Note: Descriptions are shown in the official language in which they were submitted.
R.I.F.-2245 4-20-g
TITLE: MULTIGRAIN SNACK FOOD
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a food composition in the form of a
snack food. In particular, this invention relates to a non-puffed,
cereal grain dough extrudate which can be further processed such as
for the manufacture of an oil-fried snack, particularly a
multigrain snack.
Back~round Art
Snack food products have long been prepared from wheat or corn
by mixing the respective flour with water to form an extrudate
which is then fried. Alternatively, potatoes have been thinly
sliced and deep-fat fried to produce snack foods. Snack foods can
thus include chip products, crackers, puffed dough articles and
cookies.
Fried snacks have included, for example, the snack foods
produced by the method of Willard in U~S. Patents 4,769,253 of
Sept. 6, 1988 and 4,770,891 of Sept. 13, 1988. These patents
relate to expanded fried snacks prepared from ~arious extruded
cereals.
R.I.F.--2245 4-20--91
U.S. Patent 4,517,204 of May 14, l9B5 to Mottur et al.
relates to a puffed snack product. The puffed snack contains
microcrystallinQ cellulose. In order to improve the texture and
increase the expansion of the batter upon extrusion due to the
presence of the cellulose, about 0.5% to 4% by weight of edible oil
is added to the batter. The products of the Mottur et al.patent
are preferably ~aked. A~out 0.1% to 1% of nonionic emulsifiers can
also be added to the oil in order to improve expansion of the
product.
A commercial product which is a relatively low calorie version
of Cheese Doodles~ of Borden Inc., includes corn ~eal and bran in
its composition and additionally contains about 1% of vegetable
oil. This product is baked.
Frito-Lay, Inc. has manufactured a multigrain snack, marketed
as Sunchips~, which is made from whole wheat, corn and other
natural ingredients. The Sunchips~ product is corn-based having
approximately 50% by weight corn meal and about 25% by weight whea~
on a before frying basis.
Vanderveer et al. U.S.Patent 4,777,045 of Oct. 11, 1988
relates to a ~rand containing snack of various cereal grains which
are extruded from a twin screw cooker extruder. The extruded
pieces are coated with from 1% to 10% of vegetable oil and a
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powdered flavorant is applied over the oil wherein the oil
allegedly improves adhesion of the flavor particles, enhances
flav~r acceptability and improves mouth feel organoleptically.
Irvin et al. U.S.Patent 4,985,269 of Jan. 15, 1991 relates to
use of twin screw extruders for making corn dough masa which is
further processed for the production of tortilla chips. This
reference also discloses the use of a~out 0.1% to 0.6% of a
nonionic emulsifier which can be added to the corn feed prior to
extrusion.
It is an object of the present invention to provide a cereal
grain cooked dough composition which is suitable for further
processing, such as by frying, to produce a snack product which is
low in fat and cholesterol, possesses good flavor and exhibits
improved texture and mouth feel.
It is also an object of the present invention to produce such
dough compositions and snack products from a multigrain mixture
which have visually discernable pieces of whole red wheat or other
visually discernable pieces of food in the composition.
Yet another object of the present invention is a process for
the preparation of the above dough compositions and snack products.
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SUMMARY OF THE INVE~TION
This invention is directed to the formation of a fried snack
food and its cooked dough composition precursor. The food products
of this invention are low in cholesterol and fat, possess a unique
grain flavor, and exhibit improved texture and mouth feel. In a
preferred form, the invention is directed to a multigrain product,
particularly a wheat based product. The dough composition is made
- under conditions which do not cause puffing on extrusion.
It has been found that the addition of about 3~ to 8% of a
plasticizer, e.g.vegetable oil, in dough compositions comprising
about 20% to 35% total moisture; and about 45% to 77% of grain,
minimizes the pick up of oil on frying as compared to such
compositions without the added oil. Furthermore the fried snack
can contain less plasticizer , e.~. vegetable oil, as compared to
the fried product which does not contain the added plasticizer.
