US20060019013A1 - Method for making a rolled snack food product having a light crispy texture - Google Patents

Method for making a rolled snack food product having a light crispy texture Download PDF

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Publication number
US20060019013A1
US20060019013A1 US10/896,208 US89620804A US2006019013A1 US 20060019013 A1 US20060019013 A1 US 20060019013A1 US 89620804 A US89620804 A US 89620804A US 2006019013 A1 US2006019013 A1 US 2006019013A1
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US
United States
Prior art keywords
starch
monoglyceride
dough
rolled
snack
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/896,208
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English (en)
Inventor
Thomas Crosby
Geoffrey Ley
V. N. Rao
Dianne Ripberger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Frito Lay North America Inc
Original Assignee
Frito Lay North America Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Frito Lay North America Inc filed Critical Frito Lay North America Inc
Priority to US10/896,208 priority Critical patent/US20060019013A1/en
Assigned to FRITO-LAY NORTH AMERICA, INC. reassignment FRITO-LAY NORTH AMERICA, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RAO, V.N. MOHAN, RIPBERGER, DIANNE HUSEMAN, CROSBY, THOMAS GEORGE, LEY, GEORFFREY THOMAS
Priority to CA2574747A priority patent/CA2574747C/en
Priority to PCT/US2005/024545 priority patent/WO2006019688A2/en
Priority to MX2007000817A priority patent/MX2007000817A/es
Priority to BRPI0513618-0A priority patent/BRPI0513618A/pt
Priority to EP05770024A priority patent/EP1788882A4/de
Publication of US20060019013A1 publication Critical patent/US20060019013A1/en
Priority to US12/939,680 priority patent/US8377493B2/en
Abandoned legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
    • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
    • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
    • A23L19/18—Roasted or fried products, e.g. snacks or chips
    • A23L19/19—Roasted or fried products, e.g. snacks or chips from powdered or mashed potato products
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
    • A23L7/122—Coated, filled, multilayered or hollow ready-to-eat cereals
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
    • A23L7/13—Snacks or the like obtained by oil frying of a formed cereal dough

