WO2003011052A1 - Procede pour traiter du grain entier et produits correspondants - Google Patents

Procede pour traiter du grain entier et produits correspondants Download PDF

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Publication number
WO2003011052A1
WO2003011052A1 PCT/US2001/024161 US0124161W WO03011052A1 WO 2003011052 A1 WO2003011052 A1 WO 2003011052A1 US 0124161 W US0124161 W US 0124161W WO 03011052 A1 WO03011052 A1 WO 03011052A1
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WIPO (PCT)
Prior art keywords
grains
grain
product
kernels
minutes
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PCT/US2001/024161
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English (en)
Inventor
Joseph R. Fox
Original Assignee
Fox Joseph R
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Priority to PCT/US2001/024161 priority Critical patent/WO2003011052A1/fr
Publication of WO2003011052A1 publication Critical patent/WO2003011052A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/02—Products made from whole meal; Products containing bran or rough-ground grain
    • 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
    • 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
    • A23L7/126—Snacks or the like obtained by binding, shaping or compacting together cereal grains or cereal pieces, e.g. cereal bars
    • 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
    • A23L7/196—Products in which the original granular shape is maintained, e.g. parboiled rice
    • 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 a novel process for preparing a food product suitable for human consumption from whole grains.
  • the food product may comprise a single grain or a blend of whole grains.
  • the grains may be whole kernel or milled.
  • the primary source of complex carbohydrates for populations of the earth is from grains. World coarse grain consumption is predicted to increase by 1.5% annually during the next 10 years to reach 980.5 million tons, according to the latest demand forecast issued by the U.S. Feed Grains Council on February 4, 1997. While there are other important starchy carbohydrate sources, such as potatoes, cassava, and sweet potatoes, grains are pre-eminent in providing starchy carbohydrate energy for the world's population. One reason is that grains are harvested in a naturally dry state and hence are relatively non-perishable. By contrast, potatoes, cassava, and sweet potatoes, for example, are harvested at an elevated moisture content and because of this they have a shorter storage life in their harvested state.
  • Dietary fiber consists of insoluble and soluble fiber.
  • Insoluble fiber is indigestible by monogastric mammals, such as human beings. It binds a modest amount of water and is found in the hulls and bran layers of cereal, waxy hull-less barleys, and vegetable stems. The consumption of insoluble fiber has been correlated with reduced incidence of colon cancer, hemorrhoids, and other maladies.
  • Soluble fiber differs from insoluble fiber in that it binds large amounts of water to form thick solids and gels.
  • Soluble fiber is an important component of edible fruits (pectin), cereal grains such as waxy hull-less barley, oats (beta- glucan), and psyllium.
  • Other source of soluble fiber include hydrocolloids such as carrageenan and alginates found in seaweed, xanthan prepared by fermentation of microorganisms, and some seeds, such as guar. Numerous diet studies have shown that soluble fiber provides satiety (reduces food consumption), reduces blood cholesterol, and reduces the rate of intestinal absorption of glucose.
  • U.S. Patent No. 2,930,697 issued to Miller relates to a method of processing wheat wherein the bran coat of the wheat is compressed to crack it open and expose the starch mass of the grain. However, considerable nutrients are lost from the grain during the cracking and cooking process.
  • Another method for shortening the cooking time of grains is to chemically treat the grains.
  • One such method is described in U.S. Pat. No. 3,190,754 issued to Mathews wherein wheat is treated with alkaline agents, such as sodium hydroxide (lye) and ammonia, then further treated with a dilute acidic agent and dried.
  • alkaline agents such as sodium hydroxide (lye) and ammonia
  • these chemicals are caustic to work with and, since the chemicals penetrate the grain, can give the grain an undesirable flavor or, in some instances, may even be harmful to the consumer.
  • U.S. Pat. No. 5,464,647 issued to Messick describes a method of manufacturing a quick cooking barley product. Even after this processing, however, the Messick barley product still requires at least five minutes to rehydrate the product, followed by a standing time of at least five minutes. Further, Messick does not contemplate the processing of other grains other than barley, or a mixture of grains.
  • the present invention has as its primary object the production of whole grain, quick cooking blends which may be rehydrated and/or cooked in a few minutes, providing a whole grain food which may be consumed as-is, or may be incorporated into other food products when whole grain identity is desired.
  • a further object of the present invention is the production of a grain product which retains a majority of its original nutrients.
  • a further object of the present invention is the production of a grain product which utilizes only water, grain and heat as its inputs, thereby eliminating the introduction of potentially harmful chemicals or chemical reactions within the product.
  • a further object of the present invention is the production of a grain product which has been cooked and frozen and may be consumed in its hydrated state after thawing and/or heating.
  • a further object of the present invention is the production of a grain product which has been cooked and dried that may be consumed in its dry state as a snack or a dry cereal.
  • a further object of the present invention is the production of a cooked and dried grain product which may be cut, milled, or ground into meal, flakes, granules, or powder for use in other products.
  • a further object of the present invention is the production of a grain product which is uniform in consistency. Yet a further object of the present invention is the production of grain products comprised of compressed multiple whole grains which provide superior nutritional and functional properties.
  • Still a further object of the present invention is the production of a grain product comprised of waxy hull-less barley having large amounts of dietary fiber.
