Note: Descriptions are shown in the official language in which they were submitted.
BACKGROU D OF THE INVENTION
Field of the Inventlon
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.
Backqround Art
Snack food products have long been prepared from wheat or corn
by mi~ing 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
~ s~s~
E~.l.F.-2245A.~, 11-11-91
Sept. 6, 1988 and ~,770,B~1 of Sept. 13, 19~8. Th~se patents
relate to e~:panded fried snacks prepared from vario~s extruded
cereals.
U.S. Patent 4,517,204 of May 14, 1985 to Mottur et al.
relates to a puffed snack product. The puffed snack contains
microcrystalline cellulose. In order to improve the te~ture and
incr~ase 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 baked. About 0.1% to 1% of nonionic emulsifiers can
also be added to the oil in order to improve e~pansion of the
product.
~ ommercial product which is a relatively low calorie version
o~ se Doodles~ of Borden Inc., includes corn meal and bran in
its composition and additionally contains about 1% of vegetable
oil. This product is baked.
Frito-Lay, Inc. has manufactured a ~ultigrain snack, marketed
ac Sunchips~, which is made from whole wheat, corn and other
natural ingredients. The Sunchips~ product is corn-based having
appro~ ,ately 50% by weight corn meal and about 25% by weight wheat
on a before frying basis.
~ anderveer et al. U.S.Patent 4,777,045 of Oct. 11, 1988
.. ..
R.I.F.-2245A.A l1~ 91
relates to a brand containing snack of various cereal grains which
are e~truded fro~ a twin screw cooker extruder. The extruded
pieces are coated with from 1% to 10% of vegetable oil and a
powdered flavorant is applied over the oil wherein the oil
allegedly improves adhesion of the flavor particles, enhances
flavor a_ceptability and improves mouth feel organoleptically.
Irvin et al. U.S.Patent 4,985,269 of Jan. 15, l991 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 about 0.1% to 0.6% of a
nonionic emulsifier which can be added to the corn feed prior to
extrusion.
Lewis et al. U.S. Patent 4,384,009 of May 17, 1983 relates to
snacks of dehydrated meat products containing vegetable materials
such as whole or nearly whole grains and additives such as fats,
oils, seasonings, flavors, preservatives, and emulsifiers.
A. Howard U.S. Patent 4,526,800 of July 2, 1985 relates to an
e~:panded snac~ food comprising cooked portions of dough containing
gelatinized starch, including 10% to 70% by weight of bran and 5
to 35~ by weight of oil or fat.
.I.F.-2245A.A 11-11-91
AR~' OF THE INVENTION
This invention is directed to the formation of a fried snack
food and its 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.
It has been found that the addition of about 3~ to ~% of a
plasticizer, e.g. vegetable oil, in the preparation of the dough
compositions comprising a~out 20% to 35% total moisture, and about
45% to ,7% of grain such as ground grain with or without smaller
quantitles of pieces of whole red wheat or dried fruit, minimizes
the pic~ up of oil on frying as compared to such compositions
without the added oil. Purthermore the fried snack can contain
less plasticizer , e.g. 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 3.5% or
4% to about 7% by weight of the dough composition. Also, about 3%
to ~O of plasticizer improves the mouth feel or texture of the
fried snac~ product.
In one embodiment of the invention there is disclosed dough
co~positions as described above suitable for making fried snacXs,
as well as snack products produced from such compositions which
contain one or a va iety of cereal grains.
~ ln ancther embodiment of the invention there is disclosed
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R.l.F.-2295A.A 11-11-gl
cooked dough compositions and snack products which have visually
discernible pieces of grain or fruit 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 be
accomplished by conventional means such as by merely permitting the
pieces to air dry overnight, e.g. to about 10% to 14% of moisture.
Although there are a number of different embodiments in this
invention, one of the embodiments, referred to as the First
Embodiment, uses a cooker extruder to cook the ground grain and
form the dough with or without the addition of pregelatinized
unground whole red wheat or pieces of dried fruit. Another
embodiment, referred to as the Second Embodiment, does not cook the
dough in the extruder but instead part of the ground grain is
gelatinized and enters the extruder together with unground
gelatinized whole red wheat. In the Second Embodiment the extruder
is maintained at a temperature of no higher than about 70 F in
formation of the dough .
