WO2016176736A1

WO2016176736A1 - An improved process for the production of puffed food products

Info

Publication number: WO2016176736A1
Application number: PCT/AU2016/050328
Authority: WO
Inventors: Thomas Woods; Angus WOODS
Original assignee: Woods Foods Pty Ltd
Priority date: 2015-05-06
Filing date: 2016-05-06
Publication date: 2016-11-10
Also published as: AU2020102972A4; AU2016257144A1

Abstract

A process for the production of a puffed food product, including the steps of hydrating a seed and puffing said hydrated seed is provided. Puffing the seed includes exposing the seed to elevated temperature, and may include exposing the seed to elevated pressure. The process may further include heating the seed, such as boiling or simmering the seed in water, during hydration and/or prior to puffing. Also provided is an apparatus and a system for production of a puffed food product from a seed.

Description

TITLE

AN IMPROVED PROCESS FOR THE PRODUCTION OF PUFFED FOOD

PRODUCTS FIELD OF THE INVENTION THE present invention relates to food products. More particularly, the invention relates to a process for the production of puffed seed food products.

Additionally, the invention relates to an apparatus for the production of puffed seed food products, and a system for the production of puffed seed food products.

BACKGROUND

Plant materials such as staple cereals wheat, rice, and barley, are used for a diverse range of food products including breads, cakes, breakfast cereals, snacks, pet foods and meat analogues.

Sorghum is a cereal crop of major global importance as a food, particularly in Africa, Central America, and South Asia. Sorghum possesses many desirable nutritional qualities including high concentrations of potassium, calcium, thiamin, and niacin. Sorghum is also gluten-free, and human consumption of sorghum has been reported to have anti-cancer benefits and to help prevent diabetes.

In addition to cereals, many legumes (family Fabaceae), particularly the 'grain legumes' or 'pulse legumes' (e.g. beans, broad beans, lentils, peas and lupins) are food and/or forage crops. Legumes are relatively high in fibre, protein, antioxidants, and many vitamins including folate, thiamine, and pantothenic acid; contain low levels of saturated fat; and have a low glycaemic index (GI).

Food products derived from processed cereals and legumes can potentially be highly nutritious. However, such food products often include additives and residues from food processing, or flavourings, salt and/or sweeteners that may detract from the natural nutritional value of the cereals and legumes.

SUMMARY OF THE INVENTION

The invention is at least partly predicated on the realization that there is a need in the market for nutritious food products and, more particularly, nutritious snack food products with high consumer desirability. The present invention is broadly directed to a process for the production of puffed seed-based food products.

In a first aspect, the invention provides a process for the production of a puffed food product, including the steps of: (a) hydrating a seed; and (b) puffing said hydrated seed to thereby produce the puffed food product. In a second aspect, the invention provides a puffed food product produced according to the process of the first aspect.

In a third aspect, the invention provides a puffed food product obtainable from a seed comprising:

(a) a total energy content of about 1200-1800 kJ per 100 g;

(b) a total saturated fat content of less than about 1.5 g per 100 g;

(c) a total sodium content of less than about 25 mg;

(d) a total fibre content of about 10-22 g per 100 g; and

(e) a moisture content of less than about 10 g per 100 g.

Preferably, the puffed seed according to this aspect has a density of about 5 kg/m 3 to about 50 kg/m 3.

Preferably the seed of the aforementioned aspects is a cereal grain or a leguminous bean.

In a fourth aspect, the invention provides a food comprising the puffed food product of the second or third aspect.

In a fifth aspect, the invention provides a method of producing a food including the step of processing the puffed food product of the second or third aspect to thereby produce the food.

In a sixth aspect, the invention provides a food produced according to the method of the fifth aspect.

In a seventh aspect, the invention provides use of a puffed food product according to the second, third, fourth, or sixth aspects, for human consumption.

In an eighth aspect, the invention provides an apparatus for the production of a puffed food product from a seed, wherein said apparatus comprises a hydrating device for hydrating the seed operably connected to a puffing device for puffing the seed.

In a ninth aspect, the invention provides a system for the production of a puffed food product from a seed, wherein said system comprises:

(a) a hydrating device for hydrating the seed;

(b) a puffing device for puffing the seed operably connected to said hydrating device; and

(c) a control interface that controls the production of the puffed food product from the seed. Optionally, the apparatus of the eighth aspect or the system of the ninth aspect comprises a heater for heating the seed between the hydrating device and the puffing device. In a preferred embodiment, the heater is a boiler.

Preferably, the apparatus of the eighth aspect or the system of the ninth is capable of processing a seed at a rate of at least 30 kg/h to at least 400 kg/h to produce the puffed food product from the seed.

Suitably, the puffed food product of the aforementioned aspects is desirable for human consumption.

Throughout this specification, unless the context requires otherwise, the words "comprise", "comprises" and "comprising" will be understood to mean the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

BRIEF DESCRIPTION OF THE FIGURES

In order that the invention may be readily understood and put into practical effect, preferred embodiments will now be described by way of example with reference to the accompanying figure, wherein:

Figure 1 shows a schematic representation of a preferred embodiment of the apparatus and system.

DETAILED DESCRIPTION OF THE INVENTION

There is a need in the market for nutritious food products and, more particularly, nutritious snack food products with high consumer desirability. Certain cereal and legume seeds possess beneficial nutritional characteristics and therefore have excellent potential for the production of nutritious snack food products. Puffed food products comprising said cereal and legume seeds that are substantially free of, or low in, residues from food processing, and/or additives such as salts and sweetening agents, are particularly desirable. However, variation in conditions used for the production of puffed food products can strongly affect certain properties of puffed seed food products, including flavour, aroma, texture, nutritional properties and/or shelf life. Therefore, to achieve consistent results, controlled conditions are required.

The present invention provides a process for the production of a puffed seed food product. More particularly, the invention provides controlled conditions for said process which thereby produce consistent results. The present invention also provides puffed cereal food products and puffed legume food products with desirable characteristics for consumption by a human.

Additionally, the present invention provides an apparatus for the production of a puffed seed food product

Furthermore, the present invention provides a system for the production of a puffed seed food product.