  • the present invention relates to a novel processing method for grains and multi-grain mixtures.
  • the process of the invention first includes the step of cooking grains to achieve a moisture content of from 40-80%.
  • the grains are cooked in water preheated to a temperature of from about 80°C to about 150°C.
  • this cooking step is conducted for about 5-45 minutes and for hard grains this step is conducted for about 5-90 minutes.
  • the ratio of grain to water is from about 1:2 to about 1:10, with a preferred ratio of about 1:4.
  • the cooked grain product is then rinsed with cool water to halt the cooking process and to remove excess starch.
  • the grains are then either dried or optionally flash frozen at a temperature of from about -18°C to -30°C to form a free- flowing grain product.
  • the resulting grain product may be thawed or rehydrated using conventional methods, utilized as a ready-to-eat snack or cereal, or further processed for use as an ingredient in other food products.
  • the individual grain components in the product retain their flavor, color, and nutrients during the treatment process.
  • the present invention also relates to a novel processing method for waxy hull-less barley.
  • the waxy hull-less barley is first hydrated to a moisture content of between about 50-75% in water preheated to a temperature of from about 75°C to about 150°C. This cooking step is conducted for a time period of between about 15-120 minutes, with about 50-65 minutes being preferred.
  • the cooked barley is then rapidly cooled to a temperature of less than about 60°C to halt the cooking process. Following the cooling step, the cooked barley is dried to a moisture level of between about 6-12 percent.
  • the resulting grain products of this invention may be thawed or rehydrated using conventional methods, utilized as a ready-to-eat snack or cereal, or further processed for use as an ingredient in other food products.
  • the individual grain components in the product retain their flavor, color, and nutrients during the treatment process.
  • the present invention further relates to the manufacture of food products derived from the resulting grain product.
  • the food products include whole grain or milled grain fractions for structure in combination with a very fine milled grain fraction which serves as a binder to provide superior nutritional and functional properties.
  • the present invention describes a novel method of processing grains which can be performed on nearly all types and classes of grains, including wheat (all varieties), durum wheat, conventional barley (all varieties), waxy barley (all varieties), oats, rye, triticale, rice (all varieties), corn, buckwheat, millet, amaranth, quinoa, spelt, kamut, durum, flax, wild rice, and sorghum.
  • the whole grains are first cleaned and sized according to standard procedures. Foreign matter, shriveled and broken grains are discarded. The whole grains are then weighed and blended as per specific formulas which yield the desired flavor, texture, and appearance characteristics.
  • the cooking times for soft grains such as once pearled barley, brown rice, and whole oat groats, are shorter than that of hard grains, such as black barley, wheat, rye, and triticale, the grains can be divided for staggered timed processing.
  • the grains are first cooked to fully hydrate the grains and to gelatinize the starches within the grains. It is preferred, but not required, that the starches are cooked until they are fully gelatinized.
  • the whole grains are heated in water at a ratio of from 2:1 to 10:1 water to grain by weight.
  • the preferred ratio of water to grain is from 3:1 to 5:1 and the most preferred ratio is about 4:1 water to grain. Ratios of grain to water higher than 1:4 are less preferred due to increased levels of starch in the water during processing which, while not affecting the quality of the final product, complicate the cooling and rinsing step.
  • the water temperature for the cooking step can range from about 80°C to about 150°C, with a preferred temperature of about 88-122°C and a most preferred temperature of about 90-105°C. The water is heated to the requisite temperature prior to adding the grain.
  • the grains are cooked under a pressure of one to three atmospheres until the moisture content of the grain is from 40-80%.
  • the cooking time to achieve this moisture level is from 5 to 90 minutes, depending on the type of grains being cooked and the temperature of the cooking water. For instance, if the grains are soft, the cooking time will be from 5-45 minutes with a preferred time of 15-35 minutes and a most preferred time of about 25 minutes.
  • the resulting moisture content of the soft grains will be from 40-80%.
  • Soft grains include but are not limited to pearled barley, brown rice, and whole oat groats. If the grains are hard, the cooking time will be longer due to the intrinsic hardness and particular composition of the grains.
  • the cooking time for hard grains will range from 5-90 minutes with a preferred time of 60-70 minutes and a most preferred time of about 65 minutes.
  • the resulting moisture content of the hard grains will be from 60-80%.
  • Hard grains include but are not limited to triticale, rye, and wheat.
  • the cooking time of black barley falls somewhere in between the cooking times for soft and hard grains and can range from 45-65 minutes.
  • the hard grains can be cooked for a predetermined length of time and the soft grains added later so that all of the grains finish cooking at the same time. For example, once the hard grains have cooked for about 40 minutes, the soft grains can be added and the entire mixture cooked together for an additional 25 minutes. Overall, the cooking of the whole grain product ranges in conditions from single atmospheric aqueous cooking at 80°C for 90 minutes to high pressure up to 3 atmospheres cooking up to 150°C for 5 minutes.
  • the invention allows for preblended subsets of whole grain blends to be processed together in a single cooking vessel.
  • Hard composition grain blends may be cooked for longer time periods than softer composition grain blends.