BR~EF_DEC,ÇR~lPTION 0 ~ E DRAWING
Fig. l is a process flow diagram of the present invention.
~ ~ $ ~3 ~
.I.F.-2245A.A 11-11-91
~ig. 2 is a schematic side elevation of a twin screw eY~trUSion
apparatus which ~an 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.2.
DETA LED DESCRIPTION OF THE INVENTION
Fig. 1 is a process flow diagram of an embodiment of the
present invention wherein the extrudate is prepared by the First
Embodiment. 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, in the First Embodiment, 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
coo~ed in the extruder. However, such addition is made through a
secondary feed opening which ls near the extruder eY.it or die head.
There is some mixing of the gelatinized unground whole red wheat
~ith the previously coo~ed and ground base feed in the extruder.
~7~ 3
R.I.F.-22~5A.A 11-11-91
The mixing of the gelatinized unground whole red wheat is not
vigorous and does not completely blend the unground whole red wheat
in the mixture so that after extrusion, whole red wheat pieces are
~isually discernible in the dough. In some cases such as when
pieces of dried nuts, e.g. roasted nuts, are added to the base feed
through the secondary feed opening, the nuts are added without
going through the steaming step. Alternatively, the base feed
which is cooked in the extruder can pass through the extruder
without addition of the unground whole red wheat or dried fruit
pieces for subse~uent processing, e.g. frying.
In both the First and Second Embodiments, various dies such as
sheeting dies can be mounted on the exit end of the extruder. After
extrusion, the extrudate can go into a 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 co~position 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
R.I.F.-7245A.A 11-11-~1
final product will be about 1% to 3% by weight.
In both the First and Second ~mbodiments, the fried pieces are
optionally conveyed through a coater where 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 or other
flavorant is applied by dusting on to the pieces such as at a
quantity of about 1% to 10% 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
coo~ extruder apparatus which can be used in the First
E- , ant. The apparatus 1 includes a twin screw extruder 2, a die
mou ng 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
2 ~ ~,
R.I.F.-224~A.A 11-11-91
for heating the extruder barrel of the second section, and cooling
water inlet ports 15 ls~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
e~truder screws l9 19 in the same direction (co-rotating) within
e~truder barrel 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-
Fig. 3 is a view taken along line 3-3 of Fig 2 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 coo~er e~truders but are preferably twin screw e~truders. 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 the
composition of the extrudate, particularly when gelatini~ed
unground whole red wheat or pieces of dried fruit are added to the
base feed through funnel 24 of Fig. 2. The twin screw e~truders
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 mi~:ture or dough. Heat is generated by
higher shearing forces, principally in the second (coo~ing) section
~ ~ $ ~ 3
R.l.F.-22~A.A ll-ll-gl
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 each section can be further
subdivided, generally into two subsections. The three main
sections 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
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 by the screws to the
cooking section where some external heat is generally added, such
as by thermostatically controlled induction heaters, e.g. 13 in Fig
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 Te~perature, i.e. the hiahest
temperature attained in the extruder. Most of the cooking and
qelatinization of the dough takes place in this second section of
the extruder.
The dough is conveyed by the screws from the second sectior tc
the third section where the dough is cooled prior to discharge from
the e~:truder. Also, secondary feed 24 as shown in Fig 2 can provide
pieces of food directly into the moving dough of the base feed in
.
R.I.F.-22~5A.A ]1-ll-gl
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 thro~gh the secondary feed 2~. 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
exits the extruder. Puffed products are ~ade 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 square
inch at the outlet of the extruder. In contrast to ~Ipuff
conditions'l, applicants' dough composition, at the outlet of the
extruder. is extruded, in the First Embodiment, at a te~perature
belo~ about 165 F and preferably below about 155 E 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 extruders such as cooking extruders in the
First Embodiment or cooled press extruders in the Second
Embodi~ent, other equipment for cooking all or a portion of the
base feed, or mixing and preparing the dough composition can be
used, e.g., the use of a Hamilton type kettle or a Stephan cooker-
.