Definitions

  • the present invention relates to a method for making an improved rolled snack food and more particularly to a method for making a rolled snack food having a light and crispy texture.
  • Conventional tortilla snack piece products are prepared from corn masa dough made from a traditional nixtamalization process.
  • the masa dough is then compressed between a pair of counter rotating sheeter/cutter rollers that are located closely together, thereby providing a pinch point through which the dough is formed into sheets and cut into a desired shape.
  • the desired snack piece shape is that of a triangle.
  • the snack pieces are transported towards and through a toaster oven for an increased stiffness for insertion into the fryer.
  • the toasted snack pieces are then passed through a proofing stage where the snack pieces are exposed to ambient air to equilibrate moisture throughout the snack piece.
  • the snack pieces are then fried in hot oil before being routed into a seasoning tumbler where flavored seasonings or salts are added to the snack pieces.
  • the snack pieces are then sent to be packaged.
  • Snack pieces made from this process typically have a substantially flat geometry, even if the snack pieces have a curl as a result of the frying process.
  • a rolled snack piece can be more easily placed into a consumer's mouth, resulting in a bite-sized or more easily consumable snack.
  • the bulk density of rolled snacks is higher than the bulk density of snacks having a substantially flat geometry. As a result, less packaging can be used to contain the same weight of rolled snacks. Accordingly, a need exists for a rolled snack food.
  • a rolled snack food can be made by rolling the cut dough pieces following sheeting before the pieces are toasted.
  • One such apparatus for rolling pieces of dough is disclosed is U.S. Pat. No. 6,393,974.
  • texture problems that do not occur in prior art flat snack pieces arise during cooking of rolled dough pieces.
  • steam within the dough can cause the snack pieces to expand mostly outward. This outward expansion creates voids within the snack piece. These voids help create a lighter, crispier texture.
  • inward radial expansion further compresses the inner portion of the snack piece which increases the particulate density, and decreases any voids that help provide a lighter, crispier texture.
  • a higher particulate density means there are fewer voids to provide a lighter, crispier texture.
  • a hard texture is created throughout the inner portion of the rolled snack food.
  • the moisture content upon leaving the toast oven in a prior art substantially flat masa-based snack piece is between about 25% and about 35% moisture
  • the moisture content of a rolled dough snack piece, upon leaving the toast oven is about 45% to 50% moisture.
  • the temperature of the inner part of a rolled snack piece is lower than the temperature of the outer, exposed part. This results in uneven moisture removal, and higher moisture contents near the inner portion of the rolled snack piece.
  • the inner portion of the snack piece is closed off during frying, it is difficult to remove the moisture by oil displacement in the inner portion of the snack piece. Higher moisture contents in the finished snack piece product can contribute to a harder texture.
  • one prior art solution for softening a fried dough involves using a potato or rice starch.
  • these starches When these starches are heated and fried at high moisture contents, the starch binds tightly to itself resulting in a glassy, hard texture. This glassy texture typically allows for rapid breakdown of the snack during mastication.
  • potato or rice starch was added to the masa used in the rolled snack piece, the rolled snack pieces expanded radially inward, forcing the rolled snack piece to close up upon frying, and made the product bind so tightly that breakdown failed to occur during mastication.
  • adding potato or rice starch rather than resulting in a softer texture, resulted in a highly undesirably hard texture.
  • the proposed invention is a method for making a rolled snack food having a light, crispy texture.
  • monoglyceride with a judicious choice of particle size distribution is mixed with a starch-based dough.
  • a particulate triglyceride is mixed with a starch-based dough followed by addition of a liquid monoglyceride.
  • this invention produces a method that provides a bite-sized rolled snack food having a light, crispy texture.
  • the invention provides a rolled snack food having a higher bulk density than prior art substantially flat snack food products thereby requiring less packaging.
  • FIG. 1 is a schematic representation of one embodiment in the new process.
  • FIG. 2 is a perspective schematic representation of one embodiment of the rolled snack piece of the present invention.
  • FIG. 3 a is an illustration of the chemical structure of a monoglyceride and an amylose helix complex.
  • FIG. 3 b is an alternative perspective representation of FIG. 3 a.
  • FIG. 1 is a schematic representation of one embodiment in the new process.
  • a starch based material 110 , a monoglyceride 120 , and water 130 are mixed 140 together in a continuous batch, or other mixer.
  • the starch-based material can comprise corn masa made from a standard nixtalization process, a dry corn masa mix, potato flour, potato flakes, potato granules, corn flour, and mixtures thereof.
  • any starch-based material comprising amylose including, but not limited to, corn, rice, tapioca, potato, and mixtures thereof can be used.
  • a monoglyceride is defined as a solid particulate monoglyceride having a reduced average particle size of less than about 400 microns and more preferably less than about 150 microns, and most preferably less than about 75 microns.
  • the monoglyceride is added with only trace amounts of diglycerides and triglycerides.
  • the monoglyceride is a fully saturated (hydrogenated) monoglyceride.
  • An example of an acceptable monoglyceride comprises Dimodan HS® 75 available from Danisco of New Century, Kans.
  • the monoglyceride is partially hydrogenated.
  • the dough can be formed 150 into uncooked snack pieces.
  • Forming 150 the dough can be achieved by compressing the dough between a pair of counter rotating sheeter/cutter rollers that are located closely together, thereby providing a pinch point through which the dough is formed into sheets and cut into a desired chip shape.
  • the dough can be cut into any desired shape including, but not limited to, circles, triangles, squares, rectangles, pentagons, and hexagons or any other polygon.
  • forming of the dough comprises extruding the dough and cutting the extruded dough into a desired shape. After the dough has been cut into a plurality of uncooked snack pieces, the dough pieces are rolled 160 by using known methods in the prior art. (see U.S. Pat. No. 6,393,974)
  • FIG. 2 is a perspective schematic representation of one embodiment of the rolled snack piece of the present invention.
  • the rolled snack piece comprises an inner facing surface 205 and an outer facing surface 210 .
  • the rolled snack piece is in the shape of a spiral having an overlap area. As used herein, an overlap area is created when at least a portion of the inner facing surface 205 is adjacent to at least a portion of the outer facing surface 210 .
  • the snack piece can be rolled into a spiral having an overlap area of varying lengths.
  • the dough is rolled about one and one-half full turns.
  • the inner portion 220 and outer portion 250 can substantially mate together in the overlap area, it can be desirable to have a gap (not shown) in the overlap area between the inner portion 220 and outer portion 250 to allow for expansion and oil contact during frying.