  • the processing method of this invention has the advantage of not requiring the use of chemicals or additives as described in U.S. Pat. No. 3,190,754 issued to Mathews wherein wheat is treated with alkaline agents, such as sodium hydroxide (lye) and ammonia, then further treated with a dilute acidic agent. Instead, Applicant's processing method cooks the grains to the desired texture without the need for such caustic chemicals. "Substantially free of chemicals" is herein defined as meaning that Applicant's processing method is operative in the absence of a caustic amount of chemicals.
  • the whole grain blend is cooked, it is then rinsed with water having a temperature of less than 20°C (room temperature). Sufficient rinsing should occur so that excess starch is removed from the cooked whole grains and the internal temperature of the cooked whole grains is reduced to less than 60°C.
  • the rinsed and cooked whole grain blend is drained of excess water.
  • the drained whole grain blend becomes free flowing when excess water is removed.
  • the free flowing, preferably completely gelatinized (fully cooked), whole grains are then either dried or flash frozen. If the grains are dried, they should be dried until the moisture level of the dried grains is 12% or less by weight.
  • a convenient means of doing this is through the use of a high air velocity drier.
  • the air inlet temperature of the drier is between 135°C and 235°C, with a preferred temperature of between 185°C and 205°C, and the outlet temperature of the drier is between 70°C and 120°C, with a preferred temperature of between 90°C and 100°C.
  • the drying time is between 5 and 20 minutes, depending on the temperature of the air, i.e. hotter air drying temperatures will require less time drying.
  • Other standard means for drying the grains can also be used, so long as the requisite moisture level is attained.
  • the grains can be flash frozen and stored at a temperature of between -18°C to -30°C, with a preferred temperature of about - 24°C.
  • This step can be performed merely by placing the packaged grain in a storage area having this temperature or can be performed using carbon dioxide, nitrogen immersion, or blast freezing.
  • the final, completely gelatinized, grain product is free flowing and has a moisture content of from 40-80%.
  • the frozen grain product can be thawed by conventional means. If heated in a microwave, the product need only be heated for about 1-7 minutes, with 1-3 minutes usually being sufficient. The thawed product may then be consumed directly or used in various other ways by the consumer.
  • the gelatinized, dried grain product may be prepared for direct consumption by heating in water or milk.
  • the dried grain product should be heated for about 1-7 minutes.
  • the gelatinized dried grain product can also be milled or further processed and added as an ingredient to other food products.
  • the milled grain products may be rehydrated by adding half to two and one-half parts water to one part grain and allowing the grain to absorb the water.
  • the rehydration process may be expedited by placing the grain/water mixture in the microwave for up to 4 minutes or otherwise heating in water. Usually, about 2 minutes is sufficient, depending on the type of microwave. Since different grains mill differently depending upon the degree of gelatinization and moisture level in the grain at the time of milling, this rehydration time will vary somewhat. For instance, if the very finely milled grain particles will be instantly rehydrated upon the addition of water.
  • the finer milled fragments will rehydrate instantly by just adding water, milk or other liquid of the consumer's choice.
  • This product may be consumed as a breakfast cereal or included in various beverages as a convenient means for consumers to add fiber to their diets. For instance, the product may be added to malts, shakes, milk, water, fruit juices, soda, and other beverages.
  • the present invention also relates to the processing of waxy hull-less barley.
  • Waxy hull-less barley is a preferred grain for use in this invention due to its high percentage of dietary fiber. Further, waxy hull-less barley is remarkably free of the "sliminess" that normally accompanies other high soluble fiber foods, such as oats.
  • waxy hull-less barley has a bland taste, and is therefore suited for inclusion in many types of foods, including hot and cold cereal, ground beef, dough-based bakery products, and high fiber drinks. It is also suitable for consumption by itself, for instance, as a replacement for rice, potato, and/or pasta in side dishes.
  • waxy hull-less barley also provides improved texture.
  • waxy hull-less barley is first hydrated to a moisture level of between about 57-65% by cooking the barley in water having a temperature of between about 75-150°C so that the starch is substantially gelatinized.
  • the preferred cooking temperature is between about 75-100°C, with a preferred hydration level of between about 57- 63%.
  • Typical hydration times are between about 15-120 minutes, with about 50-65 minutes being preferred.
  • the ratio of water to waxy hull-less barley during the hydration step ranges from about 2:1 to about 10:1.
  • the waxy hull-less barley kernel Prior to hydration, the waxy hull-less barley kernel is preferably cracked into coarse pieces in order to increase the surface area of barley exposed to the water.
  • the cooked waxy hull-less barley is rapidly cooled to an internal temperature of less than 60°C in order to halt the cooking process.
  • the cooling step is preferably performed in less than about five minutes.
  • the waxy hull-less barley is next dried or flash-frozen as described above to a moisture level of less than about 14% by weight, with about 6-12% moisture level being preferred.
  • the drying process may be performed using conventional methods, such as air-drying, spray drying, etc.
  • the barley is preferably dried at a temperature ranging between about 150-225°C, with about 190-215°C being preferred, and about 190-205°C being most preferred.
  • the barley is dried/toasted in two stages which improves the taste and flavor of the barley: first at a temperature range of about 150-175°C for 3-5 minutes, then for 2-4 minutes at 190-225°C. Further, it is preferred that the barley kernels are dried in a manner such that the kernels are rendered slightly porous to rehydrate more quickly. This can be accomplished by drying the kernels individually, in small clumps, or as a substantial monolayer or by suspending the kernels with moving dry air. These processes are all effective in forming small voids and/or crevices in the kernels which provide greater surface area for the water to contact the kernels and rehydrate them more quickly.