Suitably, said system and apparatus can be used to produce puffed cereal food products and puffed legume food products with desirable characteristics for human consumption.

Therefore, the present invention overcomes some disadvantages and limitations of existing puffed seed food products. The present invention also overcomes disadvantages and limitations associated with the production of said puffed said food products.

A food or food product of the present invention may be for the consumption of any animal. For example, said animal may include a fish, an avian animal (e.g. poultry), a mammal such as a human, livestock (e.g. cattle and sheep), a domestic pet (e.g. cats and dogs), a performance animal (e.g. racehorses), and a laboratory animal (e.g. rats, mice and rabbits), although without limitation thereto.

Preferably, said animal is a human.

In one aspect, the invention provides a process for the production of a puffed food product, including the steps of: (a) hydrating a seed; and (b) puffing said hydrated seed, to thereby produce the puffed food product.

It will be appreciated by one skilled in the relevant art that a "seed" comprises an embryonic plant enclosed in a covering or 'seed coat'. Usually, seeds further comprise stored nutrients. Plants that produce seeds are classified as spermatophytes, and further classified within several subgroups. Seeds, particularly the cereal grains and the leguminous beans, are widely used as food and in the production of food products. As will be understood by one skilled in the relevant art, a "bean" may refer to a particular form of seed produced by some legumes that is often large and 'fleshy', relative to, for example, a cereal grain.

Throughout this specification it will be understood that the terms "seed", "a seed", and "the seed" will not be limited to the singular form, and may refer to a plurality of individual seeds, as the context requires. Preferably, a seed subjected to processing according to this aspect is a cereal or a legume. As will be understood by one skilled in the relevant art, "legume" refers to any species of plant of the family 'Fabaceae', and "leguminous" means of or relating to legumes.

In preferred embodiments of this aspect wherein the seed is a legume, said seed is chickpea or faba bean.

In preferred embodiments wherein the seed is a cereal, said seed is sorghum, or more preferably red sorghum.

In one alternative aspect of the process of the invention relating to sorghum, the process excludes hydration of the seed. Although hydration is desirable, it has been found that exclusion of hydration may be suitable for processing of sorghum according to the invention.

As used throughout this specification, "hydrate", "hydrated", or "hydrating" will be understood to mean causing a seed to absorb a fluid such as water.

Suitably, hydration of a seed according to this aspect may include:

(i) hydration at or around ambient temperature; and/or

(ii) hydration at an elevated temperature.

Suitably, in embodiments wherein hydration includes hydration at an elevated temperature, the seed is heated by said hydration at an elevated temperature.

Some seeds, such as sorghum, may be particularly amenable to processing according to this aspect wherein hydration of a seed includes hydration at an elevated temperature, but does not include hydration at or around ambient temperature.

In certain embodiments of the process of the present invention, a seed is hydrated at or around ambient temperature by exposure to water for between about 2 and about 24 hours; including about 4 hours, about 6 hours, about 8 hours, about 10 hours, about 12 hours, about 14 hours, about 16 hours, about 18 hours, about 20 hours, and about 22 hours.

In other embodiments, a seed is hydrated at or around ambient temperature by exposure to water for between about 6 hours and about 20 hours, including about 7 hours, about 8 hours, about 9 hours, about 10 hours, about 11 hours, about 12 hours, about 13 hours, about 14 hours, about 15 hours, about 16 hours, about 17 hours, about

18 hours, and about 19 hours. Preferably, a seed is hydrated by exposure to water at or around ambient temperature for between about 12 hours and about 18 hours, including about 13 hours, about 14 hours, about 15 hours, about 16 hours, about 17 hours.

As hereinabove described, according to certain embodiments of the process of the invention, the seed is hydrated at an elevated temperature.

Additionally or alternatively, the seed may be heated after hydration and/or prior to puffing according to this aspect. In some such embodiments, the seed may be roasted, fried, or heated in air.

In certain embodiments, the temperature during heating of a seed according to this aspect is between about 80°C and about 120°C, including about 85°C, about 90°C, about 95°C, about 100°C, about 105°C, about 110°C, and about 115°C.

In one preferred embodiment, the temperature during heating is around 100°C.

In another preferred embodiment, the temperature during heating is around

90°C.

In some preferred embodiments, wherein the seed is hydrated at an elevated temperature, the seed is heated in said water that is boiling for at least part of said heating. It will be appreciated that under conditions of standard atmospheric pressure (1 atm or ~ 100 kPa) the boiling point of water is 100°C.

In certain embodiments of the process that include heating a seed, the duration of heating is between about 1 and about 20 minutes, including about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes, about 8 minutes, about 9 minutes, about 10 minutes, about 11 minutes, about 12 minutes, about 13 minutes, about 14 minutes, about 15 minutes, about 16 minutes, about 17 minutes, about 18 minutes, and about 19 minutes.

In certain preferred embodiments relating to faba bean and/or chickpea, the duration of heating is about 2 minutes or about 3 minutes.

In other preferred embodiments relating to chickpea, the duration of heating is about 10 minutes or about 15 minutes.

In some embodiments of the process, a hydrated seed may be drained after said hydration (i.e. with or without heating during hydration) and/or prior to puffing. It will be appreciated that draining can serve to modify or reduce the amount of water contained in and/or on a hydrated and/or heated seed.

In certain embodiments, the duration of draining is about 1 minute to about 15 minutes, including about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes, about 8 minutes, about 9 minutes, about 10 minutes, about 11 minutes, about 12 minutes, about 13 minutes, and about 14 minutes.

In one preferred embodiment relating to faba bean, the duration of draining is about 2 minutes.

In one preferred embodiment relating to chickpea, the duration of draining is about 5 minutes. In another preferred embodiment relating to chickpea, the duration of draining is about 10 minutes.

As hereinbefore described, after hydration or optionally, heating or boiling, the seed is puffed. As used herein, "puffed", "puffing", or "puff refers to a process for treating a seed such that said seed has reduced density, as compared to a corresponding seed that is not puffed.