  • the rolled snack pieces can be seasoned 190 in a tumbler, topping unit, or other seasoning device known to those in the art.
  • the cooked, rolled snack piece comprises between about 0.05% to about 3.0% monoglyceride, about 25% to about 34% oil, about 0.8% to about 2.0% moisture, about 60% to about 80% of a starch-based component, and about 0% to about 8% seasoning.
  • Starch is typically made up of amylose and amylopectin molecules.
  • Amylose primarily consisting of ⁇ -1,4 linked glucose rings is a straight chain helical molecule.
  • Amylopectin is a highly branched molecule that comprises both ⁇ -1,4 and ⁇ -1,6 linked glucose rings. It is theorized that the amylose helix collapses as a result of expansion that occurs during frying. Voids formed during frying near outer surfaces create inward expansion forces and cause the amylose helix near inner less-exposed surfaces to collapse.
  • FIG. 3 a depicts an illustration of a monoglyceride 300 a and an amylose helix 360 a .
  • a monoglyceride 300 a typically comprises a glycerol 310 a and a fatty acid chain 340 a .
  • a diglyceride would have a fatty acid chain attached to the oxygen adjacent to second carbon atom 314 a of the glycerol molecule 310 a , or attached to the third glycerol carbon 316 a .
  • a triglyceride would have a fatty acid chains attached to each of the oxygens attached to the second and third glycerol carbons 314 a 316 a.
  • FIG. 3 b is an alternative perspective representation of FIG. 3 a .
  • an amylose molecule 360 b forms a single helix. It is believed that a lipid-carbohydrate complex is formed when the monoglycerides long hydrophobic fatty acid chain 340 b is inserted into the amylose starch helix 360 b . It is believed that the fatty acid chain 340 b of the starch monoglyceride complex effectively builds bridges of support inside the amylose helix 360 b . This bridging may prevent the amylose starch from collapsing due to inward expansion forces during frying.
  • the monoglyceride is contributing to the structural integrity of the masa or other starch-based material matrix by forming a lipid-carbohydrate complex.
  • a hydrogenated monoglyceride has a better chance to complex due to the linear nature of the molecule.
  • Unsaturated fatty acid molecules especially those having a cis configuration can have kinks that lower their ability to complex with the linear form of the amylose helix.
  • a trans rather than a cis configuration at the double bond is preferred to permit a better interaction with the starch.
  • Particulate diglycerides and triglycerides may work, but are less desirable because they are not as effective as the monoglyceride.
  • using an emulsifier having significant amounts of particulate glycerides other than monoglyceride lowers efficiency and results in increased costs.
  • blends of monoglycerides with other glycerides can be used, but may be less desirable.
  • emulsifiers can be used including, but not limited, lysolecithin (lysophosphatidyl choline powder), succinic acid esters of monoglyceride, diacetlylated tartaric acid esters of monoglyceride (DATEM), stearoyl lactylate, and its salts (stearoyl 2-lactylate, sodium stearoyl 2-lacylate, calcium 2-lactylate).
  • the second theory is that monoglyceride “lubricates” the dough.
  • the lubrication takes place both within the dough (intra-lubrication) and outside the dough (inter-lubrication).
  • the inter-lubrication allows for better release from the roller and from the cutter.
  • the inter-lubrication may provide a small gap in the overlap area that allows for better oil contact within the overlap area during frying.
  • the inter-lubrication provided by the monoglyceride also prevents the rolled dough piece from sticking to itself in some portions at the overlap area, allowing oil in the fryer to contact the dough piece in the overlap area.
  • the third theory is that monoglyceride changes the thermal transfer properties of the dough. Addition of the monoglyceride may impact the rate in which water leaves the starch during frying, or affect the amount of unbound or free water that exits the starch-based dough during frying. For example, the monoglyceride interaction may displace free water from the starch and the polar end of the monoglyceride will be more likely to hold the bound water in the system. Thus, rate of moisture removal and final amount of moisture in the fried chip can be affected by the monoglyceride. The longer dough is fried, the harder it becomes. A shorter fry dwell time results in a more tender, less hard chip.
  • the amount of monoglyceride used in the dough is one variable of the invention that must be controlled for a number of reasons.
  • monoglyceride is not very elastic. Thus, dough rolling becomes more difficult when the monoglyceride is used at higher levels. For example, if high levels (e.g. more than about 3% by finished product weight) of monoglyceride are used, the dough, after it is sheeted and cut, can retain shape memory. As a result, rolled uncooked snack pieces have a tendency to unroll as higher amounts of monoglyceride are used.
  • the melting temperature of monoglyceride powder is about 150° F. In one embodiment, the toast oven is operated at over 450° F.
  • monoglycerides tend to lubricate the dough and allow more moisture to escape during frying. Too much moisture escape during frying results in reduced blistering of the chip surface. Less blistering results in a harder texture and less desirable look in a tortilla chip embodiment. Moreover, the resulting fried chip would have an oil soaked appearance. Fifth, a high level of monoglyceride can result in monoglyceride leaching into the oil, affecting oil quality. Thus, any addition of monoglyceride must proceed with caution.
  • a monoglyceride having an average particle size of less than about 150 microns and more preferably less than about 75 microns provides monoglyceride having an increased surface area, allowing even lower levels of monoglyceride to be used. Moreover, better mixing of the monoglyceride throughout the dough matrix can occur, increasing the monoglyceride availability to the starch molecule.
  • the present invention provides a method for making a rolled snack food having a light and crispy texture.
  • a rolled snack piece does not have the tendency to unroll in the toast oven, undesirable texture and off-flavors are minimized, and the cost of producing the rolled snack piece can be reduced.
  • oil quality is not substantially impacted.
  • a particulate triglyceride can be used in place of the solid particulate monoglyceride 120 .
  • a particulate triglyceride is defined as a triglyceride having a reduced average particle size of less than about 400 microns and more preferably less than about 150 microns, and most preferably less than about 75 microns.
  • a liquid monoglyceride could then be applied, for example by a spray, to the dough during mixing 140 to produce similar textural effects in a rolled snack piece. For example, it is believed that the overall functionality (expansion control, lubrication, thermal transfer properties) can be enhanced in this manner.
  • both the particulate triglyceride and liquid monoglyceride provide lubrication.
  • a particulate monoglyceride is used.
  • the particulate triglyceride may provide better void space functionality and liquid monoglyceride provides better starch interaction that results in expansion control.
  • the texture of the snack piece can be controlled by changing the particulate size and/or concentration of the triglyceride, while keeping the starch interaction constant, and vice-versa. Such optimization may be more difficult with only monoglyceride.
  • the liquid monoglyceride and particulate triglyceride added should be less than 3% by weight of the finished product.

