WO1997029647A1 - Procede pour produire une farine pour masa - Google Patents

Procede pour produire une farine pour masa

Info

Publication number
WO1997029647A1
WO1997029647A1 PCT/US1997/002474 US9702474W WO9729647A1 WO 1997029647 A1 WO1997029647 A1 WO 1997029647A1 US 9702474 W US9702474 W US 9702474W WO 9729647 A1 WO9729647 A1 WO 9729647A1
Authority
WO
WIPO (PCT)
Prior art keywords
meal
com
corn
particles
masa flour
Prior art date
Application number
PCT/US1997/002474
Other languages
English (en)
Inventor
John H. Lange
Michael J. Wolt
Original Assignee
Conagra, 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 Conagra, Inc. filed Critical Conagra, Inc.
Priority to AU21284/97A priority Critical patent/AU2128497A/en
Publication of WO1997029647A1 publication Critical patent/WO1997029647A1/fr

Links

Classifications

    • 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
    • A23L7/198—Dry unshaped finely divided cereal products, not provided for in groups A23L7/117 - A23L7/196 and A23L29/00, e.g. meal, flour, powder, dried cereal creams or extracts

Definitions

  • the present invention relates to methods for producing masa flour involving a hydration step, and more particularly, the present invention relates to a method for producing a masa flour that degerminates kernels of com prior to hydration.
  • Masa flour is a fiour made from corn that is typically used to make soft corn tortillas, tortilla chips, corn chips, taco shells, and other food products derived from flour made from com.
  • the known prior art processes for making masa flour do not involve the step of degerminating the com kernels prior to hydrating the com. Instead, the known processes generally begin by hydrating whole kernels of com, followed by cooking the kernels of com, grinding the cooked com kernels, and then drying the ground cooked corn into a masa flour.
  • the prior art processes initiate the formation of the masa flour by first hydrating whole kernels of com, followed by grinding the hydrated com kernels.
  • the prior art processes suffer from a number of disadvantages because the processes initiate formation of the masa flour by hydrating ground com that has not been degerminated and more typically whole kernels of com.
  • the use of corn that has not been degerminated results in a number of problems which are discussed as follows.
  • the known prior art methods of producing a masa flour using whole kernels of com generally use large amounts of water when hydrating the com kernels.
  • the water becomes contaminated with lime and organic waste products from the corn during the hydration step in the production of the masa flour, which creates a waste water disposal problem.
  • the creation of contaminated waste water is undesirable as it can be expensive to dispose of and/or clean.
  • the gelatinized starch is contributed to the masa flour by the two types of endosperm at different rates, with the floury endosperm contributing gelatinized starch first followed by the homy endosperm contributing gelatinized starch.
  • gelatinized starch As gelatinized starch is cooked it can over-gelatinize, which can result in the masa flour being too sticky.
  • the two types of endosperm contribute gelatinized starch at different rates, it is difficult to control the amount of gelatinized starch that will be present in the masa flour. If the com particles are cooked long enough to have the horny endosperm contribute a significant percentage of the overall gelatinized starch content of the masa flour, then the earlier released starch from the floury endosperm will over-gelatinize.
  • the homy endosperm typically does not contribute enough gelatinized starch to the masa flour resulting in a masa flour dough that is not cohesive enough. Consequently, it is desired to have a method allowing for greater control over the amount of gelatinized starch placed into the masa flour.
  • a further problem with the prior art methods is an inability to easily alter or adjust the amount of gelatinized starch placed into the masa flour, so as to adjust the masa flour characteristics to meet a specific request.
  • attempts to significantly alter the amount of gelatinized starch placed in the masa flour results in a dough produced from the masa flour that ranges from too sticky to not sticky enough.
  • This is disadvantageous because the prior art processes are not responsive to the varying gelatinized starch content requirements in different food products.
  • the inability to precisely control the amount of gelatinized starch is a shortcoming as it limits the controllability and flexibility in the production of the masa flour, meaning gelatinized starch amounts cannot be altered to readily fit the needs of the user. Consequently, it is desirable to have a method that allows the user to respond easily to needs for placement of different amounts of gelatinized starch in the masa flour and to readily control with predictability the amount of gelatinized starch placed into the masa flour.
  • Another problem associated with the previously known processes using whole kemels of com is that they typically cannot be used in a continuous process, but instead are batch processes.
  • the prior art methods use batch processes because it takes a long time to hydrate whole kemels of com.
  • batch processes require the use of more than one production line or a large number of holding tanks in which to hydrate the whole kernels of com. Therefore, it would be desirable to use a continuous process because it requires a single production line and fewer pieces of equipment, which is less costly than production using a batch process.
  • masa flour that allows the amount of gelatinized starch in the masa flour to be more closely controlled, and produces lower levels of contaminated water.
  • a process is developed for producing a masa flour using degerminated kemels of com.
  • a process for producing a masa flour that allows for control over the placement of gelatinized starch in the masa flour.
  • it has been found when producing a masa flour that it is highly advantageous to include a step prior to hydrating the corn kemels whereby the co kemels are degerminated. Degerminating the com kemels before they are hydrated, allows for greater predictability and control over the amount of gelatinized starch in the completed masa flour product.
  • degermination is the separation of the horny endosperm from the remainder of each kernel of co , specifically the germ, floury endosperm, and hull. It is obvious, of course, that degermination reduces the size of the com kemels from whole kemels of com into homy endosperm or corn grit particles. It should be noted that it is easier to predict the rate at which smaller corn particles will rupture as compared to larger corn particles, either whole com kemels or com particles that have not been degerminated. Furthermore, smaller com particles rupture at a more consistent rate than larger com particles. Thus, it is harder to predict the rate at which large corn particles will rupture, and large particles rupture in a less controlled manner.