The skilled person will appreciate that various techniques for puffing seeds exist. As per the process of the invention, puffing of a seed involves exposing the seed to an elevated temperature, i.e. heating the seed. Preferably, heating the seed during puffing comprises exposing the seed to a gas, such as air, having an elevated temperature.

Suitably, during puffing, escape of a gas contained or 'entrained' within the seed may result in expansion of the seed. By way of example, it will be understood that heat treatment of a seed can result in moisture contained within the seed being converted to water vapour. Furthermore, rapid escape of said water vapour from the seed can result in expansion of the seed.

For some seeds, such as sorghum, suitable puffing may be achieved by exposing the seed to hydration at elevated temperature without pre-soaking of the seed. However, pre-soaking of seeds, as hereinabove described, can be effective to increase moisture content of the seed prior to puffing, which may improve puffing characteristics.

In certain embodiments of the process of the invention, the heating temperature during puffing is between about 125°C and about 235°C, including about 135°C, about 145°C, about 155°C, about 165°C, about 175°C, about 185°C, about 195°C, about 205°C, about 215°C, and about 225°C.

In certain preferred embodiments relating to chickpea and/or faba bean the heating temperature during puffing is between about 130°C and about 170°C, including about 135°C, about 140°C about 145°C, about 150°C, about 155°C, about 160°C, and about 165°C.

In one preferred embodiment relating to chickpea the heating temperature during puffing is about 147°C.

In certain preferred embodiments relating to sorghum, the heating temperature during puffing is between about 190°C and about 230°C, including about 200°C, about 205°C about 210°C, about 215°C, about 220°C, and about 225°C. In some embodiments of the process of the invention, puffing of the seed further involves exposing the seed to conditions of elevated pressure. Such conditions may assist with achieving a suitable degree and/or consistency of puffing as per the invention.

Preferably, said elevated pressure is achieved by exposing the seed to a gas, such as air, having an elevated pressure. By way of example, said gas may be pressurised or 'forced' air, such as fan-forced air although without limitation thereto. Suitably, said gas has an elevated temperature, and facilitates both heating the seed, as hereinabove described, and exposing the seed to elevated pressure, during puffing.

Generally, elevated pressure is a pressure that is increased or higher than an absolute pressure of 100 kPa. In certain embodiments of the process of the invention the pressure of a gas during puffing is about 102 kPa to about 110 kPa, including about 103 kPa, about 104 kPa, about 105 kPa, about 106 kPa, about 107 kPa, about 108 kPa, and about 109 kPa.

In certain embodiments of the process of the invention, the duration of puffing is between about 1 minute and about 30 minutes, including about 5 minutes, about 10 minutes, about 15 minutes, about 20 minutes, and about 25 minutes.

In certain preferred embodiments relating to faba bean and/or chickpea, the duration of puffing is between about 13 minutes and about 20 minutes, including about 14 minutes, about 15 minutes, about 16 minutes, about 17 minutes, about 18 minutes, and about 19 minutes.

In other preferred embodiments relating to chickpea, the duration of puffing is between about 23 minutes and about 29 minutes, including about 24 minutes, about 25 minutes, about 26 minutes, about 27 minutes, and about 28 minutes.

In certain preferred embodiments relating to sorghum the duration of puffing is between about 3 minutes and about 12 minutes, including about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes, about 8 minutes, about 9 minutes, about 10 minutes, and about 11 minutes. In preferred embodiments, during the puffing, a seed is "suspended in a continuous fluid stream", and more preferably a fluidising stream. In the context of the present invention, by "suspended in a continuous fluid stream" is meant distributed, mixed, dispersed, floated or otherwise maintained in a fluid stream or field so that the fluid-seed mixture behaves or exhibits fluid-like properties. This may be achieved by the introduction of pressurised gas through a seed at a rate or velocity sufficient to support the weight of the seed in a fluidised state. Suitably, exposing the seed to an elevated pressure by exposing the seed to a gas, such as air, having an elevated pressure, as hereinabove described, achieves fluidisation of the seed.

It will be further appreciated that the application of heating or cooling to a seed which is suspended in a fluid stream results in a homogenous or uniform temperature field. It will be appreciated that temperature transfer under such conditions results in consistent and controlled temperature treatment of the seed, thereby eliminating or minimising burnt seed and uneven temperature treatment.

In certain embodiments a puffed seed is cooled after puffing said seed.

In embodiments of the process of the invention wherein a puffed seed is cooled after puffing, said cooling may be performed by exposure to a gas or a liquid. Preferably, said cooling is performed by exposure to a gas. Preferably said gas is air.

In some preferred embodiments, cooling of a puffed seed is performed by exposing said puffed seed to pressurised air, thereby distributing said pressurised air throughout said puffed seed.

In certain embodiments wherein a puffed seed is exposed to pressurised air during a cooling phase, said seed is suspended in a continuous fluid stream during said cooling phase.

In certain embodiments wherein a puffed seed is cooled, the cooling temperature is at or below ambient temperature, for example between about 5°C and 30°C, including about 10°C, 15°C or 20°C or any temperature therebetween.

In certain embodiments of the process of the invention, the duration of the cooling phase is sufficient to cool the puffed seed to 22°C or lower.

In one preferred embodiment, the duration of the cooling phase is around 5 minutes.

In certain embodiments, a seed to be processed as described herein has been dehulled. It will be appreciated that in those embodiments which contemplate dehulled seed, the dehulling of a seed may not be complete and therefore a small amount of hull may be left on a seed.

The dehulling of a seed to be processed can be carried out using a decortication machine or an alternative abrasive process such as a rice pearler, similar to that used for de-hulling and polishing rice. The de-hulling process can be either a continuous or a batch process.

In general embodiments, a seed to be dehulled may be conditioned by exposing said seed to moisture, preferably for a period of between 12 and 24 hours. It will be appreciated that conditioning may assist the process of dehulling by loosening the hulls of a seed in order to make dehulling easier and reduce losses of the seed.

In certain embodiments, a seed to be processed as herein described has germinated. Inclusion of a germination step prior to processing may increase the content of substances that are desirable for a puffed seed food product.

