RU2812835C1 - Method of producing extruded combined additive from amaranth - Google Patents

Abstract

FIELD: food and feed industries.

SUBSTANCE: method of producing an extruded combined additive from amaranth is proposed, according to the method amaranth grains are peeled, fried and sifted on a sieve. Then whole roasted and exploded amaranth grains are mixed and subjected to moisture-heat treatment with steam under pressure. The resulting mixture is processed in a four-zone screw extruder at the product temperature: in zone I – 38°C, in zone II – 99-100°C, in zone III – 175°C, in zone IV – 205°C. A protein-vitamin-lipid complex is sprayed onto the resulting extruded sticks while stirring in a vacuum.

EFFECT: invention ensures the production of an extruded combined additive from amaranth, balanced in composition, increasing its nutritional and biological value.

1 cl, 1 tbl

Description

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

The closest to the proposed technical essence is the method for the production of lentil sticks (Patent No. 2265334, IPC ⁷ A 21 D 13/00; A 23 R 1/12. Method for the production of lentil sticks / Ostrikov A.N., Platov K.V. No. 2004116610/13, Application 05/31/2004, Published 12/10/2005, B.I. No. 34.), including sifting of initial products, moistening, keeping in a hopper, extrusion, lentils, previously crushed to size, are used as initial products particles 0.16 - 0.63 mm, mix it with sunflower meal, crushed to a particle size of 0.16 - 0.63 mm and rice grits, also crushed to a particle size of 0.16 - 0.63 mm, in the ratio of % mass lentils - 42.0 - 44.0%, sunflower meal - 9.6 - 13.1%, rice groats - 44.6 - 47.4%, moisten the resulting mixture to 20-25% and process it on a screw extruder at a product temperature in front of the matrix of 373 - 393 K, a screw rotation speed of 1 - 2 s ^-1 and a pressure in the pre-matrix zone of the extruder of 6 - 10 MPa.

The disadvantages of this known method are the low biological value of the resulting product and the imbalance of its composition.

The technical objective of the invention is to obtain an extruded combined additive from amaranth of high quality, balanced in composition, increase its nutritional and biological value, expand the range of manufactured products through the use of an extruded combined additive from amaranth in their production.

The task is achieved by the fact that in the proposed method for the production of an extruded combined additive from amaranth, including sifting amaranth grains, moistening, extrusion, what is new is that at the beginning the amaranth grains are peeled to remove the hard shell, then fried at a temperature of 200°C in for 20 s and sifted on a sieve with a round hole size of 0.8 mm, then whole roasted and exploded amaranth grains are mixed in a ratio of 1: 2, subjected to moisture-heat treatment with steam under a pressure of 0.25 MPa for 4 minutes to a humidity of 22-24% and process the resulting mixture in a four-zone screw extruder at the product temperature: in zone I - 38°C, in zone II - 99-100°C, in zone III - 175°C, in zone IV - 205°C, screw rotation speed - 33.9 s ^-1 and pressure in the pre-matrix zone of the extruder - 0.35 MPa, a protein-vitamin-lipid complex is applied to the resulting extruded sticks while stirring in a vacuum.

The technical result of the invention is to obtain an extruded combined additive from amaranth, balanced in chemical composition, with high nutritional and biological value while observing rational process parameters.

The method for producing an extruded combined additive from amaranth is carried out as follows. Amaranth (GOST 28636-90) was used as the starting material. Seeds of rare forage crops - Argentine amaranth (shiritsa), white amaranth; blood amaranth (crimson, paniculate), as well as varieties "Giant" and "Voronezh".

At the beginning, amaranth grains are peeled to remove the hard fruit shell, which almost entirely consists of fiber that is indigestible by humans - it is simply not digestible due to excessive hardness, so the grain does not lose any beneficial properties. As a result of peeling, the seed coats, aleurone layer and embryos are removed from the kernel, with the shell comprising from 5.6 to 7.6%, and the mixture of shell and embryos from 7.3 to 7.9%.

Amaranth grains are roasted at a temperature of 200°C for 20 s.

