomplished by conventional means such as by merely permitting the pieces to air dry overnight, e.g. to about 10% to 14% of moisture.

Although there are a number of different embodiments in this invention, one of the embodiments, referred to as the First Embodiment, uses a cooker extruder to cook the ground grain and form the dough with or without the addition of pregelatinized unground whole red wheat or pieces of dried fruit. Another embodiment, referred to as the Second Embodiment, does not cook the dough in the extruder but instead part of the ground grain is gelatinized and enters the extruder together with unground gelatinized whole red wheat. In the Second Embodiment the extruder is maintained at a temperature of no higher than about 70*F in formation of the dough .

BRIEF DESCRIPTION OF THE DRAWING Fig. l is a process flow diagram of the present invention. - ' ? 7 o 2 R.I.r.-22<SA.A 11-11-91 Fig. 2 is a schematic side elevation of a twin screw extrusion apparatus which can be used in this invention.

Fig.2 is a schematic view of the extruder barrel and twin screws taken along line 2-2 of Fig.2.- DETAILED DESCRIPTION OF THE INVENTION Fig. 1 is a process flow diagram of an embodiment of the present invention wherein the extrudate is prepared by the First Embodiment. Ground grain from the ribbon blender, is metered into the main feed opening of the extruder. Also fed to the main feed opening of the extruder are metered amounts of oil and water, although the oil and water can be premixed with the ground grain prior to being fed to the main feed opening. The ingredients which are introduced through the main feed area of the extruder are referred to herein as the base feed. The base feed is cooked in the extruder.

Optionally, in the First Embodiment, cooked and gelatini2ed unground whole red wheat which has water added thereto and cooked and gelatinized in a steamer is added to the base feed which is cooked in the extruder. However, such addition is made through a secondary feed opening which is near the extruder exit or die head. There is some mixing of the gelatinized unground whole red wheat with the previously cooked and ground base feed in the extruder. 6 - /. 2 7 0 7 It.I tr.-2245A.A 11-11-01 The nixing of the gelatinized unground whole red wheat is not •• vigorous and does not completely blend the unground whole red wheat in the mixture so that after extrusion, whole red wheat pieces are visually discernible in the dough. In some cases such as when pieces of dried nuts, e.g. roasted nuts, are added to the base feed through the secondary feed opening, the nuts are added without going through the steaming step. Alternatively, the base feed which is cooked in the extruder can pass through the extruder without addition of the unground whole red wheat or dried fruit pieces for subsequent processing, e.g. frying.

In both the First and Second Embodiments, various dies such as sheeting dies can be mounted on the exit end of the extruder. After extrusion, the extrudate can go into a forming machine where it is sized and cut into appropriate sized and shaped pieces and then placed on a conveyer belt for transfer to the optional toaster or directly into the fryer. Alternatively, the dough composition can be extruded through narrow die slits, cut at the extruder and go directly into the toaster or fryer. The toaster is an open flame gas oven where the cut pieces are placed for about 15 to 20 seconds at about 600#F to 650*F to remove surface moisture and help equilibrate the moisture content of the cut pieces. The cut pieces then, either from the cutting operation or the oven, are placed in a fryer maintained at conventional temperatures for conventional periods of time such as a temperature of 325*F to 410*F for about 1 to 3 minutes so that the moisture content of the 7 R.I.Ti ££45A»A 11 11 01 final product will be about 1% to 3\ by weight.

In both the First and Second Embodiments, the fried pieces are optionally conveyed through a coater where some vegetable oil can be sprayed on to the surfaces of the fried pieces at a level of about 3\ to 5% by weight of the finished product or the pieces can pass through a rotary tumbler,not shown, where salt or other flavorant is applied by dusting on to the pieces such as at a quantity of about 1\ to 10* by weight of the finished product. The product is then transported to the packaging machines on conveyors.

Fig.2 is a schematic side elevation view of a twin screw cooker-extruder apparatus which can be used in the First Embodiments. The apparatus JL includes a twin screw extruder 2$ a die mounting block 2, a die head 5.and a main feed opening or funnel 2/ for receiving the base feed ingredients although liquids such as added moisture (water) or plasticizer can also be received into the extruder through conduit 2. The extruder has a first, second, and third section. Each of these sections is further divided into two parts, not shown. The first section is principally a blending section, the second is a cookinc section and the third a cooling section.

The apparatus A also has means 11. 11. and 11 for measuring temperature in each section of the extruder barrel, and element 12 8 n 111 r i ■ &a i a 11- n-9i. for heating the extruder barrel of the second section, and cooling water inlet ports 15. 15.and 15. to each section if needed, although water is used for cooling in the third section. A motor driven shaft JLZ which through gearing means not shown drives the extruder screws 19.19 in the same direction (co-rotating) within extruder barrel 21 as more fully shown in rig.J. A secondary feed funnel 2A can receive pieces of food directly into the cooling zone, namely the third section of the extruder 1.