R.I.F.-2245A.A 11-11-g
mixer.
~ nless otherwise indicated, the percentages of the various
ingredients set forth herein are by weight and based on the total
weiqht of either the feed, dough composition, 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 appropriate
composition before cutting or sizing, e.g. the extrudate which is
used to make the snack product.
Tlle coo~ed dough composition of the First Embodi~ent will
co~prise a ~ixture 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% is cooked ground grain, up to 32% is
pieces of food which are visually discernible in the composition
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 fla~ed, chopped, or shredded nuts, which can withstand
the further processing of the dou~h composition after it exits from
tlle extruder, e.g. frying, baking, etc. The pieces of food,
although visually discernable, will generally have their shape
altered by going through the e~truder die and ~ixing in the
extruàer cooling zone. Thus, in the case of coo~ed whole red wheat,
2 ~ ~
R.l.F.-22~5A.A 11~11-91
the pieces will often resemble flakes. Apart from the whole red
wheat, the food pieces can be made up of dried fruit, partlcularly
nuts.
In all instances, the plasticizer is a vegetable oil which is
in addition to any oil inherent in the grain and mi~tures 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 admi~ed with the ground grain as part of the base
feed. The plasticizer needs to be present when the mixture is
worked, i.e,, in formation of the dough, in order to obtain the
beneficial effects of this invention since such effects are not
obtained simply by coating the extrudate with the same quantity of
plasticizer.
The quantity of plasticizer used in the dough compositions of
this in~ention 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 3.5% or 4% to 7% and particularly from
about 5'0 to 7% by weight of the dough composition. At about the
3.5% or 4% to 7% 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.
Furthermore, at less than about 4% of plasticizer in the dough
compocition of the First Fmbodiment, particularly at less than
~ 3
R.I.F.-2245ti.A 11-11-91
about 3-O of plasticizer, the fried snack product is too light in
te~:ture. In the Second Embodiment, the fried product is unduly hard
at a plasticizer content of ~ess than about 3%. 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 when the quantity of
plasticizer is less than about 3~. At about 8% and particularly
above lO~ of plasticizer in the dough composition containing the
above quantity of bran, 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 as plasticizers include corn oil,
sunrl-wer oil, canola oil, coconut oil, their hydrogenated or
p~ , ly hydrogenated derivatives and mixtures thereof. Corn oil
an~ ola oil or mi~ture thereof are particularly preferred.
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 chaln 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
o~ide, sorbitol, and glycols. The polyol will preferably have from
2 to 6 hydro~yl groups. Preferred emu]sifiers are those of mono-
and di-glycerides such as that of glycerol monostearate, glycerol
dlstearate, glycerol dioleate, glycerol monopalmitate, and the
14
R.l.F.-22"5A.A 11 ll-gl
li~e.
The total ~ois~ure, as recited in this invention, 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 amount of
moisture can generally be calculated from a knowledge of the
inherent moisture content of the various ingredients plus any 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.
In the First Embodiment, water is added to the ground grain
prior to cooking. Thus, 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 the secondary feed. When
aàditions 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
R.I.F.-2245A.A 11~ 91
composition.
In the First Embodiment, the dough compositions contain from
about 20% to 35% of total moisture, preferably about 25% to 32
total moisture based on the weight of the dough composition. It is
preferred that the ~oisture 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 e~bodiment does not provide for discernible pieces
of differently colored food in the composition. In such case, 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%
moisture based on the base feed.
When a portion of the ground grain is substituted with
gelatinized unground whole red wheat or pieces of fruit in the
First Embodiment, the quantity of such pieces can vary from about
10% to 32% by weight of the dough composition, and preferably from
about 15'~ tc 30~ on a dry, moisture free basis, based on the weight
of the clough composition.
The term "gelatinized" as used herein applies to completely
16
3'~
R.1.~ 22q5A.A 11-11-91
gelatinized food as well as food which is substantially gelatinized
such as that re~uired to eliminate white streaks on extrusion of
the unground whole red wheat in preparation of the dough in this
invention, e.g., extrusion through a die having a slit opening of
about two inches long and about 0.022 inches wide, and wherein
there is partial "gelatinization" or cooking of all the starch in
the unground whole red wheat.