Roasting amaranth grains at temperatures above 200°C, for example, at 220°C, will lead to a significant deterioration of the protein-carbohydrate complex (formation of melanoidins, etc.), and vice versa, frying amaranth grains at temperatures below 200°C, for example, at 180 °C will not lead to the desired degree of protein denaturation and starch gelatinization.

Frying amaranth grains for less than 20 s, for example, at 15 s, is insufficient to change the protein-carbohydrate complex, and vice versa, frying amaranth grains for more than 20 s, for example, for 25 s will lead to thermal decomposition of valuable nutrients.

After roasting, the amaranth grains are sifted on a sieve with a round hole size of 0.8 mm, dividing them into two fractions: roasted whole amaranth grains and expanded (exploded) amaranth grains (grits).

Then whole roasted and exploded amaranth grains (grains) are mixed in a ratio of 1: 2. When justifying the choice of the proportion of components 1: 2, a number of factors were taken into account: the need to obtain high-quality extruded amaranth sticks, balanced in composition; increasing their nutritional and biological value; achieving high organoleptic characteristics: pleasant taste and aroma, good consistency.

After mixing, the resulting mixture is subjected to moisture-heat treatment with steam under a pressure of 0.25 MPa for 4 minutes to a humidity of 22-24%.

It has been experimentally established that only treating the mixture with steam under a pressure of 0.25 MPa for 4 minutes will achieve a moisture content of 22-24%. Treatment of the amaranth mixture with steam at elevated pressure, for example 0.3 MPa, as well as treatment for more than 4 minutes, for example 5 minutes, leads to excessive waterlogging of amaranth grains, for example 26%, which makes their further extrusion difficult.

Treatment of the amaranth mixture with steam at reduced pressure, for example 0.15 MPa, as well as treatment for less than 4 minutes, for example 3 minutes, leads to insufficient moisture of the amaranth grains, for example 18%, which makes their further extrusion impossible due to lack of moisture.

The need to moisten the mixture (up to 22-24%) is due to the following considerations. It has been proven that the expansion of the product at the outlet of the matrix holes is directly a consequence of the physical properties of water [Ostrikov, A.N. Extrusion in food technology / A.N. Ostrikov, O.V. Abramov, A.S. Rudometkin. - SP.b: GIORD, 2004. - 288 p.]. Under such thermal conditions (the temperature change in the extruder can be in the range of 403 - 573 K) and under very high pressure, water exists only in a liquid state. When the plasticized material leaves the matrix and reaches atmospheric pressure, the water instantly turns from a superheated liquid into steam, releasing a significant amount of energy. Under the influence of steam pressure, pores are formed in the product, and the remaining intact starch grains are torn. If the moisture in the mixture was less than 20%, then it was not enough and the product did not expand at the exit of the extruder. And, conversely, if the moisture content of the product was more than 25%, this also led to a decrease in the degree of expansion, since this resulted in the formation of a more dense product structure with a coarse consistency. The reason for these changes is that with increasing humidity, the plasticity of the mass increases, and this causes a decrease in mechanical stress in the extrudate. Consequently, the amount of heat released as a result of the work of viscous friction forces turned out to be insufficient to obtain a swelling structure.

After this, the amaranth mixture with a moisture content of 22-24% is processed in a four-zone screw extruder at the product temperature: in zone I - 38°C, in zone II - 99-100°C, in zone III - 175°C, in zone IV - 205°C, screw rotation speed - 33.9 s ^-1 and pressure in the pre-matrix zone of the extruder - 0.35 MPa.

The processed grain mixture of whole roasted and exploded amaranth grains (grains) enters the working chamber through the loading pipe, where it is moved by a screw at a rotation speed of 33.9 s ^-1 to the matrix.