Fig. 2 is a view taken along line 3-3 of Fig 2 and shows a cross-section of extruder barrel 21 and co-rotating screws 19. 19.

The cooker extruders used in this invention can be single screw cooker extruders but are preferably twin screw extruders.

The single screw extruders qive a more erratic '"ate of feed due to the low friction between the screw and base feed occasioned by the relatively high oil content of the feed. Lack of steady feed rate causes sputtering on extrusion as well as changes in the composition of the extrudate, particularly when gelatinized unground whole red wheat or pieces of dried fruit are added to the base feed through funnel 2A of Fig. 2. The twin screw extruders car. have screws which are co-rotating or counter-rotating. The rotation of the screws convey the product from the inlet to the outlet while applying a nixing action as well as various amounts of shearing force to the mixture or dough. Heat is generated by higher shearing forces, principally in the second (cooking) section Sy 24 27 02 lUItT. 22«5A.A of the extruder. The extruder outlet is equipped with a die or shaped orifice for forming or shaping of the dough, e.g. in the form of a sheet, as it is extruded.

The cooker extruders used in this invention have three main functional sections although each section can be further subdivided, generally into two subsections. The three main sections are: first, the nixing and blending section; second, the cooking section? and third, the cooling section. The first section contains a conveying screw or screws which mix the base feed and form a dough while moving the dough to the second section. The first section exerts low shear and low compression forces of the ingredients. The dough is then conveyed by the screws to the cooking section where some external heat is generally added, such as by thermostatically controlled induction heaters, e.g. 12 in Fig 2, although some of the heat is generated from the shear of the screws within the extruder barrel working against the dough. The cooker section has the Peak Temperature, i.e. the highest temperature attained in the extruder. Most of the cooking and gelatinization of the dough takes place in this second section of the extruder.

The dough is conveyed by the screws from the second section to the third section where the dough is cooled prior to discharge from the extruder. Also, secondary feed 2A as shown in Fig 2. can provide pieces of food directly into the moving dough of the base feed in "702 W.I .r .-2245A.A the third section. The third section is one of low shear.

•• Preferably, the screw configuration at the area of the secondary teed does not produce much pressure on the dough such as by the use of a reverse screw configuration. This facilitates any addition of feed through the secondary feed ££. The discharge from the extruder is generally through a die, such as a sheeting die. Cooling of the barrel in this third section is generally accomplished by tap water circulation about the extruder barrel.

The dough composition of this invention is not puffed as it exits the extruder. Puffed products are made in extruders under puff extrusion cooking conditions which are well known in the art, and generally include temperatures at or above the boiling point of water and pressures of from about 2,000 to 4,000 pounds per square inch at the outlet of the extruder. In contrast to "puff conditions", applicants' dough composition, at the outlet of the extruder, is extruded, in the First Embodiment, at a temperature below about 165*F and preferably below about 155*F and at a pressure below about 550 pounds per square inch so that there is no puffing of the extrudate.

Although the preferred process for making the dough composition is by use of extruders such as cooking extruders in the First Embodiment or cooled press extruders in the Second Embodiment, other equipment for cooking all or a portion of the base feed, or mixing and preparing the dough composition can be used, e.g., the use of a Hamilton type kettle or a Stephan cooker- 11 1 7 0 L R.I.r. ««SA.A 11-11 Qfr mixer.

•• Unless otherwise indicated, the percentages of the various • * ' ingredients set forth herein are by weight and based on the total weight of either the feed, dough composition, or the fried snack, as appropriate. Furthermore, all ingredients except water (moisture) are on a moisture free (dry) basis. By the terms "dough composition" or "cooked dough composition" we mean the appropriate composition before cutting or sizing, e.g. the extrudate which is used to make the snack product.

The cooked dough composition of the First Embodiment will comprise a mixture of: from about 20* to 35% of total moisture, from about 3% to 8% of a plasticizer, and from about 45% to 77% of grain wherein at least 45% is cooked ground grain, up to 32% is pieces of food which are visually discernible in the composition due to color differences of the food pieces from the base feed; about 0% to 10% of sugar ; and about 0% to 2% of flavorants such as malted barley. The pieces of food are in the form of whole or pieces of grain, e.g. , whole red wheat or another food e.g. such as flaked, chopped, or shredded nuts, which can withstand the further processing of the dough composition after it exits from the extruder, e.g. frying, baking, etc. The pieces of food, although visually discernable, will generally have their shape altered by going through the extruder die and mixing in the extruder cooling zone. Thus, in the case of cooked whole red wheat, 12 V ~L ! U c *.I.r.-M45A.A 11 11 >1 the pieces will often resemble flakes. Apart from the whole red •« wheat, the food pieces can be made up of dried fruit, particularly nuts.

