WO2012110972A1 - Procédé de fabrication d'un enrobage extrudé de type chapelure pour des produits alimentaires - Google Patents

Procédé de fabrication d'un enrobage extrudé de type chapelure pour des produits alimentaires Download PDF

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Publication number
WO2012110972A1
WO2012110972A1 PCT/IB2012/050704 IB2012050704W WO2012110972A1 WO 2012110972 A1 WO2012110972 A1 WO 2012110972A1 IB 2012050704 W IB2012050704 W IB 2012050704W WO 2012110972 A1 WO2012110972 A1 WO 2012110972A1
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WO
WIPO (PCT)
Prior art keywords
water
dough mixture
breadcrumb
dough
breadcrumb coating
Prior art date
Application number
PCT/IB2012/050704
Other languages
English (en)
Inventor
Daniel Fine
Original Assignee
Finecrumb Food Coatings (Proprietary) Limited
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 Finecrumb Food Coatings (Proprietary) Limited filed Critical Finecrumb Food Coatings (Proprietary) Limited
Publication of WO2012110972A1 publication Critical patent/WO2012110972A1/fr

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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 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
    • A23L7/157—Farinaceous granules for dressing meat, fish or the like
    • 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
    • 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
    • A23L29/238—Foods or foodstuffs containing additives; Preparation or treatment thereof containing gelling or thickening agents of vegetable origin from seeds, e.g. locust bean gum or guar gum
    • 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
    • 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
    • A23L29/262—Cellulose; Derivatives thereof, e.g. 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
    • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
    • A23P20/10—Coating with edible coatings, e.g. with oils or fats
    • A23P20/12—Apparatus or processes for applying powders or particles to foodstuffs, e.g. for breading; Such apparatus combined with means for pre-moistening or battering
    • 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