Germination is a complex process that results in a number of significant biochemical changes in a seed. Generally, the conditions that support germination are adequate moisture, warm temperatures, and usually little or no light. Most seeds germinate best in the dark, although some require light. Germination can be induced by exposure of a seed to moisture under controlled conditions. Preferably, germination is performed under light-deprived conditions at room temperature.

The duration of germination can vary. Preferably, germination is performed for between 12 to 48 hours. More preferably, germination is allowed to proceed for about 24 hours.

In another aspect, the present invention provides a food product produced according to the process as herein described.

In a yet another aspect, the invention provides a puffed food product obtainable from a seed comprising:

(a) a total energy content of about 1200-1800 kJ per 100 g;

(b) a total saturated fat content of less than about 1.5 g per 100 g;

(c) a total sodium content of less than about 25 mg;

(d) a total fibre content of about 10-22 g per 100 g; and

(e) a moisture content of less than about 10 g per 100 g.

In certain embodiments, the total energy content is about 1250 kJ, about 1300 kJ, about 1350 kJ, about 1400 kJ, about 1450 kJ, about 1500 kJ, about 1550 kJ, about 1600 kJ, about 1650 kJ, about 1700 kJ, or about 1750 kJ; In certain embodiments, the total saturated fat content is less than about 1 g, or less than about 0.5 g.

In certain embodiments, the total sodium content is less than about 20 mg, less than about 15 mg, less than about 10 mg, or less than about 5 mg.

In certain embodiments, the total fibre content is about 11 g, about 12 g, about

13 g, about 14 g, about 15 g, about 16 g, about 17 g, about 18 g, about 19 g, about 20 g, about 21 g.

In certain embodiments, the total moisture content is less than about 3 g, less than about 4 g, less than about 5 g, less than about 6 g, less than about 7 g, less than about 8 g, and less than about 9 g.

In certain other embodiments, said puffed food product further comprises one or more of:

a total protein content of about 11-33 g per 100 g, including about 12 g, about 13 g, about 14 g, about 15 g, about 16 g, about 17 g, about 18 g, about 19 g about 20 g, about 21 g, about 22 g, about 23 g, about 24 g, about 25 g, about 26 g, about 27 g, about 28 g, about 29 g, about 30 g, about 31 g, and about 32 g per lOOg;

a total fat content of about 2-10 g per 100 g, including about 3 g, about 4 g, about 5 g, about 6 g, about 7 g, about 8 g, and about 9 g per lOOg;

a total monounsaturated fat content of about 1-2 g per 100 g, including about 1.1 g, about 1.2 g, about 1.3 g, about 1.4 g, about 1.5 g, about 1.6 g, about 1.7 g, about 1.8 g, and about 1.9 g per lOOg;

a total polyunsaturated fat content of about 1-6 g per 100 g, including about 1.5 g, about 2 g, about 2.5 g, about 3 g, about 3.5 g, about 4 g, about 4.5 g, about 5 g, and about 5.5 g;

a total trans fat content of less than about 0.01 g per lOOg;

a total carbohydrate content of about 45-70 g per 100 g, including about 50 g, about 55 g, about 60 g, about 65 g per 100 g; and

a total ash content of less than about 3 g, including less than about 2.5 g, less than about 2 g, less than about 1.5 g, less than about 1 g, and less than about 0.5 g.

In preferred embodiments, said food puffed product has a texture corresponding to a peak force of about 5 Newtons (N) to about 50 N, including about 10 N, about 15 N, about 20 N, about 25 N, about 30 N, about 35 N, about 40 N, and about 45 N. Preferably, a puffed seed product as herein described has a volume that is substantially increased, for example increased by greater than 2x, greater than 3x, greater than 4x, greater than 5x, greater than 6x, greater than 7x, greater than 8x, greater than 9x, or greater than lOx, relative to a corresponding unprocessed seed.

Preferably, a puffed seed product as herein described has a density of about 5 kg/m 3 to about 50 kg/m 3 , including about 10 kg/m 3 , about 15 kg/m 3 , about 20 kg/m 3 , about 25 kg/m 3 , about 30 kg/m 3 , about 35 kg/m 3 , about 40 kg/m 3 , and about 45 kg/m 3.

Preferably, a puffed seed product as herein described comprises a bean or a cereal grain.

In embodiments wherein said puffed seed product is a cereal grain, preferably said cereal grain is sorghum. Preferably, said cereal grain is red sorghum.

In preferred embodiments relating to sorghum, the density of said puffed seed product is about 10 kg/m .

In embodiments wherein said puffed seed product is a bean, preferably said bean is a chickpea or a faba bean.

In one preferred embodiment said chickpea is a desi chickpea. As will be understood by one skilled in the relevant art, "desi" chickpea varieties have comparatively small, dark coloured seeds, with comparatively rough hulls.

In another preferred embodiment said chickpea is a kabuli chickpea. As will be understood by one skilled in the relevant art, "kabuli" chickpea varieties have comparatively large, light coloured seeds, with comparatively smooth hulls.

In preferred embodiments relating to chickpea or faba bean, the density of said puffed seed product is between about 30 kg/m 3 and about 50 kg/m 3 , including about

35 kg/m 3 , about 40 kg/m 3 , and about 45 kg/m 3.

In preferred embodiments relating to desi chickpea, the density of said puffed seed product is about 43 kg/m .

In preferred embodiments relating to kabuli chickpea and/or faba bean, the density of said puffed seed product is about 35 kg/m .

In certain embodiments a puffed seed produced as herein described comprises a seed that is split. As used herein a "split" seed will be understood to mean a seed wherein said seed has been separated into a plurality of sections. In certain embodiments said split seed is separated along a 'raphe' or 'seam'.

In certain embodiments, a puffed seed as herein described is used as an ingredient in a food product. In certain embodiments wherein a puffed seed is used as an ingredient in a food product, flavourings and/or additives may be combined with the puffed seed. Said flavouring and/or additives may include, but are not limited to, one or more selected from the following group: a seasoning, for example pepper, cinnamon, chilli powder, tamari, and garlic; a sweetening agent, for example sugars including sucrose and fructose, honey, agave nectar, acesulfame potassium, and saccharin; a preservative agent, for example propionic acid, sulphur dioxide, and sorbic acid; a colouring agent including annatto, betanin, lycopene, tartrazine, and allura red; and a flavour enhancer, for example monosodium glutamate.