  • the com particles specifically the homy endosperm particles
  • gelatinized starch is spilled from the com particles into the masa flour mixture, with the gelatinized starch effecting the eventual cohesiveness of the dough made from the masa flour.
  • the present method uses com particles that are smaller than whole com kemels, or even some crushed com kemels, it has been observed that it is easier to predict when the smaller particles will rupture and thus it is easier to control the amount of gelatinized starch in the masa flour. Also, the fact that the smaller com particles rupture more consistently allows for greater control over the amount of gelatinized starch placed into the masa flour.
  • the degermination step prior to hydration is desirable because, in addition to reducing the size of com particles, the degermination step separates the ho y endosperm from the remainder of com kernel, especially the floury endosperm. It has been found that the starch in the floury endosperm when cooked gelatinizes almost instantly. It has further been found that if the starch from the floury endosperm continues to cook, it will over-gelatinize and make the masa flour too sticky for use in commercial food production.
  • the starch from the floury endosperm typically has already gelatinized and in fact will begin to over-gelatinize, thereby making the final masa flour potentially too sticky.
  • Degermination eliminates the floury endosperm and thus eliminates the starch contributed to the masa flour by the floury endosperm, which gelatinizes much faster than the starch from the homy endosperm. Further, it has been observed that it can predicted with a great deal of accuracy under known conditions when the homy endosperm particles will rupture.
  • the degermination step of the present process is advantageous, as only the horny endosperm is cooked resulting in heightened control over the amount of gelatinized starch placed in the masa flour, and thus more control over the stickiness, flavor, and texture of the dough made from the masa flour.
  • An additional finding is that the present method results in the ability of a user to predict with a great deal of accuracy how much gelatinized starch will be placed in the masa flour, as well as allowing the user to readily alter the amount of gelatinized starch to conform with certain process requirements.
  • Degermination also results in removal of the germ from the homy endosperm which is desirable because the germ causes the masa flour to turn rancid if the masa flour is stored for too long. If the germ is removed, then the masa flour will turn rancid at a much slower rate, thereby increasing the amount of time the masa flour produced according to the present process can be stored.
  • the degermination step allows the present method to produce a masa flour in a shorter period of time.
  • the homy endosperm becomes hydrated at a faster rate than traditional methods of hydrating whole kemels of com.
  • the hydration takes less time making the overall method of production of the masa flour faster.
  • masa flour without producing large amounts of contaminated waste water. It has been observed that the present method is advantageous because it requires a lesser amount of water to hydrate the degerminated com and that most of the water is absorbed, thereby creating less contaminated water. Consequently, degermination is an advantageous step in the commercial production of masa flour, as the degermination step results in a method for producing a masa flour that, has greater control over the placement of gelatinized starch in the masa flour, helps prevent rancidity, increases the production time speed, decreases the costs of production, and does not create large amounts of contaminated waste water.
  • the present method of producing a masa flour involves first degerminating kemels of corn so as to separate the horny endosperm portion of each kernel of co from the remainder of the kernel, the separated homy endosperm is also known as co grit; the com grit is then hydrated so as to raise the moisture level in the corn grit to an acceptable level for the present process and to form a hydrated com meal; the hydrated com meal is then cooked at a desirable temperature so as to rupture or partially rupture some of the com meal particles which will contribute gelatinized starch to the masa flour and allow for the formation of a dough; and, the cooked com meal is then dried so as to remove the majority of the moisture thereby forming the masa flour. It is important to note that the amount of gelatinized starch placed in the masa flour effects the texture, flavor, and stickiness of the dough made from the masa flour.
  • Additional steps may be taken, such as adding lime to the hydrated com meal which will enhance the flavor of the final masa flour and will assist in hydrating the com meal.
  • a standard meal derived from the floury endosperm, the hull or pericarp, and the germ portions may be added to the final masa flour composition so as to dilute any potentially damaged starch present in the dough formed from the masa flour.
  • the co grit may be ground before it is hydrated to form a com meal having different particle sizes. Ground com grit allows for even greater control over the amount of gelatinized starch placed in the masa flour.
  • a food product can be formed by eliminating the drying step and passing the cooked com meal directly into a food production process.
  • the present method allows the user to have a great deal of control over the temperature and residence time of the different stages in the production of the masa flour so that the production speed and flour characteristics can be readily controlled.
  • the present method results in a masa flour that produces a dough having desirable flavor, texture, and stickiness characteristics.
  • Fig. 1 is a schematic flow diagram of the preferred method for producing a masa flour from kemels of com.
  • Fig. 2 is a graph showing the different particle sizes and sifter screen sizes used in the production of a tortilla, a com chip, and a taco shell.
  • a method for producing a masa flour that may be used in the production of commercial food products such as soft com tortillas, corn chips, and taco shells, as well as other food products made from masa flour.
  • the process for making the masa flour includes, but is not limited to, the steps of degerminating kemels of com so as to separate the homy endosperm from each kernel of corn; grinding the homy endosperm to form a com meal; hydrating the com meal; cooking the hydrated com meal; and drying the cooked corn meal to form the masa flour.
  • the most preferred method of production of the masa flour is detailed in Figure 1.
  • the present method may be a continuous process or a batch process, however, the continuous process is preferred.
  • the present method is advantageous because it allows a user to easily control the temperature and residence time of the com, thereby allowing for better control over the characteristics of the masa flour, such as texture and stickiness. Thus, the characteristics of texture and stickiness can be altered to suit a customer's needs. Also, the present method can be readily implemented into an existing processing plant to produce a masa flour which has desirable dough formation qualities.
  • the process for making the masa flour is initiated by selecting a desired amount of com kemels, with the amount of the kemels used dependent upon the desired amount of masa flour. Because the process is preferably continuous, a large amount of com may be used, including at least up to 5000 pounds of degerminated com per hour.