In all instances, the plasticizer is a vegetable oil which is in addition to any oil inherent in the grain and mixtures of vegetable oil with a nonionic emulsifier wherein the quantity of emulsifier is not more than about 2% and preferably not more than C.5%, based or. the weight of the dough composition. The plasticizer is intimately admixed with the ground grain as part of the base feed. The plasticizer needs to be present when the mixture is worked, i.e,, in formation of the dough, in order to obtain the beneficial effects of this invention since such effects are not obtained simply by coating the extrudate with the same quantity of plasticizer.

The quantity of plasticizer used in the dough compositions of this invention can vary from about 31 to 8%, based on the weight of the dough composition. A preferred amount of plasticizer in the dough composition is from 3.5% or 4% to 7% and particularly from about 5% to 7% by weight of the dough composition. At about the 3.5% or 4% to 7% level of plasticizer addition, it has been found that the fried product contains less oil than when the dough composition is fried without the addition of plasticizer. Furthermore, at less than about 4% of plasticizer in the dough composition of the First Embodiment, particularly at less than 13 n.i.r. aa46A»A 11 11 01 about 3% of plasticizer, the friedsnack product is too light in texture. In the Second Embodiment, the fried product is unduly hard at a plasticizer content of less than about 3%. Additionally, when the dough composition contains at least 10% of unhulled grain or bran equivalent to the amount found in about 10% of unhulled grain, the fried product has a gummy mouthfeel when the quantity of plasticizer is less than about 3%. At about 8% and particularly above 10% of plasticizer in the dough composition containing the above quantity of bran, the fried snack becomes mealy and falls apart in one's mouth.

Vegetable oils which are preferred for incorporation into the dough of the present invention as plasticizers include corn oil, sunflower oil, canola oil, coconut oil, their hydrogenated or partially hydrogenated derivatives and mixtures thereof. Corn oil ar.d canola oil or mixture thereof are particularly preferred.

The nonior.ic emulsifiers which can be used with the vegetable c:l are those having an HLB of about 3.2 to 5.0, The emulsifier is preferably an ester of a polyol and a long chain fatty acid such as that having from about 12 to 20 carbon atoms. Illustrative of suitable polyols there can be mentioned those of glycerin, ethylene oxide, sorbitol, and glycols. The polyol will preferably have from 2 to 6 hydroxy1 groups. Preferred emulsifiers are those of mono-and di-glycerides such as that of glycerol monostearate, glycerol distearate, glycerol dioleate, glycerol monopaImitate, and the 14 . ' C. I f \# ■— K.I.P."tl45A.A ll-ll-SI like. m* The total moisture, as recited in this invention, is the sub #* * of moisture (water) in the dough composition such as that which may be added with the base ingredients, pieces of food or otherwise to the composition as well as the inherent moisture of the grain and other ingredients in the dough composition. The total amount of moisture can generally be calculated from a knowledge of the inherent moisture content of the various ingredients plus any added water. Also the total moisture can be determined by the analytical method found in the Fifteenth Edition of the AOAC, Method A in part 926.07 which is by the vacuum oven moisture technique. The quantity of all ingredients, apart from the water, e.g.grain,pieces of food and plasticizer are on a dry or moisture free basis, e.g. in the case of grain it is the weight of the grain less it's inherent moisture content.

In the First Embodiment, water is added to the ground grain prior to cooking. Thus, about 5% to 15% of water based on the weight of the finished dough composition is normally added to the ground grain and plasticizer prior to cooking when gelatinized whole red wheat is added through the secondary feed. When additions are not made to the dough through the secondary feed, the entire amount of added water is mixed with the ingredients prior to addition or at the time of addition to the extruder. Such quantity of water can vary from about 5% to 20 % by weight of the dough \wn w K.I.r.-22«DA.A 11 11 Q1 composition.

•« In the First Embodiment, the dough compositions contain from about 20% to 35* of total moisture, preferably about 25* to 32* total moisture based on the weight of the dough composition. It is preferred that the moisture content not exceed about 30* since it has been found that increased water content causes increased oil pick-up in the frying step.

In the case when all of the ingredients are cooked in the extruder, all of the grain, e.g. 52* to 71* of the composition, is ground and such embodiment does not provide for discernible pieces of differently colored food in the composition. In such case, the added moisture which is provided with the base feed is that which will provide a total moisture content in the dough composition of from 20* to 35*, such as by the addition of from about 10* to 25* moisture based on the base feed.

When a portion of the ground grain is substituted with gelatinized unground whole red wheat or pieces of fruit in the First Embodiment, the quantity of such pieces can vary from about 10* to 32* by weight of the dough composition, and preferably from about 15* to 30% on a dry, moisture free basis, based on the weight of the dough composition.

The term "gelatinized" as used herein applies to completely 16 gelatinized food as well as food whicn is substantially gelatinized such as that required to eliminate white streaks on extrusion of the unground whole red wheat in preparation of the dough in this invention, e.g., extrusion through a die having a slit opening of %• • about two inches long and about 0.022 inches wide, and wherein there is partial "gelatinization" or cooking of all the starch in the unground whole red wheat.