It is preferred that the dough compositions of
this invention contain ground grains wherein at least 5%,
such as from about 10% to 30% based on the weight of the
dough is unhulled. Such unhulled grains include t~e whole
red ~heat when it is used. 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 beeh
removed. The dough is preferably a multigrain composition such as
one containing about 20% to 60% of wheat; 10 to 60 % corn ; 5% to
30% rice; and 5% 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 ~e used. Generally the extrudate of this invention
~ill contain up to 10% of sugar such as white cane sugar, white
beet sugar brown sugar , and the like~ It is preferred that the
level of reducing sugars be kept low because these tend to fo.m
caramelized and burnt flavors and also dar~en the color of the food
composition produced. Also, the amylopectin to amylose ratio of the
food ingredients is preferably kept to a ratio of 4Q~ to about 60%
and particularly about 50~.
R.~.F.-22~5A.A 11~ gl
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 such as hulled wheat or corn flours and can therefore be
added to achieve a desired color lightness in the fried snack
product. This facilitates the color contrast with pieces of whole
red wheat and dried fruit in the dough and in the fried 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.
Any of the different varieties of corn can be used in this
invention such as yellow corn, e.g., yellow dent corn, white corn,
or mixtures thereof.
The ground grain (flour) used in this invention is generally
ground so that 100% thereof passes through a U.S. Series No.lO
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. lO 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.
R.I.F.-~45A.A 11-11-91
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. Thus, oats
contain substantial quantities of fat (oil), namely, about 10% in
whole dried oats, but the quantity of oats is li~ited in this
invention to not more than about 15~ of the dough. 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.
The unground whole red wheat used in this invention is cooked
in an excess of water under conditions sufficient to cause the
wheat to imbibe or absorb up to about 35% to 55% by weight of water
based on the dry weight of the whole red wheat. The cooking of the
whole red wheat can be, for example, by exposure to steam or by
soa~ing in boiling water. During cooking it is preferred that
partial gelatinization of all the starch in the wheat takes place.
In the First Embodiment the hydrated, whole cooked red wheat lS
preferably chilled to below 60 F and more preferably to about qO F
before being placed in the extruder. 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
~xtrudate at the die is achieved.
Still another reason for partially gelatinizing all of the
starch in the unground whole red wheat before blending with the
19
~J' ~ ',t ~ ~t
R.I.F.-2245A.A 11~11-91
other grains in either the First or the Second Embodiment, is that
when there is no partial gelatinization of al], of the starch in the
whole red wheat, the subsequent break up of the grains on
e~trusion leaves undesirable white streaks on the extrudate as ~ell
as on the fried product from the raw starch in the wheat.
The pieces of whole red wheat or dried fruit such as nuts are
substantially larger than the ground grain or flour so that the
difference in coloration of the large pieces is easily discernible.
The pieces of food become macerated in the extruder and
particularly on extrusion through the narrow slit dies so that the
pieces may resemble flakes, The size of such pieces varies greatly
but, as mentioned before, are much larger than the ground (flour)
grain even though such pieces may be broken even before being
pl '~n the extruder. Generally, such pieces of food have at
let a dimension which is at least about one-thirty-second (1/32)
of an inch (about 0.03) inches.
The dough composition of this invention can also contain
fillers such as potatoes or other starchy foods.
In a preferred formulation of the First Embodiment, the
quantity of the various ingredients is: from about 4~ to 7% of
added plasticizer; from about 25% to 32% of total ~oisture; about
19~ to 26% of fine corn meal; about 15% to 21% of gelatinized
unground whole red wheat; about 8% to 12% of whole brown rice
flour; about 4% to 6% of ground white wheat flour; about 4~ to 6%
~ .I.F.-22~5~.A 11~ 91
of ground white oat flour; about ~% to 6% Or powdered brown sugar;
and from about 0.5% to 1% of malted barley. In all embodi~ents, the
malted barley should have any remaining enzyme activity neutralized
or substantially neutralized since the enzyme adversely affects the
texture and organoleptic properties of the product.