This is the case when the quantity of added plasticizer is from
about 4% to about 7% by weight of the dough composition. Also,
about 3% to 8% of plasticizer improves the mouth feel or texture of
the fried snack product.
In one embodiment of the invention there is disclosed dough
compositions as described above suitable for making fried snacks,
as well as snack products produced from such compositions wherein
such compositions contain one or a variety of cereal grains.
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In another embodiment of the invention there is disclosed
cooked dough compositions and snack products which have visually
discernable pieces of food in the product.
In still another embodiment the dough composition is sheeted,
shaped and cut into pieces which are dried to prepare pellets or
half products which are then packaged for cooking by the consumer,
e.g., by baking, frying or ~icrowaving. The drying can ~e
accomplished by conventional means such as by merely permitting the
pieces to air dry overnight, e.g. to about 10% to 14% of moisture.
In still a further embodiment there is disclosed processes for
the production of the above mentioned dough compositions and snack
products, particularly by the use of cooker extruders such as twin
screw extruders.
BRIEF DESCRIPTION OF THE DRAWING
Fig. l is a process flow diagram of the present invention.
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Fig. 2 is a schematic side elevation of a twin screw extrusion
apparatus which can be used in this invention.
Fig.3 is a schematic view of the extruder barrel and twin
screws taken along line 3-3 of Fig.~.
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DETAILED DESCRIPTION OF THE INVENTION
Fig. 1 is a process flow diagram of a preferred embodi~ent of
the present invention. Ground grain from the ribbon blender, is
metered into the main feed opening of the extruder. Also fed to
the main feed opening of the extruder are metered amounts of oil
and water, although the oil and water can be premixed with the
ground grain prior to being fed to the main feed opening. The
ingredients which are introduced through the main feed area of the
extruder are referred to herein as the base feed. The base feed is
cooked in the extruder.
Optionally, cooked and gelatinized unground whole red wheat
which has water added thereto and cooked and gelatinized in a
steamer is added to the base feed which is cooked in the extruder.
Such addition is made through a secondary feed opening which is
near the extruder exit or die head. There is some mixing of the
unground whole red wheat with the previously cooked and ground base
feed in the extruder and eventually the mixture is expelled from
the extruder. The mixing of the unground whole red whe3t is not
vigorous and does not completely blend the unground whole rèd wheat
in the mixture so that even after extrusion, whole red wheat pieces
are visually discernible in the dough composition. In some cases
such as when pieces of dried nuts, e.g. roasted nuts, are added to
the base feed, the nuts are added without going through the
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steaming step. Alternatively, the base feed which is cooked in the
extruder can pass through the extruder without addition of the
whole red wheat or other food pieces for subsequent processing,
e.g. frying.
Various dies such as sheeting dies can be mounted on the exit
end of the extruder. After extrusion, the extrudate goes into the
forming machine where it is sized and cut into appropriate sized
and shaped pieces and then placed on a conveyer belt for transfer
to the optional toaster or directly into the fryer. Alternatively,
the dough composition can be extruded through narrow die slits, cut
at the extruder and go directly into the toaster or fryer. The
toaster is an open flame gas oven where the cut pieces are placed
for about 15 to 20 seconds at about 600 F to 650 F to remove
surface moisture and help equilibrate the moisture content of the
cut pieces. The cut pieces then, either from the cutting operation
or the oven, are placed in a fryer maintained at conventional
temperatures for conventional periods of time such as a temperature
of 325 F to 410 F for about 1 to 3 minutes so that the moisture
content of the final product will be about 1% to 3% by weight.
The fried pieces are then conveyed through a coater where
optionally some vegetable oil can be sprayed on to the surfaces of
the fried pieces at a level of about 3% to 5% by weight of the
finished product or the pieces can pass through a rotary
tumbler,not shown, where salt is applied by dusting on to the
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R.I.F.-2245 4-20-91
pieces such as at a quantity of about 1% to 2% by weight of the
finished product. The product is then transported to the packaging
machines on conveyors.
