Note: Descriptions are shown in the official language in which they were submitted.
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The present invention relates to a process for
preparing ready-to-eat cereal flakes having edible
particulate matter embedded therein and attached thereto.
Ready-to-eat breakfast cereals in flake form have
been produced by cereal companies for years. These cereal
flakes typically contain cereal grains such as wheat,
rice, oats, corn, etc. The cereal flakes also contain a
number of ancillary ingredients such as vitamins for
fortification, sugars, salts, natural and artificial
flavoring agents and other agents such as oils, coloring
agents and natural and artificial preservatives. In
addition to the ingredients incorporated into the~cereal
flake itself, other separate ingredients are included with
the cereal flake in the cereal produce as packaged and
sold to the consumer. Examples of such added ingredients
include nuts and nut pieces, fruit and fruit pieces, etc.
These added ingredients are typically included to impart
desirable flavor and texture properties to the packaged
cereal product.
However, there are several problems which arise
when combining such added ingredients with the cereal
flakes in the packaged cereal product. One problem is
that the added nuts and nut pieces and fruit and fruit
pieces are not uniformly distributed throughout the cereal
package. This is due to several factors, the primary
factor being that the cereal and added ingredients are
typically introduced to the packaged cereal product from
separate process streams, and thus tend to remain separate
upon packaging. Another source of this non-uniform
distribution is unequal settling rates due to the
differing densities of the cereal flakes and the added
ingredients. The ingredient having the greater density
tends to settle faster than the ingredient having the
lesser density. This lack of uniform distribution of
flakes and added ingredients is undesirable because the ,
cereal product, when consumed, does not provide a uniform
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taste sensation, which would be preferred. While it may
be possible to remedy this separation problem by
mechanically manipulating the cereal flakes and added
ingredients to achieve greater mixing, such a solution
carries the risk of physically damaging the cereal flakes.
The art teaches preparing cereal flakes via a
process which utilizes an extrusion step. The article
"Twin Screw Extrusion of Corn Flakes", T. Midden, Cereal
Foods World, Vol. 34, No. 11, pp. 941-943 (1989), teaches
a method for preparing corn flakes wherein the flake
ingredients are batch mixed and fed into an extruder. In
the extruder, the ingredients are cooked, cooled and
processed into spaghetti-like strands. After cooling,
these strands are cut into pellets, which are sent forward
for flaking and toasting according to traditional
methods. However, this reference does not teach or
suggest any method fox incorporating edible particle
matter, such as nuts, ete., directly into the cereal flake.
U.S. Patent 4,949,628 teaches an apparatus for
producing a product having a cookie-like crumb structure.
The apparatus generally comprises, among othex components,
an extruder, a temperature control means for the extruder,
a microwave applicator incorporated into the extruder, and
a second stage mixing apparatus which includes an inlet
port coupled to the downstream end of the extruder
housing. The second stage mixing apparatus is preferably
an extruder when a pressure build up is. required for
shaping, for example through an extrusion die. As with
the Midden publication discussed above, this reference
also fails to teach or suggest any method for
incorporating edible particulate matter directly into a
cereal flake.
