Note: Descriptions are shown in the official language in which they were submitted.
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The prior ark has long sought methods of pro-
ducing starchy foodstuffs which the consumer could prepare
directly from the freezer. The commercial prodllction of
such foodstuPfs generally involves hydrating and mixing a
starchy base, shaping into a specific shape and then
optionally precooking then freezing and packaging. Many
problems were faced in several of these steps.
Using fresh vegetables as the starchy foodstuff
base seemed to result in a product which had a less than
optimum flavor. In the prior art as in the instant inven-
tion it has been found that using dehydrated vegetables
produces a product with a decided flavor advantage.
However, in using dry starchy foodstuff bases such as
dehydrated vegetables, the serious limitation that once
hydrated they would not bind sufficiently to hold a specific
shape was encountered. The prior art attempted to solve
this problem by using thermal gelling binders with dehy
drated vegetables, as in U.5. Patent 3,399,062. Generally
this combination still did not bind together sufficiently
to be used in high speed patty making machines or the like
where strong binding properties in the product were neces-
sary. Also using gums as binders generally resulted in a
sticky gummy product with a slimy texture. Thus, the taste
and texture of the resultant were considered inadequate.
The prior art also attempted to use starch binders
as in U.S. Patent 2,785,981 but generally the product
obtained could not keep a shape, was very sticky, wet and
gummy and was difEicult to handle. These binders wexe
unsuitable where strong binding properties were needed.
Not only would most of the common starch binders not have
sufficient binding properties to enable one to make patties
but upon introduction of the patty into the fryer the
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patties would fall apartu Many of these starches also had
drawbacks as to the resultant texture and Elavor, resulting
sometimes in a grainy texture and other times in a sticky,
wet or slimy texture.
When the additional step of pre-cooking by deep
fat frying is desired for the starchy foodstuf the result
of this step is characterized by substantial product loss
and oil pickup. This greatly increases the costs and
decreases the quality of the product and thereby limits it.
The present invention is intended to sa~isfy the
need for a process of making a product based on a dry
starchy foodstuf which can hold its form in shaping pro-
cesses, and produce a product with desirable texture and
taste which can be handled relatively easily.
The present invention also provides a process for '
minimizing solids loss and oil pickup which occur in deep
fat frying.
The objects of this invention are accomplished by
hydrating a dry starchy foodstuff base, where an effective ~ -
20 amount of a raw or pregelatinized modiied tapioca starch -~
is added to bind the starchy foodstuf when shaped. The
tapioca starch which is added is either pregelatinized and
then modified to cleave the granules sufficiently to pro-
duce a shorter less stringy textured starch or is a raw
tapioca starch which is partially gelatinized before the
shaping step through subjecting the raw tapioca starch to
temperatures over the ~elatinization temperature range of
tapioca starch (125~F-145F~ for a period of time effective
to partially gelatinize the tapioca starch. The starchy
foodstuff base is then shaped within the temperature range
of about 32F to about 150F and preferably within about
32F to ab~ut 50F.
The optional frying step is carried out by placing
the shaped starchy foodstuff into the fryer with the food-
stuff as cool as practical without being frozen and prePer-
ably within the temperature range of about 32F to 50F.
Then either after the shaping or frying step the foodstuff
can be subsequently frozen, stored, and packaged for latter
use.
The objects, aspects, features and advantages of
the instant invention will become manifest during the
following description of the invention.
The process of this invention comprehends working
a dry starchy foodstuff base which has been hydrated. This ~
dry starchy foodstuff base includes such items as dehydrated ; --
potato shreds, dehydrated potato flakes, rice, macaron:i r
etc. The dry staxchy foodstuff base is not thus limited hy
these examples but include such categories as dehydrated
v getahles and alimentary pastes. The moisture level of
the starchy foodstuff base prior to hydration with water is
preferably less than 10% and after preferably from about
65~ to 85~. The temperature of hydration used is not
critical and has no significant effect on the resultant
product. The only diference being the lower the tempera-
ture the more time will have to be allowed for the parti-
cles to rehydrate~ The tapioca starch is added to the
starchy foodstuff base in an amount effective to bind the
hydrated starchy foodstuff in the shaping step. The
tapioca starch used i~ either a raw tapioca or a pregela-
tinized modified tapioca~
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The raw tapioca starch is added before the shaping
step and is then subjected to temperatures over the gela-
tinization range (125F - 145F) of tapioca starch Eor a
period of time effective to partially gelatinize the
tapioca starch. The raw tapioca starch is ef~ectively
employed at levels of about 5% to 20% by weight and prefer-
ably about 9 to 11~ by weight (the total weight being the
final weight of the shaped starchy foodstuff). If hydration
temperatures above the gelatinization range of tapioca
starch are employed, it is then preferable to add the raw
tapioca starch after hydration so the raw tapioca starch is
not subjected to gelatinization temperatures for a pro--
longed period of time. If the raw tapioca starch is
subjected to gelatinization temperatures for a prolonged
period of time it becomes completely gelatinized thus
making the product sticky and gummy. This partial gelatini~
zation imparts the tapioca starch with the binding properties
necessary to bind the hydrated starchy base without the
sticky wet or gummy characteristics common to other starch
binders such as pregelatinized (completely gelatinized)
tapioca starch, corn starch, potato starch and others.