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 be
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.
The product produced from the frying step of this invention 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 unique texture and mouthfeel,
particularly when a blend of grains is used. The pieces of whole
2 ~ ?~
R.I.E.-2245A.A 11~ 91
red wheat, when used, provide darker spots on the fried product.
Illustratively, the fried product, as well as the dough, will
generally be tan or light brown in color with the whole red wheat
pieces providing darker spots dispersed throughout the product.
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 from 22% or from 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 plastici~er and at times at
least 50% of plasticizer. Of course much of this plasticizer
content is oil which is picked up in the frying step.
In order that tho5e 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
dough composition, e.g.extrudate, or fried snack, as appropriate.
P~R~OCEDl~RE U ~D 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 prepared by use of a twin screw cooker
R.l.F.-2245A.A 11-11-gl
e~truder, e~cept for added water and added plasticizer in the base
feed. The a~ount 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 co~position, which was part of the
base feed, based on the weight of the extrudate, for some of the
e~amples is shown in Table 2.
In the case where the pieces of whole red wheat were used,
e~g. E~amples 2-6 and 11-15 the process was as follows: The
e~trudates were prepared by pre-blending the ground grains in a
mixer until the moisture was of uniform consistency and
homo~eneity. 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
uniEorm. Each mixture was then fed into a Clextral BC 45 twin
screw e~truder at a rate of from 180 to 1000 grams per minute.
Ungrouild 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 heat t~as turned up to high for about 15 minutes. The cover was
then re~o~-ed fro~ the kettle and cooking was continued (about 15
minutes) until a ~oisture content in the wheat of about 40% weight
was attained.
~ .I.Y. 22~A.A ll-11-sl
The whole cooked red wheat was fed into the extruder
containing the mixture of ground grains. The addition to the
e~truder was made at the secondary feed 24 near the discharge end
of the extruder at a rate of about 26% of the pre-blended grain
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-t~pe 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 3500F for
about ~0 seconds.
Specific parameters used for the manufacture of the dough
composition prepared in Example 11 of Table 1 by the use of a
Clextral BC 45 Twin screw extruder with a low shear screw were as
follows: screw speed of 100 rpm; motor amps of 17; feed rate for
the base feed of 230 grams/minute ; cooled whole red wheat feed
rate of lO0 grams/min.; thrust bearing pressure of 50~ psi; die
head pressure of 420 psi; die head temperature of 13~F ; and
24
~ 3
R.I.F.-2245A.A 11 ll-gl
extrudate te~perature of 150 F. Each of the three sections of the
extruder are subdivided into two zones with zones 1-2 being part of
section l; zones 3-~ 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 F; zone 3 of 300 F; 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
thic~ness, cut to round shape and subsequently fried at 350 F for
60 seconds.
3 ",3J ~ ~3
9Z
~ .,~ ~ ~5"...~
L~ ~ ~ ~~ L~- ~ ' ~ I
t ~ L
il ~ ~L~
~ : t h
16 ~ 517ZZ -~
L 7
R . I . P .--22~15A .A 11 -ll-gl
TABLE: 1 ( CONTINUED )
H 0% SQ On Dry Basis
Example 14 15 16 17
Unground, Whole
Red Wheat (Cooked) 40 27.3 25.7 26.0 25.9
~hole 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 Xernel 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
BrOWJ1 Sugar --- 7.2 6.8 6.9 6.8
Popped Popcorn 5.5 --- --- --- ---
GMS --- --_ ___ ___ ___
Corn Or Canola Oil --- --- 5.7 6.2 6.1
EXAMPLE 1 8
The added plasticizer in the extrudates for some of the
e~amples from Table 1 were compared with the total amount of
plasticizer in the fried snack after frying. The results are shown
in Table 2. It can be seen fro~ Table 2 that the use of about 3%
to about 85o 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 G~.S
27
R.l.F.-2245A.A 11~ 91
in the table as well as the previous Tabl.e 1 refers to glycerol
monostearate which was used at the 1.9% level in the e~trudate
whereas the remaining examples were with corn oil or canola oil as
the plasticizer. The frying mediu~ 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
~bove 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
to the amount picked up on frying without the added plasticizer. It
has also been discovered that at levels above about ~% or 10% of
added oil the final product becornes unacceptably ~ushy and falls
apart in the consumer's mouth. Thus, while conventional oil frying
of snack foods typi.cally results in an oil( plasticizer~ content in
the snac~ 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
~S~ by weight.
