SK7184Y1 - Process for the preparation of the hydrolyzed cereal and pseudocereal concentrates, hydrolyzed cereal concentrates obtained in this way and equipment for their preparation - Google Patents

Abstract

Process for the preparation of hydrolyzed cereal and pseudocereal concentrates consists of the fact that the cereal and / or Pseudocereals grains or materials and products with a majority interest cereals or pseudocereals, or mixtures were diluted with water 1: 1 to 1: 8 by weight, at 30 � C to 85 � C are added the amylolytic enzymes, or one or more enzymes selected from the group of proteases, xylanases, hemicellulases, lipases. Each enzyme has a volume which is at a given temperature, pH and the fermentation time needed for the cleavage of at least 5.0% of the total of starch and/or dextrin to products of the enzymatic hydrolysis of cereal in the dry matter of the concentrate, typically in a concentration of 0.05 to 10.0% by weight on the dry ingredients. If necessary, the pH was adjusted to 4.0 to 7.0 and the mixture is stirred for 1 to 15 hours fermented, then the mixture is heated to 90 � C to 140 � C where it is left 5 to 45 min . Also disclosed is a cereal enzymatically hydrolysed concentrate which contains in the dry state of at least 5.0% by weight glucose, maltose, maltotriose alone or in a mixture, generated by enzymatic hydrolysis, the viscosity of the end of the fermentation is from 5 AU to 2500 AU at 65 � C and a pH of 4.0 to 7.0 and an apparatus for preparing a concentrate of hydrolysed cereal.

Description

SK 7184 Υ1

Technical field

The technical solution relates to the processing of cereal and pseudo-cereal grains as well as by-products, intermediates and cereal products into sugar-fiber products intended as raw materials for food, especially cereal products.

BACKGROUND OF THE INVENTION

Currently, various industrial process equipment, technological processes, as well as raw materials that are specific to unit technology operations in the bakery, pastry, pastry, pastry, confectionery, industry, cereals and snack products with cereal content are used to produce cereal products as well as cereal and pseudo-cereal products. Generally, the cereal technologies mentioned above result in production losses, which consist of technological losses and material losses. Technological losses are mass losses due to physico-chemical changes (eg evaporation of water, transformation of substances in chemical reactions, gas evolution and the like). Material losses are losses on the mass remaining in production as a by-product, in the form of non-products, poorly prepared dough or other materials and mixtures (especially doughs, poorly baked or dried products), fragments and cuttings, deformed and mechanically damaged products, unsold products. , stock balances and other products that are no longer distributed for consumption. This share Material losses represent a total mass or by-product containing major polysaccharides such as starch, hemicellulose, cellulose, also pentosans, proteins specific to the cereal or pseudocereal contained in the recipe, as well as added and original fats. By-products from these cereal industries (semi-finished products, unsold and damaged cereal products) have been used in several ways to date. In the bakery industry, some of the unused or damaged products are used for crumb production, cereal industry waste materials have also been used as feed for livestock feed, but also for the production of industrial feed preparations for livestock, for example as described in US 20040086627 A1. In bakery, pastry and pastry production and less in other cereal products, by-products (masses) are used as an addition up to a maximum of 5,0% by weight of the raw materials in the recipes for further production. Another method of utilizing cereal by-products is disclosed in U.S. Pat. US 4046789 A. It is the regeneration of fats, carbohydrates and proteins with starch as separate fractions, where in a first step the fats are separated by means of ethanol, followed by starch and a mixture of proteins with starch as the other two fractions. The components thus recovered are intended for further use in the food industry. Several authors in scientific literature, eg. Joanna KawaRygielska_et. al. (2012), or Choi C. H. et. al. (1995) describe various fermentation processes using defined strains of ethanol yeast of the genus Saccharomyces cerevisiae, in which the materials constituting the material waste from the cereal industry, in particular the bakery industry, are used to produce ethanol or to increase the efficiency of fermentation in ethanol production. Various enzymatic preparations (amylases, proteases, enzymes that break down non-starch polysaccharides) are used in order to make fermentable sugars (especially glucose) more readily accessible and to reduce viscosity. Subsequently, the mashes are inoculated with distillery yeast strains that produce ethanol and organic acids. The same principle is based on US patent 20110039318 A1, which solves the production of fuel ethanol just from the masses produced in the production of the described cereal products. In addition to enzymatic hydrolysis, acid hydrolysis using inorganic acids such as e.g. sulfuric acid or nitric acid. The purpose of this acid hydrolysis is to obtain simple sugars from which the polysaccharide chains are formed, or to obtain polysaccharide fragments of different chain lengths. This principle of cereal and waste processing is described, for example, by Kapdan et. al. (2011) Choi et al. al. (1996), or Ahmed et. al. (1983). Cereal materials and wastes are also used as substrates for production strains of microorganisms, in particular fungi and bacteria, in the production of enzymes or for the cultivation of algae of the genus Microalgae as described by Pleissner et.al. (2013). In US 5324442 A, cereal by-products, particularly dry bread, have been used to produce calcium road salt using fermentation technology with the P. acidi-propionici genus. U.S. Pat. No. 4,613,506 A discloses a process in which bakery by-products are processed in an aqueous environment in a cylindrical unicameral or bicameral mixing device. Subsequently, in the next step, homofermentative or heterofermentative strains of Lactobacillus are added, the mixture is allowed to ferment for 15 to 40 hours at a temperature of 20 ° C to 30 ° C, the product being an acidic fermented dough, directly usable for bread and bakery production. U.S. Pat. No. 4,377,602 A, 1983, describes a process for hydrolyzing cereal grains or scrap to obtain products in the form of individually separated cereal grain fractions after hydrolysis by amylolytic and proteolytic enzymes. The resulting product was separated fractions of soluble cereal proteins with a defined amino acid content and a defined proportion and composition of sugars. The product contained a defined quantity