In certain embodiments wherein a puffed seed is used as an ingredient in a food product, said food product may be selected from, but is not limited to, the following group: a grain-based food product, a dairy based food product, a breakfast cereal, a baked product, a meat analogue, a crisp, a cookie, a cracker, a health bar, a nutrition bar, a snack bar, a liquid food product, a semi-liquid food product, a fruit juice, a vegetable juice, a sauce, a flour, a seasoning, and a spreadable food product.

In another aspect, the invention provides an apparatus for the production of a puffed food product from a seed, wherein said apparatus comprises a hydrating device for hydrating the seed operably connected to a puffing device for puffing the seed.

In yet another aspect, the present invention provides a system for the production of a puffed food product from a seed, wherein said system comprises:

(a) a hydrating device for hydrating the seed;

(b) a puffing device for puffing the hydrated seed operably connected to the hydrating device; and

(c) a control interface that controls the production of the puffed food product from the seed.

The apparatus and/or system may further comprise one or more of:

a heater or boiler for heating, or heating and hydrating the seed, between the hydrating device and/or the puffing device;

a draining device for draining the seed between the hydration device and/or the heater or boiler, and the puffing device; and

a cooling device for cooling the puffed seed from the puffing device.

In certain embodiments, the apparatus and/or system is capable of processing a seed at a rate of at least 30 kg/h to at least 400 kg/h to produce the puffed food product from the seed; including at least 50 kg/h, at least 100 kg/h, at least 150 kg/h, at least 200 kg/h, at least 250 kg/h, at least 300 kg/h, and at least 350 kg/h.

In preferred embodiments relating to faba bean, said apparatus and/or system is capable of processing the seed at a rate of at least 100 kg/h, at least 110 kg/h, or at least 120 kg/h.

In preferred embodiments relating to desi chickpea, said apparatus and/or system is capable of processing the seed at a rate of at least 110 kg/h, at least 120 kg/h, or at least 128 kg/h.

In preferred embodiments relating to kabuli chickpea, said apparatus and/or system is capable processing the seed at a rate of at least 30 kg/h, at least 35 kg/h, or at least 40 kg/h.

In preferred embodiments relating to sorghum, said apparatus and/or system is capable processing the seed at a rate of at least 300 kg/h, at least 350 kg/h, or at least 400 kg/h.

It will be appreciated that the above processing rates may refer to the rate of processing of a hydrated seed, after hydration of the seed by the hydration device of the apparatus and/or system.

Reference is now made to FIG. 1 which describes an embodiment of the apparatus and/or system.

System 10 comprises hydrating device 100 which receives seed or grain (e.g. chickpea, faba bean or sorghum) for hydration with water. Hydrating device 100 comprises bin 110. Typically, bin 110 is made of plastic and has a volume of about 120 litres, but this can be varied as desired. A seed or grain hydrated in bin 110 is transferred to work basket 510, such as by a bin tipper.

Work basket 510 containing seed or grain is then transferred to loading station

520. Loading station 520 positions work basket 510, such as using a pneumatic ram, for collection by a conveyor 500A, which may be a gantry crane. Conveyor 500A then transfers work basket 510 to boiler 200 for boiling of the hydrated seed or grain.

Boiler 200 comprises tank 210, such as a stainless steel tank, typically comprising a drain point for cleaning and/or as an additional point of water circulation. Boiler 200 further comprises heat source 220 for heating tank 210. Typically heat source 220 is a gas burner such as a liquid petroleum gas burner, but this can be varied as desired. Typically, boiler 200 further comprises: a reservoir for replacing liquid contained within tank 210 and/or diluting a seed or grain contained within tank 210; an exhaust point for removing heat, combustion products and/or steam; and an elevator for raising a work basket out of tank 210.

Optionally, system 10 may further comprise a draining device (not shown).

Seed or grain hydrated by hydrating by hydrating device 100, and/or heated by boiler 200, can be transferred to the draining device such as by a conveyer which may be a gantry crane. Excess water is then drained from seed or grain by the draining device.

Seed or grain hydrated by hydrating device 100, and/or heated by boiler 200, and/or drained by the draining device, can be transferred to puffing device 300 such as by conveyor 500B, which may be a gantry crane. Puffing device 300 then performs puffing of hydrated and/or boiled seed or grain contained by work basket 510.

Puffing device 300 comprises tank 310, such as an enclosable, stainless steel tank, typically comprising a rotating paddle for stirring seed or grain. Puffing device 300 further comprises pressurised air source 330, such as a high pressure fan, for delivering pressurised air to tank 310. Additionally, puffing device 300 comprises heat source 320 for heating tank 310. Typically, heat source 320 comprises a gas burner such as a liquid petroleum gas burner, but this can be varied as desired.

Typically, puffing device 300 further comprises: an exhaust point for releasing gas and/or removing dust and seed or grain fragments from tank 310; and an elevator that can raise a work basket out of tank 310.

Seed or grain puffed by puffing device 300 can be transferred to cooling device 400, such as by conveyor 500C, which may be a gantry crane. Cooling device 400 then performs cooling of seed or grain contained by work basket 510 by exposure to pressurised air.

Cooling device 400 comprises tank 410, such as an enclosable, stainless steel tank. Cooling device 400 further comprises pressurised gas source 420, such as a high pressure fan, for delivering pressurised air to tank 410. Typically, cooling device 400 further comprises: an exhaust point for releasing gas and/or extracting heat from tank 410; and an elevator for raising a work basket out of tank 400.

Seed or grain cooled by cooling device 400 can be transferred to storage device 600 for storage. Typically, storage device 600 is separated from hydrating device 100, boiler 200, puffing device 300, and cooling device 400 by one or more walls. Typically, a cooled seed or grain contained by work basket 510 is transferred to storage device 600 through a retractable opening in one of said walls, such as a 'separation opening baffle'.