  • the amount of com processed into masa flour according to the present method is controlled primarily by the size and speed of the equipment used, thus larger or faster machines can be used to process more kemels of com.
  • the com used in the present process may be selected from different varieties of corn including, but not limited to, yellow and white dent com, yellow and white semi-dent corn, flint corn, popcorn, indian com, and blue corn, as well as any other variety of corn that is acceptable for use in the masa flour.
  • the variety of com is degerminated using a standard degermination process so as to remove the endosperm portion from the remainder of each kemel of com, specifically the homy endosperm and floury endosperm are separated from the pericarp or hull, and germ.
  • the germ and hull are separated because they prevent the masa flour from forming a cohesive sticky dough, and the hull and germ can also increase the potential of the masa flour to turn rancid.
  • the homy endosperm is then separated from the floury endosperm.
  • the separated homy endosperm is also known as com grit.
  • each kemel of com includes, in addition to the homy endosperm, a floury endosperm portion, a germ portion, and a pericarp portion, with each portion separated from the remainder of the corn seed through a standard dry milling process.
  • the homy endosperm is used to make the masa flour because it contains starch, which is necessary in the formulation of an acceptable masa flour. When the starch is cooked it begins to gelatinize which makes it sticky. The gelatinized starch particles will stick to one another to form a cohesive dough made from the masa flour.
  • the starch is not cooked, it will not gelatinize so that when the masa flour is re-hydrated it will not absorb water properly and the gelatinized starch particles will not stick to one another, thereby preventing the formation of an acceptable dough.
  • the homy endosperm is used because it contains starch, which permits the formation of a dough for use in the manufacturing of consumer food products.
  • the floury endosperm, germ, and pericarp portions are separated from the homy endosperm they are ground, combined, sifted, and dried to form a standard meal, which may be added to the masa flour at a later point in the process.
  • the kemels can instead be ground and passed directly into the hydration stage without separation of the com kemel portions. But, it is preferred to separate and hydrate the homy endosperm.
  • the degerminated com can be used for other purposes, such as the production of animal feed and human food products.
  • the degermination of the corn kemels is, however, preferred in the present method, as it allows for the advantageous characteristics of the present method.
  • the homy endosperm or com grit is then ground into different particle sizes to form a degerminated corn meal.
  • a standard roller mill is preferably used to grind the corn grit into the corn meal, however, other devices such as a hammer mill or a disk mill may be used to grind the corn grit into corn meal. The particles may all be ground to the same size.
  • the com grit into a com meal consisting of different particle sizes ranging from between about 297 microns to about 1 191 microns, which means the particles are retained on a plurality of sieves having a mesh or screen profile between a US 50 mesh sieve and a US 16 mesh sieve.
  • a Smico-Norvell Sifter manufactured by Smico Manufacturing, Oklahoma City, Oklahoma, is used to separate the com meal particles.
  • Other particle sizes may be used dependent upon the conditions existing in the process and the desired characteristics of the masa flour.
  • the com meal particles after grinding may then be sifted, which separates the com meal particles according to their size.
  • the com meal particles are sifted and separated because this allows for greater control over the size of the particles utilized in the process, which in turn controls the amount of gelatinized starch in the masa flour. Grinding the com grit into com meal particles typically does not provide for enough control over the percentage of each particle size placed in the com meal mixture. Thus, separating the particles allows for exact percentages of the various particle sizes to be placed into a mixture and prevents undesirable particle sizes from being placed into a mixture. Also, in a standard processing plant com meal particles may be used for other purposes, thus sifting separates out the various particle sizes so that they can be used in any desired combination.
  • the particles can be ground and then immediately hydrated. Sifting is preferred, however, because it allows for more control over the percentage of each particle size added to a mixture, and thus more control over the amount of gelatinized starch in the masa flour.
  • the com meal is ground and then sifted so that the following particle size percentages are separated, and then mixed together to form a corn meal mixture that when processed results in a desirable masa flour.
  • the desirable distribution of corn meal particle sizes after grinding is as follows, approximately 1% by weight of the total corn meal particles will be retained on a sifter screen having 16 openings per inch, approximately 10% of the corn meal is retained on a sifter screen having 20 openings per inch, approximately 13% of the com meal is retained on a sifter screen having 25 openings per inch, approximately 23% of the com meal is retained on a sifter screen having 30 openings per inch, approximately 36% of the com meal is retained on a sifter screen having 40 openings per inch and approximately 1 1% of the corn meal is retained on a sifter screen having 50 openings per inch, with the remaining 6 % passing through the screen having 50 openings per inch which is known as pan.
  • the com meal may be ground differently so that the particle size percentages retained on each sifter screen will be different.
  • the above mentioned distribution of particle sizes is preferred because it allows for the formation of a masa flour having desirable texture, flavor, and gelatinization characteristics for tortilla chip manufacturing.
  • the particle size distribution is dependent primarily upon the desired final characteristics of the masa flour.
  • the co meal is hydrated to prepare the com meal for cooking. Hydration allows for faster cooking by increasing the surface area of the com meal particles. Greater surface area allows for more heat exchange between the corn meal and the object cooking the corn meal, thus increasing the rate at which the com meal is cooked. Also, hydration prevents the com meal from burning when cooked, as un-hydrated com meal will readily blister when exposed to the heat associated with the cooking stage of the present process. Thus, hydration is an important step used to prepare the com meal for cooking. The surface area of the com meal particles is increased because the com meal particles contain starch cells which when exposed to water swell, thereby causing the com meal particles to swell and expand their surface area.