Definitions

  • This invention relates to a method of producing an extruded breadcrumb coating for food products.
  • Baked bread is typically produced from baked dough which includes a mixture of flour, water and yeast. Other ingredients may be mixed into the dough, such as, for example, sugars, proteins, fats, spices, emulsifiers, improvers, flavouring and other additives.
  • the dough is typically processed in a number of well known procedures including mixing, fermenting, punching, scaling, rounding, benching, proofing and finally baking the dough.
  • Baked bread typically has a moisture content of between 30 % and 40 %.
  • the baked bread is allowed to stale to a moisture content of roughly 20% or more.
  • the stale bread is then placed into a hammer mill which breaks the bread into crumbs and the crumbs are then dried.
  • the above described process for baking bread and for producing breadcrumb from baked bread is thus both time consuming and energy intensive.
  • extruder-cooker An improvement in the production of breadcrumbs which reduces the production time and cost involves extruding the dough through an extrusion cooking apparatus (referred to as an "extruder-cooker") which extrudes and cooks the dough.
  • the dough which is fed through a die of an extruder-cooker typically has a moisture content of roughly 18%. After being forced through the die, the dough emerges from an output end of the extruder-cooker to form an elongate sausage-shaped product which is cut into sections to form "bread like" cooked pellets.
  • the cooked pellets are fed into a hammer mill and broken into crumbs, in a so called “wet milling process", and then dried thereafter.
  • the pellets can be dried first and then fed into the hammer mill thereafter, in a so-called “dry milling process”.
  • the breadcrumbs are then used to coat food products, such as, for example, chicken breasts, to form breadcrumb coated products.
  • the breadcrumb coated food products are then typically flash fried, deep-fried, or baked and thereafter flash frozen.
  • a known problem with the known extrusion process described hereinabove is that the breadcrumbs are required to be dried to a moisture content of 6% or less to prevent so-called "frosting" of the breadcrumb coated products during the freezing thereof.
  • Frosting is an undesirable result of freezing of breadcrumbs which have a moisture content of more than 6 %. Frosting typically occurs when moisture within the breadcrumb coating is unevenly distributed causing visible undesirable uneven freezing or frosting of the moisture within the breadcrumbs. The visual appearance of 'frosted' breadcrumb is undesirable and unacceptable to end users.
  • the process for coating food products to produce breadcrumb coated products typically requires a machine known as a dry crumb enrober.
  • a dry crumb enrober comprises a conveyor on which the food products to be coated are conveyed; an upper bin arranged above the conveyor for holding and dropping a curtain of breadcrumbs onto the food products which pass on the conveyor under the upper bin; a lower bin arranged below the conveyor for collecting excess breadcrumbs which fail to adhere to the food products; and a screw conveyor for returning the excess breadcrumbs from the lower bin to the upper bin so as to continue the crumbing process.
  • An example of a dry crumb enrober which is extensively used in the industry is known as a "Stein J crumb enrober" supplied by JBT Corporation of 70 West Madison, Suite 4400, Chicago, IL 60602, USA.
  • a known problem with the use of a dry crumb enrober is that breadcrumbs having a moisture content of greater than 10% are squashed Into a "dough-like emulsion" forming blockages in the screw conveyor preventing the return of the excess breadcrumbs from the lower bin to the upper bin.
  • breadcrumb coated food products are sold by weight, it is desirable for breadcrumb coating to have a high moisture content above 12%, as an increase in the moisture content of the breadcrumb coating results in an increase in the weight and therefore the profitability of the breadcrumb coated food products.
  • a problem associated with a breadcrumb coating having a moisture content of above 12% is that, as stated above, breadcrumbs having a moisture content of greater than 10% are squashed into a "dough-like emulsion" and cause blockages in the screw conveyor of a dry crumb enrober preventing the return of the excess breadcrumbs from the lower bin to the upper bin.
  • a second problem associated with a breadcrumb coating having a relatively high moisture content is that, as stated above, a breadcrumb having a moisture content of higher than 6% forms undesirable frosting when frozen.
  • room temperature must be interpreted to mean ambient temperature of between 15°C to 28 °C.
  • a gel must be interpreted to mean a colloid mixture in which molecules of a liquid are dispersed within a solid so as to form a three-dimensional cross-linked network structure within the liquid wherein the solid is the continuous phase and the liquid is the discontinuous phase.
  • any reference in the specification to a "gelling agent” must be interpreted to mean a substance or composition which forms a gel in a liquid when mixed with the liquid. Any reference herein to a “thickening agent” must be interpreted to mean any substance or composition which increases the viscosity of a solution or liquid/solid mixture but which does not by itself form a gel in a liquid.
  • a method of producing extruded breadcrumb coating for food products including: preparing a dough mixture by mixing together a predetermined amount of water; a farinaceous material; a gelling agent in a predetermined quantity sufficient to form a gel with a predetermined amount of the water but not all of the water thereby leaving some of the water in a ungelled state; and a thickening agent in a predetermined quantity to thicken said water in the dough mixture which is in an ungelled state; extruding the dough mixture in an extrusion cooking apparatus to form at least partially cooked pellets; and milling the pellets to form breadcrumb coating, the moisture content by weight of the resultant breadcrumb coating produced after milling, being no less than 12% and no more than 22% at room temperature and being determined by the amount of water used in the dough mixture.
  • the gelling agent may be provided in sufficient quantity to form a gel with no less than 30% and no more than 70% of the water in the dough mixture.
  • the gelling agent may be in the form of a gelling composition comprising a gellable polysaccharide and a predetermined amount of an activation agent for activating a predetermined amount of the gellable polysaccharide to form a gel in the water of the dough mixture, the amount of the activation agent being sufficient to form a gel with the gellable polysaccharide with between 30% and 70% of the water in the dough mixture, the thickening agent comprising the gellable polysaccharide in the gelling composition which is in said ungelled state.
  • the method may include selecting the gellable polysaccharide from a group comprising guar gum and hydroxypropylmethylcellulose.
  • the method may include making the dough mixture by mixing water together with, by percentage of total dry weight of the dough mixture, 80% to 95% of the farinaceous material, and the gelling agent comprising 0.4% to 2% of the gellable polysaccharide and 0.05% to 0.2% of the activation agent.
  • the balance of the total dry weight of the dough mixture may comprise one or more of: salts, sugars, proteins, fats, emulsifiers, non-fermentable gas generating agents and preservatives.
  • the method may include adding a predetermined amount of hydroxypropylmethylcellulose to the dough mixture.
  • the method may include adding, by percentage of total dry weight of the dough mixture, 0.01 % to 0.05% of hydroxypropylmethylcellulose to the dough mixture.
  • the activation agent may be in the form of a calcium ion salt. More specifically, the activation agent may be in the form of calcium chloride.
