Note: Descriptions are shown in the official language in which they were submitted.
1 1~13~)~
PRODUCTION OF ORIENTAL-STYLE BREADING CRUMBS
The present invention relates to the production
of oriental-style breading crumbs.
Oriental-style breading crumbs, also referred
to as Japanese-style breading crumbs and Panko-style
breading crumbs, are characterized by an elongate shape
having a coarse, splintered appearance. These breading
crumbs are used to provide a tender texture and
crispiness to a variety of fried food products, such as,
seafoods, poultry and red meat, which is considered
desirable.
These breading crumbs conventionally are formed
15 by a procedure which involves a conventional proofed
dough preparation followed by rapid baking using the
electrical resistance of the dough as a means of heating.
Bread flour, optionally in admixture with rice 10ur, is
combined with water, salt and yeast, and optionally
sugars and shortening, in proportions normally used in
conventional bread making. The ingredients are mixed in
a standard batch dough mixer for about 5 to 8 minutes and
the dough batch so formed is transferred to a container
for a bulk fermentation period of about 30 to 60 minutes.
The dough then is divided into five to seven
pound portions and placed in rectangular wooden
containers in which the longer dimension is vertical and
approximately 18 inches with the horizontal surface being
about 6 inches x 10 inches in cross section. The two
larger vertical faces of the container are covered with
3 a sheet metal, which acts as an electrical conductor.
The dough is allowed to proof in the containers
for an hour, during which period the dough expands
vertically. Baking is effected by passing an electrical
current through the proofed dough for about 12 minutes,
~3~
,,,
, i1
~ lSl~
which further elongates the dough by expansion of the
yeast-formed gas cells and formation of water vapour in
the porous dough. The cooked dough is removed from the
containers after a brief cooling period and allowed to
fully cool, evaporate and stale overnight. The bread is
then ground to the required mesh size and dried to the
desired final moisture content.
The present invention is concerned with an
improved process for the formation of oriental-style
breading crumbs which is continuous in nature, involves
considerably shorter time periods and greatly reduced
space and labour requirements than the prior art, and is
more versatile than the prior art with respect to the
form of the product which is produced.
In accordance with the present invention, a
leavened dough first is formed from bread forming
ingredients, a tow is formed from the dough, the tow is
stretched to effect elongation of the pores within the
leavened dough, the stretched dough i~ baked while
maintaining the dough in its stretched form, the baked
dough is comminuted to form the breading particles, and
the comminuted particles are dried to the desired
moisture level.
The initial bread-forming ingredients used in
the process of the invention may comprise any of the
25 components conventionally used in bread-making and
itemized under the Standards of Identity, U.S. FDA
Regulations 21 C.F.R. 136.110 to .180 inclusive. The
basic components of any dough are flour and water, the
term "flour" including farinaceous flours used alone or
30 in combination with other flours and meals, such as, the
permitted materials outlined in 21 C.F.R. 137.105 to .350
inclusive, as well as those of legumes, rye, sorghum and
rice. Usually the flour used comprises a major
proporti~n of hard wheat flour.
Varying amounts of dough-fGrming components may
be used, usually including sugar, salt and vegetable
I i&~
shortening in varying proportions, depending on the
characteristics desired in the product and the flour
used. Other bread-forming components which may be used
include oxidizing, maturing and improving agents, such
as, potassium bromate, azodicarbonamide, cysteine
hydrochloride and ascorbic acid. Yeast, and amylolytic
and proteolytic enzymes also may be included, to modify
texture and flavour in the product. Emulsifiers and
cell-wall improvers may be used.
Leavening of the dough may be effected in this
invention utilizing any convenient leavening agent. It
is preferred to effect the leavening using gaseous
materials, such as, carbon dioxide, nitrogen, air, or
mixtures of gases, alone or in combination with chemical
leavening using leavening gas-producing chemicals. Such
leavening gas-producing chemicals include a combination
of sodium bicarbonate and sodium aluminum phosphate or a
combination of sodium bicarbonate and monocalcium
phosphate.
Yeast leavening may be used but is less
preferred since longer holding times are required,
thereby increasing equipment space requirements, and a
lesser quality of product is obtained. The presence of
more than small quantities of salt tends to inhibit the
25 leavening effect of yeast. Where leavening i5 effected
using gaseous materials, more than the usual small
quantities of salt may be used, enabling variations in
flavour to be achieved.