Typically, storage device 600 transfers cooled seed or grain from a work basket using a vacuum, into a temporary storage container such as a stainless steel hopper.

Control interface 1000 controls the production of a puffed food product from a seed or grain (e.g. chickpea, faba bean, or sorghum) by system 10. Typically, control interface 1000 can control the production of the food product automatically. Control interface 1000 is connected to hydrating device 100, boiler 200, puffing device 300, and cooling device 400, via data portals 1300A-1300D, respectively. Typically, data portals 1300B-1300D convey data comprising information on temperature during boiling, puffing, and cooling performed by boiler 200; puffing device 300; and cooling device 400, respectively, typically as measured by a thermocouple. Control interface 1000 is further connected to conveyors 500A, 500B, and 500C, via data portals 1300E-1300G, respectively. Typically, control interface 1000 is also connected to loading device 520 via data portal 1300H and storage device 600 via data portal 13001. Typically, 1000 is further connected to a separating opening baffle via a data portal (not shown). Optionally, control interface 1000 may be connected to a draining device, and/or conveyors for moving seed to and/or from the draining device, by data portals (not shown).

Typically, control interface 1000 comprises a Programmable Logic Controller (PLC) 1100 for automatic control of system 10, and a Human Machine Interface (HMI) 1200 for manual control of system 10. Typically, HMI 1200 allows a user to create, edit, and/or store 'recipes' comprising specific parameters for the production of a puffed food product from a seed or grain.

Control interface 1000 typically further comprises a variable speed drive (VSD) recirculating fan; a high temperature limit controller; gas burner controllers; and exhaust controllers.

EXAMPLES

Examples 1-7 set forth preferred embodiments of the process of the present invention, and the specifications of products produced according to these preferred embodiments.

Example 1. Puffed Sorghum - Protocol I.

Methods All steps were performed using system 10 of the present invention as described above with reference to Figure 1.

1. Hydration. Raw sorghum grain was hydrated in potable mains supply water at 22°C for a period of 15 h in 120L plastic bin 110 using hydrating device 100.

2. Puffing. Hydrated sorghum grain was transferred to puffing device 300 and fluidised for 4 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the sorghum grain was continuously stirred by the rotating paddle. Air pressure was 103 kPa, and air temperature was 210°C. After 4 minutes fluidisation, pressure was released.

3. Cooling. Puffed sorghum grain was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. When the temperature of the product reached 22°C, cooling was ceased automatically by control interface 1000.

Results

After hydration as per step 1, sorghum grain was processed at a rate of 400 kg/h according to the above process to produce Puffed Sorghum. The specifications of the resulting Puffed Sorghum are set forth in Table 1.

Example 2. Puffed Sorghum - Protocol II.

Methods

All steps were performed using system 10 of the present invention as described above with reference to Figure 1.

1. Boiling. Raw sorghum grain was placed in boiler 200 and boiled for 15 minutes in stainless steel tank 210 for heating and hydration.

2. Puffing. Boiled, hydrated sorghum grain was transferred to puffing device 300 and fluidised for 4.5 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the sorghum grain was continuously stirred by the rotating paddle. Air pressure was 103 kPa, and air temperature was 210°C. After 4.5 minutes fluidisation, pressure was released.

3. Cooling. Puffed sorghum grain was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. After 5 minutes, cooling was ceased.

Results Raw sorghum grain was processed at a rate of 200 kg/h according to the above process to produce Puffed Sorghum. The specifications of the resulting Puffed Sorghum were as set forth in Table 1.

Example 3. Whole or Split Desi Chickpea Puffs - Protocol I.

Methods

1. Hydration. Raw whole or raw split desi chickpea was hydrated in potable mains supply water at 22°C for a period of 15 h in 120L plastic bin 110 using hydrating device 100.

2. Boiling. Hydrated whole or split desi chickpea was transferred to boiler 200 and boiled for 2 minutes in stainless steel tank 210 for heating and additional hydration.

3. Puffing. Boiled whole desi or split chickpea was transferred to puffing device 300 and fluidised for 17 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the desi chickpea was continuously stirred by the rotating paddle. Air pressure was 103 kPa and air temperature was 147°C. After 17 minutes fluidisation, pressure was released.

4. Cooling. Puffed whole or split desi chickpea was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. When the temperature of the product reached 22°C (~ 5 minutes) cooling was ceased automatically by control interface 1000.

Results

After hydration as per step 1, whole or split desi chickpea was processed at a rate of 128 kg/h according to the above process to produce Whole Desi Chickpea Puffs and Split Desi Chickpea Puffs. The specifications of the resulting Whole Desi Chickpea Puffs and Split Desi Chickpea Puffs are set forth in Table 2 and Table 3, respectively. Example 4. Whole or Split Desi Chickpea Puffs - Protocol II.

Methods

1. Hydration. Raw whole or split desi chickpea was hydrated at 22°C for a period of 12 h in 120L plastic bin 110 using hydrating device 100. 2. Simmering. Hydrated whole or split desi chickpea was transferred to boiler 200 and simmered at 90°C for 3 minutes in stainless steel tank 210 for heating and additional hydration.

3. Draining. Simmered whole or split desi chickpea was transferred to a drainer and drained for 5 minutes.

4. Puffing. Drained whole or split desi chickpea was transferred to puffing device 300 and fluidised for 16 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the desi chickpea was continuously stirred by the rotating paddle. Air pressure was 103 kPa and air temperature was 174°C. After 16 minutes fluidisation, pressure was released.

5. Cooling. Puffed whole or split desi chickpea was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. After 5 minutes, cooling was ceased.

Results

After hydration as per step 1, whole or split desi chickpea was processed at a rate of about 80 kg/h according to the above process to produce Whole Desi Chickpea Puffs and Split Desi Chickpea Puffs. The specifications of the resulting Whole Desi Chickpea Puffs and Split Desi Chickpea Puffs were as set forth in Table 2 and Table 3, respectively.

Example 5. Whole or Split Kabuli Chickpea Puffs - Protocol I.