  • the water passes through the com meal particle to the starch cells located inside the com meal, where the water is absorbed and the starch cells swell causing the size of the corn meal particles to expand. Furthermore, hydration causes the cell walls of the corn meal particles to weaken because of the swelling, which allows the com meal particles to more readily burst when heated. Finally, the water absorbed into com meal results in the com meal particles cooking from the inside out because the water within the com meal particles heats quickly and cooks the particles internally.
  • the mixing step involves placing the corn meal in a device that will thoroughly mix the corn meal and water, so that the surface of each com meal particle is coated with water.
  • the mixing step preferably uses a device known as a Turbulizer, manufactured by Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota, to mix the com meal water mixture.
  • the Bepex Turbulizer is a device that heats and mixes the com meal, water mixture allowing for the initiation of hydration.
  • Potable water is used to hydrate the com meal, with enough water added to raise the moisture level in the com meal so that the amount of water equals approximately 35% of the total weight of the corn meal before cooking.
  • the amount of water added varies with each specie of com as different seeds contain different amounts of water. However, in order to raise the moisture in the corn meal to a sufficient level, the amount of potable water added to the entire mixture is typically equal to about 38.5% by weight of the total corn meal.
  • the temperature of the water added to the com meal will preferably range between about 20°C and about 70°C, with the most preferred temperature being approximately 50°C.
  • calcium hydroxide or food grade lime may be added to the mixture of com meal and water.
  • the lime is optional, but is preferred as it has been found that the addition of the lime enhances the taste of the final food product made from the masa flour.
  • the lime aids in the hydration of the com meal by causing the corn meal to more readily absorb water.
  • Other bases or alkaline substances besides lime may be used that aid in hydration.
  • the lime is added in an amount equal to from about 0 to about 1% by weight of the total com meal, with the preferable amount added being about .1% by weight of the total com meal.
  • the bran contains hemi-cellulose, which is hard and not easily solubilized therefore the lime is useful because it allows the water to solubilize the bran. It is desirable to solubilize the bran because this causes the bran to breakup when cooked. If the bran is allowed to remain in an unsolublized form it can cause the masa flour to darken and prevents good dough formation.
  • the Turbulizer is the preferred device to be used in the hydration of the corn meal.
  • the Turbulizer is steam jacketed so that the mixture of com meal and water is heated to a desired temperature.
  • the jacket temperature of the Turbulizer generally ranges from about 35°C to about 100°C, with the most preferred jacket temperature being approximately 75°C.
  • Heating the com meal mixture is important because it speeds up and promotes the hydration of the co meal particles. Also, heating the mixture prepares it for cooking by raising the temperature close to the cooking temperature.
  • the Turbulizer has paddles that rotate between about 900 and 1000 revolutions per minute, with the preferred speed being approximately 1000 revolutions per minute, which results in a thorough mixing of the com meal, water, lime mixture.
  • the Turbulizer agitates the com meal, water, lime mixture to ensure that the com meal is coated with water and that the lime is dispersed.
  • the corn meal, water mixture is mixed in the Turbulizer for 10 to 15 seconds, however, other residence times may be used dependent upon the level of mixing required.
  • the corn meal has a temperature ranging between about 30°C and about 70°C, with the preferred temperature being approximately 50°C.
  • the hydration of the com meal is preferably completed in what is known as the resting stage.
  • the mixture of com meal and water is not mixed as vigorously as in the mixing stage, with the resting stage preferably occurring in an insulated screw conveyor or Thermoscrew.
  • Thermoscrew serves two pu ⁇ oses, to complete the hydration of the com meal and to act as a conveyor to transfer the corn meal from the mixing step to the next step in the process which is the cooking step.
  • the insulated screw conveyor called a Thermoscrew, is manufactured by Hosokawa Bepex Co ⁇ oration Minneapolis, Minnesota, and is preferred because it allows for a continuous process and maintains the heated condition of the com meal.
  • Any conveyor type device that is heated or insulated may be used as long as it allows for the completion of hydration, as well as the continuous passage of the com meal from the mixing step to the cooking step.
  • the Thermoscrew passes the com meal from the Turbulizer to the cooking device in approximately 15 minutes, however, the time may be altered dependent upon the level of hydration desired in the com meal and how hydrolyzed the com meal particles are when they leave the mixing step.
  • the starch granules in the com meal continue to swell as the water on the surface of the corn meal particles is absorbed into the starch cells.
  • Thermoscrew is insulated so that it maintains a temperature ranging between about 35°C and about 70°C, as can be expected other temperatures may be maintained dependent upon the conditions developed in the Turbulizer. It is preferable for the Thermoscrew to maintain a temperature of approximately 55°C.
  • the com meal is conveyed through the Thermoscrew, it preferably has a temperature of approximately 50°C, however, the com meal may have a temperature ranging between about 35°C and about 70°C. It is preferable to maintain the temperature of the com meal the same as when it exited the Turbulizer. Also, the hydration of the corn meal is completed upon passing through the resting stage resulting in the co meal having a moisture content equal to about 35% by weight of the total corn meal.
  • the com meal is then cooked so as to rupture or partially rupture the com meal particles and to alter the structure of the starch cells.
  • Cooking alters the structure of the exposed starch cells and the starch cells in the unruptured com meal particles so that when the masa flour containing the starch is later re-hydrated the starch will form a cohesive dough. More specifically, the cooking process causes the starch cells to gelatinize or at least partially gelatinize. However, drying breaks up the gelatinized starch cells that attached to one another during the cooking process. As discussed previously, cooking ruptures the com meal particles dependent upon their size and the length of time the particles are cooked, with the smaller particles rupturing or exploding first and the larger particles taking longer to rupture.
  • the ruptured or partially ruptured co meal particles release starch and protein into the co meal mixture so that the masa flour can be formed.
  • the gelatinized starch cells from the ruptured particles will bind to each other allowing a dough to be formed.