The amount of peptides and amino acids with hydrolyzed starch to glucose or other degradation products at pH 4.0 - 4.5. The published patent applications WO 2012076051 A1 and WO 2012076056 A1 of 2010 deal with the preparation of products containing hydrolysed whole cereal grains for use in foodstuffs under specific conditions. The first document relates to the preparation of cereal grain foods which, in addition to the whole grain matrix, contain additive raisers and have a moisture content below 10% by weight, such as biscuits. They can be produced with or without the addition of alpha-amylases, beta-amylases and proteases, but which have no declared hydrolytic activity against cereal fiber. The second application addresses the preparation of food products containing whole grain hydrolysed cereals by amylolytic and proteolytic enzymes, as well as having no declared hydrolytic activity against cereal fiber, for use in food formulations containing hydrocolloids (single or in mixtures) for pudding, confectionery, confectionery and confectionery desserts, profiteroles and the like.

These solutions utilize cereal by-products in such a way that these materials are transferred to another type of cereal, food, or other industrial processing industry, or are processed into usable semi-finished products in a way that is more economically and technologically demanding, or in the case of fermentation to baking dough, such blanks have a limited usability over time and a limited workability in quantity. In the first case, it is not economically advantageous for the by-product producers themselves to sell them as a secondary raw material. In the case of yeast production, the product has a limited use of time and quantity.

The essence of the technical solution

The subject of the technical solution is a method of processing by-products, materials, cereal products (such as bakeries, bakeries, pastry, confectionery, confectionery and mussels and snack products containing cereals and pseudo-cereals), but also cereal grains (wheat, rye, maize, triticale, oat, barley, rice) and pseudocereal crops (millet, sesame, buckwheat, amaranth, quinoy and others) by controlled enzymatic hydrolysis, through specific groups of hydrolytic enzymes, by controlling enzymatic fermentation conditions in a device developed for this purpose, so-called. reactor (or fermenter), it is possible to produce a number of defined products with different properties that are directly applicable in the processing plant or else in cereal production other than the raw material for further incorporation into new products.

The technological process is based on diluting cereal and / or pseudocereal grains or materials and cereal or pseudocereal products or their mixture with water at a ratio of 1: 1 to 1: 8 by weight, at a temperature of 30 ° C to 85 ° C amylolytic enzymes (catalyzing the hydrolytic cleavage of starch into dextrins to glucose), optionally one or more enzymes selected from the group consisting of proteases (catalyzing the hydrolytic cleavage of proteins to lower molecular proteins to peptides and amino acids), xylanases (catalyzing the hydrolytic cleavage of pentytes) cereal matrices), hemicellulases (catalyzing the hydrolytic cleavage of hemicelluloses), cellulases (catalyzing the hydrolytic cleavage of cellulose), pullulanases (catalyzing the hydrolytic cleavage of β-glucan bonds), lipases (catalyzing the hydrolytic cleavage of lipids to mono- to diglycerides). Each enzyme is added in an amount required at a given temperature, pH and fermentation time to cleave at least 5.0% by weight of the total amount of starches and / or dextrins to enzymatic hydrolysis products in the dry matter of the cereal concentrate, most often at a concentration of 0.05 to 10.0 wt. based on the catalytic activity of the enzyme preparation used. If necessary, adjust the pH of the mixture to 4.0 to 7.0 and ferment the mixture with stirring for 1 to 15 hours, then heat the mixture to 90 ° C to 140 ° C, leaving it for 5 to 45 min. .

The raw materials used for the production of cereal concentrates must be microbiologically sound in accordance with the applicable national legislation. In the first step, mechanical and thermal disintegration of the cereal matrix of the raw materials to be processed may be performed to make the individual polymeric chemical chains as accessible as possible to enzymatic hydrolysis, thereby increasing the efficiency and speed of the hydrolysis process in the next steps of the proposed process. The disintegration process starts at any temperature of the mixture of water and raw materials, preferably in the range from 20 ° C to 100 ° C in aqueous medium in the ratio of dry matter to water in the ratio of 1: 1 to 1: 8 wt., Optimally 1: 2 to 1: 4, optionally adjusted to the viscosity of the resulting dispersion after homogenization, which should not exceed the gel viscosity of 2500 AU (Brabender Amylograph Unit, ICC Standard 126/1, 1992; AACC Method 22-10, 1994) at 65 ° C. Homogenization is carried out until at least 50% of the particles are below 2.0 mm in size. If the feedstock and water mixture is homogeneous to a defined extent prior to the homogenization process, the homogenization as a step may be omitted or included in any further step to reduce the particle size for the desired granulation and thus make the substrate accessible to the enzyme during hydrolytic cleavage. The viscosity of the mixture after homogenization as well as its parameters for the enzymatic cleavage process depend mainly on the composition of the feedstocks, the chemical composition and quality of which may vary within the range of

However, the resulting viscosity after homogenization prior to the start of enzymatic hydrolysis should be in the range of 5 AU to 2500 AU at 65 ° C.

The intensity of enzymatic hydrolysis is controlled by the amount of enzyme preparations added, the amount of addition being calculated based on the step length in hours of enzymatic hydrolysis and the catalytic activity of the enzymatic preparations, expressed as the cleavage of the individual or substances in the homogenized dispersion of processed materials. and acid-base conditions. The amount of each enzyme preparation added is therefore regulated in the proposed solution as a function of increasing the concentration of its catalyzed cleavage products as a function of the time of action of the enzyme at a defined catalytic activity of the enzyme.