  • the waxy hull-less barley product made in accordance with this invention may be rehydrated and prepared for consumption in the manner already outlined above. It may be incorporated into the various foods described above or served alone, with or without additives such as salts, sweeteners, flavorings, colorings, nutrients, agglomerating agents, surfactants (food emulsifiers), minerals, and/or combinations thereof.
  • the frozen grain product or dried milled grain product of this invention is ready for consumption in a substantially shorter amount of time than conventional processed grains.
  • Messick U.S. Pat. No. 5,464,467
  • Applicant's invention requires his processed grains to be cooked for at least five minutes and to stand at least another five minutes prior to consumption, for a total preparation time of at least ten minutes.
  • Applicant's invention requires no standing time, and is ready for direct consumption by the consumer with seven minutes or less of preparation time, with the milled grain product being ready in four minutes or less.
  • the dried grain product can then be milled or further processed and added as an ingredient to other food products if desired.
  • the grains may be further processed by any of the methods including, but not limited to, sizing, cooking, drying, milling, screening, blending, by-product extended milling, and recombinant blending of granulated sizes of various grains.
  • the grain product is milled, then sieved to produce milled grain of various particle sizes.
  • Whole grains are crushed in a mill to produce cut grain fragments and fines.
  • the grain fragments and fines are separated by employing sieves having 12 openings per linear inch (U.S. Standard No. 12) and greater, but less than 100 openings per linear inch (U.S. Standard No. 100).
  • Milled fragments that do not pass through the selected sieve comprise the coarse fraction, with the smaller fragments and fines that will pass through the sieve comprising the fine fraction.
  • the fine fraction preferably comprises grain fragments that will pass through a sieve having 16 openings per linear inch, but not a sieve having greater than 26 openings per linear inch.
  • the fine fraction is next preferably passed through conventional roller mills and/or ball mills to further decrease the particle size of the grains. Particles that pass through a sieve having > 100 openings per linear inch comprise the very fine fraction.
  • the very fine fraction is preferably capable of passing through a sieve having > 200 openings per linear inch.
  • the present inventor has now discovered that new food products can be manufactured using the very fine fraction in combination with whole grains, coarse fraction, and/or fine fraction of grains.
  • the very fine fraction serves as a binder in the food product, while the larger fractions provide structure.
  • the food product can essentially bind itself, without the need for additional binders, such as gums and other binders typically used in the food industry.
  • the milling procedure exposes the starchy components of the grain that are sticky and provide adhering properties to the product. Small amounts of water may be included in the grain product to provide increased adherency .
  • insoluble fiber Two types of dietary fiber, soluble and insoluble, are necessary in correct nutrition.
  • the particle size of insoluble fiber also plays an important role in nutrition. The smaller the particle size, the greater the surface area and exposure of the fiber to components in the digestive tract and, thus, the greater the ability of the fiber to bind cholesterol and other undesirable chemical and biological products.
  • fiber having a larger particle size provides more of a cleansing action to assist in the control and prevention of diverticulitis and other diseases of the digestive tract.
  • Some types of grains having more insoluble fiber, while others have a higher level of soluble fiber. Certain types of grain have a greater amount of beta-glucan soluble fiber to assist in cholesterol reduction, benefit the immune system, and provide other digestive benefits.
  • the product may be manufactured to exclude certain grains that consumers may be allergic to, or formulated to include grains that add particular flavors, textures, and/or nutrients to the product.
  • the food products of this invention include one or more components of whole grain, coarse fraction, and/or fine fraction in combination with the very fine fraction.
  • the very fine fraction should constitute at least 0.05% by weight of the food product to provide sufficient binding of the ingredients therein. From about 1% to 25% by weight very fine fraction is preferred.
  • the grains used in the food product may be of the same type or a mixture of various types of grain. In certain types of products manufactured in accordance with this invention, such as yogurt, milk, malts, nutritional supplements (i.e. Ensure®), higher concentrations of very fine fraction is preferred. In contrast, in such products as cereals and granola bars a lower percent of fine fraction would be preferred.
  • Various types of food products may be manufactured using Applicant's processed grain.
  • the grain component may constitute up to 100% of the food or drink product.
  • the products may also include up to 50% by weight of supplemental ingredients which will vary greatly depending upon the type of food or drink product, and individual tastes of the consumer. These supplemental ingredients are added to Applicant's grain food or drink product in amounts typically included in other such products in the market, and include flavorings, coloring agents, texturizing agents, fillers, vitamins, minerals, carbohydrates, and other agents to increase the nutritional value of the food or drink.
  • Pilafs are used as side dish in the U.S. and as a staple in Middle
  • Pilafs can be made from thawed, frozen whole kernel grains or rehydrated, dried whole kernel grains. Further, pilafs can also be made from dried, milled grain that does not pass through a sieve having from 12 to 20 openings per linear inch in combination with very fine milled grain for binding purposes. The very fine milled grain has a particle size such that it is capable of passing through a sieve having at least 100 openings per linear inch, and preferably 200 openings per linear inch or less. Pilafs may be enhanced with supplemental ingredients that contribute flavor, color, nutrition, texture, and eye appeal. These ingredients may comprise from about 1% to 25% by weight of the pilaf.