Pregelatinized tapioca starch which has been
modified to cleave the granules su~ficiently to produce a
shorter, les~ stringy textured starch may also be used.
The modification of the pregelatinized tapioca starch
results in the same desirable binding characteristics as
present in partially gelatinized tapioca starch. These
tapioca starches are the only starch binders known to
applicants which bind the starch foodstuff sufficiently to
be used in shaping processes which require strong binding
properties and which do not impart a sticky, wet, or gummy
characteristics to the foodstuff making their handling
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difficult and the resultant texture undesirable. The
pregelatinized modified tapioca starch does not requi.re any
gelatinization as in the raw tapioca starc:h and it is not
necessary to subject it to temperatures over the ge:La~iniza-
tion range, although it can be without any adverse effect.
The pregelatinized modified tapioca starch is added either
before hydration or preferably after hydration where it is
mixed into the hydrated starchy foodstuff base along with
any flavoring ingredients desired. The pregelatinized ~:
modified tapioca starch is effectively employed at levels
of about 1% to 15% by weight, preferably between about 2%
to 10% by weight and optimumly at about 3% to 4% by weight
(the total weight being the weight of the shaped starchy
~oodstuff).
The minimum particle size of the dry starchy
foodstuEi base is where about 80% of the particles are
greater than 40 mesh (U.S. Standard) size so as to exclude
10urs and similar sized particles. Inclusive in the term
particles are granules, shreds, flakes, noodles, pieces,
etc. The maximum particle si~e is only limited by practical-
ity and the shape and size of the product being formed.
The most preferred size is when the dry starchy oodstuff
base is in shred ~orm. In this form the optimum binding
characteristics are obseryed along with a desirable texture.
The first step o the process is hydrating the
dry starchy foodstuf base. When raw tapioca starch is
used as the binder it is added after hydration if hydration ;~
temperatures over the gelatinization range (125F - 145F)
of tapioca starch are employed. The mixture is then
subjected to temperatures greater than about 125F for a
period o time efecti~e to partially gelatinize the
tapioca starch. ~his preerably involves adding the raw
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tapioca starch to the hydrated starchy foodstuff base while
it is still over 125F due to the hydration temperatures,
then cooling the mixture to prevent complete gelatinization.
If hydration temperatures below the gelatinization range of
raw tapioca starch are employed or are below about 125F
then the raw tapioca s-tarch can be added either before or
after hydration, and subsequent to hydration the tapioca
starch is subjected to temperatures greater than about
125F for a period of time effective to partially gelatinize
10 ~che tapioca starch. -~
When pregelatinized modified tapioca starch is
used as the binder, it can be added either before or after
the hydration step with the temperature of hydration not
being critical as it was with raw tapioca starch. The
additional flavorings, spices or ingredients can be option-
ally added, preferably after the hydrating step, to enhance
or change the character of the resultant foodstuff. Examples
of such ingredients are onions~ eggs, butter, cheeses,
tomatoes, sour cream, etc.
After hydration, the hydrated starchy foodstuff
base with tapioca starch and any additional ingredients
desired to be mixed into it is then shaped. This shaping
can take several forms as commonly known in the prior art
~patty making, extruding, sheeting, etc.)~ Because the
mixture has su~ficient binders the mixture is easily shaped
within the temperature range of about 32F to 150F and ^~
handles and ~inds sufficiently, overcoming the limitations
that hinaered prior art. Preferably the shaping is carried
out while the hydrated starchy foodstuff is within the
temperature range from about 32F to 50F as the binding
properties of the tapioca starches are maximized in this
ranye.