Fig.2 is a schematic side elevation view of a twin screw
cooker-extruder apparatus which can be used in this invention. The
apparatus 1 includes a twin screw extruder 2, a die mounting block
3, a die head 5,and a main feed opening or funnel 7, for receiving
the base feed ingredients although liquids such as added moisture
(water) or plasticizer can also be received into the extruder
through conduit 9. The extruder has a first, second, and third
section. Each of these sections is further divided into two
parts, not shown. The first section is principally a blending
section, the second is a cooking section and the third a cooling
section.
The apparatus 1 also has means 11, 11. and 11 for measuring
temperature in each section of the extruder barrel, and element 13
for heating the extruder barrel of the second section, and cooling
water inlet ports 15 15.and 15, to each section if needed,
although water is used for cooling in the third section. A motor
driven shaft 17 which through gearing means not shown drives the
extruder screws 19.19 in the same direction (co rotating) within
extruder ~arrel 21 as more fully shown in Fig.3. A secondary feed
funnel 24 can receive pieces of food directly into the cooling
zone, namely the third section of the extruder 1-
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R.I.F.-2245 4-20-91
Fig. 3 is a view taken along line 3-3 of Fig ~ and shows a
cross-section of extruder barrel 21 and co-rotating screws 19! 19.
The cooker extruders used in this invention can be single
screw extruders but are preferably twin screw extruders. The single
screw extruders give a more erratic rate of feed due to the low
friction between the screw and base feed occasioned by the
relatively high oil content of the feed. Lack of steady feed rate
causes sputtering on extrusion as well as changes in ~he
composition of the extrudate, particularly when pieces of food are
added to the base feed through funnel 24 of Fig. 2. The twin screw
extruders can have screws which are co-rotating or counter-
rotating. The rotation of the screws convey the product from the
inlet to the outlet while applying a mixing action as well as
various amounts of shearing force to the mixture or dough. Heat is
generated by higher shearing forces, principally in the second
(cooking) section of the extruder. The extruder outlet is equipped
with a die or shaped orifice for forming or shaping of the dough,
e.g. in the form of a sheet, as it is extruded.
The cooker extruders used in this invention have three main
functional sections although eash section can be further
subdivided, generally into two subsections. The three main
~ections are: first, the mixing and blending section; second, the
cooking section; and third, the cooling section. The first section
contains a conveying screw or screws which mix the base feed and
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form a dough while moving the dough to the second section. The
first section exerts low shear and low compression forces of the
ingredients. The dough is then conveyed ~y the screws to the
cooking section where some external heat is generally added, such
as by thermostatically controlled induction heaters, e.g. 13 in Pig
2, although some of the heat is generated from the shear of the
screws within the extruder barrel working against the dough. The
cooker section has the Peak Tempèrature, i.e. the highest
temperature attained in the extruder. Most of the cooking and
gelatinization of the dough takes place in this second section of
the extruder.
The dough is conveyed by the screws from the second section to
the third section where the dough is cooled prior to discharge from
the extruder. Also, secondary feed 24 as shown in Fig 2 can provide
pieces of food directly into the ~oving dough of the base feed in
the third section. The third section is one of low shear.
Preferably, the screw configuration at the area of the secondary
feed does not produce much pressure on the dough such as by the use
of a reverse screw configuration. This facilitates any addition of
feed through the secondary feed 24. The discharge from the extruder
is generally through a die, such as a sheeting die. Cooling of the
barrel in this third section is generally accomplished by tap water
circulation about the extruder barrel.
- The dough composition of this invention is not puffed as it
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exits the extruder. Puf~ed products are made in extruders under
puff extrusion cooking conditions which are well known in the art,
and generally include temperatures at or above the boiling point of
water and pressures of from about 2,000 to 4,000 pounds per s~uare
inch at the outlet of the extruder. In contrast to "puff
conditions", applicants' dough composition, at the outlet of the
extruder, is extruded at a temperature below a~out 165 F and
preferably below about 155 F and at a pressure below about 550
pounds per square inch so that there is no puffing of the
extrudate.