  • Toppings are used to enhance the flavor, texture, and appearance of foods ranging from salads, to pastas, to ice cream. Their flavor ranges from sweet to savory depending upon the type of supplemental ingredients included.
  • Toppings can be made from dried, milled grain that does not pass through a sieve having from 12 to 20 openings per linear inch in combination with very fine milled grain for binding purposes.
  • the very fine milled grain has a particle size such that it is capable of passing through a sieve having at least 100 openings per linear inch, and preferably 200 openings per linear inch or less.
  • Toppings may be enhanced with other components that contribute flavor, color, nutrition, texture, and eye appeal, which may comprise from about 1% to 25% by weight of the toppings.
  • Bars are a convenient means for providing energy and/or nutrient-dense foods. Bars are the ideal handheld food. They are further shelf-stable, easy to store and carry, and appealing to persons of all ages. Bars can be made from a combination of particle sizes ranging from whole kernel grains to particles small enough to pass through a U.S. No. 200 sieve. Bars are preferably made from dried, milled grain that does not pass through a sieve having from 12 to 20 openings per linear inch in combination with very fine milled grain for binding purposes. The very fine milled grain has a particle size such that it is capable of passing through a sieve having at least 100 openings per linear inch, and preferably 200 openings per linear inch or less. Bars may be enhanced with supplemental ingredients that contribute agglomeration, flavor, color, nutrition, texture, and eye appeal, which may comprise up to 50% by weight of the bars.
  • Cookies are another convenient, popular food, similar to bars, and generally consist of grain products that carry flavor or texture-contributing components. Cookies can be made with grains having a particle size ranging from whole kernel to as small as particles that will pass through a U.S. No. 200 sieve. Cookies can also be made from dried, milled grain that does not pass through a sieve having from 12 to 20 openings per linear inch in combination with very fine milled grain for binding purposes. The very fine milled grain has a particle size such that is capable of passing through a sieve having at least 100 openings per linear inch, and preferably 200 openings per linear inch or less. Cookies may be enhanced with supplemental ingredients that contribute agglomeration, flavor, color nutrition, texture, and eye appeal, which may comprise up to 50% by weight of the cookies.
  • Snacks range in flavor from sweet, to savory, to salty. Snacks may be configured in a wide variety of shapes and provide between-meal calories and nutrition. Snacks can be made with grains having a particle size ranging from whole kernel to as small as particles that will pass through a U.S. No. 200 sieve. Snacks can also be made from dried, milled grain that does not pass through a sieve having from 12 to 20 openings per linear inch in combination with very fine milled grain for binding purposes. The very fine milled grain has a particle size such that is capable of passing through a sieve having at least 100 openings per linear inch, and preferably 200 openings per linear inch or less. Snacks may be enhanced with supplemental ingredients that contribute agglomeration, flavor, color, nutrition, texture, and eye appeal, which may comprise up to 30% by weight of the snacks.
  • Wafers are hard, cookie-like convenience foods which are similar to snacks in ingredients and flavors. Wafers may be made from dried, milled grain that passes through a sieve having from about 12 to 200 openings or less per linear inch.
  • Cereals may be consumed hot or cold.
  • Cereals can be made from whole kernel grains to dried, milled grain having a particle size that passes through a sieve having from about 12 to 100 openings per linear inch.
  • Cereals may be enhanced with supplemental ingredients that contribute agglomeration, flavor, color, nutrition, texture, and eye appeal, which may comprise from about 1% to about 25% by weight of the cereal.
  • Meatless burgers provide the texture, mouth feel, and flavor of meat products without the saturated fat and cholesterol associated with meat products. Meatless burgers are most preferably prepared using the finely milled grain of the present invention.
  • Meatless burgers can be made from dried, milled grain that does not pass through a sieve having from 12 to 20 openings per linear inch in combination with very fine milled grain for binding purposes.
  • the very fine milled grain has a particle size such that it is capable of passing through a sieve having at least 100 openings per linear inch, and preferably 200 openings per linear inch or less.
  • Meatless burgers may be enhanced with supplemental ingredients that contribute agglomeration, flavor, color, nutrition, texture, and eye appeal, which may comprise from about 1% to 25% by weight of the burgers.
  • Drink products such as malts, shakes, milk, soda, fruit juices, and other grain-enhanced beverages can be made from dried, milled grain that passes through a sieve having from about 20 to 150 openings per linear inch.
  • Instant breakfast products can be made from dried, milled grain that passes through a sieve having from about 12 to 200 openings per linear inch.
  • Instant breakfast products are most preferably made from dried, milled grain that passes through a sieve having from 21 to 150 openings per linear inch.
  • the bonded grain fractions can be shaped and formed into a wide variety of food products. These grain and/or multi-grain food products are a convenient, healthy, alternative for consumers to receive their daily requirement of fiber, vitamin and mineral nutrition.
  • the grain product of the present invention offers several advantages over other grain products.
  • the grain product can be rehydrated quickly, compared to raw, hard grains which can normally take up to 180 minutes to cook before reaching the desired consistency.
  • the consistency of the product is uniform, without hard uncooked centers or mushiness.
  • the product can be consumed as-is for snacking and dry cereals or rehydrated quickly.
