RU2841519C1 - Method for production of dry granulated product based on potato flakes - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: method for production of a dry granulated product based on potato flakes envisages usage of potato flakes, starches, salt and spices as dry initial components. Starches used are native starches and/or modified starch derivatives. Initial components are taken in the following ratio, wt.%: potato flakes 87.42-95; starches 2.8-7.8; salt 1.1-4.1; spices 0.37-0.68. Components are mixed into a homogeneous mixture with water for dough formation; the moistened dough is compacted. Amorphous granulate is formed from dough. Formed amorphous granulate has moisture content of 30-60 wt.%. Formed amorphous granulate is then calibrated to the required size and subjected to tumbling. That is followed by convective drying of the tumbled granulate at temperature of 55-56 °C for 4-6 hours until achieving weight fraction of moisture from 3 to 8.5%. Then the dried granulate is packed into cooking filter bags in the form of triangular pyramids with the ratio of the granulate volume to the cooking filter bag volume filled with it equal to 0.35-0.65.

EFFECT: invention is aimed at manufacture of a dry granulated product based on potato flakes with homogeneous and stable shape of the ready product produced by way of heat treatment in a cooking filter bag.

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Description

Field of technology

The invention relates to the food industry, namely to a method for producing a dry granulated product based on potato flakes with various components, namely potato dumplings.

State of the art

From source [1] (US 5556661 A, 17.09.1996) a method is known for obtaining a dry granulated starch-containing product using potato-based raw materials, which includes partial gelatinization of starch-containing initial components, their subsequent freezing, grinding of the frozen starch-containing material, subsequent defrosting and dehydration by pressing and/or drying to form a dried granulate, packaging the dried granulate in cooking filter bags for subsequent heat treatment of the product in a boiling liquid.

From source [4] (DE 3401596 C2, 24.10.1985) a method for producing granulated dry products using potato-based raw materials is known, characterized in that a mixture of starting materials, including from 30 to 40% dried potato granules, from 5 to 15% dried mashed potatoes, from 15 to 25% potato starch, from 3 to 8% corn starch, from 1 to 3% hydrogenated vegetable fat, 3% table salt and various flavoring ingredients are mixed into a dough with a water content of 30 to 50% by weight and the resulting crumbly dough is granulated using a sieve insert of a granulating device, the resulting dough granules are fed into a dryer and dried at a temperature of about 70 ° C to a final water content of 6-7%, after which the dried granulate is packaged in cooking filter bags for subsequent heat treatment of the product in boiling liquid.

A common disadvantage of the methods known from sources [1] and [2] for obtaining a dry granulated product using potato-based raw materials is the low quality of the granulate prepared for heat treatment, which leads to uneven water absorption of the contents of the filter bag during the cooking process, and, consequently, to heterogeneity and unstable shape of the finished product.

The objective of the invention is to create a technology for producing a dry granulated product based on potato flakes, ensuring homogeneity and stability of the shape of the finished product obtained through heat treatment in a cooking filter bag.

The technical result consists in solving the stated problem of the invention.

Disclosure of invention

In order to achieve the above technical result, a method for obtaining a dry granulated product based on potato flakes is proposed, which provides for the use of potato flakes, starches, salt and spices as dry initial components, wherein native starches and/or modified starch derivatives are used as starches, with the following ratio of initial components, wt.%:

potato flakes 87,42-95 starches 2.8-7.8 salt 1.1-4.1 spices 0.37-0.68

which are mixed with water until a homogeneous mixture is obtained to form a dough, the moistened dough is compacted, an amorphous granulate is formed from it, wherein the formed amorphous granulate has a moisture content of 30 to 60 wt. %, the formed amorphous granulate is then calibrated to the required size, tumbled, after which the tumbled granulate is convection dried at a temperature of 55 to 56 ° C for 4-6 hours until the moisture mass fraction reaches 3 to 8.5%, the dried granulate is packaged in cooking filter bags in the form of triangular pyramids, with the ratio of the granulate volume to the volume of the cooking filter bag filled with it being 0.35-0.65.

Implementation of the invention

The proposed method for obtaining a dry granulated product based on potato flakes is carried out as follows.

First, dry recipe components are prepared: potato flakes, starches, salt, spices. In this case, native starches and/or modified starch derivatives obtained by physical, enzymatic or chemical processing of native starch to change its properties are used as starches, for example:

a) distarch phosphate (INS 1412, El412) modified by esterification, which changes the rheology and texture of starch;

b) acetylated starch (INS 1420, El420) esterified with acetic anhydride;

c) hydroxypropylated starch (INS 1440, El440) - starch ester with propylene oxide, which increases viscosity stability.