Further, where leavening is effected using
30 gaseous materials, alone or in combination with chemical
leavening, as in the preferred embodiment of the
invention, yeast, however, may be used as a flavour
enhancer in the dough.
The various proportions of dough-forming
35 ingredients used to form the dough depend on the
properties desired, the flour used and also on the nature
and choice of components. One suitable composition of
ingredients, exclusive of water, which may be utilized in
this invention, as a dry mi~, includes:
1 16~3~)~
Hard wheat flour - 100 parts by weight
Sugar - up to about 5~ by weight of
flour
Salt - up to about 5% by weight of
flour
Vegetable shortening - up to about 8% by weight of
flour
In addition, one or more of the following optional
components may be present, based on the weight of flour:
Yeast - 0 to about 4% by weight
Yeast food - about 0.2 to about 0.35% by weight
when yeast is present
Corn sugar - 0 to about 1.0% by weight
Mono and/or
diglycerides - 0 to about 0.5% by weight
TWEEN
surfactant - 0 to about 1.0% by weight
Another suitable composition of ingredients
also useful as a dry mix in this invention, utilizing a
mixture of flours, may comprise:
Hard wheat flour - about 67 parts by weight
Soft wheat flour - about 33 parts by weight
Sugar - up to about 5~ by weight
of flour
Vegetable shortening - up to about 8~ by weight
of flour
Salt - up to about 5~ by weight of
flour
In addition, one or more of the following
optional components may be present in the latter dry mix,
based on the weight of flour:
Yeast - 0 to about 4~ by weight
Yeast food - about 0.2 to about 0.35~ by weight
when yeast is present
Protease - about 10,000 to 50,000 H.U.
(haemoglobin units)/100 lbs of
flour
Amylase - about 2000 to about 8000 SKB
units) Standstedt, Keen, and
* Trademark
,
~'. L
.
Blish)/100 lbs of flour
Mono and/or
diglycerides - 0 to about 0.5% by weight
"Tween"
5 surfactant - 0 to about 1.0~ by weight
Corn sugar - 0 to about 1.0% by weight
Products made from the preceding compositions,
while use~ul in certain end uses, are somewhat inferior,
in that they lack fry tolerance, lack flavour, have
inferior structure and tend to have a dark appearance.
In a preferred embodiment of this invention,
flavour-enhancing and texture-modifying premixes or brews
are used to improve texture, flavour, fry tolerance and
structure of the product and to provide a wide variety of
15 properties. One or more of these properties may be
improved over the corresponding property of the
oriental-style crumb produced by conventional procedures.
The flavour-enhancing and texture-modifying
premixes include enzyme systems which are used in a
20 concentrated brew along with a minor proportion, usually
less than about 20~ by weight, of the total proportion of
flour used and a major proportion, usually about 50 to
80% by weight, ~f the inlet moisture. The brew is
fermented for a short perio~ of time, typically about 30
25 minutes at about 90 to 105F, during which time the
amylases and proteases have suficient timeOto modify the
flour and provide a desired texture and other properties
in the final product.
A brew mix which may be used in this way
30 contains, based on total flour in the overall
dough-forming composition:
Hard wheat flour - about 5 to about 20% by weight
Water - about 35 to about 55% by weight
Proteolytic enzyme - about 25,000 to about 85,000
H.U.per 100 lb of flour
Amylolytic enzyme - about 1250 to about 8000 SKB
units per 100 lb of flour
The above-described brew mix, after completion
of the fermenting period, is used in this embodiment of
the invention in association with such addit-ional water
as may be required to provide the desired overall
moisture content and with a dry mix comprising, by weight
of total flour in the overall dough-forming composition:
Hard wheat flour - about 80 to about 95% by weight
Vegetable shortening - up to about 8~ by weight
Chemical leavening
agents - up to about 4% by weight
Sugar - up to about 5% by weight
Salt - up to about 5% by weight
This dry mix may also contain optional
ingredients, based on total flour in the overall
dough-forming composition, namely:
Mono and/or
diglycerides - 0 to about 0~5% by weight
Tween surfactant - O to about 1.0% by weight
Corn sugar - 0 to about 1.0% by weight
The dough-forming ingredients are mixed
together to form a dough. In a preferred embodiment of
the procesn of this invention, the dough-forming
ingredients are fed to inlets at one end of a continuous
mixing zone capable of plug flow therethrough. The
mixing zone may take the form of an elongate screw-type
mixer-extruder, suitably modified to provide the required
processing conditions therein. The dough-forming
components are fed to one end of the mixer in relative
proportions suitable to provide an overall moisture
content of intermixed components of about 38 to about 50%
by weight, preferably about 42 to about 47~ by weight.