  • the grain product may be cut, milled, or ground into meal, flakes, granules, or powder for use in other products. These products may not require the addition of binders since the very fine grain fraction serves this function.
  • the grains have a uniform consistency without hard, uncooked centers or mushiness. In addition, the grains retain their nutritious value, taste, and flavor during the treatment process. Further, since the production of the grain product utilizes only water, grain and heat as its inputs, it eliminates the introduction of potentially harmful chemicals or chemical reactions within the product.
  • EXAMPLE 3 Multi-Grain Hydration Procedures Water is added to the blender as set forth above in an amount of four times the amount of grain to be added, by weight. The water is then heated to about 93°C. Triticale, rye, and wheat are added to the water and cooked for 10 minutes. The black barley is then added and the grain mixture is cooked for an additional 30 minutes (40 minutes total). The pearled barley, brown rice, and whole oat groats are then added. The mixture is cooked for an additional 25 minutes (65 minutes total). The grains are then cooled and stored in a freezer at -30°C.
  • EXAMPLE 4 Cooling Process The grains were processed in accordance with Example 3 using 30 pounds each of the seven grains (210 pounds dry weight total) and 100 gallons of water.
  • the process initially started with 20 psi steam pressure on the blender jacket to heat the water to about 98°C. The steam pressure was then reduced to 10 psi on the blender jacket and the triticale, rye, and wheat were added, causing the water temperature to drop to 95°C.
  • the grains were cooled to stop the cooking process by emptying about Vi of the blender contents into a portable tank containing about 75 gallons of cool water (about 13°C). Also, cool water was added to the product remaining in the blender. Grain temperatures were 56°C in the portable tank and 52°C in the blender. This study quickly reduced the temperature of the grains to less than 60°C to halt the cooking process.
  • the seven grain mixture was hydrating according to Example 3 using 30 pounds of each of the seven grains and 100 gallons of water.
  • the grains were cooled to stop the cooking process by emptying about Vi of the blender contents into a portable tank containing about 75 gallons of cool water (13°C). Also, cool water was added to the product remaining in the blender. The grain temperatures were 56°C in the portable tank and 53°C in the blender.
  • EXAMPLE 6 Grain Hydration Procedure The grains were processed in accordance with Example 5, only the water was heated to 98°C. The steam pressure was reduced to 10 psi on the blender jacket and the triticale, rye, and wheat were added to the water (water temperature dropped to 94°C).
  • the grains were cooled in accordance with Example 5.
  • the final grain temperatures were 56°C in the portable tank and 51°C in the blender.
  • EXAMPLE 7 Grain Hydration Procedure The grains were processed in accordance with Example 5, except the water was heated to 93°C. Following reduction of the steam pressure to 10 psi on the blender jacket and adding the triticale, rye, and wheat, the water temperature dropped to 91°C.
  • Example 5 Following the same grain cooling procedure in Example 5, the grain temperatures were 59°C in the portable tank and 52°C in the blender.
  • EXAMPLE 8 Grain Hydration Procedure The grains were processed in accordance with Example 5, except the water was heated to 96°C. Following reduction of the steam pressure to 10 psi on the blender jacket and adding the triticale, rye, and wheat, the water temperature dropped to 93°C.
  • Blend A comprises equal parts of hard red spring wheat, rye, triticale, black barley, pearled barley oat groats, and brown rice processed using the cooking method described in the Examples above. Blend A was dried to a moisture level of less than 12%.
  • Blend B comprises equal parts of hard red spring wheat, rye, triticale, black barley, pearled barley oat groats, and brown rice processed using the cooking and freezing method described in the Examples above.
  • Blend C comprises equal parts of hard red spring wheat, rye, triticale, black barley, pearled barley oat groats, and brown rice in an unprocessed, raw state.
  • Soluble Fiber 2.8 0.9 2.4 Protein by Kjeldahl (F 6.25) 13.8 4.0 13.0 Iron by AA (mg/lOOg) 3.34 1.14 3.16 Vitamin Bl by Fluorometer 0.0376 0.0329 0.0336 (mg/lOOg on a dry basis) Vitamin B2 (riboflavin) 2.12 2.13 2.13
  • Dry processed grains are first milled using a roller mill equipped with LePage rolls.
  • the roll size if preferable of a 6-inch diameter.
  • the LePage corrugation per inch is 16, speed of rolls of parallel rolls is 378 RPM, with the speed of perpendicular rolls being 104 RPM.
  • Grain moisture percent, roll size, corrugation type, RPM of rolls are all determinative of the texture and size plus shrink of the product milled.
  • Step 3 Grains milled in Step 1 are separated by using a sieving procedure employing a U.S. No. 12 through U.S. No. 26 sieve to produce a fine milled fraction.
  • Step 2 The fine milled fraction of Step 2 is further milled through the use of a smooth roller mill and ball mills. This procedure produces a very fine fraction that is sieved through the U.S. No. 100 sieve to a U.S. No. 200 sieve, producing a powder-like product that can be further used in the manufacture of food products.
  • Dr. Saari has a Bachelor of Science degree in Chemistry (1959) and a Master of Science degree in Food Science (1960) from Michigan State University. I also have a Ph.D. in Food Chemistry/Science from the University of Wisconsin, Madison (1963). Dr. Saari has done post-doctorate work in biochemistry at the University of Minnesota, St. Paul from 1963-1965. 2. From 1965-1994, Dr. Saari worked at General Mills Inc. His duties there included staff chemist in the areas of cereal processing and bakery mixes.