  • the amount of gelatinized starch is important because if not enough gelatinized starch is in the final masa flour, the dough will not congeal or be cohesive enough to form a dough to make com chips, soft corn tortillas, or any other product made from masa flour. Furthermore, if too much gelatinized starch is in the mixture it will be too sticky and unsuitable for present commercial food production.
  • the cooking stage is an important step because overcooking will cause the masa flour to have too much gelatinized starch for presently known pu ⁇ oses, for example 50% of the particles cooked will completely rupture. And undercooking, such as 10% of the particles completely rupture, will not allow for enough gelatinized starch, thereby affecting the dough qualities of the masa flour.
  • the percentage of ruptured com meal particles or homy endosperm particles is roughly equivalent to the amount of gelatinized starch placed in the masa flour. For example, if 25% of the total com meal particles rupture, then roughly 25% of the total starch cells will be gelatinized. Thus, the typically the amount of cells ruptured or partially ruptured equals the amount of gelatinized starch placed in the masa flour.
  • the preferred cooking method is a two part cooking process, with the first part involving the placement of the corn meal in a cooking vessel that initiates vigorous cooking and the second part involving placement in a resting stage where cooking is completed at a slower rate.
  • the first part of the cooking step it is desirable for the preferred method to use a cooking vessel that allows for easy control over the temperature. Also, it is preferable for a heat exchange to take place between the cooking vessel and the corn meal particles, thereby causing the com meal particles to cook from within.
  • the cooking vessel used is preferably a Solidaire cooker, manufactured by Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota which is preferable because it causes the water within the com meal particles to be heated and results in the com meal particles rupturing or partially rupturing.
  • the Solidaire cooker is also preferred because it provides for easy control over the temperature and the level of cooking of the com meal and it rotates or agitates the com meal to facilitate a heat transfer between the Solidaire cooker and the corn meal.
  • Other cooking vessels may be used as long as the corn meal is properly cooked.
  • the Solidaire cooking vessel is steam jacketed and has a rotor unit, which rotates a series of paddles at a speed between about 400 and 500 revolutions per minute, with preferred speed being approximately 480 revolutions per minute.
  • the paddles in the Solidaire wipe the hydrated com meal against the heated side walls, so that when the com meal contacts the heated side wall a heat transfer results thereby cooking the com meal.
  • the Solidaire cooker has a jacket temperature ranging between about 100°C and about 150°C, with the preferred jacket temperature being approximately 130°C. Also, the cooker maintains a humidity level of about 100% relative humidity so as to prevent the com meal from dehydrating during the cooking process. If the co meal dehydrates there is a chance that it will burn. The temperature and humidity results in the com meal having a temperature ranging between about 70°C and about 90°C, with the preferable temperature being approximately 80°C upon exiting the Solidaire.
  • corn meal may have other temperatures as long as sufficient cooking occurs and the corn meal is not burned.
  • the corn meal upon completion of the entire cooking process prefferably has a moisture level ranging between about 30% to about 40% of the total weight of the corn meal, with the preferred moisture level in the com meal being about 33% of the total weight of the corn meal.
  • the cooking time within the Solidaire cooker can vary dependent upon the temperature of the jacket and the level of agitation of the corn meal, as well as the particle size of the com meal.
  • the corn meal is in the Solidaire cooker for approximately 5 minutes which results in from about 20% to about 30% of the com meal particles completely rupturing, with the preferable amount of particles completely ruptured by completion of the entire cooking process being about 25% of the total com meal particles.
  • the com meal is then transferred to a second resting stage, which completes the desired gelatinization of the starch cells, as well as to allow some further rupturing of the com meal particles.
  • the lime is included, it is at this stage where the lime works to develop the flavor characteristics of the masa flour.
  • the resting stage is not required, but it is a preferred part of the cooking process. The resting stage is advantageous because it allows for better control over the level of cooking of the com meal and helps to prevent the corn meal particles from burning. Furthermore, the resting stage allows for slower cooking which is easier to control and monitor.
  • the second resting stage preferably uses a hot water jacketed Thermoscrew, manufactured by Hosokawa Bepex Corporation, Minneapolis, Minnesota to complete the cooking process of the com meal.
  • the Thermoscrew is preferable because it is heated and acts as a conveyor.
  • the temperature of the hot water jacketed Thermoscrew may range from about 55°C to about 95°C, with the preferred temperate being about 75°C.
  • the co meal remains in the resting stage or jacketed Thermoscrew for approximately 15 minutes, however, the time may be varied according to the condition of the com meal upon exiting the cooker and the conditions present in the thermoscrew.
  • the com meal it is desirable for the com meal to have a temperature of approximately 75°C, however, the temperature may vary between about 65°C and about 85°C.
  • the preferred amount of moisture in the com meal is approximately 32.5% by weight of the total corn meal, however, other moisture levels may be used. Again, as mentioned previously, approximately 25% of the total com meal particles will be completely ruptured.
  • the cooking of the com meal it is preferred for the cooking of the com meal to occur as a result of a two step process that alters the starch cells and ruptures some of the corn meal particles so that the masa flour will contain a desirable amount of gelatinized starch.
  • the corn meal is then dried to form the masa flour.
  • the corn meal may be dried in a number of ways as long as the moisture is adequately removed and the drying occurs at a quickened rate. Also, at this point the corn meal may be further broken up so that it can be more easily dried and so that the particles will be of an acceptable size for the masa flour.
  • the particle sizes for the masa flour tend to be smaller than the particle sizes for the corn meal. The reason the exact masa flour particle sizes are typically not used initially in the present process is because the particles will rupture too quickly when cooked and they are susceptible to over-cooking. Thus, it is preferred to further grind the corn meal upon completion of cooking.
