PT88127A - Storable potato based dough for snack prod. mfr. - made by dry mixing precooked potato flour with natural and modified starch, forming dough with water, extruding, shaping and drying - Google Patents

Abstract

Edible sheets of potato dough are made from freshly gathered potatoes which have been washed in the usual way such that all contaminants have been removed. The potatoes are cut into slice, boiled in water, kneaded and dehydrated, then the precooked dried potato is dry mixed with naturak potato starch and potato starch that has previously been subjected to a phosphate treatment, and opt. wheat starch, maize starch or other grain starches, salt, flavour enhancers, binders, flavourings and vitamin concentrates; water is added to form a dough with a moisture content of 25-40%, the dough is extruded, rolled and punched out, subjected to a drying process, packaged and stored, and ultimately cooked.

Description

88 = 3325

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DESCRIPTION OF THE PREFERRED EMBODIMENT The object of the invention is to provide a process by which an edible slide is obtained. of potato dough which is provided in disks or other shapes and which is dimensionally stable up to the final sealing operation in a hot oil or other heat transfer medium.

Another object of the invention is to provide ready-to-fry potato slice appetizers manufacturers allowing them to store, between receipt of the product and the pre-packaging final operation of more than two years. It is also an object of the invention to homogenize the product quality by offering the consumer a constant aspect, size and flavor of the product, regardless of the quality of the potato oscillations at different times of the year, totally eliminating defects caused by biological changes and by the ata than of microorganisms and insects.

A further aim of the invention is to provide the sector with a means of regulating its commercial campaign, irrespective of the fluctuation during the course of the year of producing the batata.

BACKGROUND OF THE INVENTION Potato chips or "chips", as it is known in the market, is produced by a process consisting of washing, peeling, chopping and frying in a continuous process of potato, that is to say, by industrialization of the domestic process commonly used.

Accordingly, said process is completely removed from the initial definition of the subject matter of the invention, in which potato dough is formed which is treated to obtain a stable laminated dough. The obtaining of products from a mass is not in itself a novelty, there are on the market products extruded from a mass which are then fried in continuoj as exe_mio of products of this type we can cite the classics " Churros " (farturas), but these products, however, must be fried 68 052 88 = 3325

immediately after the dough is prepared.

There are other products that are not appetizer, starting with a mass of flour; are the so-called pasta extruded vermicelli, spaghetti, pasta, etc .; * cu laminadas: " cannel, lone " or lasagne, etc.

Also in this case the process differs from the process of the invention, firstly because there is no final pharmacological operation and secondly because the flours used are raw whereas, as will be seen later, in the present case, are pre-sewn.

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Description of the Invention

In summary, it may be said that the invention consists in a process whereby, from a food mass based on treated potato flour and to which leaven from potato and additives such as salt are added, a blade that can be divided into portions of ellite or oval shapes - when it comes to imitating the shape of the potato, in whimsical ways in other cases - parts that can be stored for more than two years, without losing food, taste or aspect to finally be treated by heat in an oil whose temperature oscillates between 170 and 230 degrees Celsius.

Justification of the Invention

The main difficulty in the production of conventional chips is the supply of raw material of the appropriate quality.

Not all varieties of potatoes are suitable for frying, nor can all land or climates in which potatoes are grown give the appropriate quality for frying, whose main requirements are the low content of reducing sugars and the high dry matter content.

On the other hand, it can be seen that there is no harvest in the peninsula from October to April, and that the potato chip maker has to resort to stored potatoes. Potato storage for frying has critical

68 052 88 = 3325 for the quality of the finished product, which are not fully resolved: bacterial and fungicidal treatments together with a low storage temperature are used to prevent deterioration of the potato by bacterial and fungal attack. it is usually sufficient for the potato to arrive in good condition until the new crop arrives, but at low temperature it causes a concentration of reducing sugars in the potato which makes it unusable to fry because it makes the fried brown.

To avoid the formation of reducing sugars, the only known system is the highest temperature packing, 18-20 ° C, but in this case pathogenic microbiological attacks and acceleration of germination.

In view of this dilemma, it is customary to adopt a compromise solution without completely avoiding any of the drawbacks, and it is well known that in winter and spring conventional potato chips are always affected by obscuration, staining and damage by microorganisms attack.

Another drawback of the direct processing of the potato tubers is the dispersion of sizes that require prior classification, with loss of the marginal fractions, to avoid the difficulties that arise in automatic packaging; weight dispersion, bulk volume unevenness, and browning of packaging material by welded parts.

Advantages of the Invention

All of the disadvantages and disadvantages described in the previous chapter are eliminated by the present invention, which provides the industrial fryer with a potato dough sheet of equal size, constant organoleptic quality, a product without sanitary flotation and with a minimum assured conservation of two years before the final frying process.

Another additional advantage is the lower absorption of oleo during frying.

Conventional chips (Chips) have an oil content of 35 and 45, while the product produced in accordance with the invention contains 20 to 30 g of oil which is a dietary advantage.

Process Description Process is performed from freshly harvested fresh potatoes of the most suitable varieties for frying. The potatoes are subjected to washing, peeling, separating impurities, cutting, sewing in water, kneading, dehydrating the fluid bed or other means and are finally tempered.

The potato thus processed, with a moisture content of 5 to 10%, upon being hydrated again converts to a mass which retains the organoleptic properties of the fresh potato sewn.

This sewn and dehydrated potato is blended, as will be seen later, with potato starch which has been subjected to a phosphate treatment, sewing and dehydration.

The porosity and texture of the finished product is controlled by balancing the native starch and the treated starch.