As whole fried and exploded amaranth grains (grains) move in the first mixing zone, the amaranth mixture is partially mixed and heated due to the dissipation effect (conversion of the mechanical energy of the moving grain mixture into thermal energy due to friction forces due to friction between the product particles and the turns of the auger) to 38°C, in the second compression zone there is an abrupt increase in pressure and the product is compacted due to a decrease in the size of the screw channel, heating up to 99-100°C. In homogenization zone III, softened grains are transformed into a homogeneous melt due to increasing pressure. The pressure of the melt of the amaranth mixture in this zone reaches the required value, which ensures the final melting of small inclusions and forms a melt homogeneous in structure at a melt heating temperature of up to 175°C.

In the IV (pre-matrix) stabilization zone, the pressure equalizes to 0.35 MPa and the melt temperature to 205°C. It is then extruded through the exit hole in the die.

After the amaranth melt leaves the matrix, as a result of a sharp change in temperature and pressure, instantaneous evaporation of moisture occurs; the energy accumulated by the product is released at a speed approximately equal to the speed of the explosion, which leads to the formation of a porous structure and an increase in the volume of the extrudate (expansion). At the same time, as a result of the “explosion” of the product (or “decompression shock”), profound transformations of its structure occur: rupture of cell walls, destruction, hydrolysis [Ostrikov, A.N. Extrusion in food technology / A.N. Ostrikov, O.V. Abramov, A.S. Rudometkin. - SP.b: GIORD, 2004. - 288 p.].

The resulting extruded amaranth sticks, the distinctive feature of which is a high proportion of protein (up to 16.47%), fat (up to 5.62%), a high level of metabolic energy when used as an additive in feed for poultry, pigs, and cattle (Cattle) (table).

Table - Chemical composition of the original amaranth and extruded amaranth sticks Name of indicators, units of measurement Indicator values Regulatory documentation for test methods Original amaranth Extruded mixture of roasted amaranth and semolina Moisture content, % 11.29 7.8 GOST 31640 Mass fraction of crude protein, % 15.56 16.47 GOST 32044.1 Mass fraction of crude fat, % 6.7 5.62 GOST 32905 Mass fraction of crude fiber, % 6.3-7.4 6.7 GOST 31675 Mass fraction of raw ash, % 2.88 2.68 GOST 32933 Mass fraction of calcium, % 0.16 0.51 GOST 32904 Mass fraction of phosphorus, % 0.46 0.38 GOST 26657 Mass fraction of carbohydrates, % 66.7 18.23 GOST 26176 Metabolic energy:
- poultry kcal/100 g
- pigs kcal/100 g
- Cattle kcal/100 g -
-
- 343.95
13.35
12.05 VNITIP
VIZH

Then, the resulting extruded amaranth sticks, while stirring in a vacuum (under a pressure of 0.02-0.03 MPa), are sprayed with a protein-vitamin-lipid complex, resulting in an extruded combined amaranth additive, balanced in chemical composition, with high nutritional and biological value.

The method is illustrated by the following example.

Example. First, amaranth grains are peeled to remove the hard fruit shell, which consists almost entirely of fiber that is indigestible to humans.

Then the amaranth grains are roasted at a temperature of 200°C for 20 s.

After roasting, the amaranth grains are sifted on a sieve with a round hole size of 0.8 mm, dividing them into two fractions: roasted whole amaranth grains and expanded (exploded) amaranth grains (grits).

Then whole roasted and exploded amaranth grains (grains) are mixed in a ratio of 1:2, after which the resulting mixture is subjected to moisture-heat treatment with steam under a pressure of 0.25 MPa for 4 minutes to a humidity of 22-24%.

After this, the amaranth mixture with a moisture content of 22-24% is processed in a four-zone screw extruder at the product temperature: in zone I - 38°C, in zone II - 99-100°C, in zone III - 175°C, in zone IV - 205°C, screw rotation speed - 33.9 s ^-1 and pressure in the pre-matrix zone of the extruder - 0.35 MPa.

The processed grain mixture of whole roasted and exploded amaranth grains (grains) enters the working chamber through the loading pipe, where it is moved by a screw at a rotation speed of 33.9 s ^-1 to the matrix.