30 The dry mix, water, and any flavour-enhancing and texture
modifying ferment, are usually separately fed to the
mixer.
Within the mixing zone, the dough-forming
ingredients are continuously intermixed while they are
35 conveyed from one end of the mixing zone to the other,
over a period of time about 20 to about 120 seconds,
preferably about 30 to about 60 seconds.
A plurality of spaced gaseous inlets is
provided along the length of the mixing ~one and a
gaseous leavening material, or mixture of such gaseous
materials, is injected into the mix through the openings.
Carbon dioxide usually is used as the gaseous leavening
material, often in admixture with nitrogen, although
other gaseous leavening materials may be used, including
air and oxygen. The total gas feed to the ~ixing zone is
in the range of about 1.0 to about 10 SCF, preferably
about 2 to about 4 SCF, per 100 lb of dough.
The carbon dioxide, or other gaseous material,
may be used as the sole leavening agent, although it is
usually preferred in the continuous process mode of the
invention to employ chemical leavening agents in addition
to the carbon dioxide. When such chemical leavening
agents are present, the carbon dioxide tends to stabilize
the pore structure.
The dough-forming components and the injected
gas, as well as in-situ produced gas when the chemical
leavening agents are used, are subjected to high shear
forces within the mixing zone, sufficient to cause
simultaneous uniform mixing of the components and
dispersion of the gases throughout the mix. The work
done ~n the dough within the mixing zone varies from
about 4 to about 16 watt hr/lb of dough, preferably about
8 to about 12 watt hx/lb.
The mix of dough-forming components and inert
gas usually is heated within the mixing zone for at least
a major proportion, typically about 75~, of the length of
the mixing zone to cause partial swelling of starch
granules contained in the dough-forming components.
The temperature in the mixing zone is
maintained sufficiently high that the heat applied,
combined with that resulting from the high shear mixing,
results in a dough emerging from the mixing zone having a
temperature of about 85 to about 120F, preferably about
35 95 to about 105F.
The dough resulting from the operations in the
continuous mixing zone is extruded therefrom under a back
pressure which is usually in the range of about 50 to
about 500 psig, and is preferably a relatively low back
3 5
.
pressure in the range of about 75 to about 120 psig,
achieved by suitable design of the extrusion nozzle. The
mixing operations effected in the mixing zone are
controlled by the above-described parameters to result in
an extruded dough having a viscosity comparable to that
achieved from a conventional batch dough-forming
procedure.
The dough formed by the above-described
continuous mixing procedure is extruded from the mixing
zone as a continuous tow, which generally has a
transverse dimension of about 2 to about 6 inches.
The extruded dough tow is allowed to "relax"
for a time period sufficient to achieve an extensible
dough. Where leavening is effected using gaseous
leavening agents, preferably also with chemical leavening
agents, this relaxation time usually is about 1 to about
7 minutes, typically about 2 minutes. Where, however,
leavening is achieved using yeast, a longer relaxation
period is required followed by a proofing period~
20 The stretching of the extruded dough tow may be effected
in a batch manner or, more preferably, in a continuous
manner.
In the batch procedure, the tow is cut into
convenient lengths, usually about 6 to about 12 inches,
25 and the individual lengths are longitudinally stretched,
usually to about 3 to about 8 times their original
length, to effect elongation of the pores within the
dough. The degree of stretching of the tow lengths is
critical to the invention, in that if the stretching is
30 insufficient, then splintering of baked dough to form the
Oriental-style crumbs does not occur, while if the
stretching is too great, then the tow lengths break and
the porous structure collapses.
