RU2366277C2 - Production method of multicereal flakes - Google Patents

Abstract

FIELD: food industry. ^ SUBSTANCE: invention relates to food-concentrates industry, namely to production methods of extruded products. At least two different mixtures are prepared. They differ as the content is different. One of them, before going to the cooking room extruder is additionally condensed by water vapour in the horizontal continuously-operating blending machine for obtaining humidity of 18Ç25% during 30Ç600 seconds. After that mixture is going to the cooking room turn-screw extruder for processing. Second and following mixtures are condensed by water vapour in the horizontal continuously-operating blending machine for obtaining humidity of 30Ç60% during 30Ç900 seconds and put in butt zones of cooking room extruder for mixing with extrudate. Homogeneous consistence suspension is obtained, transported to the cutting device, the suspension is cut with fly knife into separate particles of freeform. Flakes are formed and fried with humidity reduction 1Ç4%. ^ EFFECT: usage of invention allows to obtain extracted flakes presenting the mixture of two or more grain components with distinct surface of discontinuity of components on the surface of flakes with high consumer properties. ^ 1 dwg, 1 ex

Description

The invention relates to food-concentrate industry, in particular to methods for the production of extruded products.

Closest to the proposed technical essence is a method of preparing cereal flakes, comprising preparing a mixture of recipe components, processing the mixture in a cooking extruder, molding through a flat slit-like opening of the forming head to obtain an extrudate in the form of a porous tape, transporting the extrudate to a cutting device, cutting and frying with a decrease in humidity of 1-4% (Pat. No. 2014786, MKP ⁵ A23L 1/164, 1/18 // A23P 1/14, 06/30/1994).

The disadvantages of this method are the low quality of the obtained flakes and the difficulty of obtaining flakes of various sizes without readjusting the line.

The technical task of the invention is to obtain high-quality cereal flakes, expanding the range of products by obtaining cereals from various types of grain raw materials.

The problem is achieved in that in a method of producing cereal flakes, including preparing a mixture of recipe components, processing the mixture in a cooking extruder, transporting the extrudate to a cutting device, cutting it, molding flakes and frying with a moisture reduction of 1 ... 4%, new is that at least two different mixtures are prepared that differ in the composition of the recipe components, one of which is additionally conditioned with water vapor in the horizon before being fed to the cooking extruder a continuous mixer until a moisture content of 18 ... 25% is reached within 30 ... 600 seconds and is fed to a twin-screw extruder for processing, and the second and subsequent mixtures are conditioned with water vapor in a horizontal continuous mixer until a humidity of 30 ... 60% is reached within 60 ... 900 seconds and fed to the end zones of the cooking extruder for mixing with the extrudate until a homogeneous suspension is obtained, the suspension obtained is transported to the cutting device by at least one single screw with a struder, cutting the suspension into individual particles of arbitrary shape is carried out by a rotating knife, and the formation of flakes is carried out by at least one pair of smooth rollers

The technical result of the invention is to obtain flakes representing a mixture of two or more grain components with a pronounced interface between the components on the surface of the flakes and controlling the size of the flakes by changing the rotation speed of the rotating knife.

The drawing shows a flow chart of the production of multigrain cereals.

The proposed method is applicable for the production of flakes from any grain raw materials suitable for extrusion processing for both sweet and salty products, and is carried out in general form as follows.

According to the recipe, grain components are preliminarily prepared, and at least one of them must be milled into particles with an average size of at least 1 mm, in extreme cases, not milled at all. Prepared grain components are divided into two mixtures, and mixture No. 2 consists of a component having a coarse grinding. Also, the mixture No. 2 may consist of several coarsely ground components having the required particle size. In the case of a large difference in the preparation time of various grain components having a large grinding size, a mixture of No. 3, etc. can be formed, each of which forms a separate semi-finished product stream.