As whole fried and exploded amaranth grains (grains) move in the first mixing zone, the amaranth mixture is partially mixed and heated due to the dissipation effect (conversion of the mechanical energy of the moving grain mixture into thermal energy due to friction forces due to friction between the product particles and the turns of the auger) to 38°C, in the second compression zone there is an abrupt increase in pressure and the product is compacted due to a decrease in the size of the screw channel, heating up to 99-100°C. In homogenization zone III, softened grains are transformed into a homogeneous melt due to increasing pressure. The pressure of the melt of the amaranth mixture in this zone reaches the required value, which ensures the final melting of small inclusions and forms a melt homogeneous in structure at a melt heating temperature of up to 175°C.

In the IV (pre-matrix) stabilization zone, the pressure equalizes to 0.35 MPa and the melt temperature to 205°C. It is then extruded through the exit hole in the die.

After the amaranth melt leaves the matrix, as a result of a sharp change in temperature and pressure, instantaneous evaporation of moisture occurs; the energy accumulated by the product is released at a speed approximately equal to the speed of the explosion, which leads to the formation of a porous structure and an increase in the volume of the extrudate (expansion).

The extruder must operate at a product pressure in the pre-matrix zone that does not exceed the optimal value. This is necessary, since the pressure value uniquely determines the processing temperature of the product, which in turn determines the quality of the finished product. It has been established that the main components (carbohydrates, proteins, fats, vitamins, etc.) of amaranth have different optimal temperatures necessary for complete and qualitative physical and chemical changes to occur during extrusion.

For efficient and high-quality extrusion, it is necessary to select a temperature change pattern in which the main components of the products would be subjected, on the one hand, to complete hydrothermal treatment, and on the other hand, they would be exposed to a “soft” (gentle) temperature effect, preventing their thermal decomposition.

It has been established experimentally that it is the screw rotation speed of 33.9 s ^-1 that makes it possible to achieve a pressure in the pre-matrix zone of the extruder of 0.35 MPa, which precisely ensures that the product temperature in front of the matrix reaches 205°C. In this temperature range, complete and profound physical and chemical changes occur in proteins, carbohydrates and other components of amaranth, giving them properties that are most suitable for complete absorption by the human body.

The resulting amaranth sticks were studied according to a set of indicators characterizing the consumer properties, nutritional and energy value of the finished product. Extruded crispy amaranth sticks were analyzed for organoleptic indicators, humidity and acidity according to GOST 9846-88.

Organoleptic characteristics: the product was obtained in the form of straight or curved short sticks with a round cross section, with a rough surface and developed porosity. In terms of light gray color, taste and aroma (corresponding to the original type of raw material), the extrudate has satisfactory consumer data.

To assess the qualitative characteristics of amaranth sticks, their following physicochemical properties were studied: swelling (water absorption capacity), solubility and water-holding capacity. These important indicators, demonstrating the ability of the extrudate to bind water and dissolve in it, characterize its carbohydrate composition, as well as consumer properties and partial digestibility of the product.

Thus, the proposed invention will allow:

- obtain extruded amaranth sticks with good consumer properties and high biological and nutritional value;

- obtaining an extruded combined additive from amaranth, balanced in chemical composition, with high nutritional and biological value;

- expand the range of manufactured products through the use of an extruded combined additive from amaranth in their production.

Claims (1)

A method for producing an extruded combined additive from amaranth, including sifting amaranth grains, moistening, extruding, characterized in that first the amaranth grains are peeled to remove the hard shell, then fried at a temperature of 200°C for 20 s and sifted on a sieve with a round size holes 0.8 mm, then whole roasted and exploded amaranth grains are mixed in a ratio of 1:2, subjected to moisture-heat treatment with steam under a pressure of 0.25 MPa for 4 minutes to a humidity of 22-24% and the resulting mixture is processed in a four-zone screw extruder at product temperature: in zone I - 38°C, in zone II - 99-100°C, in zone III - 175°C, in zone IV - 205°C, screw rotation speed - 33.9 s ^-1 and pressure in in the pre-matrix zone of the extruder - 0.35 MPa, a protein-vitamin-lipid complex is applied to the resulting extruded sticks while stirring in a vacuum.