U.S. Patent 3,544,332, teaches a process wherein
powdered or granulated additives are incorporated into the
cereal flake. In the Leebens' process a cereal mix which
comprises primarily wheat flour is introduced into an
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extruder. The cereal mix is cooked in the extruder to
form a dough. The cooked dough is then puffed, either by
conventional puffing guns or by other puffing methods,
thereby forming voids in the dough. The puffed dough is
then formed into pieces which are the proper size fox
flaking, typically by cutting the dough rope into slices
with a cutter. The cut slices of dough, together with
powdered or granulated additives such as flavoring agents,
sweetening agents, enriching agents and the like, are
placed in a rotary drum together. The slices are coated
by the powdered or granulated additive in the rotary drum
in such a manner that the additives form a layer of
material on the outer surface of the pieces and on the
surface or walls of the voids in the pieces. The coated
pieces are discharged from the rotary drum and depasited
on a belt which cooperates with a flaking roller to
perform the flaking step. Luring the flaking step each
piece, with its many voids, is collapsed. Upon
collapsing, the voids are closed and the piece is formed
into a flake, which has a number of breaks extending from
the surface of the flake toward the interior of the
flake. The powdered or granulated additives which were
sticking to the walls of the voids and on the surface of
the expanded slice are trapped in the breaks and
consequently are trapped at or near the surface of the
flake. When a consumer eats one of the flakes, the
concentrated form of the additive which is at or near the
flake surface is allegedly recognized by the consumer's
taste buds. Further, the patent claims that any additives
Which are difficult to incorporate into ready-to-eat
cereal flakes may be incorporated in this manner without
destruction due to cooking or the like.
There are several shortcomings of the U.S: Patent
3,544,332 process. Foremost, the additives incorporated
into the cereal flake must be powdered or granulated.
This is necessary because the additives must be small
enough to fit into the voids in the flake and stick to the
walls of
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said voids. This limitation on the additive size
effectively precludes the use of several additives. For
example, whole grains, fruit pieces, nut pieces, etc.,
couldn't be used in heebens' process. Therefore, products
having the taste and texture profile that can be achieved
using larger, non-powdered and non-granulated particles,
cannot be prepared by the Leebens' process.
Additionally, the mechanical processing necessary
to powder or granulate the additive in the process can
have a detrimental effect on the flavor of certain
ingredients. Another shortcoming is in the appearance of
the flake, which lacks any 'aesthetic benefit from the
inclusion of fruit pieces and nut pieces. Since the
additives must be powdered or granulated, they will not be
very noticeable and thus will not enhance the appearance
or texture of the flake. A final, potential disadvantage
of the process of U.S. Patent 3,544,332 is that the
additives tend to be concentrated on the surface of the
flake, resulting in a non-blended, non-uniform flour
profile.
Given the shortcomings of the prior art, it would
be desirable to provide a process for preparing ready-to-
eat cereal flakes having added ingredients embedded
therein, wherein such ingredients are of sufficient size
to provide a unique taste and texture profile and render
the flake more aesthetically appealing, wherein such
additions have undergone a limited amount of mechanical
and thermal processing so as to not negatively impact on ,
their flavor, and wherein such additives are distributed
throughout the flake in a substantially uniform manner.
It would further be desirable to provide a process wherein
the additive embedded in the flake can be embedded in the
cooked flake without being subjected to the extreme
cooking conditions which the cereal dough is subjected to.
It is therefore an object of the present
invention to provide a process for preparing a unique
cereal flake wherein edible particulate matter, such as
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fruit and fruit pieces, granola, nuts and nut pieces, and
cereal grains such as oat flakes, and mixtures thereof, is
embedded in the cereal flake in a substantially uniform
manner.
The present invention provides a process for
producing ready-to-eat cereal flakes having edible
particulate matter embedded therein, said process
characterized by (a) preparing a dry mix comprising cereal
grain and a plasticizer: (b) introducing the dry mix and
water into an initial cooking and forming step under
conditions sufficient to produce a cooked cereal dough
product; (c) introducing edible particulate matter and the
cooked cereal dough product into a secondary forming step
under conditions sufficient to form a secondary cereal
dough product having particulate matter dispersed therein;
and (d) converting the secondary cereal dough into flakes.
~n one embodiment of the invention, the flakes
may be enrobed with edible particulate matter and a
vehicle for attaching said edible particulate matter to
said flakes.
The present invention provides a solution to this
problem of non-uniform distribution by providing a unique
process for preparing a cereal flake wherein the added
ingredients are embedded into the flake itself in a
substantially uniform manner throughout the flake, and in
a preferred mode are also attached to the flake surface.