  • the method may further include the step of drying one of the pellets and the breadcrumb coating to obtain breadcrumb coating having not less than 12 % and not more than 16% moisture content by weight.
  • the invention extends to breadcrumb coating produced in accordance with the method of the invention.
  • the invention extends also to food products including breadcrumb coating produced in accordance with the method of the invention.
  • Figure 1 shows a flow diagram illustrating various steps in a method of producing extruded breadcrumb coating in accordance with the invention.
  • a method of producing extruded breadcrumb coating for food products is designated generally by the reference numeral 10.
  • the method 10 of producing extruded breadcrumb coating for food products includes, broadly, the steps of making a dough mixture 12 having a predetermined amount of water; extruding the dough to form bread-like cooked pellets 16; allowing the pellets to cool 20; and milling the pellets to form breadcrumb coating 22, the moisture content by weight of the breadcrumb coating after milling, being no less than 12% and no more than 22% at room temperature and being determined by the amount of water in the dough mixture.
  • the dough mixture is made by mixing together the predetermined amount of water, a farinaceous material such as wheat flour; a gelling agent which is provided in sufficient quantity to gel with approximately 50% of the water but not all of the water, thereby leaving some of the water in an ungelled state; and a thickening agent in a predetermined quantity to thicken the water in the dough mixture which is in the ungelled state (step 12).
  • a farinaceous material such as wheat flour
  • a gelling agent which is provided in sufficient quantity to gel with approximately 50% of the water but not all of the water, thereby leaving some of the water in an ungelled state
  • a thickening agent in a predetermined quantity to thicken the water in the dough mixture which is in the ungelled state
  • the dough mixture is made by mixing water at room temperature together with, by percentage of total dry weight of the dough mixture, 80% to 95% of the farinaceous material, and a gelling composition comprising 0.4% to 2% of a first gellable polysaccharide in the form of guar gum, 0.03% of a second gellable polysaccharide in the form of hydroxypropylmethylcellulose (HPMC), and 0.05% to 0.2% of the gelling agent in the form of a calcium ion salt, such as, for example, calcium chloride.
  • the balance of the total of the dry weight of the dough mixture comprises one or more of: salts, sugars, proteins, fats, emulsifiers, non-fermentable gas generating agents and preservatives.
  • the HPMC of the dough mixture more particularly, has an ideal hydration temperature of between 25 °C and 30 °C and a 2% solution viscosity ranging from 80,000 mPars to 120,000 mPars.
  • HPMC enhances the texture of the breadcrumb coating and in particular results in a crunchier cooked breadcrumb coated food product.
  • the gellable polysaccharide may be added to water along with the salt, sugar and other additives to form an aqueous solution which can then be pumped into the extruder-cooker along with the balance of the ingredients constituting the dough mixture.
  • the dough is fed into the input end of the extruder-cooker and forced through the die.
  • the dough emerges from the die and is released from the output end of the extruder- cooker to form an elongate rope-like structure which is cut into sections to form the bread-like cooked pellets (step 16).
  • the pellets are then allowed to cool to room temperature (step 20).
  • the pellets are then fed into a hammer mill and broken into breadcrumbs in the so-called wet milling process (step 22).
  • the Applicant has found that the guar gum under the action of calcium chloride enables production of a high moisture containing breadcrumb coating which can be processed in various types of dry crumb enrobers.
  • the breadcrumb coating produced by the method 10 are required to be used to coat food products by using a Stein J crumb enrober.
  • the amount of water added to the dough mixture, in Step 12 is regulated such that the breadcrumb coating produced by the method 10 particularly has a moisture content by weight of the breadcrumb coating of not less than 12% and not more than 16%.
  • the method further includes the step of drying the pellets or the breadcrumb coating to obtain breadcrumb coating having not less than 12 % and not more than 16% moisture content by weight.
  • the thickening agent comprises the ungelled guar gum which absorbs water in the dough thereby distributing the water evenly throughout the dough to form a homogeneous mixture.
  • the Applicant has found that the homogeneous characteristics of the dough and particularly the even distribution of water in the dough is beneficial in that breadcrumb coating formed from baked pellets made of the dough have superior properties when freezing. More particularly, due to the homogeneous characteristics of the breadcrumb coating, the moisture within the breadcrumb is evenly distributed therethrough, inhibiting ice crystal growth and thus avoiding frosting. Furthermore, the thickening agent binds the water in the dough thereby preserving the dough and inhibiting growth of mould.
  • a breadcrumb coating produced in accordance with the method 10 of the invention, to have properties which make the breadcrumb coating suitable to be used in a dry crumb enrober as described hereinabove. More particularly, a breadcrumb coating produced in accordance with the method of the invention, is sufficiently resilient to prevent the breadcrumb coating from causing a blockage in the screw conveyor of a dry crumb enrober.
  • the Applicant has found that if a gel is formed with more than 70% of the water in the dough mixture, the texture of the final breadcrumb coating produced is adversely affected. More specifically, the breadcrumb coating does not exhibit sufficient crispiness which is a critical property of breadcrumb coating.
  • the Applicant believes that the breadcrumb coating, produced in accordance with the method of the invention, are consequently more profitable to produce than breadcrumb coating produced by other methods, for two reasons.
  • a greater moisture content results in greater profitability because the breadcrumb coated food products are sold by weight.
  • composition of the dough mixture may vary while still incorporating the essential features of the invention as described above.
  • a suitable gellable polysaccharide is guar gum which is used on its own.
  • the dough mixture provided in step 12 will not contain HPMC.
  • the quantities of the constituents making up the dough mixture may vary, while still incorporating the essential features of the invention as described above.
  • calcium chloride in the range of 0.05% to 0.2% by weight of the dough mixture has been found to be effective concentrations of calcium ion salts.
  • guar gum is effective when used in combination with Hydroxypropylmethylcellulose (HMPC), wherein the HMPC makes up 0.01 % to 0.1 % of dry weight of the dough mixture and wherein the guar gum makes up 0.4% to 2% of the weight of the dough mixture.
  • HMPC Hydroxypropylmethylcellulose
  • the step of making the dough mixture in Step 12, described hereinabove may be substituted by the step of making a dough mixture by mixing together a predetermined amount of water, a farinaceous material such as, for example, flour; and a combination of two polysaccharides, such as, for example, xanthan gum and locust bean gum.
  • a farinaceous material such as, for example, flour
  • a combination of two polysaccharides such as, for example, xanthan gum and locust bean gum.
  • one of the xanthan gum and the locust bean gum acts as the gellable polysaccharide, as hereinabove described, with the other one of the xanthan gum and the locust bean gum acting as the gelling agent, as hereinabove described.