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After this step the shaped mixture can be option-
ally pre-cooked and, if pre-cooked it is usually deep fat
fried. The vital point of this step is to introduce the
shaped starchy foodstuff into the deep fat fryer while the
shaped starchy foodstuff is as cool as practical without
being frozen and preferably is within the tempera-ture range
of about 32F to about 50~F. This may involve an additional
cooling step before introduction into the fryer to adjust
the temperature of the shaped starchy foodstuff. As shown
in Tables I and II the cooler the temperature of the shaped
starchy foodstuff upon introduction into the fryer, the
less weight loss and oil pickup occurs. This is especially
important as it is critical in obtaining an eficient
process to minimize weight loss and oil pickup.
The following preferred steps are common to the
prior art and in an embodiment of this invention can be
eliminated, substituted, or switched around w~th other
common steps.
Either after the optional frying step, or after
the shaping step, the product is cartoned, then frozen, and
subsequently cased. The product can then be distributed
and when used by the consumer can be prepared directly from
the freezer by frying, baking, broiling or grilling. In
this process, a product which has an extremely easy prepara-
tion by the consumer, which also has variety, can be formed
into individual servings, requires minimal clean-up and
which is resistant to shipplng damage r is produced.
EXAMP~E I
Fifteen pounds of dehydrated po~ato shreds having
a moisture content of about ~.5% and an average particle
size of 3/2" x 3~16" x 1~16" are mixed with 70 pounds of
boiling water and allowed to stand for 30 minutes to insure
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rehydration of the potato shreds. Then the flavorings and
10 pounds of raw tapioca starch axe added and mixed
thoroughly into the hydrated potato shreds while the
hydrated potato shreds are above about 125~. ;
The mixture is then shaped into round 2 ounce
patties through use of a high speed patty making machine ;
and the patties are then cooled to within the temperature
range of about 32F to about 50F and then fried in oil at
a temperature of 375F for 50 seconds or until the desired ~-~
amount of browning of the patties, is achieved.
The fried patties are then packaged and subse-
quently frozen for storage.
EXAMæLE II
22.5 pounds of dehydrated potato flakes, having a
moisture content of about 5% and a particle size where less
than 20% of the flakes are less than 40 mesh and less than
10% greater than 4 mesh (U.S. Standard) are mixed with 1
pound of pregelatinized modified tapioca starch and 55
pounds of boiling water. Then any additional flavoring
desired is added and subsequently the resultant mixture is
shaped into round 2 ounce patties by a high speed patty
making machine. The patties are then frozen and packaged
and stored for later use.
When the consumer prepares the frozen patties,
the patties can be taken directl~ from the ~reezer and ~ ;
either grilled, fried, baked or broiled for approximateLy
15 minutes or until ~rowned.
The xesultant flavor and texture is surprisingly
good and with a potato texture and flavor not previously ~; -
expected ~rom frozen potato patties~
EXAMPLE III
Fifteen pounds of dehydrated potato shreds having
a moisture content of about 2.5% and an average size of
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about 3/2" x 3/16" x 1/16'i are mixed with 70 pounds of
boiling water and allowed to stand for 30 minutes to insure
rehydration of the potato shreds. Then flavorings and 4
pounds of pregelatinized modified tapioca starch are added
and mixed thoroughly into the hydrated potato shreds.
The mixture is then shaped into round 2 ounce
patties through use of a high speed patty making machine
and the patties are then cooled to within the temperature
range of about 32F to about 50F and then fried in oil at "`' ,
a temperature of 375F for 50 seconds or until the desired ~ ';,
amount of browning of the patties.
The fried patties are then packaged and subse- ~ ,
quently fro~en for storage. '
EXAMPLE IV
The temperature of the patties before introduction
into the fryer is varied to determine its effects on weight ~ '
loss and oil pickup. ~ ,
The patties were prepared according to Example
III and were fried in oil at a temperature of 375F for 50
20 seconds or until browned.
TABLE I
Patty Temperature % Net W,e_ght Loss
,.
35F
60F 6.0
70F 5 9 ;
90F 8.0
lOQF 8.9
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TABLE II ::
Patty Temperature % Fat Uptake
43F 3.6
55F 3.2
70F 3.
75F 4.00
94F 4.20
100F 5.05 .
The results as shown in Table I and II clearly
show that the higher the patty temperature before intro-
duction into the fryer the greater the weight loss and oil :~
pickup. Therefore when frying is the next des.ired step one ~.
can obtain a more efficient process through lowering the
patty temperature to as cool as practical without freezing
the patty before its introduction into the fryer.
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