28
~$~
1~ . I . F . -Z245A .A 11-11-91
TABLE 2
COMPARISON OF AMOUNT OF PLASTICIZER ADDED TO DOUGH WITH AMOUNT OF
OIL IN FRIED PRODUCT OF THE EXAMPLES IN TABLE 1
Example Plasticizer Added Total Oil
14 ~% 3~.3
1 1.9% 31%
13 2% 31%
3.4% 30.3%
9 4.8% 27.7%
5.7% 26.~%
16 6.2% 25%
17 6.1% 25%
11 6.5% 29.4%
12 8% 33.3%
In the Second Embodiment a portion of the flour, such as
40% to 60% of the flour on a dry basis, is pregelatinized and then
mixed wlth the remaining flour and unground whole red wheat which
is also pregelatinized. This mixture is fed.through an extruder
which does not further cook the ingredients. After the dough is
extruded, the process is substantially the same for both the First
Embodiment and the Second Embodiment.
29
~ J~ 3
I~.I.F.-2245A.A 11-11-91
The Second Embodiment is particularly preferred. In the
Second Embodiment the feed to the extruder comprises from about 25~
to 35% of total moisture and preferably from 28% to 32% of total
moisture; about 50% to 70% of grain on a moisture free basis,
wherein about 30% to 40% is ground grain (flour) and preferably 32%
to 38% is flour and 20% to 30%, preferably 22% to 28% is unground
gelatinized whole red wheat. From about 40% to 60% of the flour in
the Second Embodiment is gelatinized before entering the extruder.
Preferably about 45% to 55% of the flour is gelatinized before
entering the extruder. In the Second embodiment, the plasticizer
and the quantities thereof are the same as in the First Emb~diment.
Optionally, the composition can contain additional vegetable or
dried fruit ingredients as in the First Embodiment.
In the process for making the dougn of the Second
Embodiment, the flours, including the pregelatinized flours are
blended and mixed in the appropriate proportions with the unground
and gelatinized whole red wheat as well as the plasticizer and any
other feed ingredients. This mixture then enters into an extruder
which is maintained at a temperature not above 70 F, such as that
of about 50 to 70 F
A suitable extruder for the Second Embodiment is a tubular
press with a compression screw such as a conventional pasta press,
e.g., a Mapampianti pasta press. In this process the press is not
2 ~ s
~ .I.F.-22~A.A 11~11-91
heated but heat builds up during the friction and extrusion of the
feed mi~ture. The heat is removed and the temperature is
maintained at about 50 ~ to 70 F. This is achieved by circulation
of tap or cold water through the hollow screw and the jacketed
barrel of the press. This is in contrast to the temperatures
normally employed in such presses such as in the ~anufacture of
pasta wherein the temperature is generally above 100 ~ or 110 F.
The reason for maintaining the lower te~perature is that better
friction is developed between the feed material the extruder screw
and inside surface of the barrel.
The problems in the use of the single screw cooker extruders
are overcome in the Second Embodiment by: having a higher total
moisture content in the initial feed; pregelatinizing a portion of
the flour feed; and keeping a low temperature in the extruder.
Preferably, in the Second E~bodiment, the mixture is extruded
through a die having a narrow opening such as a die having an
opening of about 0.022 inches wide and about two inches long. Such
die can have a straight or wavy slit opening so as to produce the
corresponding dough configuration. The extrudate emerging from
such die is then face cut at the die, preferably directly into a
~ryer. l`he cut pieces of dough with the above mention die, will
thus have a thickness of about 0.022 inches, a length of about 2
inches and can be face cut to have various widths such as a width
of about one and a half inches.