It is preferred that the dough compositions of this invention contain ground grains wherein at least 5%, such as from about 10% to 30% based on the weight of the dough is unhulled. Such unhulled grains include the whole red wheat when it is used. By "unhulled" we mean grain which contains its bran. Also, by the term "whole" as it relates to grain we again mean unhulled grain wherein its hull has not been removed. Tne dcugn is preferably a multigrain composition such as one containing about 20t to 60% of wheat; 10 to 60 t corn ; 5% to 30% rice; and 5% to 15% oats. However, minor quantities, e.g., not r.cre tr.ar. abcut .5% of ctner grains such as sorghum, soya, rye, and barley car. slsc be used. Generally the extrudate of this invention will contain up to 10% of sugar such as white cane sugar, white beet sugar browr. sugar , and the like. It is preferred that the level of reducing sugars be kept low because these tend to form caramelized and burnt flavors and also darken the color of the food compositier, produced. Also, the amylopectin to amylose ratio of the food ingredients is preferably kept to a ratio of 40% to about 60% and particularly about 50%. 17 c. / \j L.

Rii.r.-aatsA.A The grains used in this invention can be in vari'ous forms. Thus, the ground rice can be that of various rice flours such as that of brown or white rice. Rice is also lighter in color than wheat such as hulled wheat or corn flours and can therefore be added to achieve a desired color lightness in the fried snack product. This facilitates the color contrast with pieces of whole red wheat and dried fruit in the dough and in the fried product. The ground wheat in the present invention can be various fractions of the wheat kernel. Soft wheat, in both the spring or winter wheat varieties, are particularly useful in the present invention.

Any of the different varieties of corn can be used in this invention such as yellow corn, e.g., yellow dent corn, white corn, or mixtures thereof.

The ground grain (flour) used in this invention is generally ground so that 100% thereof passes through a U.S. Series No. 10 sieve. Preferably, hard horny grains are milled to a size wherein 100% passes through a No.16 sieve and less than 20% remains on a No. 20 sieve. Examples of hard horny grains include certain dent corns, brown rice, and popcorn. Preferably, soft grains are milled to a size wherein 100% pass through a No. 10 sieve and less than 20% remain on a No. 20 sieve. Examples of soft grains include red wheat, oats, various varieties of corn, and white wheat. 18 /. H L f IJ f. n.I.r. 2245A.A 11 11 01 Although the grains used in this invention contain some oil, the quantity of such inherent oil is not sufficient to significantly affect the properties of the fried snacks. Thus, oats contain substantial quantities of fat (oil), namely, about 10% in whole dried oats, but the quantity of oats is limited in this invention to not more than about 15% of the dough. Furthermore, there is little or no oil in corn meal, about 4% in whole dried corn, about 2% oil in whole dried wheat, and less than 1%, generally, less than 0.5% in whole dried brown rice.

The unground whole red wheat used in this invention is cooked in an excess of water under conditions sufficient to cause the wheat to imbibe or absorb up to about 35% to 55% by weight of water based on the dry weight of the whole red wheat. The cooking of the whole red wheat can be, for example, by exposure to steam or by soaking in boiling water. During cooking it is preferred that partial gelatinization of all the starch in the wheat takes place. In the First Embodiment the hydrated, whole cooked red wheat is preferably chilled to below 60*F and more preferably to about 40*F before being placed in the extruder. It has been found that if the cooked and hydrated wheat is cold (e.g., 40*F) when added to the other cooked grains, a significant reduction in expansion of the extrudate at the die is achieved.

Still another reason for partially gelatinizing all of the starch in the unground whole red wheat before blending with the 19 9 24270: n.i.r. me/,.* 11 it 01 other grains in either the First or the Second Embodiment, is that when there is no partial gelatinization of all of the starch in the whole red wheat, the subsequent break up of the grains on extrusion leaves undesirable white streaks on the extrudate as Well as on the fried product from the raw starch in the wheat.

The pieces of whole red whoat cr dried fruit such as nuts are substantially larger than the ground grain or flour so that the difference in coloration of the large pieces is easily discernible. The pieces of food become macerated in the extruder and particularly on extrusion through the narrow slit dies so that the pieces may resemble flakes, The size of such pieces varies greatly but, as mentioned before, are much larger than the ground (flour) grain even though such pieces may be broken even before being placed in the extruder. Generally, such pieces of food have at least cr< dimension which is at least about one-thirty-second (1/32) of an inch (about 0.03) inches.

The dough composition of 'this invention can also contain fillers such as potatoes or other starchy foods.