  • the masa flour particle sizes may range between about 150 microns and about 1 191 microns. As can be seen in Fig. 2, the percentage of particle sizes used in the masa flour below 250 microns is significantly higher than the percentage used in the corn meal.
  • the preferred apparatus used for drying the cooked com meal is an MDH micron flash dryer, manufactured by Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota.
  • MDH flash dryer manufactured by Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota.
  • a hammer mill which breaks up agglomerates of the com meal, as well as reduces the particle size of the com meal. Breaking up the corn meal agglomerates allows for adequate drying and ensures that most of the moisture will be removed from the corn meal. As the com meal is broken up, the corn meal is then exposed to circulating hot air.
  • the MDH flash dryer exposes the com meal to air heated by a natural gas fired burner having a temperature ranging between about 175°C and about 400°C, with the preferred air temperature being about 360°C. It takes only a few seconds to dry the com meal to a desirable level, with the moisture level in the com meal being reduced from approximately 32.5% by weight of the total com meal to an amount ranging between about 6% and about 14% by weight of the total co meal, with the preferred moisture level being about 10% by weight of the total com meal. Also, the product will have a final temperature ranging between about 52°C and about 95°C, with the preferred temperature of the masa flour being about 75°C.
  • the MDH flash dryer includes a part known as a classifier that prevents clumps of com meal from exiting the flash dryer.
  • the classifier allows permissible masa flour particles to pass and redirects particles that are too large back to the hammer mill for further breakage and drying.
  • the rapid drying and removal of the moisture from the com meal is important as it prevents the retro-gradation of the starch granules. Preventing retro-gradation is important because it results in a high water abso ⁇ tion in the masa flour and allows for adequate formation of a dough. Retro-gradation is where the starch cells return to their original shape, thereby preventing the starch cells from absorbing as much water as starch cells that have not retro-graded.
  • the masa flour will absorb less water later when dough formation is initiated and the starch cells will not bind to one another, thereby preventing the masa flour from forming an acceptable dough.
  • the quick drying is important because it causes the starch particles to collapse rapidly, thereby preventing retro-gradation.
  • the masa flour may have the standard meal, previously mentioned above, added to enhance the flour and dough qualities. However, the addition of the standard meal is optional. If the standard meal is added, then the masa flour is passed into a mixer and preferably mixed with an amount of standard meal equal to approximately 10% by weight of the total masa flour. The standard meal, however, may be added in an amount equal to from about 0% to about 25% by weight of the total masa flour.
  • the standard meal is derived from the floury endosperm, the perica ⁇ , and the germ and has a moisture content equal to approximately 10% by weight of the total standard meal. Generally, the standard meal has a particle size of about 706 microns or less.
  • the standard meal is preferred because it introduces unprocessed natural starch into the masa flour, which enhances the quality of the finished masa flour by reducing potential starch damage and resulting stickiness.
  • the undamaged natural starch offsets the damaged starch and gives the dough desirable abso ⁇ tion characteristics, without making the dough too sticky.
  • the natural starch gives an appearance more like whole ground com which is desirable in some food products.
  • a final optional step is to pass the masa flour through a sifter. This provides another assurance that the particle size in the masa flour is what the user wants.
  • the masa flour, with or without the standard meal may be passed through a sifter, specifically a Great Western Tru-Balance Sifter, model 321, manufactured by Great Western Manufacturing Company, Leavenworth, Kansas, so that the masa flour has a distribution of particle sizes that conforms to a customer's needs.
  • the particle sizes are selected according to the characteristics that are desirable in the final product, which depend upon whether a tortilla chip, a soft tortilla or some other food product inco ⁇ orating masa flour is produced.
  • the particle size of the masa flour will range between about 150 microns and about 1 191 microns.
  • particles that are too small can be returned to the process or can be segregated and used for animal feed or other uses.
  • Particles that are oversized can be reduced in size by a reduction device such as a disk mill size reduction system and then returned to the sifter so that the particles may be used in the masa flour.
  • a reduction device such as a disk mill size reduction system
  • particles that cannot pass through a US wire 35 on a Great Western True Balance Sifter or particles that are 501 microns or larger are separated and passed through a disk mill so that the particles are of an appropriate size for the masa flour.
  • Emulsifiers may be added to the masa flour, as well as preservatives dependent upon what the end user desires in the masa flour.
  • the process is preferably continuous, with the speed of the process dependent, in part, upon the size of the equipment. As mentioned, the process may be altered slightly so that the com may be processed in a batch process.
  • the present method can process a variety of different pounds per hour, however, the preferred rate is 5000 pounds of degerminated com per hour. The process preferably takes approximately one half hour.
  • the process at a minimum includes degermination and preferably hydration and cooking. If an actual flour is produced drying must also be included. But, the process can be altered slightly so that after cooking the cooked com meal is directly processed into a food product such as a co chip. Thus, the process can be used in a food production plant where the co is processed and then immediately made into a food product.
  • Example 1
  • a masa flour used to form a dough for use in a food product such as a corn chip was made by initially degerminating 1000 pounds of yellow com kemels.
  • the com was degerminated by a Beall Degerminator, model # 2, manufactured by Beall Degerminator Co., Decatur, Illinois, wherein the hull or perica ⁇ and germ were removed from each kemel of com and left the ho y endosperm and the floury endosperm attached to each other.
  • the floury endosperm of each com kemel was then separated from the homy endosperm by the Beall Degerminator model #2, with the degerminated horny endosperm known as corn grit.
  • the Beall Degerminator is a standard dry milling processor known in the industry.
  • the com grit was then passed into a series of Buhler Roller Mills, model number MDDB, made by Buhler, Inc., Utzwil, Switzerland, where the com grit was ground into particle sizes ranging between about 297 microns and about 1 191 microns.
