WO2009094421A1 - Extrusion process using pregelatinized starch to produce puffed/expanded food product - Google Patents

Extrusion process using pregelatinized starch to produce puffed/expanded food product Download PDF

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Publication number
WO2009094421A1
WO2009094421A1 PCT/US2009/031657 US2009031657W WO2009094421A1 WO 2009094421 A1 WO2009094421 A1 WO 2009094421A1 US 2009031657 W US2009031657 W US 2009031657W WO 2009094421 A1 WO2009094421 A1 WO 2009094421A1
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WO
WIPO (PCT)
Prior art keywords
extruder
feed composition
extrusion process
starch
gelatinized
Prior art date
Application number
PCT/US2009/031657
Other languages
French (fr)
Inventor
Xie Luke
Judy Turner
Brenda Waite
Lori Napier
Original Assignee
Tate And Lyle Ingredients Americas, 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 Tate And Lyle Ingredients Americas, Inc. filed Critical Tate And Lyle Ingredients Americas, Inc.
Publication of WO2009094421A1 publication Critical patent/WO2009094421A1/en

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Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
    • A23L29/00—Foods or foodstuffs containing additives; Preparation or treatment thereof
    • A23L29/20—Foods or foodstuffs containing additives; Preparation or treatment thereof containing gelling or thickening agents
    • A23L29/206—Foods or foodstuffs containing additives; Preparation or treatment thereof containing gelling or thickening agents of vegetable origin
    • A23L29/212—Starch; Modified starch; Starch derivatives, e.g. esters or ethers
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/20—Extruding
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/30—Puffing or expanding
    • A23P30/32—Puffing or expanding by pressure release, e.g. explosion puffing; by vacuum treatment

Definitions

  • the invention relates to a process for manufacture of extruded foods that may contain heat sensitive ingredients and/or ingredients associated with reduced expansion.
  • One aspect of the invention is an extrusion process for producing a puffed food.
  • the process comprises: (1) providing a feed composition that comprises pre-gelatinized starch and at least one heat sensitive ingredient, such as fiber, protein, vitamins, omega 3 fatty acids, choline, flavors or sugars, and (2) extruding the feed composition through an extruder that comprises at least one die.
  • the feed composition comprises sufficient water to plasticize the composition in the extruder, and the barrel temperatures are below about 6O 0 C.
  • the feed composition also comprises starch that is not pre- gelatinized.
  • the feed composition comprises 25-75% pre-gelatinized starch; 25-75% heat sensitive materials, and the balance starch that is not pre-gelatinized, on a dry weight basis.
  • Puffed foods with heat sensitive ingredients or ingredients that retard puffing in typical extrusion processes can be produced with pre-gelatinized starches under low temperature extrusion processing, e.g. the barrel temperature of all zones can be controlled under 60 0 C.
  • the use of instant or pregelatinized starch allows the puffing and the process parameters, including screw configuration, produce the fine cell structure consistent with a high quality product.
  • the low temperature extrusion allows the incorporation of proteins, vitamins, flavors or other ingredients that would be degraded in a typical extrusion process.
  • the puffed products are fabricated from cooked farinaceous doughs that comprise, and optionally can consist essentially of 1) a pre-gelatinized starch or flour (e.g., an instantized starch or flour), which can comprise instantized starch granules or fragments of - -
  • a pre-gelatinized starch or flour e.g., an instantized starch or flour
  • starch granules typically in an amount of about 25% to about 75% of the overall composition by dry weight
  • dried heat sensitive ingredients such as fiber, protein, vitamins, omega 3 fatty acids, choline, flavors or sugars, typically in an amount of about 20% to about 45%, by dry weight
  • a starch flour or powder such as tapioca starch powder, corn flour, rice flour or wheat flour, which have sufficient water to plasticize the dough inside of extruder. This water may also include liquid forms of heat sensitive ingredients.
  • Suitable pre-gelatinized starches heat sensitive ingredients, ingredients that can retard expansion and starch flours are known.
  • suitable pre-gelatinized starches include STA-SLIM ® 150 tapioca starch and X-PAND'R ® waxy starches, both of which are available from Tate & LyIe (Decatur, Illinois).
  • the novel extrusion process hydrates the pre-gelatinized starch inside of an extruder.
  • the viscous pre-gelatinized starch forms a matrix that embeds heat sensitive ingredients or ingredients that can retard expansion Because of the high viscosity of the pre-gelatinized starch matrix, pressure at the die face builds, creating a puffing force that when released to atmosphere (going through the die), results in expansion of the matrix.
  • the extruder barrel temperature can be controlled under 60 0 C .
  • the screw shearing zone is set up adjacent to last barrel that is next to the die (zone 5), and the vent is set up at the same zone (5) to release air and moisture.
  • the fine cell structure of the puffed product is obtained because dough flow, in the last zone (6), is laminar when traversing the die holes.
  • the degree of puffing of the extrudate is as the same as "normal" extrusion processing.
  • Extrusion Processing a. Extruder: Buhler Twin Screw Extruder BCTL-42 model, available from the Buhler Group, Buhler AG 9240 Uzwil, Switzerland b. Extruder Screw Configuration Setting Up