9 ~ 1 ?3
R.I.F.-2245~ gl
In the following preferred formulation of the Second
Embodiment, about 90% of the rice was gelatinized and 50% to 60% of
the total guantity of corn was gelatinized prior to entry in the
extruder. A suitable pregelatinized rice for the following
~ ~>~e ~r 5,~
formulation is Pre Gel Waxy Flour RF-G80~0 of the ~4~ Company
whereas a suitable pregelatinized corn flour is Pre Gel Corn Flour ,
from the ConAgra Company.
R.l.F.-2245A.A 11-11-91
A preferred formula~ion for making the dough of the Second
Embodiment is as follows:
% AS IS ~ OF MOISTURE
AND DRY BASIS
Moisture 30.56
Corn Flour (89% ts^) 16.89 15.04
Pre gel corn Flour (91.5% ts)10.09 9.23
Pre Gel Waxy Rice Flour (91.2% ts) 6.60 6.02
Whole Oat Flour (89.8% ts) 5.12 4.60
Powdered Brown Sugar 5.56 5.56
Malted Barley fla~es (91.0% ts) 0.58 0.53
~nground, Boiled,
Soft Red Whole Wheat (48% ts)51.3424.64
Canola Oil 3.80 3.80
Lecithin 0.02 0.02
TnTALS 100.00 100.00
're~ers -to total solids.
The f`ollowing procedure can be used for producing the dough of
the above formulation by use of a single screw pasta extruder with
a 2,000 pound per hour feed rate. Pre-blended flour, including the
pregelatinized flour, is placed into a metering feeder. The feed
rate is adjusted to 905.2 pounds per hour and the feeder is
224~A.A ll--11-91
started. An oil spray, at the beginning of the ~i~ing chamber
preceding the extrusion barrel, is adjusted to 75.8 pounds per
hour. I~owever, the oil may be added instead to the pieces of
gelatinized whole red wheat. The unground gelatinized whole red
wheat feed is adjusted to 1019 pounds per hour. These ingredien~s
are mi~:ed and the mixture is extruded while the barrel and screw
temperatures are maintained at about 60F. A die having a wavy
opening is at the exit end of the extruder. The extrudate is cut at
the die. Frying of the cut dough is at 350 F for about one minute.
The fried chips are then removed from the fryer and placed in a
seasoning tumbler and then sent to a packaging machine.
A typical analysis of the fried product of the above formula
and process of the Second Embodiment has a total oil content of
about 26%, a moisture content of 1.5%, and the seasoning is fine
flour salt at 1%. All of the percentages herein being on a weight
basis and apart from the moisture or water being on a dr~ or solids
basis.
A preferred feed formulation of the Second Embodiment
comprises: about 25% to 35% of total moisture; about 5% to l5G~ of
pregeled corn flour; about 15% to 25% of corn flour which has not
been gelatinized; about 4% to 8% of pregeled rice flour; about 2%
to 6% of whole oat flour which has not been gelatinized; about 65
to 10o of brown sugar; about 4% to 7% of vegetable oil as
34
~ ~f ~
R~l~F~-Z245A.A ~ -sl
plasticizer; and about 20% to 30~ of the unground, gelatinized
whole red wheat.
Broadly, a dough composition of this invention which includes
both the First Embodiment and the Second Embodiment comprises:
A. about 3% to 8% of a plasticizer, preferably 3.5~ or 4% to
7%;
B. about 20% to 35~ of total moisture, preferably 25% to
32% of total moisture;
C. A total quantity of edible plant material food, e.g.,
vege~able and fruit, of from about 50% to 77% and preferably 60% to
77%, on a dry basis, wherein the quantity of grain, both flour and
gelatinized whole red wheat pieces as well as any pieces of dried
fruit is from about 50% to 77%, wherein at least 45% of the dough
is flour and at least 40% of the flour is gelatinized, and up to
32% of the dough is gelatinized whole red wheat pieces or dried
fruit which have a different coloration from the flour and are
visibly discernible in the dough and subsequent fried product.
The composition can contain additional ingredients as described
hereinbefore.