With these raw materials as a base, an ideal formula would be: 60% dehydrated pre-cooked potato flour (40 to 80 / b) j)

15% modified potato starch (5 to 25%); 25% native potato starch (15 to 40%),

This formula is non-limiting and, for example, part of the potato flour may be replaced by pre-cooked cereal flours and part of the potato starch, both native and modified, may be replaced by equivalent types of wheat fats, of maize and others.

Another example of a dried pre-cooked potato flour formula; 20% precooked wheat flour; 15/0 of modified potato starch; 68 052 88 = 3325 -6

15 / α of native potato starch; 15 / o of native maize starch.

Apart from these basic ingredients there will be approx. and optionally flavor enhancers, flavorings, flavorings, flavorings and vitamin concentrates as may be desired by the market.

Accordingly, the process consists of the following operations: - Dry ingredients mixing; Addition of water to obtain a mass humidity of between 25 and 40%; - Extrusion; - Lamination; - Cutting (Trace); - Drying; - Packaging; - Storage; - Final heat treatment. The mixing is carried out in a twin-screw mixer in a vessel in the outlet of which there is provided a safety screen for retaining foreign elements and a conveyor to take it to the water adductor. The addition of water is done by spraying in a counterclockwise direction of the flour in a blender or hammers. The extrusion comprises an extruder which transfers the measured mass to a variable pitch screw, the pitch of which is a function of the required compression of the mass to be compacted homogeneously. The heat generated by the compression must be dissipated by a suitable cooling medium which allows the mass to be maintained at a temperature between 30 and 60Â ° C to avoid excessive gelatinization and the consequent increase in the viscosity of the mass which, 3¾

68 052 88 = 3325 -7- time, it would generate more heat by friction. The mass of the extruder leaves the sheet in the shape of a blade 1 to 3 mm thick and is fed to a rolling mill which reduces the thickness to 0.5 to 1 mm.

In the same train the blade is cut round or other shapes and the excess mass of the cutout is returned to the extruder so that the utilization is complete. The drying is carried out by means of air with controlled temperature and humidity to obtain a final humidity of 10 to 15%. The product is collected in packages that protect it from changes in ambient humidity and is stored and distributed for final processing. The typical final transformation is that of frying, which will be done in hot oil at 170 ° -21 ° C until a residual moisture of less than 5% is reached. The product during the frying has an expansion of the order of 10-20 / o obtaining a blade of golden color and crunchy texture with the own flavor of the French fries. It is not considered necessary to extend this description further so that any person skilled in the art will understand the scope of the invention and the advantages thereof.

The materials, shape and size and arrangement of the elements will be susceptible to variation as long as this does not imply a change in the essence of the invention.

The terms in which this description was described should always be taken in a broad, non-limiting sense.

Claims (11)

63 052 88 = 3525 A method of obtaining a potato dough slab from fresh, freshly picked, properly washed, impurities and broken pieces, sewed in water, kneaded and dehydrated, mixed with potato starch in the natural state and with potato starch undergoing a phosphating treatment, seeding and dehydration, and may also include wheat starch, corn and other products, and also including salt, in the appropriate proportion, as well as flavor enhancers, condiments flavorings and vitamin concentrates, among others, characterized in that it comprises the following steps: - mixing the ingredients dry, after which water is added to obtain a mass with a humidity of between 25 and 40%, and an operation extrusion, followed by rolling, and finally a cutting, the process being complemented with the drying, packaging and storage phases, and or a final stage of heat treatment of the product. A process according to claim 1, characterized in that the mixing is carried out in a twin-screw mixer in a vessel whose outlet is provided with a safety screen to retain foreign elements and a conveyor to the water adductor. A process according to claim 1, characterized in that the water addition phase is carried out by counter-current spraying of the flour, in a blade or hammer drum. Process according to claim 1, characterized in that the extrusion step is continuously carried out in an extruder, which transfers the wet mass to a variable pitch screw, the pitch of which is a function of the compression required by the mass to be compacted homogeneously. Process according to claims 1 and 4, characterized in that the mass is maintained at a temperature between 30 and 60Â ° C, to avoid excess gelatinization and the consequent increase in the viscosity of the mass, with means 68 052 88 = 3325 to dissipate the heat generated by its compression. A process according to claims 1 and 4, characterized in that the mass exits the extruder in the form of a sheet having a thickness of between 1 and 3 mm and is fed to a rolling mill which reduces the thickness to between 0.5 and 1 mm. A process according to claim 6, characterized in parallel to the rolling operation and in the same rolling mill, if the sheet of dough is cut into round shapes and other shapes and the excess mass of the cut is fed back into the extruder to its full use. 8. A process according to claim 1, characterized in that the drying step is carried out by means of air having controlled temperature and humidity, to a final humidity of between 10 and 15%. A process according to claim 1, characterized in that the final stage of the heat treatment consists of a frying carried out at a temperature of between 170 and 210Â ° C in a suitable liquid fat until a residual moisture of less than 3% is reached, an expansion between 10 and 20%. Process according to the previous claims, characterized in that the pre-sewn and dehydrated potato flour is used as a feedstock in the range of 40-80%, preferably 80%, modified potato starch, in a percentage comprised from 5% to 25%, and preferably from 15% to natural potato starch in a proportion of from 15 to 40%, preferably from 25%. A process according to claims 1 to 9, characterized in that 40% of dehydrated pre-potato flour, 20% of pre-sewn wheat flour, 15% of modified potato starch, 15% of natural potato starch and 15% of natural corn starch. 68 052 88 = 3325 -10- Lisbon, By LENG-DOR, S.A. - 0 OFIOIAL AGENT -