The enzymatic preparations used comprise mainly amylolytic enzymes, proteolytic enzymes, lipolytic enzymes and enzymes that cleave non-starch polysaccharides, which are isolated from defined food production strains of microorganisms (fungi, bacteria, yeasts). These are produced industrially by biofermentation followed by membrane or other separation and concentration on a carrier matrix, or by another specific known method. Enzyme preparations in the proposed technology are added in the form of various purified preparations with different catalytic activity for processing cereals and cereal products from the food industry to produce a product with a high or only increased content of mono- and disaccharides, especially glucose, or also with increased fissile content. protein products, or non-starch polysaccharides and carbohydrates, possibly also fats, which are contained in the by-products of the cereal products used.

By controlling the temperature in the individual steps of the process, in combination with the intensity of the homogenization of the dispersion and the particle size, the processes are controlled so as to selectively produce only some of the components than others. This changes the theological and technological properties of the final product, as well as increasing the sugar content more effectively. By selecting enzymatic preparations according to their catalytic activity and substrate specificity, a specific group of substances in the cereal mass is selectively treated in order to achieve only specific changes in product properties (such as concentration of individual sugars, polysaccharide swelling, water binding, technological strength of gluten proteins). , free fatty acid content). After homogenization or already during homogenization, the mixture is heated to a temperature of 30 ° C to 85 ° C, depending on the enzymatic preparation used in the step or the mixed enzymatic preparations which are dosed after homogenization. If the homogenization temperature is higher than the optimum temperature for application of the enzymatic preparation (s), the homogenized intermediate is allowed to cool. After reaching the optimum temperature in the entire volume of the mixture, enzyme preparations are metered in. For amylolytic cleavage (endogenous amylases and exogenous amylases) using enzymatic preparations of e.g. Bacillus amyloliquefaciens, Bacilus subtilis, Aspergilus niger, Aspergillus oryzae, or from other production strains which exhibit amylolytic activity and which do not exhibit an increased thermostability of the produced amylases, as a rule, a temperature lower than 30 ° C to 65 ° C is used. thermostability, a higher temperature of 65 ° C to 85 ° C, e.g. amylases produced from production strains of Bacillus licheniformis. After heating to the target heat and dosing of the enzyme preparations, this temperature is maintained throughout the volume of the mixture for a time depending on the amount of raw materials processed and the activity of the added preparations added as a mixture of enzymatic preparations. Generally, the duration of the enzymatic hydrolysis at temperatures of 30 ° C to 85 ° C is from 1 hour to 15 hours when the preparation is added from 0.05% to 50%.

10.0% by weight dry matter of the substrate with individual catalytic activity expressed as the equivalent of cleavage of the substrate component (e.g. starch or hemicellulose, or pentosans, or proteins and others) under defined conditions per hour. By applying these approaches and regulating the parameters, the technology is applicable to the production of several products with different properties in the individual sectors of the cereal production mentioned above, ie not only for the production of one product from defined raw materials. During enzymatic hydrolysis, the pH is adjusted, if necessary, to a value of 4.0 to 7.0, optimally to a pH of 4.0 to 6.0, depending on the enzymatic preparations added. The acid-base equilibrium conditions are adjusted by buffering agents based on food grade organic or inorganic acids and their conjugated salts.

In the processing of bakery and / or durable pastry production paths and / or unloaded sweet pastries without fillings and / or crumbs, it is preferred that water is added in a ratio of 1: 2 wt. and amylolytic and proteolytic enzymes, and pentosate and non-starch polysaccharide enzymes, each in an amount of 0.05 to 3.0% by weight, are added at a temperature of 35 ° C to 70 ° C. to dry matter of raw material according to the catalytic activity of the enzymes so as to produce at least 55% in the dry matter of amylolysis products and at least 4% of products due to hydrolysis of non-starch polysaccharides and lipids together, adjust the pH of the mixture to 4.0 to 5.5 and up to 6 h. Subsequently, the mixture is heated to a temperature of 95 ° C to 100 ° C, where it is left for 10-25 minutes.

If bread and / or long-life pastry is processed without fillers, it is preferred that they are diluted with water in a ratio of 1: 2 to 1: 5 wt. and at 30 ° C to 45 ° C, amylolytic enzymes and hemicellulolytic enzymes are added along with lipolytic enzymes, each in an amount of 0.05 to 9.0 wt. to dry matter raw materials

According to the catalytic activity of the enzyme enzymes, at least 45% of the dry matter of the amylolysis products and at least 2% of the dry matter of the non-starch polysaccharide and lipid hydrolysis products are produced together. The mixture is allowed to ferment for 1-2 hours, then the temperature is raised to 50 ° C to 60 ° C, exogenous amylase is added, followed by xylanases and hemicellulases, each in an amount of 0.05 to 9.0% by weight. to the dry matter of the raw material according to the catalytic activity of the enzymes so that at least 40% of the starch and dextrins present are hydrolytically cleaved to glucose and maltose in total and to produce at least 5% in the dry matter of the products after hydrolysis of non-starch polysaccharides in total And fermentation is continued for an additional 1 to 3 hours. Finally, the temperature is raised to 95 ° C to 100 ° C, leaving it for 10-25 minutes.

When processing biscuits and / or biscuits, and / or wafers, it is preferred that water is added in a ratio of 1: 1 to 1: 3 wt. and thermostable endogenous amylolytic enzymes, each in an amount of 0.05 to 3.0 wt. based on the catalytic activity of the enzymes so that at least 65% of the starches present are amylolytically cleaved to dextrins to oligomeric units, the mixture is fermented at 85 ° C to 95 ° C with stirring for 2 to 5 hours, after cooling to 50 ° C Exogenous amylase and protease, each in an amount of 0.05 to 5.0 wt. based on the catalytic activity of the enzymes so that at least 65% of the dextrins and starch oligomeric units present are amylolytically cleaved to glucose and maltose together and that at least 5% of the proteins present are hydrolyzed to the respective peptides and allowed to ferment for a further 4 to 7 hours the mixture is heated to 95-140 ° C, where it is left for 10-25 min.