Although the preferred process for making the dough
composition is by use of an extruder other equipment for cooking
the base feed, or cooking and mixing the dough composition can be
used , e.g. the use of a Hamilton type kettle or a Stephan cooker-
mixer. The dough composition can then be sheeted and ~ut to
appropriate size and shape by conventional equipment.
~ nless otherwise indicated, the percentages of the various
ingredients set forth herein are by weight and based on the total
weight of either the dough composition, e.g. the cooked extrudate,
or the fried snack, as appropriate. Furthermore, all ingredients
except water (moisture) are on a moisture free (dry) basis. By the
terms "dough composition" or "cooked dough composition" we mean the
cooked composition before cutting and sizing, e.g. the extrudate
which is used to make the snack product.
The cooked dough composition of this invention will comprise
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R . I . F . -2245 4--20--91
a mixture of: from about 20% to 35% of total moisture, from about
3% to 8% of a plasticizer, and from about 45% to 77% of grain
wherein at least 45% of the grain is cooked ground grain and up to
32% is pieces of food which are visually discernible in the
co~position due to color differences of the food pieces from the
base feed; about 0% to 10% of sugar , and about 0% to 2% of
flavorants such as malted barley. The pieces of food are in the
form of whole or pieces of grain, e.g., whole red wheat or another
food e.g. such as flaked, chopped, or shredded nuts, which can
withstand the further processing of the dough composition after it
exits from the extruder, e.g. frying, ~aking etc. The pieces of
food, although visually discernable, will generally have their
shape altered by going through the extruder die and due to the
mixing in the extruder cooling zoné. Thus, in the case of cooked
whole red wheat, the pieces will often resemble flakes. Apart
from the whole red wheat the food pieces can be made up of dried
fruit, particularly nuts.
The plasticizer is a vegetable oil which is in addition to any
oil inherent in the grain, and mixtures of vegetable oil with a
nonionic emulsifier wherein the quantity of emulsifier is not more
than about 2% and preferably not more than 0.5%, based on the
weight of the dough composition. The plasticizer is intimately
admixed with the ground grain as part of the base feed.
When a portion of the ground grain is substituted with whole
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red wheat or pieces of another foodstuff, the ~uantity of such
pieces can vary from about 10% to 32% by weight of the dough
composition, and preferably from about 15% to 30% on a dry,
moisture free basis, based on the weight of the dough composition.
The dough composition of this invention can also contain fillers
such as potatoes or other starchy foods.
The total moisture as recited herein is the sum of moisture
(water) in the dough composition such as that which may be added
with the base ingredients, pieces of food or otherwise to the
composition as well as the inherent moisture of the grain and other
ingredients in the dough composition. The total a~ount of moisture
can generally be calculated from a knowledge of the inherent
moisture content of the various ingredients plus the added water.
Also the total moisture can be determined by the analytical method
found in the Fifteenth Edition of the AOAC, Method A in part 926.07
which is by the vacuum oven moisture technique. The quantity of all
ingredients, apart from the water, e.g.grain,pieces of food and
plasticizer are on a dry or moisture free basis, e.g. in the case
of grain it is the weight of the grain less it's inherent moisture
content.
Water is added to the ground grain prior to cooking. ThUc~
about 5% to 15% of water based on the weight of the finished dough
composition is normally added to the ground grain and plasticizer
prior to cooking when gelatinized whole red wheat is added through
R.I.F.-2245 4-20-91
the secondary feed. When the dough composition does not contain
the pieces of foodstuff and additions are not made to the dough
through the secondary feed, the entire amount of added water is
mixed with the ingredients prior to addition or at the time of
addition to the extruder. Such quantity of water can vary from
about 5% to 20 % by weight of the dough composition. When pieces
of food is added at the secondary feed, the quantity of water added
for gelatinization of the cooked pieces can vary from 5 to 20% and
preferably 8% to 16%, based on the weight of the final dough
composition.
The dough compositions of the present invention contain from
about 20% to 35% of total moisture, preferably about 25% to 32%
total moisture and particularly about 28% to 30% thereof based on
the weight of the dough composition. It is preferred that the
moisture content not exceed about 30% since it has been found that
increased water content causes increased oil pick-up in the frying
step.