This batch procedure is somewhat
35 disadvantageous in that it is difficult to control the
degree of stretch and hence the consistency of finished
product, and loaves result which leave ends which are not
splintered and represent waste. For these reasons, it i3
preferred to utilize a continuous procedure, which
i ~13~5
produces a consistent product and no unstretched portions
are found in loaf ends.
In the continuous procedure, the dough tow is
maintained as a continuous length and is stretched over a
series of moving belts of successively increasing
conveyor speed to effect a stretch of usually about 3 to
about 8 times over a period of usually abou~ 30 seconds
to about 6 minutes. The relative surface speeds of the
belts depend on the degree of stretch required, the rate
of production of the dough from the mixing zone and the
throughput of dough required.
For example, for a dough tow stretch of 5 times
and using 5 conveyors, the initial belt speed may vary
from about 1.25 to about 16 ft/min, typically about 2.5
ft/min, increasing uniformly to a final belt speed of
about 6.25 to about 80 ft/min, typically about 12.5
ft/min. At such a final belt speed, a typical dough
throughput is about Z00 to about 3000 lb/hr.
The dimensions of the stretched tow which
results from this stretching operation depend on the
initial dimensions and the degree of stretching which is
effected. Usually, the stretched tow is about 1 to about
5 inches wide and about ~ to about 1~ inches thick.
The stretched dough next is baked. The baking
of the stretched tow may be effected in any desired
manner, including infrared baking, microwave baking and a
combination of the two. When infrared baking is
employed, either alone or in combination with microwave
baking, the bread tow must be in a twisted form to
30 maintain the desired porous structure during dough baking
and to enable splintering of the baked tow to be
effected.
Twisting of the dough prior to baking may be
effected on a continuous tow, if such is formed in the
35 continuous process discussed above. Alternatively, where
the batch process is used, the stretched pieces are
twisted together in pairs or greater numbers. The number
of twists effected depends, to some extent, on the length
of the individual tow pieces, and usually is about 4 to
about 10 times. Such twisting preferably is effected
after initial stretching, although the process is
effective if the twisting is carried out prior to
stretching.
Where microwave baking alone is used, the
baking may be effected on a continuous stretched tow
without twisting and hence is preferred.
When the baking is effected wholly in an
infra-red baking oven, the oven temperature may vary from
about 325 to about 400F to result in an internal
temperature of baked dough of about 175 to about 210F.
The bake time required is usually about 25 to about 40
minutes.
When the baking is effected by a combination of
microwave baking followed by infrared baking, the
microwave baking operation is effected at a microwave
energy input of about 1.0 to about 2.0 KWH/100 lb of
dough for a time sufficient to result in an internal
temperature of about 125 to about 175F, usually about
60 to about 180 seconds. During the microwave baking, an
aix flow is maintained to remove moisture evaporated in
the baking process. Dough passes through the microwave
oven at a throughput rate of about 50 to about 200 lb of
dough per hour.
Following completion of the microwave baking
step, the partially-baked dough is subjected to infra-red
oven baking to complete the baking step. The oven baking
may be effected at a temperature in the range of about
325F to about 400F for a time sufficient to result in a
30 dough temperature of about 175 to about 210F,
preferably about 190F, generally in about 10 to about 25
minutes.
In effecting wholly microwave baking on
stretched dough, the conveyor belt of the oven is xun
faster than the rate of feed of the tow, so as to
maintain the tension in the elongate direction of the tow
and thereby maintain the elongation of the pores during
gas expansion induced by the baking. The differential in
speed is such that the conveyor belt of the microwave
--
11
oven moves at about 5 to about 20~ faster than the feed
rate.
Preferably, when this procedure is adopted,
chemical leavening agents are used in the dough-forming
components, such chemical leavening agents being chosen
to have residual leavening activity during the microwave
baking operation, so as to counteract the compression
applied to the pores by the stretching step.
The microwave energy input is about 1.7 to
about 3.7 KWH/100 lb of dough for a time to result in an
internal temperature of preferably about 175F to about
210F, usually in about 10 to about 300 seconds. The
microwave initially sets the structure of the stretched
tow and then bakes the dough to a fully baked state.
During the microwave baking, an air flow is
maintained to remove moisture evaporated in the baking
process. Moisture loss during the microwave baking
varies rom about 3% to about 12% by weight. Such
moisture removal is neces~ary in order to reach the
desired internal temperature of the fully cooked product.