  • the ground corn grit is known as corn meal.
  • the ground corn meal then passed from the Buhler Roller Mills to a series of sifters made by Smico-Norvell, Oklahoma City, Oklahoma, where the com meal was sifted over sieves having various wire sizes which are listed below.
  • the sifters separated the com meal particles according to particle size.
  • the mesh size of the sieves, the percentage of particle sizes that were retained on each sifter, and the micron size of the particles that were retained by the sieves are listed below in the table.
  • the sieves are simply wire screens having different mesh sizes.
  • the pan was sent to another process and the remainder of the com meal particles were passed through a standard hopper and into a mixer.
  • the corn meal particles were mixed in a high speed, heated, continuous mixer known as a Turbulizer, model TJS-14, manufactured by Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota.
  • Water was added into the Turbulizer to mix with the com meal, with the amount of water added equaling 385 pounds or approximately 38.5% by weight of the total com meal.
  • the water had a temperature of 50°C.
  • an amount of lime was added to the mixture with the amount of lime equal to one pound, which was equal to .1% by weight of the total weight of the com meal.
  • the Turbulizer was steam jacketed and had a temperature of 75°C, so that the temperature of the co meal, water, lime mixture was maintained at a temperature of 50°C.
  • the Turbulizer mixed the corn meal, water, lime mixture at 1000 revolutions per minute for 15 seconds, to create an even dispersal of the constituents added to the Turbulizer.
  • Thermoscrew made by the Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota, that was 22 feet long, 18 inches in diameter and controlled by a variable speed drive.
  • the Thermoscrew allowed for the completion of hydration of the corn meal.
  • the speed of the conveyor in the Thermoscrew was such that the corn meal, water, lime mixture passed through the Thermoscrew in 15 minutes.
  • the Thermoscrew was insulated and maintained the com meal water mixture at a temperature of 50°C, with the com meal absorbing all of the water for a final moisture content equal to about 35% of the total weight of the corn meal.
  • the hydrated com meal particles then were passed from the Thermoscrew into a Solidaire cooker, model SJS-36-20, manufactured by Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota, which is a high heat transfer, high agitation cooking device.
  • the Solidaire cooker had a relative humidity of 100% inside the cooker which prevented the hydrated com meal from drying out and burning.
  • the Solidaire cooker was steam jacketed and had a temperature of 130°C that heated the hydrated com meal to a temperature of 80°C.
  • the cooker rotated a plurality of paddles at 480 revolutions per minute, which wiped the com meal against the walls of the cooker.
  • the com meal was in the Solidaire cooker for 5 minutes.
  • the 80°C temperature of the corn meal initiated the cooking of the com meal.
  • the Solidaire cooker agitated the hydrated com particles which allowed the hydrated com meal particles to contact the vessel wall of the Solidaire, thereby allowing a heat exchange to occur between the hydrated com meal particles and the vessel wall.
  • the heat exchange caused some of the com meal particles to rupture and other com meal particles to partially rupture, with the rupturing dependent on the size of com meal particles and the time in the Solidaire cooker.
  • the com then passed from the Solidaire cooker into a hot water jacketed Thermoscrew, manufactured by Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota, having a temperature of 75°C and 100% relative humidity, which maintained the cooked hydrated com meal at a temperature of 75°C.
  • the hot water jacketed Thermoscrew was 33 feet long with a 24 inch diameter and controlled by a variable speed drive.
  • the cooked com meal was in the hot water jacketed Thermoscrew for 15 minutes
  • the hot water jacketed Thermoscrew allowed the cooking process to continue at a slower pace than the rate of cooking in the Solidaire cooker, with the Thermoscrew completing the cooking of the hydrated corn.
  • the corn meal exited the Thermoscrew having a temperature of 75°C and a moisture level equal to 32.5% of the total weight of the com meal.
  • the com was then placed into a flash dryer, model MDH-4, made by Hosokawa Bepex Co ⁇ oration, Minneapolis, Minnesota, which had an inlet air temperature of 650°F.
  • the air was heated by a gas fired furnace so that the air was passed through the gas fire and was heated to 650°F.
  • the MDH flash dryer additionally had a hammer mill which was used to break apart clumps of co that had coagulated or stuck together and also to further reduce the particle size of the com meal.
  • the com and hot air passed through the hammer mill first, which turned at a speed of 3940 revolutions per minute and then into the dryer air stream.
  • the MDH flash dryer flashed most of the moisture out of the corn particles in one to two seconds.
  • the dried com meal is known as a masa flour.
  • the masa flour had a particle size wherein 5% of the total masa flour particles were equal to or greater than 420 microns, 38% of the total masa flour particles were between 419 microns and equal to or greater than 250 microns, 23% of the total masa flour particles were between 249 microns and 150 microns, and 34% of the total com meal particles had particle sizes less than 150 microns.
  • the masa flour then passed into a continuous mixer where 100 pounds of standard meal having a moisture content equal to about 10% by weight of the total standard meal and a particle size of 706 microns or less was mixed in with the masa flour.
  • the mixer was a standard mixer used in the industry.
  • the standard meal was derived from the germ portions, the floury endosperm portions, and the perica ⁇ portions of the kemels of com that were initially degerminated.
  • the standard meal was added to the masa flour in an amount equal to 10% by weight of the total degerminated com grit initially used.
  • the masa flour was then sifted through a Great Western Tru-balance sifter, model 321, manufactured by Great Western Manufacturing Co., Leavenworth, Kansas, having a wire size of 35 openings per inch.
  • the masa flour was sifted to ensure that the particle sizes listed above were present. Any particles retained by the sifter were then passed into a United Milling Systems disk mill, model MHA-600H/M, manufactured by United Milling Systems A/S, Copenhagen, Denmark, to reduce the size of the masa flour particles.