In the case when all of the ingredients are cooked in the
extruder, all of the grain, e.g. 52% to 71% of the composition, is
ground and such embodiment does not provide for discernable pieces
of differently colored food in the composition. The added
moisture which is provided with the base feed is that which will
provide a total moisture content in the dough composition of from
20% to 35%, such as by the addition of from about 10% to 25%
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R.I.F.-2245 4-20-9
moisture ~ased on the base feed.
The quantity of plasticizer used in the dough composition can
vary from about 3~ to 8~, based on the weight of the dough
composition. A preferred amount of plasticizer in the dough
composition is from 4% to 7% and particularly from about 5% to 7%
by weight of the dough composition. At about the 4% to ?~ level of
plasticizer addition it has been found that the fried product
contains less oil than when the dough composition is fried without
the addition of plasticizer. Purthermore, at less than about 4% of
plasticizer in the extrudate (dough composition), particularly at
less than about 3~ of plasticizer, the fried snack product is too
light in texture. Additionally, when the dough composition contains
at least 10% of unhulled grain or bran equivalent to the amount
found in about 10~ of unhulled grain, the fried product has a gummy
mouthfeel. At about 8% and particularly above 10~ of plasticizer
in the dough composition (extrudate), the fried snack becomes mealy
and falls apart in one's mouth.
Vegetable oils which are preferred for incorporation into the
dough of the present invention include corn oil, sunflower oil,
canola oil, coconut oil, their hydrogenated or partially
hydrogenated derivatives and mixtures thereof. Corn oil and canola
oil or mixture thereof are particularly preferred.
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The nonionic emulsifiers which can be used with the vegetable
oil are those having an HLB of about 3.2 to 5.0, The emulsifier is
preferably an ester of a polyol and a long chain fatty acid such
as that having from about 12 to 20 carbon atoms. Illustrative of
suitable polyols there can be mentioned those of glycerin, ethylene
oxide, sorbitol, and glycols. The polyol will preferably have from
2 to 6 hydroxyl groups. Preferred emulsifiers are those of mono-
and di-glycerides such as that of glycerol monostearate, glycerol
distearate, glycerol dioleate, glycerol monopalmitate, and the
like.
The quantity of grain, on a moisture free (dry) basis used in
the dough compositions of this invention can vary from about 45% to
77% by weight based on the weight of the dough composition.
Preferably the quantity of grain is from about 52% to 71% by weight
of the dough composition. The solid pieces of food in the dough
composition can vary from 0% to about 32% , dry basis, based on the
weight of the dough composition. Preferably, the pieces of food
vary from about 10% to 32% and particularly about 15% to 30%. Also,
it is preferred that the cooked dough compositions of this
invention contain grains wherein from about 10% to 30% thereof are
unhulled and particularly wherein about 12% to 28% thereof are
unhulled. By "unhulled" we mean grain which contains its bran.
Also, by the term "whole" as it relates to grain we again mean
unhulled grain wherein its hull has not been removed. In a
preferred embodiment the dough composition is a multigrain
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composition such as one containing a~out 20% to 60% of wheat; 10 to
60 % corn ; 0~ to 30% rice; and 0% to 15% oats. However, minor
quantities, e.g., not more than about 15% of other grains such as
sorghum, soya, rye, and barley can also be used. In case whole red
wheat is used as the pieces of food the quantity of whole red wheat
can vary over a broad range such as that of from about 10% to 32%
being whole red wheat with the remainder being white wheat or
another grain or mixtures thereof but the unhulled red wheat should
~e avoided in such remainder so that there is a color contrast of
the hull of the red wheat with the lighter color of the other
grains.
The grains used in this invention can be in various forms.
Thus the ground rice can be that of various rice flours such as
that of brown or white rice. Rice is also lighter in color than
wheat or corn flours and can therefore be added to achieve a
desired color lightness in the fried snack product. The ground
wheat in the present invention can be various fractions of the
wheat kernel. Soft wheat, in both the spring or winter wheat
varieties, are particularly useful in the present invention.