Following completion of the baking of the
dough, the loaves are allowed to stand for a period of
time to permit the loaves to cool. The cooling may be
effected, for microwave-baked loaves, for about 6 minutes
25 to about 4 hours and for oven-baked loaves, for about 1
to about 24 hours, usually by standing on perforated
racks.
As the tow emerges baked from the oven, it
lacks the mechanical strength to be shredded or ground
30 without compaction. ~he short cooling period permits the
bread to become more rigid and hence able to undergo
shredding or grinding.
The cooling period which is used in the
preferred embodiment of the invention contrasts markedly
35 with the procedure required when the conventional
procedure is used, in that the prior art requires a long
staling period, typically about 18 hours, before the
bread becomes rigid enough for grinding. In contrast,
the rapid process used in this invention does not give
t 16~3~5
12
rise to the formation of antistaling components and hence
the baked dough rapidly achieves a staled condition
sufficient to permit shredding to a spllnter shape only a
short time after completion of baking.
The cooled loaves next are ground to cause
comminution of the loaves and formation of Oriental-style
breading crumbs. The dried breading crumbs formed in this
way have an elongate splinter shape, characteristic of
Oriental-style breading crumbs. The crumbs are dried to
a moisture level below about 12 wt.~, preferably about 3
to about 7 wt.%.
The properties of the product which results
from the process of the invention may approximate those
of the product produced by the conventional process.
15 However, by varying the ingredients and processing
conditions, the crumbs may have less fragility and a
significantly improved shelf life when compared with the
prior art, and may have a variable browning rate and/or a
variable texture.
The invention is il~ustrated by the following
Examples:
Example 1
This Example illustrates the preparation of
Oriental-style breading crumbs wherein baking is effected
using partially microwave baking and partially infrared
baking.
Two separate compositions were prepared, namely
a dry mix and a liquid brew. The compositions had the
following constituents:
(a) Dry Mix:
Component~ by weight
Hard Wheat Flour95.3
Vegetable shortening 2.1
Salt 1.6
Sugar 1.0
(b) Liquid Brew:
Components~ bY weight
Yeast food 0.5
Corn sugar 2.3
, Flour 20.2
,:
1 16i~
13
Yeast (bulk granular) 7.7
Water 69.3
Protease 40,500 H.U
Amylase 8,300 SKB units
The liquid brew was activated 30 minutes prior to
commencement of the procedure.
The dry mix, liquid brew and additional water
were fed to one end of an extruder at the following feed
rates:
Dry mix 15 lb/min
Liquid brew 10.3 lb/min
Water 2.5 lb/min
which corresponds to an inlet moisture content of 45% by
weight.
The components were continuously intermixed
during passage ~rom one end of the extruder to the other
over a period of about 35 `seconds. Carbon dioxide was
fed into the extruder at six different locations along
the length of the extruder at a rate of 3.4 SCF/100 lb
20 dough while the extruder was heated to result in a dough
having a temperature of 110F at the exit of the
extruder. Work was applied to the dough during formation
thereof and passage through the extrud~r of 10 watt hr/lb
of dough and a back pressure of 110 psig existed at the
25 extruder outlet orifice.
A continuous dough tow of about 3 inches in
diameter was extruded from the extruder and cut into 9
inch length loaves (about 1 lb). These loaves were
stretched to about 5 times their original length. Two
30 pieces were placed side by side, twisted together about 7
times and then baked. The baking was effected using a
successive combination of microwave and infrared heating.
The microwave baking was effected to set the
dough and maintain the desired pore structure at an
35 energy input of 1.6 KWH/100 lb dough while a flow of air
at a temperature of about 250F was passed through the
oven to remove the moisture. The microwave baking was
effected to result in an internal temperature of the
dough of 150F.
1 116 1
The infrared baking of the microwave-baked
dough was effected at an oven temperature of about 350F
for 15 minutes to result in an internal temperature of
the baked dough of 190F.