  • Dr. Saari was the lead scientist on a project to commercialize shrimp aquaculture for Red Lobster with responsibility for larval and grow-out feed, disease, water quality, and processing.
  • Dr. Saari has been a self-employed consultant in the area of Food Chemistry and Humidity Control.
  • the product and texture observations for the samples are set forth in Table 2 below.
  • the first set consisted of the whole kernel product. The intake of moisture from hot water immersion is slowed by the surface, bran layer. The barrier is operative with both products.
  • the second set employed kernels that were cracked by rolling to partially crush and break up the kernels. The fines that were produced were screened off so that the particles were similar.
  • the Messick processed kernels were harder to crack and produced about 50% more fines than the Fox process kernels which are not as "hard” because they have a lower density as a consequence of the expansion during toasting.
  • the results of the comparison study prove that the product manufactured in accordance with the claimed Fox process differs substantially from product manufactured in accordance with the Messick process in several respects.
  • the Fox process involves first cooking the grains in water to allow the grains to pick up substantial moisture, then rinsing or quenching the grains in water to reduce the internal temperature of the grains to less than 60°C to stop the cooking process.
  • the starch in the grain kernel is then in the form of partially disintegrated starch granules but not in the form of a homogenous starch paste containing the beta glucan.
  • the Messick method does not include the rinsing/quenching step of the Fox process. Instead, Messick follows its cooking step with a steaming step, whereby the grain continues to be cooked. This extended cooking with steam and lack of a cooling quench leads to "pasting", which is a result of destruction of the discrete starch granules. Normally, pasting leads to loss of starch from the granules so that the endosperm of the granule becomes homogeneous with no physical structure to speak of. Due to the pasting, or loss of starch from the Messick grains that is an inevitable result of its cooking/steaming steps, the grain product resulting from the Messick process is inherently different from that resulting from the Fox process. While the Messick grain product is sticky and slimy from the release of starch and beta glucan from the grains, the Fox grain product is not sticky since little beta glucan is lost during processing of the grains.
  • the Fox process further differs from that of Messick in terms of its drying step.
  • the claimed Fox process dries the grains at a temperature of between 190°-225°C for 5 to 20 minutes, while the Messick process uses a much lower temperature range of about 160-176.7°C.
  • the higher temperature range of the Fox process causes a toasting effect which improves the flavor
  • the improved texture of the Fox grains is illustrated in the Texture Observations section of Table 2. While the Fox WHB was firm and crunchy, the Messick grain was hard and flinty. Upon simmering in hot water, the Fox kernels lose their hard centers within 4 minutes, while it takes nearly 10 minutes of simmering in hot water for the Messick kernels to lose their hard centers. The cracked Fox WHB simmering in hot water lost their hard centers in 1 minute, and upon further simmering had the consistency of cooked white rice. In contrast, the cracked Messick WHB eventually lost their hard centers, but the end product was thick, like instant oatmeal gel. The cracked Fox WHB in cold milk had a crunchy, desirable consistency after only 1 minute, while the cracked Messick WHB in cold milk remained hard and tough even after sitting in the milk for over 25 minutes.
  • the Fox drying process also causes a significant increase in the volume of the dried kernel, causing a slight "puffing" effect.
  • This puffing of the grain causes small channels or cracks to form in the kernels. These channels and cracks allow liquids, such as milk or water, to penetrate the Fox kernel more readily than the Messick kernel.
  • the unique attributes of grains produced using the Fox claimed process in comparison to grains produced using the Messick process include the following:

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Abstract

Un produit à base d'orge à grain nu cireux a une teneur en humidité entre 50 et 75 %. Il est préparé par la cuisson des grains dans l'eau pendant 15 à 120 minutes à une température entre 75 et 150 °C. Au stade suivant, on rince le grain avec de l'eau fraîche pour évacuer l'amidon en excès et stopper le processus de refroidissement. Les grains sont ensuite séchés ou réfrigérés par procédé rapide pour former un produit s'écoulant spontanément qui peut être consommé directement, rehydraté en 1 à 7 minutes dans le cas de drèche sèche ou réchauffé en 1 à 7 minutes dans le cas de grains réfrigérés par procédé rapide. L'invention concerne aussi des produits alimentaires fabriqués à partir d'orge à grain nu cireux de l'invention.