Dried dill is preferably used as a spice. However, as an alternative, any other dried herbs, vegetables, mushrooms and roots (for example, parsley, oregano, bay leaf, bell pepper, cucumber, pumpkin, carrot, dried onion, leek, garlic, wild garlic, paprika, spinach, cilantro, cultivated mushrooms and wild mushrooms) can be used in any combination with dill (or without it).

Dry prepared formula components are poured through a loading funnel equipped with sieves into the mixing chamber of the mixer, which contains two mixers with Z-shaped blades. The chamber is hermetically sealed, after which the process of mixing the formula components is started, which is carried out for 5 minutes. Then, with the mixer turned on, the required formula amount of water is added. For uniform mixing, water is added for 10-15 minutes. After adding water, the mixture is mixed for 5 minutes until a homogeneous mixture with water is formed to form dough with a certain humidity. The moistened dough obtained in this way is fed from the mixer by a belt conveyor to a rubbing machine - a mesh granulator. During the agglomeration process, using a granulator shaft with knives, the mixture is compacted due to intensive pressing of the moistened particles against each other by the shaft. At the same time, under the action of knives rotating at a given speed, the compacted mixture is crushed and further abraded against the surface of the granulator. As a result, amorphous granulate with a moisture content of 30 to 60 wt.% is formed. The obtained amorphous granules are passed through a vibrating calibration sieve to separate the small fraction (not corresponding to the specified parameters). The formation of calibrated granules of specified sizes with a grain size range from 1 mm to 6 mm is ensured by selecting the cells of the calibration sieve of the appropriate diameter, so that the small substandard fraction is sifted, and the large one is ground to the required stage.

The calibrated raw granulate is then rolled by rollers in a tumbling drum to smooth the surface of the raw granulate by mutual friction of the granules with each other. As a result, granules with a precisely specified grain size are formed.

The granulate prepared in this way is manually spread in a thin layer on mesh trays (or trays) with a layer thickness of no more than 15 mm. After that, they are placed in a platform trolley and fed into a drying cabinet, where conventional drying of the product is carried out using heated air at a temperature of 55-56 ° C for 4-6 hours until the mass fraction of moisture in the dried granulated product reaches 3.0-8.5 wt. %. A fan is provided inside the drying cabinet chamber to accelerate convection.

The obtained granulate after drying is packed on the packaging line in cooking filter bags of the "pyramid" type, with the ratio of the volume of the filled granulate to the volume of the cooking filter bag being 0.35-0.65. In this case, the filter bags are made of a heat-resistant combined material consisting of wood and polymer fibers. Filter paper for the production of cooking filter bags is obtained on paper machines using the paper production technology with the additional mixing of polymer fiber. Polymer fiber is obtained using the Meltblown technology. After the granulate is packed, the filter bags are sealed by welding the open edges. In this case, the welds are formed under the influence of temperature and pressure from pairs of pads located at 90 degrees. Then the filter bags are placed (for example, 6 pieces) in a transparent bag, after which the finished products are assembled and packaged.

To prepare a ready-made dish - potato dumplings, filter bags filled with granulate are placed in a cooking container and the product is subjected to heat treatment in boiling liquid for 7-9 minutes. During the diffusion of the heated liquid into the contents of the filter bag, the starch components, swelling, gradually fill the filter bag. At the same time, the declared ratio of the volume of granulate to the volume of the cooking filter bag filled with it is optimal, ensuring that the entire volume of the cooking bag is filled. As a result, under the pressure of the hydrated contents on the walls of the filter bag, the food product is structured and compacted.

Due to the stabilizing properties of starch and the pyramidal shape of the filter bag, the stable shape of the finished product is maintained after it is removed from the filter bag. The finished product has an original shape, good density, elasticity and is easy to cut with a knife.

The homogeneity of the resulting product is ensured by the proposed technology for producing dry granulate with a precisely specified grain size, the tumbled surfaces of which prevent the granules from sticking together, which promotes uniform water absorption.

It should be noted that the given ratio of dry recipe components is an experimentally substantiated optimal ratio of components for solving the given problem.

Claims (3)

A method for producing a dry granulated product based on potato flakes, which involves using potato flakes, starches, salt and spices as dry starting components, wherein native starches and/or modified starch derivatives are used as starches, with the following ratio of starting components, wt.%: potato flakes 87,42-95 starches 2.8-7.8 salt 1.1-4.1 spices 0.37-0.68 which are mixed with water until a homogeneous mixture is obtained to form a dough, the moistened dough is compacted, an amorphous granulate is formed from it, wherein the formed amorphous granulate has a moisture content of 30 to 60 wt.%, the formed amorphous granulate is then calibrated to the required size, tumbled, after which the tumbled granulate is convection dried at a temperature of 55 to 56°C for 4-6 hours until the moisture content reaches 3 to 8.5%, the dried granulate is packaged in cooking filter bags in the form of triangular pyramids with a ratio of the granulate volume to the volume of the cooking filter bag filled with it, amounting to 0.35-0.65.