The flake resulting from this process provides a cereal
product having a desirable taste and textural profile.
The present invention provides for cereal flakes wherein
the additives incorporated therein are larger, and thus
make the flake more visually appealing.
A further benefit of the process of the present
invention is that the added ingredients which are embedded
into the cereal flake are not subjected to the extreme
cooking conditions that the cereal dough itself is
subjected to, which can destroy or negatively alter the
-6-
flavor of certain added ingredients, such as fruit and
fruit pieces, flavors, spices, etc.
The present invention produces a ready-to-eat
cereal flake comprising cooked cereal grain and edible
particulate matter embedded therein in a substantially
uniform manner. By ready-to-eat it is meant that the
flake can be consumed without any further preparation or
processing.
The cereal flake can comprise any known cereal
.grain including, but nat limited to, oats, wheat, rice,
corn, barley and mixtures thereof, with oats being
preferred and a mixture of oats and wheat being more
preferred. The cereal grain component of the flake is
cooked prior to flaking, and preferably prior to
. incorporation of the edible particulate matter.
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The particulate matter embedded into the cereal flake
can be selected from any known edible material, although it
is preferred that the edible material be compatible in taste
with the cereal grain component of the flake. Examples of
edible particulate matter useful in the present invention
include, but are not limited to: granola; real and imitation
fruit and fruit pieces, including dehydrated fruit, such as
raisins, pieces of peaches, apples, pears, apricots,
strawberries, blueberries, raspberries, bananas: real. and
imitation nuts and pieces of nuts such as almonds, peanuts,
cashews, walnuts; whole, sliced and chopped pieces of raw
and cooked grains and seeds such as oats, wheat, barley,
corn, rice, sunflower seeds, sesame seeds; vegetables and
pieces of vegetable materials; wheat germ composite
materials prepared from wheat germ and oil; and
confectionery items, such as cookies, candies, and
marshmallows. Granola, real fruit and fruit pieces,
including dehydrated fruit and fruit pieces, and whole raw
oat particles are preferred for their flavor and nutritional
properties.
The particle size of the embedded particulate matter is
effectively limited by the size of the flake, and is
preferably in the range of from about 0.15 centimeters (cm)
to about 1.0 cm, more preferably from about 0.30 cm to about
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0.65 cm, so as to impart desirable flavor, visual and
textural properties to the flake.
As already stated herein, the edible particulate matter
is embedded in the cereal flake in a substantially uniform
manner. By "substantially uniform manner" it is meant that
the particulate matter tends to be distributed throughout
the entire flake interior, averaged over a significant
quantity of flakes, without a significant tendency to be
concentrated in any particular region of the flake.
Furthermore, the size of the embedded particles may be so
large as to cause the particle to protrude through the top
and bottom surface of the flake simultaneously, thereby
allowing for a uniform distribution throughout the flake in
the top to bottom surface direction. The meaning of the
phrase should become more apparent upon explanation and
understanding of the process for preparing the flake claimed
below.
The embedded cereal flakes produced by the process of
the present invention typically comprise on a dry basis,
from about 60% to about 85%, preferably from about 75% to
about 65% by weight cooked cereal grain, and from about 15%
to about 40%, preferably from about 25% to about 35% by
weight embedded edible particulate matter. The moisture
content of the flakes range from about 1% to about 5%,
preferably from about 2% to about 4% by weight. The cooked
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cereal grain is defined as the portion of the flake present
prior to the addition of the edible particulate matter, and
preferably comprises from about 35% to about 65%, more
preferably from about 45% to about 55% by weight oat cereal
grain and from about 35% to about 65%, preferably from about
45% to about 55% by weight wheat cereal grain.