The loaves were then cooled for about 60
minutes, ground to the desired particle size and dried to
a moisture content of about 5% by weight. The resulting
crumbs had the characteristic shape of the Oriental-style
breading crumb and had the following properties:
Screen Analysis-mesh +5 +8 +14 +20 -20
-~ retained 0 50 30 15 5
Bulk density 16.2 lb/ft3
Example 2
The procedure of Example 1 was repeated using
15 the following dry mix and liquid brew:
(a) Dry Mix:
ComPonent % bv weiqht
Hard wheat flour 63.0
Soft wheat flour 31.5
Vegetable shortening 3.8
Myvaplex 600* 0.8
Sugar 0.9
* Myvaplex 600 is a concentrated glyceryl
monostearate manufactured by Eastman Chemical
Products. MYVAPLEX is a trademark.
(b) Liquid brew:
Component ~ bv weight
Water 70.0
Sugar 1.9
Wytase* 0.8
3~ Soft wheat flour 6.5
Hard wheat flour 12.1
Yeast (bulk granular)7.8
Yeast food 0.9
Protease 25,000 H.U.
Amylase5,400 SKB units
*Wytase is an enzyme active soy flour manufactured
by Short Milling and is a trademark.
The liquid brew was activated 30 minutes prior to start
up .
,
. .
The dry mix, liquid brew and additional water
were fed to one end of the extruder at the following feed
rates: -
Dry mix 15.0 lbimin
Liquid brew 11.0 lb/min
Water 1.0 lb/min
corresponding to an inlet moisture content of about 45%
by weight.
The operating conditions of the extruder were
as follows:
Mixing time about 35 seconds
Gas inlet flow 3.1 SCF/100 lb dough
Work applied 11 watt hr/lb of dough
Extruder back pressure 110 psi
Dough exit temperature 115F
The product, which had the characteristic
appearance of Oriental-style breading crumbs, possessed
the following properties
Screen Analysis-mesh +5 ~8 +14 ~20 -20
-% retained 0 50 30 15 5
Bulk Density 17.4 lb/ft
Example 3
This Example illustrates the preparation of
Oriental-style breading crumbs wherein baking is effected
25 wholly by infrared baking.
The extruder operation of Example 1 was again
repeated using the following dry mix and liquid brew:
(a) Dry mix
Component % by weight
Hard wheat flour 93.9
Vegetable shortening 3.7
Salt 1.6
Myvaplex 600 0.8
(b) Liquid brew:
Component ~ by weight
Water 66.5
Hard wheat flour 25.7
Yeast food 1.2
Yeast (bulk granular) 4.1
16
.
Sugar 2.5
Protease 33,000 H.U.
Amylase 7,100 SKB units
The liquid brew was activated 60 minutes before start up.
The dry mix, liquid brew and additional water
were fed to one end of the extruder at the following feed
rates:
Dry Mix 16.6 lb/min
Liquid brew 10.3 lb/min
Water 3.2 lb/min
After stretching the dough tow loaves to about
4 times their original length and twisting pairs of
lengths together, the twisted-together pairs were baked
in an infrared baking ovens at an oven temperature of
15 about 350F for about 30 minutes to result in an internal
temperature of 200F.
After cooling, grinding and drying to a
moisture content of 3.6% by weight, the resulting crumbs
had the characteristic shape of the Oriental-style
20 breading crumb and had the following properties:
Screen analysis - mesh +4 +5 +8 ~14 +20 -20
-%retained trace 12 32 25 17 13
Bulk density 13.2 lb/ft3
Example 4
This Example illustrates a completely
continuous process for the preparation of Oriental-style
breading crumbs which uses microwave baking of stretched
tow.
The - extruder operation of Example 1 was
30 repeated, using the following dry mix and liquid brew:
(a) Dry mix:
Component % by wei~ht
Hard wheat flour 90.2
Vegetable shortening 3.6
Sodium bicarbonate 1.8
Sodium aluminum phosphate 1.8
Sugar 1.4
Salt 1.2
(b) Liquid brew:
17
Component % by weight
Water 72.0
Hard wheat flour 28.0
Protease 33,600 ~.U.
Amylase 7,300 SKB units
The liquid brew was activated 30 minutes before start up.
The dry mix, liquid brew and additional water
were fed to one end of the extruder at the following feed
rates:
Dry mix 15.0 lb/min
Liquid brew 10.0 lb/min
Water 3.5 lb/min
corresponding to a moisture content of 46% by weight.