In the processing of confectionery bodies and / or cereal musts and / or cereal bars with a cereal content of more than 20% in the dry matter, it is preferable to dilute with water in a ratio of 1: 2 to 1: 5 wt. amylolytic and proteolytic enzymes, each in an amount of 0.05 to 2.0 wt. % to the dry matter of the raw material according to the catalytic activity of the enzymes of the enzymes so as to produce at least 20% in the dry matter of the products of amylolysis and enzymes cleaving pentosans and non-starch polysaccharides in an amount of 0.1 to 0.5 wt. based on the catalytic activity of the enzymes to produce at least 5% of the non-starch polysaccharide and protein hydrolysis products together, then adjust the pH to 5.0 to 6.5 and add lipolytic enzymes that break down fat, each in an amount of 0.05 to 0.2 wt. to dry matter of the mixture according to the catalytic activity of the enzymes so that at least 30% of the lipids present are hydrolytically cleaved to the products and the mixture is fermented for a further 3 to 6 hours, then heated to 100 ° C to 140 ° C up to 40 min.

If wheat and / or barley, and / or rye, and / or oat, and / or corn, and / or rice grain are processed, it is preferred that water is added in a ratio of 1: 1 to 1: 4, amylolytic enzymes and one or more enzymes selected from the group consisting of hemicellulases, xylanases, cellulases, glucanases cleaving non-starch polysaccharides, each in an amount of 0.05 to 2.0 wt. to the dry matter of the raw material according to the catalytic activity of the enzymes so that at least 10% of the starches present are amylolytically cleaved to amylolysis products and at least 5% are formed in the dry matter of hydrolytically cleaved non-starch polysaccharide fiber and allowed to ferment at 55 ° C to 70 ° C The mixture is heated to 95 ° C to 100 ° C for 15-20 min.

In addition, 5% to 80% by weight of the mixture after fermentation of wheat and / or barley, and / or oat and / or corn grain may be added. wheat and / or barley, and / or oat, and / or corn, and / or buckwheat, and / or sesame, and / or amaranth and / or rice whole grains, together with amylolytic and one or more enzymes from % cellulolytic, hemicellulolytic and proteolytic enzymes, each in an amount of 0.05 to 2.0 wt. based on the catalytic activity of the enzymes. The mixture is allowed to ferment at 50 ° C to 65 ° C for 3 to 8 hours, then the mixture is heated to 95 ° C to 100 ° C for 10 to 25 minutes.

The resultant product obtained can be directly used in the production of cereal products in any ratio according to the recipe of the manufacturer, preferably in a content of 0.10% to 60.0% by weight in the dry product (bread, pastry, pastry, cakes, desserts, pastry) , pasta, biscuits and wafers, snack products, sticks, stuffing and others).

In addition, the application of the technical solution in enzymatic processing produces at the same time sugars, mainly glucose and maltose, but also fructose and other simple sugars to oligosaccharides, while the content of mono- and disaccharides in products will increase at least above 5% in dry matter. raw materials. These are a metabolizable sweetener replacing, in whole or in part, beet sugar and other sugars and sweeteners added to cereal products. Similarly, the products of this technology contribute to faster overcoming of the initial phase of fermentation and fermentation in the process of fermentation and fermentation of products where the cereal pathways are fermented by yeast or bacteria. Thus, the present invention not only allows the return of unused cereal products to their main production, but also represents a method whereby the content of simple sugars in the product is increased compared to that of the feedstock.

Another benefit in the application of products made by the proposed technology is also the improvement of sensory properties and improvement of the technological properties of cereal products (suppleness of bakery

EN 7184 Υ1 products, improving the rheological parameters of the products, extending the shelf-life) as well as semi-finished products (doughs, mixtures with different water contents) for the above-mentioned target food sectors, in particular bread and all types of bread.

The apparatus for preparing cereal and pseudocereal hydrolyzed concentrates comprises a container with a feed metering opening and a product discharge opening. The vessel is equipped with a duplicator jacket in which the cooling and heating zones are located and which has a valve for filling or draining the heating or cooling medium. The apparatus further comprises a stirrer motor positioned above the vessel in its vertical axis with a stirrer, as well as a homogenizer with a homogenizing head, a temperature sensor for sensing the temperature in the working space of the vessel, a stand / bogie. Preferably, the device comprises a pressure vessel for the coolant with a pressure and temperature coolant sensor. The coolant container is connected via a conduit to the homogenizer head.

The operation of all active elements, namely the operation of the homogenizer, stirrer and the amount of energy to heat in the duplicator jacket, can be automated and arbitrarily combined into timed steps with individual measurement and control. The apparatus essentially constitutes a fermenter as a complex apparatus for processing cereal and pseudo-cereal products and grains in such a manner in which it is possible by logically combining several individual technological operations to produce various products with specific properties, without the need for additional production equipment.