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The corn used in the compositions of the present invention can
be soft flour or break flour ~from the grinding of the soft
endosperm portion of the corn kernel), sharp flour or reduction
flour (from the horny endosperm p rtion of the corn kernel), ~ran,
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germ, fines, or the combination of these which is often called
hominy feed. Additionally, the corn useful herein can be the corn
milling products known as grits, coarse corn meal, medium corn
meal, and cones. Yellow corn, such as yellow dent corn, and white
corn, or mixtures thereof are also useful as the source of corn in
the present invèntion.
The grain fed to the main feed of the extruder is generally
ground so that 100% thereof passes through a U.S. Series No.10
sieve. Preferably, hard horny grains are milled to a size wherein
100% passes through a No.16 sieve and less than 20% remains on a
No. 20 sieve. Examples of hard horny grains include certain dent
corns, brown rice, and popcorn. Preferably, soft grains are milled
to a size wherein 100% pass through a No. 10 sieve and less than
20% remain on a No. 20 sieve. Examples of soft grains include red
wheat, oats, various varieties of corn, and white wheat.
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Although the grains used in this invention contain some
oil, the quantity of such inherent oil is not sufficient to
significantly affect the properties of the fried snacks. ~hus, oats
contain substantial guantities of fat (oil), namely, about 10% in
whole dried oats, but the quantity of oats is limited ~in this
invention to not more than about 15%. Furthermore, there is little
or no oil in corn meal, about 4% in whole dried corn, about 2% oil
in whole dried wheat, and less than 1%, generally, less than 0.5%
~; in whole dried brown rice.
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When pieces of food are added to the base ingredients thr~ugh
the secondary feed, such pieces need to have a different color from
tne base feed in order to be visually discernible in the dough
composition as well as the snack product. Preferred pieces of food
which can be used are those of unground whole red wheat and dried
fruit such as pieces of peanuts and coconut. The whole red wheat in
such embodiment is pre-cooked prior to mixing with the other
grains. The whole red wheat is, in this embodi~ent, cooked in an
excess of water under conditions sufficient to cause the wheat to
imbibe or absorb up to about 35% to 45 % and preferably 40%,by
weight of water based on the dry weight of the whole red wheat.
The cooking of the whole red wheat can be, for exa~ple, by exposure
to steam or by soaking in boiling water. During cooking it is
preferred that partial gelatinization of all the starch in the
wheat takes place. The hydrated, whole cooXed red wheat is then
preferably chilled to below 60 F and more preferably to about 40 F.
This can be achieved, for example, by refrigeration overnight. It
has been found that if the cooked and hydrated wheat is cold (e.g.,
40 F) when added to the other cooked grains, a significant
reduction in expansion of the extrudate at the die is achieved.
Still another reason for partially gelatinizing all of the starch
in the whole red wheat before blending with the other cooked grains
is that when the whole red wheat is not gelatinized, the subsequent
break up of the grains on extrusion leaves white streaks on the
extrudate as well as on the fried product from the raw starch in
~he wheat.
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In a preferred formulation, the quantity of the various
ingredients is: from about 4~ to 7% of added plasticizer; from
about 25% to 32 % of total moisture; about 19% to 26% of fine corn
meal; about 15~ to 21% of whole red wheat; about 8% to 12% of whole
brown rice; about 4% to 6% of ground white wheat; about 4% to 6% of
ground white oats;about 4% to 6% of powdered brown sugar; and from
about 0.5% to 1% of malted barley.
In another embodiment, the cut pieces of the dough composition
,e.g. the extrudate, are allowed to air dry overnight and are then
fried. The drying can take place by other means in order to limit
the moisture content ,e.g. to about 10% to 14% of the dough
composition. Such cut pieces which have been dried are known as
pellets or half products. Alternatively, the half products can ~e
packaged for frying, baking, or microwave cooking by the consumer.
The low moisture content prevents the half product from spoiling.
The half products, fried as described above, can then be topically
seasoned by methods and ingredients well known in the art.