  • the masa flour particles were then passed into the masa flour mix to again be sifted. After being sifted the masa flour was then packaged and ready to be made into a com chip. The total process time was approximately one half hour.
  • Example 2 The total process time was approximately one half hour.

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Abstract

L'invention concerne un procédé pour produire une farine pour masa ou une farine de maïs à partir des grains de maïs dégermés. De préférence, le procédé fait appel à un dégermage de grains de maïs visant à séparer l'endosperme corné du reste du grain de maïs. Ensuite, l'endosperme corné est hydraté de manière à ce que la quantité d'eau absorbée soit entre environ 32 % et environ 42 % en poids de l'endosperme corné total. Après l'hydratation, les particules d'endosperme corné sont cuites, ce qui aboutit à la rupture de certaines des particules de l'endosperme corné et à la gélatinisation de certaines des particules d'amidon contenues dans les particules d'endosperme corné. Après la cuisson, les particules d'endosperme corné sont rapidement séchées pour former la farine pour masa. La farine pour masa, produite par ce procédé, peut être utilisée pour l'obtention de produits alimentaires tels que les tortillas de maïs, les enveloppes des tacos et des chips de maïs.
PCT/US1997/002474 1996-02-20 1997-02-18 Procede pour produire une farine pour masa WO1997029647A1 (fr)

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US08/603,276 1996-02-20

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Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2773304A1 (fr) * 1998-01-08 1999-07-09 Ulice Sa Procede de preparation d'une farine masa, farine masa et ses applications
EP0948904A1 (fr) * 1998-04-10 1999-10-13 Ulice S.A. Procédé d'obtention d'ingrédients fonctionnels à partir de farine de mais cireux, ingrédients obtenus et leurs applications
WO2000010407A1 (fr) * 1998-08-20 2000-03-02 Cargill, Incorporated Procede de fabrication de farine masa
US6033709A (en) * 1998-08-20 2000-03-07 Cargill, Incorporated Process for the production of partially gelatinized rice flour
US6056990A (en) * 1997-05-15 2000-05-02 Cargill, Incorporated Milled cereal by-product which is an additive for flour and dough
US6383547B1 (en) 1998-05-12 2002-05-07 Cargill, Incorporated Process for preparing aspirated bran as a flour additive
US6610349B1 (en) 1998-05-15 2003-08-26 Cargill, Incorporated Milled cereal by-product which is an additive for increasing total dietary fiber
EP1142488A3 (fr) * 2000-04-03 2004-02-04 Bonomelli S.R.L. Procédé de fabrication de farine de mais précuite
WO2005094612A1 (fr) * 2004-03-23 2005-10-13 The Procter & Gamble Company Melange de mais non gonfle et article a commercialiser
US7220443B2 (en) 2005-02-10 2007-05-22 Sabritas, S. De R.L. De C.V. Method for making instant masa
US8110239B2 (en) 2008-05-22 2012-02-07 Sabritas, S. De R.L. De C.V. Quick corn nixtamalization process
CN104824556A (zh) * 2015-04-16 2015-08-12 辽宁曙光食品有限公司 一种玉米方便面条

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Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6056990A (en) * 1997-05-15 2000-05-02 Cargill, Incorporated Milled cereal by-product which is an additive for flour and dough
EP0928563A1 (fr) * 1998-01-08 1999-07-14 Ulice Procédé de préparation d'une farine Masa, farine Masa et ses applications
FR2773304A1 (fr) * 1998-01-08 1999-07-09 Ulice Sa Procede de preparation d'une farine masa, farine masa et ses applications
EP0948904A1 (fr) * 1998-04-10 1999-10-13 Ulice S.A. Procédé d'obtention d'ingrédients fonctionnels à partir de farine de mais cireux, ingrédients obtenus et leurs applications
FR2777160A1 (fr) * 1998-04-10 1999-10-15 Ulice Procede d'obtention d'ingredients hautement fonctionnels, ingredients ainsi obtenus et leurs applications
US6383547B1 (en) 1998-05-12 2002-05-07 Cargill, Incorporated Process for preparing aspirated bran as a flour additive
US6610349B1 (en) 1998-05-15 2003-08-26 Cargill, Incorporated Milled cereal by-product which is an additive for increasing total dietary fiber
WO2000010407A1 (fr) * 1998-08-20 2000-03-02 Cargill, Incorporated Procede de fabrication de farine masa
US6068873A (en) * 1998-08-20 2000-05-30 Cargill, Incorporated Process for the production of masa flour
US6033709A (en) * 1998-08-20 2000-03-07 Cargill, Incorporated Process for the production of partially gelatinized rice flour
EP1142488A3 (fr) * 2000-04-03 2004-02-04 Bonomelli S.R.L. Procédé de fabrication de farine de mais précuite
WO2005094612A1 (fr) * 2004-03-23 2005-10-13 The Procter & Gamble Company Melange de mais non gonfle et article a commercialiser
AU2005228172B2 (en) * 2004-03-23 2008-05-29 The Procter & Gamble Company Non-steeped corn blend and article of commerce
US7220443B2 (en) 2005-02-10 2007-05-22 Sabritas, S. De R.L. De C.V. Method for making instant masa
US7939121B2 (en) 2005-02-10 2011-05-10 Sabritas, S. De R.L. De C.V. Instant masa
US8110239B2 (en) 2008-05-22 2012-02-07 Sabritas, S. De R.L. De C.V. Quick corn nixtamalization process
CN104824556A (zh) * 2015-04-16 2015-08-12 辽宁曙光食品有限公司 一种玉米方便面条
CN104824556B (zh) * 2015-04-16 2017-08-22 辽宁曙光食品有限公司 一种玉米方便面条

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