The proposed technical solution completely solves the utilization of cereal and / or pseudocereal products and grains, with the resulting added value being higher than in feeding or in the separation and regeneration of the raw material matrix into individual fractions. In addition, it is a solution in which the entire process takes place in a single installation under defined conditions and represents one integrated technology without the need for transport and handling using this raw material. The resulting product not only reduces the raw material intensity of the original production, but also reduces the consumption of sugars in the production of products. At the same time, it increases the yield and improves the rheological properties of the products, thus contributing to increasing the quality and efficiency of production. In contrast to the use of living microorganisms, the proposed solution uses only isolated active enzymes that do not limit the shelf life of the concentrate over a short period or period. Also, due to the use of isolated enzyme preparations, the product of said technology can be used as a raw material in a substantially wider variety of product recipes than in fermenting the raw material with live cultures of microorganisms. Since no inorganic acids are used for hydrolysis in the technological process of the proposed solution, but natural enzymes are used instead, the products are free of any foreign residues. In addition, the environment with the buffered substance conditions in the proposed process makes it possible to increase the efficiency of the enzymes, thus reducing their dosage and making the process more efficient. The process involves not only adjusting the sugar content by amylolytic enzymes, but also adjusting the quality of the non-starch polysaccharides from cereals, thereby positively affecting the rheological properties of the products and their yield. Regarding the use of whole cereal grains and pseudocereal cereals, the proposed solution allows a comprehensive and more efficient utilization and utilization of grains directly in cereal products, their direct consumption without limiting their content in product formulas, further without negative effects on product texture and sensory parameters. Also the possibility of increasing the final content of the non-starch polysaccharides as well as the moisture in the products where appropriate by adjusting the properties of the non-starch polysaccharides by mechanical and thermal disintegration into the form of gels.

The product produced by the proposed solution is homogeneous, microbiologically stable compared to the products produced according to the known solutions mentioned above, after drying it can be stored for a long time or can be used in any cereal production in slurry form. These parameters make it possible to process any quantity of cereal products by the proposed solution into a new product, at a low economic cost within one installation. In addition, the raw materials processed in this way are economically and technologically utilized even without the use of preservatives and additives.

The device has proven to be particularly advantageous in its universal use for whole grains and also for water-soluble materials. Also, by intensive homogenization, i.e. by mechanical disintegration of the raw material to be processed together with its thermal treatment, the efficiency of all the enzyme preparations used in Examples 1 to 5 was increased.

The built-in stirrer allowed the entire process to be continuously stirred throughout the process and equalizing both temperature and substance concentrations, thus contributing to even hydrolysis of the entire contents of the vessel. Another benefit of the device is that the processed mixture can be homogenized, hydrolyzed and boiled in one device under controlled conditions, which reduces labor and process accuracy. Heat treatment of the product at a temperature of 95 ° C to 100 ° C reduces the possibility of microbial contamination and contamination, resulting in improved concentrate usability and prolonged shelf life. By using a pressure vessel that has been pressurized to 5.0 bar, a product temperature of up to 140 ° C can be achieved, thereby simultaneously sterilizing the product.

SK 7184 Υ1

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows a schematic view of a fermenter.

EXAMPLES

Example 1

Unprocessed pastry doughs, as well as long-life pastries and unloaded pastries without fillings, together with breadcrumbs, total 100 kg, were dosed with drinking water at a ratio of 1: 2 (raw material: drinking water) to a machine equipped with a heat-adjustable homogenizer jacket and stirrer. During a homogenization lasting 10 min, a suspension was formed with the desired rheological properties (viscosity up to 2500 AU) and particle homogeneity, where at least 50% of the particles were below 2.0 mm (at least 50% overflow through a 2.0 mm mesh sieve in dry matter) ). The homogenization was carried out with continuous heating to 55 ° C with a deviation of ± 5 ° C. This temperature was set as the temperature at which enzymatic preparations, namely specific amylases (Fungamyl BrewQ) and glucogenic amylases (Glucoamylase 200K), cleaving starch, as well as gluten-protein-cleaving proteases (Fungal protease from Novozymes), xylanases and 191 S, Rohament GE) cleaving non-starch carbohydrates. Each of the enzymes was added in an amount of 1.5 wt. to dry weight of raw material. The entire contents were adjusted to pH 4.5 ± 0.4 with a citric acid and sodium dihydrogen phosphate buffer system and allowed to hydrolyze for 5 hours at 55 ° C with a ± 5 ° C offset. After the fermentation time, the contents were heated to 98 ° C for 15 min with stirring. Subsequently, the process was terminated and the resulting product was ready for use in bakery products, for the production of breads, plain bread or pastry. The content of mono-, di- to oligosaccharides in the product produced after the end of the process in the dry matter was above 40% by weight. The viscosity of the fermented product at 65 ° C was up to 450 AU.

Example 2

Unsold breads under guarantee, as well as long-life pastries without fillings in the amount of 30 kg, together with drinking water were dosed in a ratio of 1: 5 (raw material: drinking water) into a fermenter with a total content of 200 liters. During homogenization lasting 5 min, a suspension was formed with the desired rheological properties (viscosity up to 2500 AU) and particle homogeneity, where at least 50% of the particles were below 2.0 mm in size. The homogenization was carried out with continuous heating to 30 ° C with a deviation of ± 5 ° C. This temperature was set as the temperature at which endogenous amylases (Depol 220L) were fed together with the enzymes digesting starch polysaccharides (Pentopan 500BG, Depol 761P and Celluclast BG) and the mixture was left at this temperature for 1 hour with continuous slow stirring. Subsequently, the temperature was raised to 55 ° C ± 5 ° C, exogenous amylases (Depol 371 P) were added, followed by xylanases and hemicellulases (Rohament GE, Pentopan 500BG, Depol 761P) to cleave non-starch polysaccharides. The individual enzymes were added in an amount of 8.5% by weight. to the dry weight of the feedstock and the mixture was stirred slowly at this temperature for 1 hour. The entire contents were adjusted to pH 4.8 ± 0.2 with sodium citrate and sodium phosphate dihydrogen buffer systems. After the total fermentation time, the contents were heated to 95 ° C for 20 min with stirring. Subsequently, the process was terminated and the resulting product was ready for use in bakery products, for the production of breads, plain bread or pastry. The content of mono- and disaccharides in the resulting product in the dry matter was above 40% by weight. The viscosity of the fermented product at 65 ° C was up to 350 AU.