In a preferred formulation of the First Embodiment, the quantity of the various ingredients is: from about 4% to 7% of added plasticizer; from about 251 to 32% of total moisture; about 19% to 26% cf fine corn meal; about 15% to 21% of gelatinized unground whole red wheat; about 8% to 12\ of whole brown rice flour; about 4% to 6% of ground white wheat flour; about 4% to 6% . " V '< - " > C. "T L. / V R.I.T. 2240A.A 11 11-91 of ground white oat flour; about 4% to 6% of powdered brown sugar; and from about 0.5% to 1% of malted barley. In all embodiments, the malted barley should have any remaining enzyme activity neutralized or substantially neutralized since the enzyme adversely affects the texture and organoleptic properties of the product.

In another embodiment, the cut pieces of the dough composition ,e.g. the extrudate, are allowed to air dry overnight and are then fried. The drying can take place by other means in order to limit the moisture content ,e.g. to about 10% tc 14% of the dough composition. Such cut pieces which have been dried are known as pellets or half products. Alternatively, the half products can be packaged for frying, baking, or microwave cooking by the consumer. The low moisture content prevents the half product from spoiling. The half products, fried as described above, can then be topically seasoned by methods and ingredients well known in the art.

The product produced from the frying step of this invention is a slightly expanded, cooked, oil-fried, snack food. The product exhibits no cholesterol and has a fat content dictated only by the frying conditions utilized. The oil or fat pick-up is minimized by the incorporation of the plasticizer into the formulation of the dough. After frying, the product is drained of excess frying oil and optionally topically flavored such as with salt. The resulting snack food product exhibits a unique texture and mouthfeel, particularly when a blend of grains is used. The pieces of whole 21 fi.i.t. £245A*A 11-11-91 red wheat, when used, provide darker spots on the fried product. Illustratively, the fried product, as well as the dough, will generally be tan or light brown in color with the whole red wheat pieces providing darker spots dispersed throughout the product.

The fried snack products of this invention will generally contain less than about 32% of total plasticizer (oil plus any emulsifier), by weight of the snack product, and preferably less than 28% such as from 22% or froic 25% to 27% of plasticizer. This is a relatively small quantity of oil for a fried snack which generally contain above 30% or 35% of plasticizer and at tines at least 50% of plasticizer. Of course such of this plasticizer content is oil which is picked up in the frying step.

In order that those skilled in the art may more fully understand the invention presented herein, the following examples, tables and procedures are set forth. In the examples, as well as elsewhere in this application, all percentages are by weight and unless otherwise indicated, the percentages of grains or pieces of food are on a dry ( moisture free ) basis in relation to the dough composition, e.g.extrudate, or fried snack, as appropriate.

PROCEDURE USED IN THE EXAMPLES Several examples of a multigrain snack food product were prepared according to the present invention. Table I provides the composition for 17 examples prepared by use of a twin screw cooker 22 9 . ? 7 r< ?. 8845A»A 11-11 -Q1 extruder, except for added water and added plasticizer in the base •• feed. The amount of water added to the base feed was about lot, based on the weight of the final dough composition. The quantity of added plasticizer in the dough composition, which was part of the base feed, based on the weight of the extrudate, for some of the examples is shown in Table 2.

In the case where the pieces of whole red wheat were used, e.g. Examples 2-6 and 11-15 the process was as follows: The extrudates were prepared by pre-blending the ground grains in a mixer until the moisture was of uniform consistency and homogeneity. To this mixture was added with further blending sugar (white cane), oil, and/or glycerol monostearate (GKS) as indicated in Table I. Water, 5% to 25% by weight based on the weight of the base feed was then added to the mixture with blending until uniform. Each mixture was then fed into a Clextral BC 45 twin screw extruder at a rate of from 180 to 1000 grams per minute.

Unground whole red wheat was cooked by adding the wheat and enough water to achieve 50% solids in a swept surface kettle. The wheat was cooked on medium heat for about 30 minutes covered, then the heat was turned up to high for about 15 minutes. The cover was then removed from the kettle and cooking was continued (about 15 minutes) until a moisture content in the wheat of about 40% weight was attained. 23 r) R.l.r.-»«5A.A 11 11-91 The whole cooked red wheat was fed into the extruder containing the mixture of ground grains. The addition to the extruder was made at the secondary feed near the discharge end of the extruder at a' rate of about 26% of the pre-blended grain feed rate. The mixture was then extruded at a thickness of about 0.08 inches and sheeted using either a standard pasta-type or a snack chip-type die. The peak barrel temperature during extrusion was 200-350*F and the screw speed was varied from 25 to 300 revolutions per minute. Examples which use dried fruit were run in much the same way except that the fruit was added in a relatively dry state, after being roasted.

The extrudate from the above processing was then put through sizing rolls to reduce its thickness to a thickness of between about 0.02 and 0.050 inches. The sheet was then cut into desired shapes, often called pellets. In one embodiment, the pellets were immediately fried in a vegetable oil at, for example 350of for about 60 seconds.