Generally the extrudate will contain from about 0 to 10% of
sugar such 2S white cane sugar, white beet sugar brown sugar , and
the liXe. It is preferred that the level of reducing sugars be
kept low ~ecause these tend to form caramelized and burnt flavors
and also darken the color of the food composition produced.
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The product produced from the frying step is a slightly
expanded, cooked, oil-fried, snack food. The product exhibits no
cholesterol and has a fat content dictated only by the frying
conditions utilized. The oil or fat pick-up is minimized by the
incorporation of the plasticizer into the formulation of the dough.
After frying, the product is drained of excess frying oil and
optionally topically flavored such as with salt. The resulting
snack food product exhibits a uniqu~ texture and mouthfeel,
particularly when a blend of grains is used.
The fried snack products of this invention will generally
contain less than about 32% of total plasticizer (oil plus any
emulsifier), by weight of the snack product, and preferably less
than 28% such as 25% to 27% of plasticizer. This is a relatively
small quantity of oil for a fried snack which generally contain
above 30% or 35% of plasticizer and at times at least 5~% of
plasticizer. Of course ~uch of this plasticizer content is oil
which is picked up in the frying step.
In order that those skilled in The art may more fully
understand the invention presented herein, the following examples,
tables and procedures are set forth. In the examples, as well as
elsewhere in this application, all percentages are by weight and
unless otherwise indicated, the percentages of grains or pieces of
food are on a dry ( moisture free ) basis in relation to the
R . I . F . -2245 4--20--91
dough composition, e.g.extrudate, or fried snack, as appropriate.
PROCEDURE USED IN THE EXAMPLES
Several examples of a multigrain snack food product were
prepared according to the present invention. Table I provides the
composition for 17 examples, apart from added water and added
plasticizer in the base feed. The amount of water added to the base
feed was about 10%, based on the weight of the final dough
composition. The quantity of added plasticizer in the dough
composition, which was part of the base feed, based on the weight
of the extrudate, for s~me of the examples is shown in Table 2.
In the case where the pieces of whole red wheat were used,
e.g. Examples 2-6 and 11-15 the process was as follows: The
extrudates were prepared by pre-blending the ground grains in a
mixer until the moisture was of uniform consistency and
homogeneity. To this mixture was added with further blending sugar
(white cane), oil, and/or glycerol monostearate (GMS) as indicated
in Table I. Water, 5% to 25% by weight based on the weight of the
base feed was then added to the mixture with blending until
uniform. Each mixture was then fed into a Clextral BC 45 twin
screw extruder at a rate of from 180 to 1000 grams per minu`te.
Whole red wheat was cooked by adding the wheat and enough
water to achieve 50% solids in a swept surface kettle. The wheat
was cooked on medium heat for about 30 minutes covered, then the
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R.I.F.-224S 4-20-91
heat was turned up to high for about 15 minutes. The cover was
then removed from the kettle and cooking was continued (about 15
mi-nutes) until a moisture content in the wheat of about 40~ weight
was attained.
The whole cooked red wheat was fed into the extruder
containing the mixture if grains. The addition to the extruder was
made at the secondary feed 24 near the discharge end of the
extruder at a rate of about 26% of the pre-blended ~rain feed rate.
The mixture was then extruded at a thickness of about 0.08 inches
and sheeted using either a standard pasta-type or a snack chip-
type die. The peak barrel temperature during extrusion was 200-
350 F and the screw speed was varied from 25 to 300 revolutions per
minute. Examples which use dried fruit were run in much the same
way except that the fruit was added in a relatively dry state,
after being roasted.
The extrudate from the above processing was then put through
sizing rolls to reduce its thickness to a thickness of between
about 0.02 and 0.050 inches. The sheet was then cut into desired
shapes, often called pellets. In one embodiment, the pellets were
immediately fried in a vegetable oil at, for example 350F for
about 60 seconds.