Example 3

A mixture of water, biscuit chips, biscuits and wafer trimmings was prepared as described in Example 1, the dry matter to total water ratio being 1: 2. The mixture was then heated to 60 ° C and homogenized to a particle size below 800 µm. 75% dry matter. In the next step, endogenous thermostable amylases (SE HiTA) according to Example 1 were added. The temperature was raised to 90 ° C after the addition of the enzymes and stirred vigorously at this temperature for 3 hours. Subsequently, the temperature was lowered by cooling to 55 ° C ± 5 ° C and exogenous amylases (Depol 371 P) and proteases (Fungal Protease) were added in the same amount as in Example 1. The mixture was left at this temperature for 6 hours and the pH was not adjusted. Subsequently, the temperature was raised to 140 ° C for 20 min with vigorous stirring. After completion of the process, the viscosity of the product was up to 400 AU at 65 ° C, the content of mono- and disaccharides in the dry matter was above 50% by weight. The product was applicable to all food stuffs, doughs and toppings used in the production of bakery and pastry products.

Example 4

Confectionery shavings and non-fronted cereal mues and bars with a cereal content of over 50% in the dry matter of 40 kg were mixed with water at a ratio of 1: 4 (dry: water) at 20 ° C to 25 ° C. Subsequently, homogenization was carried out for 15 min. The pH of the mixture was adjusted with acid

The change was that another type of non-starch polysaccharide (Celulase 13L) cleavage enzyme (0.2 wt.%) Was added in place of xylanases and hemicellulases. to the dry weight of the feedstock, another change was that the pH was adjusted to 5.5 to 6.0. The lipolytic enzymes (Fungal lipase), cleaving fat to the respective degradation products, were metered into the medium prepared in this step. These enzymes were added in an amount of 0.1 wt. to the dry weight of the mixture. The mixture was stirred at this temperature for 4 hours. Then the temperature was raised to 120 ° C for 30 minutes and the product was homogenized for 3 minutes. The final product after completion of the process was a pasty to creamy fine consistency with a viscosity of up to 350 AU at 65 ° C. The content of mono- and disaccharides in the dry matter was at least 35% by weight. and the soluble fiber content increased twice as much as that in the feedstock. The product was particularly suitable for the production of food sweet stuffs, all kinds of cereal doughs and as an addition to snack products including bar sticks.

Example 5

The cereal grains (wheat, oats and barley) were mixed with drinking water at a ratio of 1: 2 in an amount of 60 kg. The mixture was heated to 90 ° C by gradual heating for 35 min. Subsequently, the mixture was homogenized for 15 min so that the mixture contained at least 70% of particles smaller than 1.0 mm. The mixture was then allowed to cool to 70 ° C over 1 hour. After cooling, amylolytic enzymes (Fungamyl BrewQ, Glucoamylase 200K) and enzymatic preparations cleaving non-starch saccharides (Ultraflo Max, Rohament GE, Cellulase 75000, Optizym DX) were added, the temperature was adjusted to 65 ° C ± 5 ° C and left for 12 hours at this temperature. The amount of enzyme preparation added for each of the enzymes was 0.05 wt. to dry matter grain. After the fermentation time had elapsed, half the volume was pumped into the reservoir and the other half was heated to 100 ° C for 15 min. and homogenized for 2 min. The viscosity of the product at 65 ° C was up to 1150 AU. After cooling, the product was used as an additional raw material for the production of whole grain bakery products, mainly bread and bread leaven.

8.0 wt. wheat and barley grains. An equivalent amount of enzyme preparations was added to the mixture to the dry weight of the added grains as at the start of the process, and the mixture was allowed to ferment for a further 5 hours at a temperature of 50 ° C to 65 ° C. Subsequently, the mixture was heated to 98 ° C with stirring for 15 min and homogenized for 30 seconds after cooling. The viscosity of the product at 65 ° C was up to 650 AU. The product was suitable for use in the production of whole grain bakery products, snack products and cereal bars.

Example 6

A 50 kg bean-free mix of baked products was homogenized with water at a ratio of 1: 2 for two homogenization intervals, each lasting 4 min, at 25 ° C with continuous stirring. The mixture was heated to 55 ° C ± 5 ° C and amylases (AM3K and AMG 400K) were added in an amount of 0.15 wt%. % of the raw material, cellulase 190K) and protease (Protease BL) in an amount of 0.1 wt. to dry matter raw materials. The mixture was allowed to ferment for 6 hours at this temperature with stirring. The pH was not adjusted. After 6 hours, the temperature was raised to 95 ° C for 25 minutes and the mixture was allowed to cool. After cooling, the product had a viscosity of up to 450 AU at 65 ° C, the content of mono-, di- to oligosaccharides in the dry matter was at least 45% by weight. The product was added to fine and conventional pastries, also to pasta doughs and biscuits in a proportion above 5% by weight. to the weight of the flour.