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  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Confectionery (AREA)
US10/896,208 2004-07-21 2004-07-21 Method for making a rolled snack food product having a light crispy texture Abandoned US20060019013A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US10/896,208 US20060019013A1 (en) 2004-07-21 2004-07-21 Method for making a rolled snack food product having a light crispy texture
CA2574747A CA2574747C (en) 2004-07-21 2005-07-12 Method for making a rolled snack food product having a light crispy texture
PCT/US2005/024545 WO2006019688A2 (en) 2004-07-21 2005-07-12 Method for making a rolled snack food product having a light crispy texture
MX2007000817A MX2007000817A (es) 2004-07-21 2005-07-12 Metodo para hacer un producto alimenticio de botana enrollada que tiene una textura crujiente ligera.
BRPI0513618-0A BRPI0513618A (pt) 2004-07-21 2005-07-12 metodo para a fabricação de pedaços de petisco calandrados cozidos, produto resultante e massa
EP05770024A EP1788882A4 (de) 2004-07-21 2005-07-12 Verfahren zur herstellung eines gerollten knabberprodukts mit leichter knuspriger textur
US12/939,680 US8377493B2 (en) 2004-07-21 2010-11-04 Method for making a rolled snack food product having a light crispy texture

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US10/896,208 US20060019013A1 (en) 2004-07-21 2004-07-21 Method for making a rolled snack food product having a light crispy texture

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US12/939,680 Active US8377493B2 (en) 2004-07-21 2010-11-04 Method for making a rolled snack food product having a light crispy texture

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US (2) US20060019013A1 (de)
EP (1) EP1788882A4 (de)
BR (1) BRPI0513618A (de)
CA (1) CA2574747C (de)
MX (1) MX2007000817A (de)
WO (1) WO2006019688A2 (de)

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US20080199569A1 (en) * 2007-02-21 2008-08-21 Baumeister Joaquin Fernandez Apparatus and method for production of rolled dough food piece
EP2227968A1 (de) 2009-03-10 2010-09-15 Kraft Foods R & D, Inc. Verfahren zur Herstellung von Lebensmitteln und Ofen zum Trocknen und/oder Erhitzen von flachen Teigstücken, gewalzte Lebensmittel und Vorrichtung zum Walzen von flachen Teigstücken
JP2016214213A (ja) * 2015-05-26 2016-12-22 日清製粉株式会社 油揚げ菓子及びその製造方法
WO2017023453A1 (en) * 2015-07-31 2017-02-09 Frito-Lay North America, Inc. Yogurt crisp and method for making same
WO2023007037A1 (es) * 2021-07-28 2023-02-02 Cyl Ibersnacks, S.L Snack de maíz con forma de churro

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US7585531B2 (en) 2007-02-21 2009-09-08 Frito-Lay North America, Inc. Method for production of rolled dough food piece
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CA2574747A1 (en) 2006-02-23
WO2006019688A3 (en) 2006-12-21
CA2574747C (en) 2010-10-05
EP1788882A2 (de) 2007-05-30
BRPI0513618A (pt) 2008-05-13
US20110052777A1 (en) 2011-03-03
US8377493B2 (en) 2013-02-19
WO2006019688A2 (en) 2006-02-23
EP1788882A4 (de) 2009-07-08

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