Specific parameters used for the manufacture of the dough composition prepared in Example 11 of Table 1 by the use of a Clextral BC 45 Twin screw extruder with a low shear screw were as follows: screw speed of 100 rpm; aotor amps of 17; feed rate for the base feed of 230 grams/minute ; cooled whole red wheat feed rate of 100 grains/min.; thrust bearing pressure of 508 psi; die head pressure of 420 psi? die head temperature of 134*F ; and 24 2 4 2 7 0/ R.I .F.-3846*.A li-U-ftl extrudate temperature of 150*F. Each of the three sections of the extruder are subdivided into two zones with zones 1-2 being part of section 1; zones 3-4 being part of section 2 and zones 5-6 being part of section 3 ( the cooling zone). The barrel temperatures in the various zones were as follows; zone 1 of 150*F; zone 2 of 300*F; zone 3 of 300*F; zone 4 of 300*F; zone 5 of 6l"F and zone 6 of 119*F. The extrudate of Example 11 was sheeted to 0.025 inches thickness, cut to round shape and subsequently fried at 350*F for 60 seconds.

TABLE I WjO 1 ON IIIIV IIASIN KJIAHfU NUHUUt • • 1 2 ) 4 !» 6 7 ■ 9 11 12 1) Wtiola Ho J (CookaJ) «0.0 2b.9 2b. 9 2b. 9 2b.9 2b. 9 24.0 24.4 2b.7 2b.) 24.0 wtiola Mttita Whaat I'lour 12.0 4b. « 7. J 7. J 11.1 II.) 11.1 19.0 19.0 7. ) 7.4 7.2 7.1 7.4 Mtiolo Oat Clour 11.b 4.9 *.9 4.9 2b.9 4.9 4.9 | 7.) 7.3 7.0 7.1 4.9 4.4 7.2 Corn Nual II.• 12. 7 2).b 21.4 M. 1 I4.J 14.) 14.) )2. ) )2 .1 11. • ) 1 • 4 )).) Mftola Karnul Corn flour 12.0 2b.9 14. J MUtU Drown die* Flour 11.7 21. b 2).b 14.■ 14.11 14.1 14.1 14.) 14.7 14.9 14.b 14.) lb. 1 M*lta4 ftdrlay flakaa 9.0 1.0 1 .O 1.1 I.I 1.1 1.0 1.0 l.O 1.0 1.0 Su<j«r 4.9 4.9 4.9 4.9 4.9 4.9 4.9 |>a|^>«il fupcui n b.S 14.9 CMS 1.9 Corn Ot1 b.O S.O b.O b.O b.O b.O • Ciiwlt Oil b.o 4. • 3.4 4.1 7.4 2.0 CrouiMl Paanuts 19.O 4.9 7.0 4.0 4.7 7.1 Coconut* (flakau) - 19.0 -V Z4 L I u L Ril .F* ■2245a.A frl-ll-Sl TABLE 1 (CONTINUED) \ on Cxy Basis Example 14 15 16 17 Unground, Whole Red Wheat (Cooked) 40 27.3 .7 26.0 .9 Whole White Wheat Flour 12.8 7.7 7.3 9.2 7.2 Whole Oat Flour 11.5 7.4 7.0 6.9 6.9 Corn Meal 11.8 34.0 32.1 34.9 31.9 Whole Kernel Corn Flour 12.0 Whole Brown Rice Flour 11.7 .4 14.5 9.2 14.5 Malted Barley Flakes 9.0 1.0 0.9 1.0 1.0 Brown Sugar — 7.2 6.8 6.9 6.8 Popped Popcorn 5.5 GMS Corn Or Canola oil -— 5.7 6.2 6.1 EXAMPLE 18 The added plasticizer in the extrudates for some of the examples from Table 1 were compared with the total amount of plasticizer in the fried snack after frying. The results are shown in Table 2. It can be seen from Table 2 that the use of about 3% to about 8% of added plasticizer inhibited the amount of oil picked up from the frying step. The plasticizer in all cases is measured on a moisture free basis for the extrudate. The abbreviation of GMS 27 R.I .T. ■ 224SA.A 11 11 01 in the table as well as the previous Table 1 refers to glycerol •• monostearate which was used at the 1.9% level in the extrudate whereas the remaining examples were with corn oil or canola oil as the plasticizer. The frying medium was either corn oil or canola oil and the procedures for preparing the extrudate and frying of the product is that which has been set forth hereinbefore.