Specific parameters used for the manufacture of the dough
composition prepared in Example ll of Table 1 by the use of a
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R.I.F.-2245 4-20-91
Clextral RC 45 Twin screw extruder with a low shear screw were as
follows: screw speed of 100 rp~; motor amps of 17; feed rate for
the base feed of 230 grams/minute ; cooled whole red wheat feed
ra~e of 100 grams/min.; thrust bearing pressure of 508 psi; die
head pressure of 420 psi; die head temperature of 134 F ; and
extrudate temperature of 150 F. Each of the three sections of the
extruder are subdivided into two zones with zones 1-2 being part of
section 1; zones 3-4 being part of section 2 and zones 5-6 being
part of section 3 ( the cooling zone). The barrel temperatures in
the various zones were as follows; zone 1 of 150 F; zone 2 of
300 P; zone 3 of 300 P; zone 4 of 300 F; zone 5 of 61 F and zone 6
of 119 F. The extrudate of Example 11 was sheeted to 0.025 inches
thickness, cut to round shape and subsequently fried at 350 F for
60 seconds.
'
24
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R.I.F.-2245 4-20-91
TABLE 1 (CONTINUED)
H~% % On _ Dry Basis
Example 14 15 16 17
Whole Red Wheat (Cooked) 40 27.3 25.7 26.0 25.9
Whole White Wheat Flour 12.8 7.7 7.3 9.2 7.2
Whole Oat Flour 11.5 7.4 7.0 6.9 6.9
Corn Meal 11.8 34.0 32.1 34.9 31.9
Whole Kernel Corn Flour 12.0
Whole Brown Rice Flour 11.7 15.4 14.5 9.2 14.5
Malted Barley Flakes 9.0 1.0 0.9 1.0 1.0
Brown Sugar --- 7.2 6.8 6.9 6.8
Popped Popcorn 5.5 --- --- ~-- ---
GMS --- --~
Corn Or Canola Oil --- --- 5.7 6.2 6.1
26
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R.I.F.-2245 4-20-91
EXAMPLE 18
The added plasticizer in the extrudates for some of the
examples from Ta~le 1 were compared with the total amount Qf
plasticier in the fried snack after ~ryin~. The results are shown
in Table 2. It can be seen from Table 2 that the use of about 3%
to about 8~ of added plasticizer inhibited the amount of oil picked
up from the frying step. The plasticizer in all cases is measured
on a moisture free basis for the extrudate. The abbreviation of GMS
in the table as well as the previous Table 1 refers to glycerol
monostearate which was used at the 1.9% level in the extrudate
whereas the remaining examples were with corn oil or canola oil as
the plasticizer. The frying medium was either corn oil or canola
oil and the procedures for preparing the extrudate and frying of
the product is that which has been set forth hereinbefore.
It can be seen from Table 2 that at levels of about 4% to
about 7%, the added plasticizer in the base feed provides a fried
product with less total plasticizer than frying of the product
without the added plasticizer. However, even below about 3~ and
abo~e about 7% of added plasticizer the total quantity of
plasticizer ~ generally vegetable oil~ in the fried product is
less than that which is calculated by adding the added plasticizer
.. : . . . .
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R. I . F.--2245 4--20--91
to the a~ount picked up on frying without the added plasticizer. It
has also been discovered that at levels above about 8% or 10~ of
added oil the final product becomes unacceptably mushy and falls
apart in the consumer's mouth. Thus, while conventional oil frying
of snack foods typically results in an oil( plasticizer) content in
the snack food of 30% to 35% by weight and often 50% by weight or
higher, the present invention can produce a fried snack food with
less than about 30% by weight total oil, and preferably less than
28% by weight.
28
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R.I.F.-2245 4-20-91
- TABLE 2
COMPARISON OF AMOUNT OF PLASTICIZER ADDED TO DOUGH WITH AMOUNT OF
OIL IN FRIED PRODUCT OP THE EXAMPLES IN TABLE 1
Example Plasticizer Added Total Oil
14 0% 30.3
1 1.9% 31%
13 2% 31%
3.4% 30 . 3%
9 4.8% 27.7%
S.7% 26 . 4%
16 6.2% 25%
17 6 . 1% 25%
11 6.5% 29.4%
12 8% 33.3%
.