The following operating conditions were used:
Mixing time about 35 seconds
Gas inlet flow 2.4 SCF/100 lb dough
Work applied 9 watt hr/lb dough
Extruder back pressure 120 psi
Dough exit temperature 100F
A continuous dough tow of about 3 inches in
diameter was extruded and conveyed along a cloth belt in
2 minutes to a stretching apparatus comprising a
plurality of continuous conveyor belts which move at
successively increasing speeds. The continuous tow was
stretched to about 5.5 times its original length on the
stretching conveyors over a period of about 3 minutes and
then was passed into a tunnel microwave oven through
which the stretched tow was conveyed on a belt.
The belt of the oven moved at a speed about 10%
30 faster than that of the last conveyor of the stretching
apparatus to maintain the elongated structure of the
pores in the dough. The dough was baked in the microwave
oven at an energy input of 2.7 KWH/100 lb of dough while
an air flow was passed through the oven to remove
35 moisture. The microwave cooking was effected to result
in a moisture loss from the dough of about 6~ by weight
and an internal temperature at the oven exit of about
185F
18
As the tow exited the microwave oven, the tow
was cut into lengths of about 24 inches and cooled for
about 15 minutes. The pieces were then ground in a
Mikawa mill Model 18RT37 and the resulting crumbs were
dried to a moisture content of about 8~ by weight.
The resulting crumbs had the characteristic
appearance of Oriental-style breading crumbs and
possessed the following properties:
Screen analysis - mesh +5 +8 +14 +20 -20
-~ retained 0 50 30 15 5
Bulk density 14.5 lb/ft
Example 5
The procedure of Example 4 was repeated, except
that the dry mix comprised:
15 Component % bY weight
Hard Wheat flour 91.0
Vegetable Shortening 3.6
Sodium bicarbonate 1.4
Sodium aluminum phosphate 1.4
Sugar 0.9
Atmul 500* 0.5
Salt 1.2~
* Atmul 500 is a mixture of mono-and di-glyceridés
manufactured by ICI America Inc. ATMUL is a
trademark.
and the brew mix comprised:
Component% bv weiqht
Water 72.0
Hard Wheat Flour 28.0
Protease 35,500 H.U.
Amylase7,700 SKB units
The resulting crumbs had the characteristic
appearance of Oriental-style breading crumbs and
possessed the following properties:
Screen Analysis - mesh +5 +8 ~14 +20 -20
3~ -%retained 0 35 40 10 15
Bulk Density 12.5 lb/ft
; Example 6
This Example illustrates the properties Gf the
Oriental-style breading crumbs in use.
...~
1 ~6~ 5
19
(a) Fry test
Samples of the products of Examples 4 and 5
were subjected to frying for 3~ minutes at 350F and the
results compared with those obtained when frying samples
of a commercially-available Oriental-style breading
crumb.
The product of Example 4 and the commercial
product were found to exhibit similar browning rates and
to produce similar texture. The product of Example 4
exhibited a more pronounced splinter shape than the
commercial product.
The product of Example 5 exhibited a higher
browning rate and produced a more tender product than the
product of Example 4, illustrating the variation in
properties which may be attained by varying the
dough-forming components.
(bJ Breadin~ test
Oriental-style breading crumbs produced by the
procedure of Example 4 possessed the following
properties:
Screen analysis - mesh +8 +14 +20 -20
-~retained 34 42 6 18
Bulk density - 12.5 lb/ft3
25Moisture content- ~.2 wt.%
These crumbs were circulated in a Stein
Breading machine Model MB2B for 1 hour and the screen
analysis repeated and compared with the screen analysis
for a commercially-available Oriental-style breading
crumb subjected to the same conditions. The results
obtained are as follows:
Screen analysis - mesh ~8 +14 +20 -20
- % change*
-Eg 4 -69 -5 +72 +118
35-Commercial -90 -58 +78 +260
Product
(* - is decrease and + is increase)
These results show that, although both products
were degraded by the action of the breading machine,
~ ~13l)5
there was much less degradation and the formation of
fines in the case of the product of Example 4.
In summary of thls disclosure, the present
invention provides an improved method of forming
Oriental-style breading crumbs which is capable of
producing a superior product as compared with the prior
art. Modifications are possible within the scope of this
invention.
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