It can be seen from Table 2 that at levels of about 4% to about 7%, the added plasticizer in the base feed provides a fried product with less total plasticizer than frying of the product without the added plasticizer. However, even below about 3% and above about 7% of added plasticizer the total quantity of plasticizer ( generally vegetable oil) in the fried product is less than that which is calculated by adding the added plasticizer to the amount picked up on frying without the added plasticizer. It has also been discovered that at levels above about 8% or 10% of added oil the final product becomes unacceptably mushy and falls apart in the consumer's mouth. Thus, while conventional oil frying of snack foods typically results in an oil( plasticizer) content in the snack food cf 30% to 35% by weight and often 50% by weight or higher, the present invention can produce a fried snack food with less than about 30% by weight total oil, and preferably less than 28% by weight. 28 ? * 0 7 0 2 R.I.T. ■ 2245A.A 11 11-91 TABLE 2 •• COMPARISON OF AMOUNT OF PLASTICIZER ADDED TO DOUGH WITH AMOUNT OF OIL IN FRIED PRODUCT OF THE EXAMPLES IN TABLE Example Plasticizer Added Total 14 0% .3 1 1.9% 31% 13 2% 31% 3.4% .3% 9 4.8% 27.7% .7% 26.4% 16 6.2% % 17 6.1% % 11 6.5% 29.4% 12 8% 33.3% In the Second Embodiment a portion of the flour, such as 40% to 60% of the flour on a dry basis, is pregelatinized and then mixed with the remaining flour and unground whole red wheat which is also pregelatinized. This mixture is fed through an extruder which does not further cook the ingredients. After the dough is extruded, the process is substantially the same for both the First Embodiment and the Second Embodiment. 29 y.H l I u R.I.T. 2245A.A 11 11 91 The Second Embodiment is particularly preferred. In the Second Embodiment the feed to the extruder comprises froar about 251 to 35% of total moisture and preferably from 28% to 32% of total moisture; about 50% '"to 70% of grain on a moisture free basis, wherein about 30% to 40% is ground grain (flour) and preferably 32% to 38% is flour and 20% to 301, preferably 22% to 28% is unground gelatinized whole red wheat. From about 40% to 60% of the flour in the second Embodiment is gelatinized before entering the extruder. Preferably about 45% to 55% of the flour is gelatinized before entering the extruder. In the Second embodiment, the plasticizer and the quantities thereof are the same as in the First Embodiment. Optionally, the composition can contain additional vegetable or dried fruit ingredients as in the First Embodiment.

In the process for making the dough of the Second Embodiment, the flours, including the pregelatinized flours are blended and mixed in the appropriate proportions with the unground and gelatinized whole red wheat as well as the plasticizer and any other feed ingredients. This mixture then enters into an extruder which is maintained at a temperature not above 70*F, such as that of about 50* to 70"F A suitable extruder for the Second Embodiment is a tubular press with a compression screw such as a conventional pasta press, e.g., a Kapampianti pasta press. In this process the press is not c H C / V - *.l.r.-22<DA.A heated but heat builds up during the friction and extrusion of the feed mixture. The heat is removed and the temperature is maintained at about 50*F to 70*F. This is achieved by circulation of tap or cold water' through the hollow screw and the jacketed barrel of the press. This is in contrast to the temperatures normally employed in such presses such as in the manufacture of pasta wherein the temperature is generally above 100*F or 110*F. The reason for maintaining the lower temperature is that better friction is developed between the feed material the extruder screw and inside surface of the barrel.

The problems in the use of the single screw cooker extruders are overcome in the Second Embodiment by: having a higher total moisture content in the initial feed; pregelatinizing a portion of the flour feed; and keeping a low temperature in the extruder.

Preferably, in the Second Embodiment, the mixture is extruded through a die having a narrow opening such as a die having an opening of about 0.022 inches wide and about two inches long. Such die can have a straight or wavy slit opening so as to produce the corresponding dough configuration. The extrudate emerging from such die is then face cut at the die, preferably directly into a fryer. The cut pieces of dough with the above mention die, will thus have a thickness of about 0.022 inches, a length of about 2 inches and can be face cut to have various widths such as a width of about one and a half inches. 31 R.I .r. "284SA.A ll-ll-n In the following preferred formulation of the Second Embodiment, about 90% of the rice was gelatinized and 50$ to 60% of the total quantity of com was gelatinized prior to entry in the extruder. A suitable .pregelatinized rice for the following formulation is Pre Gel Waxy Flour RF-GBOBO of the comet Company whereas a suitable pregelatinized corn flour is Pre Gel Corn Flour from the ConAgra Company. 32 ft.I ,r.-2245A.A 11-11 01 A preferred formulation for making the dough of the Second Embodiment is as follows: \ AS IS Moisture Corn Flour (89% ts*) Pre gel Corn Flour (91.5% ts) Pre Gel Waxy Rice Flour (91.2% ts) Whole Oat Flour (89.8% ts) Powdered Brown Sugar Malted Barley flakes (91.0% ts) Unground, Boiled, Soft Red Whole Wheat (48% ts) Canola Oil Lecithin 16.89 .09 6.60 .12 .56 0.58 51.34 3.80 0.02 % OF MOISTURE AND DRY BASIS 30.56 15.04 9.23 6.02 4.60 5.56 0.53 24.64 3.80 P.P2 TOTALS 'refers to total solids. 100.00 100.00 The following procedure can be used for producing the dough of the above formulation by use of a single screw pasta extruder with a 2,000 pound per hour feed rate. Pre-blended flour, including the pregelatinized flour, is placed into a metering feeder. The feed rate is adjusted to 905.2 pounds per hour and the feeder is 33 ft.I.T.-2240A.A 11-11- »1 started. An oil spray, at the beginning of the mixing chamber preceding the extrusion barrel, is adjusted to 75.8 -pounds per hour. However, the oil may be added instead to the pieces of gelatinized whole red wh/iat. The unground gelatinized whole red wheat feed is adjusted to 1019 pounds per hour. These ingredients are nixed and the mixture is extruded while the barrel and screw temperatures are maintained at about 60*F. A die having a wavy opening is at the exit end of the extruder. The extrudate is cut at the die. Frying of the cut dough is at 350*F for about one minute. The fried chips are then removed from the fryer and placed in a seasoning tumbler and then sent to a packaging machine.