Methods

1. Hydration. Raw whole or split kabuli chickpea was hydrated in potable mains supply water at 22°C for a period of 15 h in 120L plastic bin 110 using hydrating device 100.

2. Boiling. Hydrated whole or split kabuli chickpea was transferred to boiler 200 and boiled for 15 minutes in stainless steel tank 210 for heating and additional hydration.

3. Puffing. Boiled whole or split kabuli chickpea grain was transferred to puffing device 300 and fluidised for 26 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the kabuli chickpea was continuously stirred by the rotating paddle. Air pressure was 103 kPa, and air temperature was 147°C. After 26 minutes fluidisation, pressure was released. 4. Cooling. Puffed whole or split kabuli chickpea was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. When the temperature of the product reached 22°C (~ 5 minutes) cooling was ceased automatically by control interface 1000.

Results

After hydration as per step 1, whole and split kabuli chickpea was processed at a rate of 80 kg/h according to the above process. The specifications of the resulting Whole Kabuli Chickpea Puffs and Split Kabuli Chickpea Puffs are set forth in Table 4 and Table 5, respectively.

Example 6. Whole or Split Kabuli Chickpea Puffs - Protocol II.

Methods

1. Hydration. Raw whole or split kabuli chickpea was hydrated in potable mains supply water at 22°C for a period of 12 h in 120L plastic bin 110 using hydrating device 100.

2. Simmering. Hydrated whole or split kabuli chickpea was transferred to boiler 200 and simmered at 90°C in water for 15 minutes in stainless steel tank 210 for heating and additional hydration.

3. Draining. Simmered whole or split kabuli chickpea was transferred to a drainer and drained for 10 minutes.

4. Puffing. Drained whole or split kabuli chickpea grain was transferred to puffing device 300 and fluidised for 26 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the kabuli chickpea was continuously stirred by the rotating paddle. Air pressure was 103 kPa and air temperature was 147°C. After 26 minutes fluidisation, pressure was released.

5. Cooling. Puffed whole or split kabuli chickpea was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. After 5 minutes, cooling was ceased.

Results

After hydration as per step 1, split kabuli chickpea was processed at a rate of 80 kg/h according to the above process. The specifications of the resulting Whole Kabuli Chickpea Puffs and Split Kabuli Chickpea Puffs were as set forth in Table 4 and Table 5, respectively. Example 7. Faba Bean Splits - Protocol I

Methods

1. Hydration. Raw split faba bean was hydrated in potable mains supply water at 22°C for a period of 15 h in 120L plastic bin 110 using hydrating device 100.

2. Boiling. Hydrated split faba bean was transferred to boiler 200 and boiled in water for 2 minutes in stainless steel tank 210 for heating and additional hydration.

3. Puffing. Boiled split faba bean was transferred to puffing device 300 and fluidised for 16 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the faba bean was continuously stirred by the rotating paddle. Air pressure was 103 kPa and air temperature was 160°C. After 16 minutes fluidisation, pressure was released.

4. Cooling. Puffed split faba bean was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. When the temperature of the product reached 22°C cooling was ceased automatically by control interface

1000.

Results

After hydration as per step 1, split faba bean was processed at a rate of 120 kg/h according to the above process to produce Faba Bean Splits. The specifications of the resulting Faba Bean Splits are set forth in Table 6.

Example 8. Faba Bean Splits - Protocol II

Methods

1. Hydration. Raw split faba bean was hydrated in potable mains supply water at 22°C for a period of 12 h in 120L plastic bin 110 using hydrating device 100.

2. Simmering. Hydrated split faba bean was transferred to boiler 200 and simmered at 90°C in water for 2 minutes in stainless steel tank 210 for heating and additional hydration.

3. Draining. Simmered whole or split kabuli chickpea was transferred to a drainer and drained for 2 minutes.

4. Puffing. Drained split faba bean was transferred to puffing device 300 and fluidised for 16 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the faba bean was continuously stirred by the rotating paddle. Air pressure was 103 kPa and air temperature was 160°C. After 16 minutes fluidisation, pressure was released.

5. Cooling. Puffed split faba bean was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. When the temperature of the product reached 22°C (~ 5 minutes) cooling was ceased automatically by control interface 1000.

Results

After hydration as per step 1, split faba bean was processed at a rate of about 80 kg/h according to the above process to produce Faba Bean Splits. The specifications of the resulting Faba Bean Splits were as set forth in Table 6.

Example 9. Chana Dahl - Protocol I.

Methods

1. Hydration. Raw split desi chickpea was hydrated in potable mains supply water at 22°C for a period of 15 h in 120L plastic bin 110 using hydrating device 100.

2. Boiling. Hydrated split desi chickpea was transferred to boiler 200 and boiled in water for 10 minutes in stainless steel tank 210 for heating and additional hydration. 3. Puffing. Boiled split desi chickpea was transferred to puffing device 300 and fluidised for 17 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the desi chickpea was continuously stirred by the rotating paddle. Air pressure was 103 kPa and air temperature was 150°C. After 17 minutes fluidisation, pressure was released.

4. Cooling. Puffed split desi chickpea was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. When the temperature of the product reached 22°C cooling was ceased automatically by control interface 1000.

Results

After hydration as per step 1, split desi chickpea was processed at a rate of 128 kg/h according to the above process to produce Chana Dahl. The resulting Chana Dahl had a density of 43.5 kg/m .

Example 10. Chana Dahl - Protocol II.

1. Hydration. Raw split desi chickpea was hydrated in potable mains supply water at 22°C for a period of 12 h in 120L plastic bin 110 using hydrating device 100.

2. Simmering. Hydrated split desi chickpea was transferred to boiler 200 and simmered at 90°C in water for 10 minutes in stainless steel tank 210 for heating and additional hydration.

3. Draining. Simmered split desi chickpea was transferred to a drainer and drained for 5 minutes.

3. Puffing. Drained split desi chickpea was transferred to puffing device 300 and fluidised for 1 minutes in pressurised, heated air in enclosed, stainless steel tank 310 comprising a rotating paddle. During fluidisation, the desi chickpea was continuously stirred by the rotating paddle. Air pressure was 103 kPa and air temperature was 150°C. After 17 minutes fluidisation, pressure was released.