In addition to the cereal grain and edible particulate
matter, the embedded cereal flakes of the present invention
may contain additional edible components typically~found in
ready-to-eat cereal flakes. Examples of such additional
components include, but are not limited to, sweeteners such
.. as brown sugar, fructose, sucrose, and mixtures thereof and
artificial non-nutritive sweeteners such as saccharine,
cyclamates and aspartame and mixtures thereof: vitamins;
natural and artificial preservatives such as tocopherols,
vitamin C, BHA, BHT and mixtures thereof: additional fiber
sources such as wheat bran and carboxymethylcellulose
(°'CMC")s natural and artificial flavoring agents such as
vanilla, vanillin and benzaldehyde: salt, and leavening
agents such as sodium bicarbonate, sodium aluminum phosphate
and trisodium phosphate. iahen included in the cereal flakes
of the present invention, such additional components are
typically present at the following concentrations: from
about 1% to about 20%, preferably from about 5% to about 10%
by weight sweetener; from about 0.1% to about 0.5%,
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preferably from about 0.2% to about 0.4% by weight total
vitamins; from about 0.1% to about 0.5%, preferably from
about 0.2% to about 0.3% by weight preservatives; from about
0.5% to about 3.0%, preferably from about 1.0% to about 2.0%
by weight salt; and from about 0.1% to about 0.5%,
preferably from about 0.2% to about 0.4% by weight natural
and artificial flavoring agents.
A preferred embedded cereal flake of the present
invention additionally comprises edible particulate matter
attached thereto and a vehicle for attaching said edible
particulate matter. The attachment of edible particulate
matter to the surface provides for a flake having further
unique flavor and texture properties, in addition to the
properties of the embedded flake.
The edible particulate matter attached to the flake is
of the same general type as embedded in the flake, although
it need not be identical. For example, a particular cereal
flake could have embedded therein granola and fruit-and have
attached thereto rolled, raw oat flakes, which are preferred
for their flavor, textural and nutritional properties.
The vehicle for attaching the edible particle may be
any known to those skilled in the art. Examples of vehicles
useful herein include syrups or gels, such as hydrated
starches,'' with syrups being preferred. Such syrups
typically comprise water; one or more sweeteners -such as
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brown sugar, sucrose, fructose, and mixtures thereof; one or
more non-nutritive sweeteners such as saccharine,
cyclamates, aspartame, and mixtures thereof: salt; corn
syrup solids, and natural and artificial flavoring agents
such as coconut, vanilla, vanillin and benzaldehyde. Such
syrups may additionally contain optional ingredients such as
natural and artificial preservatives such as tocopherols,
vitamin C, BHA and B~iT. A preferred syrup comprises from
about 40% to about 60%, more preferably from about 45% to
about 55% by weight sweetener, preferably brown sugar; from
about 15% to about 30%, more preferably from about 20% to
about 25% by weight corn syrup solids; from about 20% to
about 40%, more preferably from about 25% to about 35% by
weight water; from about 0.0~.% to about 0.10%; more
preferably from about 0.025% to about 0.075% flavoring
agents, preferably natural coconut flavor; and from about
1.0% to about 2.5%, more preferably from about 1.25% to
about 1.75% by weight salt, preferably sodium chloride.
This preferred flake having attached and embedded
edible particulate matter typically comprises, on a dry
basis, from about 30% to about 50%, preferably from about
35% to about 45% by weight of cooked cereal grain, said
cooked cereal grain component comprising from about 35% to
about 65%, preferably from about 45% to about 55% by weight
oat cereal grain and from about 35% to about 65%, preferably
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from about 45% to about 55% by weight wheat cereal grain;
from about 10% to about 30%, preferably from about 15 % to
about 25% by weight embedded edible particulate matter; from
about 5% to about 25%, preferably from about 10% to about
20% by weight attached edible particulate matter; from about
10% to about 30%, preferably from about 15% to about 25% by
weight (on a wet basis) vehicle for attaching said edible
particulate matter to said flake: and has a moisture content
in the range of from about 20% to about 40%, preferably from
about 25% to about 35% by weight.