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Dispersion Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Grain Derivatives (AREA)
  • Fodder In General (AREA)
  • General Preparation And Processing Of Foods (AREA)

Abstract

An extrusion process for producing a puffed food comprises: (1) providing a feed composition that comprises pre-gelatinized starch, and at least one heat sensitive ingredient, such as fiber, protein, vitamins, omega 3 fatty acids, choline, flavors or sugars, and (2) extruding the feed composition through an extruder that comprises at least one die. The feed composition comprises sufficient water to plasticize the composition in the extruder, and the barrel temperatures are below about 6O0C.

Description

EXTRUSION PROCESS USING PREGELATINIZED STARCH TO PRODUCE PUFFED/EXPANDED FOOD PRODUCT
BACKGROUND OF THE INVENTION
The invention relates to a process for manufacture of extruded foods that may contain heat sensitive ingredients and/or ingredients associated with reduced expansion.
SUMMARY OF THE INVENTION
One aspect of the invention is an extrusion process for producing a puffed food. The process comprises: (1) providing a feed composition that comprises pre-gelatinized starch and at least one heat sensitive ingredient, such as fiber, protein, vitamins, omega 3 fatty acids, choline, flavors or sugars, and (2) extruding the feed composition through an extruder that comprises at least one die. The feed composition comprises sufficient water to plasticize the composition in the extruder, and the barrel temperatures are below about 6O0C. In some embodiments, the feed composition also comprises starch that is not pre- gelatinized. In one specific embodiment of the invention, the feed composition comprises 25-75% pre-gelatinized starch; 25-75% heat sensitive materials, and the balance starch that is not pre-gelatinized, on a dry weight basis.
DESCRIPTION OF SPECIFIC EMBODIMENTS
Puffed foods with heat sensitive ingredients or ingredients that retard puffing in typical extrusion processes can be produced with pre-gelatinized starches under low temperature extrusion processing, e.g. the barrel temperature of all zones can be controlled under 600C. The use of instant or pregelatinized starch allows the puffing and the process parameters, including screw configuration, produce the fine cell structure consistent with a high quality product. The low temperature extrusion allows the incorporation of proteins, vitamins, flavors or other ingredients that would be degraded in a typical extrusion process.
The puffed products are fabricated from cooked farinaceous doughs that comprise, and optionally can consist essentially of 1) a pre-gelatinized starch or flour (e.g., an instantized starch or flour), which can comprise instantized starch granules or fragments of - -
starch granules, typically in an amount of about 25% to about 75% of the overall composition by dry weight, 2) dried heat sensitive ingredients such as fiber, protein, vitamins, omega 3 fatty acids, choline, flavors or sugars, typically in an amount of about 20% to about 45%, by dry weight, and 3) a starch flour or powder, such as tapioca starch powder, corn flour, rice flour or wheat flour, which have sufficient water to plasticize the dough inside of extruder. This water may also include liquid forms of heat sensitive ingredients.
Suitable pre-gelatinized starches, heat sensitive ingredients, ingredients that can retard expansion and starch flours are known. For example, suitable pre-gelatinized starches include STA-SLIM® 150 tapioca starch and X-PAND'R® waxy starches, both of which are available from Tate & LyIe (Decatur, Illinois).
The novel extrusion process hydrates the pre-gelatinized starch inside of an extruder. The viscous pre-gelatinized starch forms a matrix that embeds heat sensitive ingredients or ingredients that can retard expansion Because of the high viscosity of the pre-gelatinized starch matrix, pressure at the die face builds, creating a puffing force that when released to atmosphere (going through the die), results in expansion of the matrix. To prevent degradation of heat sensitive ingredients or ingredients that can retard expansion the extruder barrel temperature can be controlled under 600C . The screw shearing zone is set up adjacent to last barrel that is next to the die (zone 5), and the vent is set up at the same zone (5) to release air and moisture. The fine cell structure of the puffed product is obtained because dough flow, in the last zone (6), is laminar when traversing the die holes.
The degree of puffing of the extrudate is as the same as "normal" extrusion processing.
EXAMPLES 1) Ingredients and Formula a. Prototype formulas (A, B, and C)
Figure imgf000003_0001
- -
(Pet = %) b. Each formula was dry blended in the ribbon blender, respectively, for extrusion processing.
2) Extrusion Processing a. Extruder: Buhler Twin Screw Extruder BCTL-42 model, available from the Buhler Group, Buhler AG 9240 Uzwil, Switzerland b. Extruder Screw Configuration Setting Up
Figure imgf000004_0001
c. 2 dies of 3.5 mm in diameter convergent die d. Extrusion Processing
i. Temperature profile of the extruder for each formula - -
Product Zone 6 Zone 5 Zone 4 Zone 3 Zone 2 Tern 0C Tem c C Tem c C Tem c C Tem c C Tem c C
Formula A 127 42 19 15 15 15
Formula B 133 42 18 23 23 24
Formula C 109 42 25 23 23 22
ii. Extruder Processing Parameters
Figure imgf000005_0001
The cutter speed was 1000 rpm for all runs. (SME = specific mechanical energy)
iii. Puffs Physical Attributes
Figure imgf000005_0002
3) Post Extrusion Processing
All the extrudates from extruder were dried in the convection oven at 2000F for 20 minutes.
The preceding description is not intended to be an exhaustive list of every possible embodiment of the present invention. Persons skilled in the art will recognize that modifications could be made to the embodiments described above which would remain within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:
1. An extrusion process for producing a puffed or expanded food, comprising: providing a feed composition that comprises pre-gelatinized starch and at least one heat sensitive ingredient and/or ingredient that can retard expansion; and extruding the feed composition through an extruder that comprises at least one die; wherein the feed composition comprises sufficient water to plasticize the composition in the extruder; and wherein the barrel temperatures of the extruder are maintained below about 6O0C.
2. The extrusion process of claim 1, wherein the feed composition further comprises starch that is not pre-gelatinized.
3. The extrusion process of claim 2, wherein the feed composition comprises 25-75% pre- gelatinized starch; heat sensitive ingredients and/or ingredients that can retard expansion, and the balance starch that is not pre-gelatinized, on a dry weight basis.
PCT/US2009/031657 2008-01-25 2009-01-22 Extrusion process using pregelatinized starch to produce puffed/expanded food product WO2009094421A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US2375108P 2008-01-25 2008-01-25
US61/023,751 2008-01-25