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  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Dispersion Chemistry (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Manufacturing & Machinery (AREA)
  • Zoology (AREA)
  • Bakery Products And Manufacturing Methods Therefor (AREA)
  • Grain Derivatives (AREA)

Abstract

L'invention porte sur un procédé de fabrication d'un enrobage extrudé de type chapelure pour des produits alimentaires, lequel procédé comprend les étapes consistant à fabriquer un mélange de pâte (12) ayant une quantité d'eau prédéterminée ; à extruder la pâte dans un cuiseur-extrudeur pour former des boulettes cuites de type pain (16) ; à amener les boulettes à refroidir (20) ; et à broyer les boulettes pour former un enrobage de type chapelure (22). La quantité d'eau ajoutée au mélange de pâte est telle que la teneur en humidité en poids de l'enrobage de type chapelure après broyage est comprise entre 12 % et 22 % à température ambiante. Le mélange de pâte est fabriqué par mélange de l'eau conjointement avec une matière farineuse, un agent gélifiant dans une quantité prédéterminée pour former un gel ayant environ 50 % de l'eau mais non toute l'eau, laissant une certaine partie de l'eau dans un état non gélifié ; et un agent épaississant dans une quantité prédéterminée pour épaissir l'eau qui est dans un état non gélifié.
PCT/IB2012/050704 2011-02-16 2012-02-16 Procédé de fabrication d'un enrobage extrudé de type chapelure pour des produits alimentaires WO2012110972A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA201101249 2011-02-16
ZA2011/01249 2011-02-16