Example 7

A 50 kg bean-free mix of baked products was homogenized with water at a ratio of 1: 2 for three homogenization intervals, each lasting 2 min, at 25 ° C with continuous stirring. In the homogenized mixture, the reducing sugars expressed on dry weight of the mixture were determined spectrophotometrically by the method of Schoorl and then by the DNS method (determination of reducing sugars by the 3,5-dinitrosalicylic acid method). The Schoorl assay revealed a reducing sugar content of the mixture of 6% ± 1%, and a DNS sugars content of reducing sugars of 8% ± 1%. After homogenization, the mixture was heated to 55 ° C ± 5 ° C and 0.05% w / w amylases (AM3K) were added. to dry matter raw materials. The mixture was allowed to ferment for 3 hours at this temperature with stirring. The pH was not adjusted. After three hours, the temperature was raised to 95 ° C for 25 minutes and the mixture was allowed to cool. After cooling, the product had a viscosity of up to 550 AU at 65 ° C, the content of reducing sugars, expressed as dry matter, was determined by the Schoorl method at a level of 15% ± 2% by weight. and 19% ± 2% DNS. The product was added to conventional pastry, bread dough, pasta dough and also biscuits in a proportion above 10% by weight. to the weight of the flour.

Example 8

The apparatus suitable for the preparation of cereal concentrates consists of a stainless steel container 1 with a duplicator jacket 8 which has formed at least 70% of the surface area of the cooling and heating surface.

The duplicator jacket 8 has a valve 13 at the bottom for filling or draining the heating or cooling medium. Furthermore, the apparatus is equipped with a stirrer motor 2 located above the vessel 1, a homogenizer 4 in the vertical axis, possibly outside the vertical axis of the vessel 1, a pressure and temperature sensor 6 detecting the temperature and pressure values of the cooling circuit of the homogenizer 4, agitator 7, homogenization head 10). in a plane with the inner shell of the container 1 or in a position extended into the working space of the container 1, a temperature sensor 11 for sensing the temperature in the working space of the container 1, a stand / bogie 12, a pressure vessel 14 for a coolant The cooling circuit of the homogenizer is closed by means of fixed or plastic fittings. A metering orifice 3 for dispensing the raw materials opens into a container at the top and an outlet 5 for discharging the product at the bottom. The stirrer 7 is shaped to follow the walls of the container 1, spaced from the inner surface of the shell up to a maximum of 25 mm. The outlet opening of the device is situated on a sloped or conical bottom of the inner shell of the container 1 so that the product can be discharged through the outlet opening out of the device due to gravity. Acceleration of the discharge of the contents of the container 1 can be achieved by switching on the stirrer 7 or possibly by turning on the homogenizer 10. The device is equipped with safety safeguards against self-damage or possible injury to the operator.

Before dosing the raw materials, an appropriate amount of water is introduced into the container. The feedstocks are added sequentially through the opening 3 and the mixture is homogenized with a homogenizer 10, optionally under stirring with a stirrer 7. The temperature of the mixture in vessel 1 is detected by a temperature sensor 11 and controlled by a liquid in the cooling and heating zone 9. Prior to the first start-up of the homogenizer 10, the coolant pressure of the homogenizer 10 in the coolant circuit, as measured in the container 14, is always checked. The presence of sufficient coolant in the absence of air has been shown to increase the pressure in the circuit above 0.5 bar. liquid. After reaching the required time and temperatures in each step of the process, the device will shut down.

Industrial usability

The present invention provides a process for the production of cereal and pseudocereal concentrates, which can be used mainly as a substitute for added sugars and sweeteners in cereal-containing foods, but also as a protein source and also as an additive with emulsifying, texturing and sensory effects. In the case of cereal grain concentrates, the product is also a rich source of fiber.

PROTECTION REQUIREMENTS

Claims (13)