PCT/US2001/024161 2001-07-31 2001-07-31 Procede pour traiter du grain entier et produits correspondants WO2003011052A1 (fr)

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012091581A2 (fr) * 2010-12-30 2012-07-05 Uniwersytet Ekonomiczny We Wrocławiu Pâtisserie et, notamment, gaufrettes, et procédé de production de pâtisseries et, notamment, de gaufrettes
US8586113B2 (en) 2009-06-14 2013-11-19 The Quaker Oats Company Method of preparing highly dispersible whole grain flour
WO2014124005A1 (fr) * 2013-02-05 2014-08-14 The Quaker Oats Company Pépites de céréales de type granola croquantes et produits préparés à partir de celles-ci
US8852665B2 (en) 2003-12-17 2014-10-07 Ardent Mills, Llc Whole grain flour and products including same
US9011947B2 (en) 2009-06-14 2015-04-21 The Quaker Oats Company Method of preparing highly dispersible whole grain flour with an increased avenanthramide content
US9504272B2 (en) 2008-11-04 2016-11-29 The Quaker Oats Company Method of processing oats to achieve oats with an increased avenanthramide content
US9510614B2 (en) 2008-11-04 2016-12-06 The Quaker Oats Company Food products prepared with soluble whole grain oat flour
US9622500B2 (en) 2008-11-04 2017-04-18 The Quaker Oats Company Food products prepared with soluble whole grain oat flour
US10092016B2 (en) 2011-07-12 2018-10-09 Pepsico, Inc. Method of preparing an oat-containing dairy beverage
US10426181B2 (en) 2011-03-21 2019-10-01 The Quaker Oats Company Method for preparing high acid RTD whole grain beverages
US10913963B2 (en) 2016-03-22 2021-02-09 The Quaker Oats Company Method and apparatus for controlled hydrolysis
US10975404B2 (en) 2008-11-04 2021-04-13 The Quaker Oats Company Method and composition comprising hydrolyzed starch
CN113142478A (zh) * 2021-03-27 2021-07-23 湖北金棒棒食品开发有限公司 一种无添加剂熟制开袋即食的五谷杂粮制品及其生产工艺
US11172695B2 (en) 2016-03-22 2021-11-16 The Quaker Oats Company Method, apparatus, and product providing hydrolyzed starch and fiber
US20220295836A1 (en) * 2021-03-19 2022-09-22 Ssial Food Inc. Novel method for processing sprouted whole grain mixture

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BE540379A (fr) *
GB771378A (en) * 1953-09-30 1957-04-03 Unilever Ltd Improvements in the preparation of quick-cooking cereal products
US3086867A (en) * 1960-02-12 1963-04-23 Gen Foods Corp Process of preparing a quick-cooking brown rice
US4042717A (en) * 1974-04-23 1977-08-16 Michel Gayte Freezing rice
US4308295A (en) * 1977-12-27 1981-12-29 General Foods Corporation Process for preparing a pre-cooked frozen rice product
US4707371A (en) * 1985-02-26 1987-11-17 House Food Industrial Company Limited Process for preparing dried pre-gelatinized cereal grain
US5464647A (en) * 1993-10-13 1995-11-07 Kraft Foods, Inc. Quick cooking barley and process for preparation
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WO1999008546A1 (fr) * 1997-08-19 1999-02-25 Barkley Seed Inc. Cereale de viscosite elevee et ingredient alimentaire tire de l'orge nature visqueux

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8852665B2 (en) 2003-12-17 2014-10-07 Ardent Mills, Llc Whole grain flour and products including same
US9392811B2 (en) 2003-12-17 2016-07-19 Ardent Mills, Llc Whole grain flour and products including same
US9510614B2 (en) 2008-11-04 2016-12-06 The Quaker Oats Company Food products prepared with soluble whole grain oat flour
US9622500B2 (en) 2008-11-04 2017-04-18 The Quaker Oats Company Food products prepared with soluble whole grain oat flour
US10975404B2 (en) 2008-11-04 2021-04-13 The Quaker Oats Company Method and composition comprising hydrolyzed starch
US9504272B2 (en) 2008-11-04 2016-11-29 The Quaker Oats Company Method of processing oats to achieve oats with an increased avenanthramide content
US8586113B2 (en) 2009-06-14 2013-11-19 The Quaker Oats Company Method of preparing highly dispersible whole grain flour
US9011947B2 (en) 2009-06-14 2015-04-21 The Quaker Oats Company Method of preparing highly dispersible whole grain flour with an increased avenanthramide content
WO2012091581A3 (fr) * 2010-12-30 2012-08-23 Uniwersytet Ekonomiczny We Wrocławiu Pâtisserie et, notamment, gaufrettes, et procédé de production de pâtisseries et, notamment, de gaufrettes
WO2012091581A2 (fr) * 2010-12-30 2012-07-05 Uniwersytet Ekonomiczny We Wrocławiu Pâtisserie et, notamment, gaufrettes, et procédé de production de pâtisseries et, notamment, de gaufrettes
US10426181B2 (en) 2011-03-21 2019-10-01 The Quaker Oats Company Method for preparing high acid RTD whole grain beverages
US10092016B2 (en) 2011-07-12 2018-10-09 Pepsico, Inc. Method of preparing an oat-containing dairy beverage
WO2014124005A1 (fr) * 2013-02-05 2014-08-14 The Quaker Oats Company Pépites de céréales de type granola croquantes et produits préparés à partir de celles-ci
US10913963B2 (en) 2016-03-22 2021-02-09 The Quaker Oats Company Method and apparatus for controlled hydrolysis
US11172695B2 (en) 2016-03-22 2021-11-16 The Quaker Oats Company Method, apparatus, and product providing hydrolyzed starch and fiber
US20220295836A1 (en) * 2021-03-19 2022-09-22 Ssial Food Inc. Novel method for processing sprouted whole grain mixture
CN113142478A (zh) * 2021-03-27 2021-07-23 湖北金棒棒食品开发有限公司 一种无添加剂熟制开袋即食的五谷杂粮制品及其生产工艺

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