Grain ingredients of mixture No. 1 are mixed in a belt mixer. The prepared mixture is fed into a paddle mixer with a flow rate of 150 ... 600 kg / h, where water vapor is also supplied under a pressure of 0.5 ... 3 bar. The feed rate of the mixture is regulated using a screw feeder.

The residence time and final humidity of the mixture of grain ingredients at the outlet of the mixer are one of the main factors determining the parameters of the further cooking process and the quality of the resulting flakes. The residence time of grain ingredients in the mixer is 30 ... 600 seconds, humidity is 18 ... 25%, these parameters can be adjusted by changing the design and dynamic characteristics of the paddle mixer.

The conditioned mixture is then fed into a twin-screw cooking extruder. Also, the water is supplied to the extruder in the required amount to conduct the cooking process and maintain the extrudate moisture in the range of 20 ... 35%, depending on the used grain raw materials. Flavoring ingredients such as sugar, salt, malt extract and others can be added to the cooking extruder if desired. Processing the mixture in an extruder is carried out at a temperature of 50-180 ° C for 100 ... 600 seconds.

When passing through an extruder, the grain components are mixed with water and other ingredients, melted, undergoing various physical and chemical changes, such as gelatinization of starch, protein denaturation and others.

Grain ingredients of mixture No. 2 are mixed in a belt mixer. The prepared mixture is fed into a paddle mixer with a flow rate of 150 ... 600 kg / h, where water vapor is also supplied at a pressure of 0.5 ... 3 bar and water in the required amount to achieve a humidity of the mixture of 30 ... 60%. The feed rate of the mixture is regulated using a screw feeder. The residence time and final humidity of mixture No. 2 is selected so that at the outlet of the mixer the grain components are ready for use in food. The mixer operating parameters are regulated by changing its structural and dynamic characteristics, as well as varying the amount of steam and water supplied. The main quality indicator of the obtained semi-finished product is the preservation of the integrity of individual particles of grain components.

Next, the mixture No. 2 is fed into the end zones of the cooking extruder for mixing with the boiled mixture No. 1. As a result of the process of cooking mixture No. 1 and mixing it with mixture No. 2, a homogeneous plastic dough is formed at the exit of the extruder, which is a suspension in which the extrudate from mixture No. 1 acts as a dispersion medium, and evenly distributed as a dispersed phase particles of mixture No. 2.

Using a twin-screw extruder as a cooking extruder allows you to increase the range of characteristics of the processed raw materials, extends the technological capabilities of the cooking process of the components of mixture No. 1 and allows you to flexibly control the degree of mixing of two or more streams of grain ingredients. The moisture content of the suspension at the outlet of the cooking extruder is 15 ... 25%.

Then the mixture is continuously reloaded into a conveying single screw extruder or extruders, depending on the ratio of their productivity with the productivity of the cooking extruder.

At the exit of the single-screw extruder, a rotating knife is installed, which separates the strands of the extrudate emerging from the extruder matrix into individual particles of arbitrary shape - blanks for individual flakes. By adjusting the speed of rotation of the knife, granules of various sizes can be obtained, from which flakes are formed during rolling. In a single screw extruder, the destruction of particles of mixture No. 2 does not occur either.

The granules are then fed onto smooth rollers to form flakes. The thickness of the obtained raw flakes is 0.1 ... 1 mm, depending on the raw materials used and the gap between the rollers. On the surface of the rolled flakes there is a continuous phase of mixture No. 1 with uniformly distributed inclusions of unbroken particles of mixture No. 2.

Rolled flakes are fed into a fryer of various types: gas, electric, etc., where at a temperature of 150 ... 250 ° C for 2 ... 7 minutes, moisture is quickly removed from the rolled flakes. As a result, the flakes acquire a delicate crisp structure and acquire an attractive surface and color due to the presence and random distribution on the surface of a single unit of production of individual particles of some grain components in the continuous phase of others, differing from each other in structure and color.