4. Cooling phase. Puffed desi chickpea was transferred to cooling device 400 and exposed to pressurised air at 22°C in enclosed, stainless steel tank 410. When the temperature of the product reached 22°C (~ 5 minutes) cooling was ceased automatically by control interface 1000.

Results

After hydration as per step 1, split desi chickpea was processed at a rate of 80 kg/h according to the above process to produce Chana Dahl. The resulting Chana Dahl had a density of 43.5 kg/m .

Throughout the specification, the aim has been to describe the preferred embodiments of the invention without limiting the invention to any one embodiment or specific collection of features. Various changes and modifications may be made to the embodiments described and illustrated without departing from the present invention. The disclosure of each patent and scientific document, computer program and algorithm referred to in this specification is incorporated by reference in its entirety. TABLES

Table 1. Specifications of Puffed Sorghum produced according to the processes described in Example 1 and Example 2.

Table 2. Specifications of Whole Desi Chickpea Puffs produced according to the processes described in Example 3 and Example 4.

Density 42.74 kg/m

Table 3. Specifications of Split Desi Chickpea Puffs produced according to the processes described in Example 3 and Example 4.

Table 4. Specifications of Whole Kabuli Chickpea Puffs produced according to the processes described in Example 5 and Example 6.

Density 34.0 kg/n

Table 5. Specifications of Split Kabuli Chickpea Puffs produced according to the processes described in Example 5 and Example 6.

Table 6. Specifications of Faba Bean Splits produced according to the processes described in Example 7 and Example 8.

Claims

1. A process for the production of a puffed food product, including the steps of: (a) hydrating a seed; and (b) puffing said hydrated seed to thereby produce the puffed food product, wherein said puffing includes heating at a temperature between about 125°C and about 235°C.

2. The process of Claim 1, wherein the duration of hydration is between about 2 hours and about 24 hours; between about 6 hours and about 20 hours; or between about 12 hours and about 18 hours.

3. The process of Claim 1 or Claim 2, wherein the heating temperature during puffing is between about 130°C and about 170°C, or between about 190°C and about 230°C.

4. The process of any one of Claims 1-3, wherein the duration of puffing is between about 3 minutes and about 30 minutes, between about 13 minutes and about 20 minutes, between about 3 minutes and about 12 minutes, or between about 17 minutes and about 22 minutes.

5. The process of any one of the preceding claims, wherein said puffing includes exposing the seed to elevated pressure, and the pressure during puffing is greater than 100 kPa, around 102 kPa to around 110 kPa, around 103 kPa, or around 104 kPa.

6. The process of any one of the preceding claims, wherein the hydrated seed is heated after hydration and/or prior to puffing said seed.

7. The process of Claim 6 wherein the temperature during heating is between about 90°C to about 100°C.

8. The process of Claim 6 or Claim 7, wherein the seed is heated in water during hydration and/or prior to puffing.

9. The process of any one of Claims 6-8, wherein the duration of heating is between about 1 and about 20 minutes, about 2 minutes, about 10 minutes, or about 15 minutes.

10. The process of claim 8 or claim 9, wherein the seed is drained after heating in water, and wherein the duration of draining is between about 1 minute to about 15 minutes.

11. The process of any one of the preceding claims, wherein the seed is cooled after puffing by exposure to a pressurised gas, wherein the temperature of said gas is between about 5°C and about 30°C.

12. The process of Claim 11, wherein the cooling is ceased after about 5 minutes, and/or after the puffed seed reaches a temperature of about 22°C.

13. The process of any one of the preceding claims, wherein the seed is a cereal or a bean.

14. The process of Claim 13, wherein the seed is sorghum.

15. The process of Claim 14, wherein the bean is a faba bean or a chickpea.

16. A food product produced according to the process of any one of the preceding claims.

17. A food product obtainable from a seed comprising:

(a) a total energy content of about 1200-1800 kJ per lOOg;

(b) a total saturated fat content of less than about 1.5g per lOOg;

(c) a total sodium content of less than about 25 mg;

(d) a total fibre content of about 10-22g per lOOg; and

(e) a moisture content of less than about lOg per lOOg.

18. The food product of Claim 17 comprising one or more

(a) a total protein content of about 11-33 g per 100 g; (b) a total fat content of about 2-10 g per 100 g;

(c) a total monounsaturated fat content of about 1-2 g per 100 g;

(d) a total polyunsaturated fat content of about 1-5 g per 100 g;

(e) a total carbohydrate content of about 45-70 g per 100 g;

(f) a total ash content of less than about 3 g;

19. The food product of any one of Claims 16-18 comprising a density of about 5 kg/m 3 to about 50 kg/m 3 , about 30 kg/m 3 to about 50 kg/m 3 , about 10 kg/m 3 , about 35 kg/m 3 , or about 43 kg/m 3.

20. The food product of any one of Claims 16-19 comprising a texture of about 5 N to about 50 N.

21. The food product of any one of Claims 16-20, wherein the food product is a cereal or a bean.

22. The food product of Claim 21, wherein the seed is sorghum.

23. The food product of Claim 21, wherein the bean is faba bean or chickpea.

24. A method of producing a food product including the step processing the puffed food product of any one of Claims 16-23 to thereby produce the food product.

25. The use of any one of Claims 16-23 for human consumption.

26. An apparatus for the production of a puffed food product from a seed, wherein said apparatus comprises a hydrating device for hydrating the seed operably connected to a puffing device for puffing the seed.

27. A system for the production of a puffed food product from a seed, wherein said system comprises:

(a) a hydrating device for hydrating the seed;

(b) a puffing device for puffing the seed operably connected to the hydrating device; and (c) a control interface that controls the production of the puffed food product from the seed.

28. The apparatus of Claim 26 or the system of Claim 27, comprising a heater for heating the seed between the hydrating device and the puffing device.

29. The apparatus or system of Claim 27, wherein said apparatus or system is capable of processing a seed at a rate of at least 30 kg/h to at least 400 kg/h to produce a puffed food product.