Publications (1)

Publication Number Publication Date
WO2012110972A1 true WO2012110972A1 (fr) 2012-08-23

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WO (1) WO2012110972A1 (fr)
ZA (1) ZA201201404B (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015500652A (ja) * 2011-12-20 2015-01-08 クリスプ センセーション ホールディング エスエーＣｒｉｓｐ Ｓｅｎｓａｔｉｏｎ Ｈｏｌｄｉｎｇ ＳＡ パン粉の製造

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4364961A (en) * 1981-03-30 1982-12-21 The Griffith Laboratories, Limited Manufacture of bread crumb-like product
US4440793A (en) * 1981-05-08 1984-04-03 Fuji Foods Industry Co., Ltd. Method for producing bread crumbs
US4609558A (en) * 1985-05-23 1986-09-02 General Foods Corporation Bread crumb-like product has its manufacture
US4943438A (en) * 1986-07-07 1990-07-24 Conagra, Inc. Bread crumb coating composition and process for imparting fried-like texture and flavor to food products
EP0619082A1 (fr) * 1993-04-07 1994-10-12 Societe Des Produits Nestle S.A. Procédé de préparation de panure et produit pané obtenu
WO1995007629A1 (fr) * 1993-09-14 1995-03-23 Unilever Plc Substance d'enrobage expansee
WO1995023523A1 (fr) * 1994-03-02 1995-09-08 Griffith Laboratories Worldwide, Inc. Amelioration des miettes de chapelure
WO1999044439A1 (fr) * 1998-03-03 1999-09-10 Novus Ingredients Ltd Enrobage en chapelure pour aliments
US20060053650A1 (en) * 2004-09-13 2006-03-16 George Manak Breadcrumb Manufacturing System and Method
WO2010001101A2 (fr) * 2008-07-01 2010-01-07 Magsnack Bv Enrobage de chapelure pour produits alimentaires

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4364961A (en) * 1981-03-30 1982-12-21 The Griffith Laboratories, Limited Manufacture of bread crumb-like product
US4440793A (en) * 1981-05-08 1984-04-03 Fuji Foods Industry Co., Ltd. Method for producing bread crumbs
US4609558A (en) * 1985-05-23 1986-09-02 General Foods Corporation Bread crumb-like product has its manufacture
US4943438A (en) * 1986-07-07 1990-07-24 Conagra, Inc. Bread crumb coating composition and process for imparting fried-like texture and flavor to food products
EP0619082A1 (fr) * 1993-04-07 1994-10-12 Societe Des Produits Nestle S.A. Procédé de préparation de panure et produit pané obtenu
WO1995007629A1 (fr) * 1993-09-14 1995-03-23 Unilever Plc Substance d'enrobage expansee
WO1995023523A1 (fr) * 1994-03-02 1995-09-08 Griffith Laboratories Worldwide, Inc. Amelioration des miettes de chapelure
WO1999044439A1 (fr) * 1998-03-03 1999-09-10 Novus Ingredients Ltd Enrobage en chapelure pour aliments
US20060053650A1 (en) * 2004-09-13 2006-03-16 George Manak Breadcrumb Manufacturing System and Method
WO2010001101A2 (fr) * 2008-07-01 2010-01-07 Magsnack Bv Enrobage de chapelure pour produits alimentaires

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015500652A (ja) * 2011-12-20 2015-01-08 クリスプ センセーション ホールディング エスエーＣｒｉｓｐ Ｓｅｎｓａｔｉｏｎ Ｈｏｌｄｉｎｇ ＳＡ パン粉の製造

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