Publications (1)

Publication Number Publication Date
WO2009094421A1 true WO2009094421A1 (en) 2009-07-30

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WO (1) WO2009094421A1 (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104470375A (en) * 2012-07-18 2015-03-25 雀巢产品技术援助有限公司 Extruded food
DE202019101763U1 (en) 2019-03-28 2019-04-10 Daniel Schaaf Expanded food or feed extrudate
CN110583776A (en) * 2019-10-22 2019-12-20 江南大学 Efficient preparation method of flavored vegetable dissolved beans based on collard
US10689566B2 (en) 2015-11-23 2020-06-23 Anavo Technologies, Llc Coated particles and methods of making and using the same
WO2020192828A1 (en) 2019-03-28 2020-10-01 Daniel Schaaf Expanded foodstuff- or animal feed extrudate
US10982013B2 (en) 2014-06-02 2021-04-20 Anavo Technologies, Llc Modified biopolymers and methods of producing and using the same
US11395803B2 (en) * 2017-02-27 2022-07-26 Bioscreen Technologies S.R.L. Composition for controlled release of physiologically active substances and process for its preparation

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6022574A (en) * 1996-01-16 2000-02-08 Lanner; David Arthur Process for making a fried snack product
WO2001037672A1 (en) * 1999-11-24 2001-05-31 The Procter & Gamble Company Extruded and fried snack
US20040086616A1 (en) * 2002-10-30 2004-05-06 Mgp Ingredients, Inc. Extrusion processed starch-based, long lasting dog chew product

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6022574A (en) * 1996-01-16 2000-02-08 Lanner; David Arthur Process for making a fried snack product
WO2001037672A1 (en) * 1999-11-24 2001-05-31 The Procter & Gamble Company Extruded and fried snack
US20040086616A1 (en) * 2002-10-30 2004-05-06 Mgp Ingredients, Inc. Extrusion processed starch-based, long lasting dog chew product

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104470375A (en) * 2012-07-18 2015-03-25 雀巢产品技术援助有限公司 Extruded food
US10982013B2 (en) 2014-06-02 2021-04-20 Anavo Technologies, Llc Modified biopolymers and methods of producing and using the same
US10689566B2 (en) 2015-11-23 2020-06-23 Anavo Technologies, Llc Coated particles and methods of making and using the same
US11395803B2 (en) * 2017-02-27 2022-07-26 Bioscreen Technologies S.R.L. Composition for controlled release of physiologically active substances and process for its preparation
DE202019101763U1 (en) 2019-03-28 2019-04-10 Daniel Schaaf Expanded food or feed extrudate
WO2020192828A1 (en) 2019-03-28 2020-10-01 Daniel Schaaf Expanded foodstuff- or animal feed extrudate
DE102019108011B4 (en) 2019-03-28 2022-07-28 Daniel Schaaf Expanded food or feed extrudate
CN110583776A (en) * 2019-10-22 2019-12-20 江南大学 Efficient preparation method of flavored vegetable dissolved beans based on collard

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