A typical analysis of the fried product of the above formula and process of the Second Embodiment has a total oil content of about 26%, a moisture content of 1.5%, and the seasoning is fine flour salt at 1%. All of the percentages herein being on a weight basis and apart from the moisture or water being on a dry or solids basis.

A preferred feed formulation of the Second Embodiment comprises: about 25% to 35% of total moisture; about 5% to 15% of pregeled corn flour; about 15% to 25% of corn flour which has not been gelatinized; about 4% to 8% of pregeled rice flour; about 25« to 6% of whole oat flour which has not been gelatinized; about 6\ to 10% of brown sugar; about 4% to 7% of vegetable oil as 34 plasticizer; and about 20% to 30% of the unground, gelatinized whole red wheat.

Broadly, a dough composition of this invention which includes both the First Embodiment and the Second Embodiment comprises; A. about 3% to 6% of a plasticizer, preferably 3.5i or 4% to 7%; B. about 20% to 35% of total moisture, preferably 25% to 32% of total moisture; C. A total quantity of edible plant material food, e.g., vegetable and fruit, of from about 50% to 77% and preferably 60% to 77%, on a dry basis, wherein the quantity of grain, both flour and gelatinized whole red wheat pieces as well as any pieces of dried fruit is from about 50% to 77%, wherein at least 45% of the dough is flour and at least 40% of the flour is gelatinized, and up to 32% of the dough is gelatinized whole red wheat pieces or dried fruit which have a different coloration from the flour and are visibly discernible in the dough and subsequent fried product. The composition can contain additional ingredients as described hereinbefore.

Claims (8)

WHAT WE CLAIM IS v *"

1. A process for making a dough extrudate suitable for a snack food which comprises the steps of: A. providing to an extruder a feed which, by weight, comprises: a. 30% to 40% of grain flour on a moisture free basis, said flour selected from the group consisting of wheat, rice, corn, not more than 15% of oats, and mixtures thereof with 40% to 60% of said flour being gelatinized; b. 20% to 30% on a moisture free basis of unground gelatinized whole red wheat; and c. 3% to 8% of a plasticizer selected from the group consisting of a vegetable oil and a mixture of a vegetable oil and not more than 0.5% of a nonionic emulsifier said oil being in addition to oil inherent in said grain; d. said feed containing 25% to 35% of total moisture; and B. extruding said feed mixture while maintaining the screw and barrel of the extruder at a temperature of from 50°F to 70°F by removing heat from the extruder to produce an extrudate wherein pieces of whole red wheat are dispersed throughout the extrudate and are visible therein due to the darker color of the whole red wheat.

2. The process of claim 1 wherein the plasticizer is from 3.5% to 7% of a vegetable oil.

3. The process of claim 1 wherein the feed includes gelatinized rice flour.

4. The process of claim 1 wherein the feed includes from 4% to 8% of sugar.

5. The process of claim 1 wherein: the plasticizer is vegetable oil in quantity of 3.5% to 7%; the flour is a mixture of grain flours which includes from 3% to 10% of pregelatinized rice flour; the whole red wheat pieces have one dimension of at least 0.03 inches and all of the starch in the whole red wheat is partially gelatinized; and the temperature of the extruder barrel is maintained at 55°F to 65°F by cooling.

6. The process of claim 1 wherein the dough extrudate is made into a snack food by the steps of cutting the extrudate into predetermined sized pieces and then fiyinj pieces in vegetable oil to produce a fried chip product containing less than of vegetable oil. 36 C>\L / UZ

7. A process as claimed in claim 1 for making a dough extrudate when performed substantially as herein described with reference to any one example thereof.

8. A dough extrudate when produced by the process claimed in any one of claims 1 to 5. DATED THIS f ivLemte/ A. J. PARK & SON PER: AGENTS FOR THE APPLICANTS