Process for the preparation of a cereal hydrolyzed concentrate, characterized in that the cereal and / or pseudocereal grains or masses and products with a major proportion of cereal or pseudocereal or a mixture thereof are diluted with water in a ratio of 1: 1 to 1: 8 by weight, amylolytic enzymes, each in an amount necessary to cleave at least 5.0% by weight of the total amount of starches and / or dextrins to enzymatic hydrolysis products in the dry matter of the cereal concentrate, at a given temperature, pH and fermentation time, adjusting the pH of the mixture if necessary 0 to 7.0, and the mixture is fermented at 20 ° C to 85 ° C with stirring for 1 to 15 hours, then heated to 90 ° C to 140 ° C for 5 to 45 minutes. A method according to claim 1, characterized in that one or more enzymes selected from the group consisting of proteases, xylanases, hemicellulases, cellulases, glucanases, pullulanases, lipases, each in an amount necessary for cleavage of at least 1, are added with amylolytic enzymes. 0% by weight of the total amount of raw materials for the products specific to the enzyme preparation used during enzymatic hydrolysis, calculated on dry weight, at a given temperature, pH and fermentation time. Method of preparation according to claim 1 and 2, characterized in that water is added to the unprocessed doughs for the production of conventional bakery pastry and / or durable pastry, and / or unloaded sweet pastry without fillings, and / or crumb, 1: Amylolytic, proteolytic enzymes, xylanases and hemicellulases, each in an amount of 0.05 to 3.0 wt. to dry matter of raw material according to the catalytic activity of the enzymes to obtain at least 55% of amylolysis products and at least 4% of products due to hydrolysis of non-starch polysaccharides and lipids in the dry matter, pH adjusted to 4.0 to 5.5, mixture at 45 ° C to 70 The mixture is allowed to ferment for 3 to 6 hours, then the mixture is heated to a temperature of 95 ° C to 100 ° C, where it is left for 10-25 minutes. Process according to claim 1 and 2, characterized in that water is added to the bread and / or the non-stuffed pastry in a ratio of 1: 2 to 1: 5 by weight, amylolytic enzymes and hemicellulolytic enzymes are added together with lipolytic enzymes each. % thereof, in an amount of 0.05 to 9.0 wt. based on the catalytic activity of enzymes to obtain at least 45% of amylolysis and mini products SK 7184 álne1 at least 2% hydrolysis products of non-starch polysaccharides and lipids in dry matter, the mixture is allowed to ferment at 30 ° C to 45 ° C for 1 to 2 hours, then the temperature is raised to 50 ° C to 60 ° C, exogenous amylase is added and xylanases and hemicellulases, each in an amount of 0.05 to 9.0 wt. to the dry matter of the raw material according to the catalytic activity of the enzymes so that at least 40% of the starch and dextrins present are hydrolytically cleaved to glucose and maltose and to obtain at least 5% of products after hydrolysis of the non-starch polysaccharides in the dry matter; the fermentation is continued for a further 1 to 3 hours, then the temperature is raised to 95 ° C to 100 ° C, leaving it for 10-25 minutes. Preparation process according to claim 1 and 2, characterized in that water is added to the confectionery bodies and / or cereal mussels and / or cereal bars with a cereal content above 50% in the dry matter in a ratio of 1: 2 to 1: 5 wt. % amylolytic and proteolytic enzymes, each in an amount of 0.05 to 2.0 wt. % of the raw material, and cellulolytic enzymes, each in an amount of 0.1% to 0.5% by weight; to dry matter of raw material according to the catalytic activity of the enzymes, to obtain at least 20% amylolysis products and at least 5% hydrolysis products of non-starch polysaccharides and proteins in the dry matter, adjust the pH to 4 to 4.5 and ferment the mixture at 45 ° C to 65 ° C with stirring for 2 to 5 hours, then the pH is adjusted to 5.0 to 6.5 and lipolytic enzymes are added, each in an amount of 0.05 to 0.2% by weight. to dry matter of the mixture according to the catalytic activity of the enzymes, so that at least 30% of the lipids present are hydrolytically cleaved to the products and the mixture is fermented for a further 3 to 6 hours, then heated to 100 ° C to 140 ° C. 40 min. Method according to claim 1 and 2, characterized in that water is added to the biscuits and / or biscuits and / or wafers in a ratio of 1: 1 to 1: 3 by weight, thermostable endogenous amylolytic enzymes each in an amount of 0.05 to 3.0 wt. to dry matter of the raw material according to the catalytic activity of the enzymes so that at least 65% of the starches present are amylolytically cleaved to dextrins to oligomeric units, the mixture is fermented at 85 ° C to 95 ° C with stirring for 2 to 5 h, after cooling to 50 ° Exogenous amylase and protease, each in an amount of 0.05 to 5.0 wt. to dry matter of the raw material according to the catalytic activity of the enzymes so that at least 65% of the dextrins and starch oligomeric units present are amylolytically cleaved to glucose and maltose and at least 5% of the proteins present are hydrolyzed to the respective peptides and allowed to ferment for 4 to 7 hours. to 95-140 ° C, where it is left for 10-25 min. A process according to claim 1 or 2, characterized in that water is added to the wheat and / or barley, and / or rye, and / or oat, and / or corn and / or rice grain in a ratio of 1: 1 to 1. 1: 4, amylolytic enzymes and one or more enzymes selected from the group consisting of hemicelllulases, xylanases, cellulases, glucanases, proteases, each in an amount of 0.05 to 2.0 wt. to the dry matter of the raw material according to the catalytic activity of the enzymes, so that at least 10% of the starches present are amylolytically cleaved to amylolysis products to produce at least 5% in the hydrolytically cleaved pulp of non-starch polysaccharides. 12 h, then the mixture is heated to 100 ° C, where it is left for 15-20 min. Process according to claim 7, characterized in that 5 to 80% by weight of the mixture is added to the mixture after fermentation of wheat and / or barley, and / or oat and / or rye and / or corn grain. wheat and / or barley, and / or oat, and / or corn grain, and / or buckwheat and / or sesame grain, and / or amaranth, and / or rice whole grain, amylolytic and one or more enzymes from the group comprising % cellulolytic, hemicellulolytic and proteolytic enzymes, each in an amount of 0.05 to 2.0 wt. The mixture is allowed to ferment at 50 ° C to 65 ° C for 3 to 8 hours, then the mixture is heated to 95 ° C to 100 ° C for 10 to 25 minutes. A process according to any one of claims 1 to 8, characterized in that the feedstock is homogenized by gradual heating to a temperature of 30 ° C to 100 ° C until at least 50% of the particles have a size below 2.0 mm. Process according to any one of claims 1 to 5, characterized in that the PH is treated with a buffer system by citric acid and sodium dihydrogen phosphate or sodium citrate and sodium dihydrogen phosphate, or only by lactic acid. Ceramic enzymatically hydrolyzed concentrate obtained by the process according to any one of claims 1 to 10, characterized in that it contains at least 5.0 wt. glucose, maltose, maltotriose in a mixture or alone, formed by enzymatic hydrolysis, wherein the viscosity after fermentation is from 5 AU to 2000 AU at 65 ° C and the pH is 4.0 to 7.0. Apparatus for the preparation of a cereal hydrolyzed concentrate, characterized in that it comprises a container (1) with a feed opening (3) and a product discharge opening (5), provided with a duplicator jacket (8) containing a cooling and heating device zone (9) and having a valve (13) for filling or draining the heating or cooling medium, further comprising a stirrer motor (2) located above the stirrer container (1) (7), a homogenizer (4) with a homogenizing head (10) , a temperature sensor (11) for sensing the temperature in the working space of the container (1), the stand / chassis (12). SK 7184 Υ1 Apparatus according to claim 12, characterized in that it comprises a pressure vessel (14) for the coolant, with a pressure and temperature coolant sensor (6) connected by a conduit to the head of the homogenizer (10).