The finished flakes have a moisture content of 1 ... 4% and a thickness of 1 ... 3 mm, and the thickness of an individual plate may be uneven in its area due to the different expansion of each recipe component of the flakes in the fryer.

Then the flakes are sent to the packaging. Before packing, the flakes can be coated with various flavors to improve the organoleptic characteristics of the finished product or mixed with other ingredients.

If there are more mixtures, each of them is processed similarly to mixture No. 2 using the appropriate mixer operation parameters.

The method is illustrated by the following example.

Example. Wheat groats with an initial moisture content of 14% are cleaned of impurities and continuously fed into a paddle mixer with a screw feeder at a speed of 300 kg / h. Also, steam is supplied to the paddle mixer at a pressure of 1 bar. The average residence time of the mixture is 60 seconds, the humidity at the outlet of the mixer is 20%.

A solution of flavoring ingredients is prepared in advance according to the following recipe,%: 70% sugar, 10% salt, 10% malt extract, 10% water.

From the paddle mixer, the mixture is continuously charged into the twin-screw cooking extruder. Also, water in an amount of 30 kg / h and a solution of flavoring ingredients in an amount of 20 kg / h are supplied to the extruder. Processing the mixture in an extruder is carried out at a temperature of from 60 ° C in the loading zone to 140 ° C in the cooking zone for 120 seconds.

Crushed rice groats with a moisture content of 13% are cleaned of impurities and continuously fed into a paddle mixer with a screw feeder at a speed of 200 kg / h. Also in the paddle mixer is supplied steam with a pressure of 1.5 bar and water in an amount of 30 kg / h. The average residence time of the mixture is 150 seconds, the humidity at the outlet of the mixer is 30%. Then the rice grits are loaded into the last zone of the cooking extruder.

In the last zone of the cooking extruder, wheat dough is mixed with steamed rice groats, forming a uniform plastic suspension, which is continuously loaded into a transporting single-screw extruder. The moisture content of the extrudate at the outlet of the cooking extruder is 22%.

A knife mounted at the exit of a single-screw extruder rotates at a speed of 400 rpm and cuts the extrudate emerging from the forming matrix with continuous bundles into granules with a diameter of 6 mm.

Then the granules are fed onto smooth rollers, where flakes are formed with a thickness of 0.5 mm and a diameter of 19 mm.

The rolled flakes are fed into a gas fryer, where at a temperature of 190 ° C for 4 minutes, the flakes are fried in a fluidized bed. The moisture content of the prepared flakes is 3%. In appearance, the flakes are flat plates of light brown color with a thickness of 0.8 mm with pronounced impregnations of white rice cereal with a thickness of 2 mm distributed over the entire surface of the plate.

Thus, the use of the invention will allow:

- receive extruded cereal flakes with high consumer properties;

- use as a source mixture components a wide range of grain raw materials;

- expand the range of products.

Claims (2)

1. A method of producing cereal flakes, comprising preparing a mixture of recipe components, processing the mixture in a cooking extruder, transporting the extrudate to a cutting device, cutting it, molding flakes and frying with a reduction in importance to 1 ... 4%, characterized in that it is prepared at least two different mixtures of different compositional components, one of which, before being fed into the cooking extruder, is additionally air-conditioned by steam in a horizontal continuous mixer until moisture reduction of 18 ... 25% for 30 ... 600 s, and enters the twin-screw extruder for processing, and the second mixture is conditioned with water vapor in a horizontal continuous mixer until a humidity of 30 ... 60% is reached within 60 ... 900 s and is fed to the end cooking extruder zones for mixing with the extrudate until a homogeneous suspension is obtained, the suspension obtained is transported to the cutting device by one single screw extruder, the suspension is cut into individual particles of arbitrary shape by rotating knife, and the formation of flakes is done with one pair of smooth rollers. 2. The method according to claim 1, characterized in that in the presence of a larger number of mixtures, each of them is processed similarly to the second mixture.