The present invention comprises a process for preparing
the ready-to-eat cereal flakes of the general type already
described herein as having edible particulate matter
embedded therein in a substantially uniform manner. This
process comprises: (a) preparing a dry mix comprising
cereal grain and a plasticizes; (b) introducing the dry mix
and water into an initial cooking and forming step under
conditions sufficient to produce a cooked cereal dough
product; (c) introducing edible particulate mattEr and the
cooked cereal dough. product into a secondary forming step
under conditions sufficient to form a secondary cereal dough
product having particulate matter dispersed therein; and (d)
con'~erting the_secondary cereal. dough to flakes.
The dry mix used in the process of the present
invention comprises cereal grain and a plasticizes. The
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cereal grain can be any cereal grain known to those skilled
in the art, and may be cooked or raw, with raw being
preferred. Examples of such cereal grain include, but are
not limited to, oats, wheat, rice, corn, barley, and
mixtures thereof, with oats being preferred and a mixture of
oats and.wheat being more preferred.
The plasticizer used in the dry mix can be
maltodextrin, brown sugar, fructose, sucrose, glucose,
dextrose and mixtures thereof, with sucrose being preferred.
The plasticizer is necessary for preparing a cooked cereal
dough product which has the physical properties desired for
the process of the present invention. Examples of such
properties include expansion limiting effects, dough
cohesiveness, and crispness.
In a preferred embodiment, the dry mix comprises from
about 40% to about 60%, preferably from about 45% to about
55% by weight oat cereal grain, from about 35% to about 55%,
preferably from about 40% to about 50% by weight wheat
cereal grain, and from about 1% to about 10%, preferably
from. about 2% to about 8% by weight plasticizer.
In addition to the cereal grain and plasticizes, the
dry mix may contain additional, optional ingredients
including, but not limited to, non-nutritive sweeteners such
as saccharine, cyclamates, aspartame and mixtures thereof:
vitamins; natural and artificial preservatives such as
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tocopherols, vitamin C, BHA, BHT and mixtures thereof;
additional fiber sources such as wheat bran, corn bran, CMC;
natural and artificial flavoring agents such as vanilla,
vanillin, benzaldehyde, honey; salt; arid maltodextrin. When
included in the dry mix, these additional components
typically comprise from about 0.01% to about 0.10%,
preferably from about 0.03% to about 0.07% by weight non-
nutritive sweetener; from about 0.05% to about 0.3%,
preferably from about 0.15% to about 0.20% by weight total
vitamins; from about 0.1% to about 0.8%, preferably from
about 0.2% to about 0.6% by weight preservatives; from about
0.5% to about 2.0%, preferably from about 1.0% to about 1.5%
by weight salt; and from about 0.5% to about 3.0%,
preferably from about 1.0% to about 2.0% by weight flavoring
agents. These additional optional ingredients may also be
incorporated into the process via the secondary foraning step
which is discussed in greater detail below, instead of in
the dry mix.,
The dry mix and water are introduced into an initial
cooking and forming step. In the initial cooking and
forming step, the dry mix is mixed further, cooked, and,
optionally, cooled, and is thereby formed into a cooked
cereal dough product. The initial cooking and forming step
is preferably carried out in an extrusion device, which is
referred' to hereinafter as an initial extruder. When
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utilized, the z.nitial extruder plasticizes the food mass,
reduces microbial load, denatures enzymes, gelatinizes
starch, polymerizes proteins, and texturizes the cooked
cereal dough product. When an extruder is utilized in the
process of the present invention, the cooked cereal dough
product will typically be in the form of a continuous strand
or rope.
Examples of extruders useful in the process of the
present invention include, but are not limited tn; single-
screw and twin-screw extruders. The selection of the type
of extruder will depend upon numerous considerations such as
the composition of the dry mix, desired throughput, texture
of the extrudate, degree of cooking, etc. Tn the present
invention a twin-screw extruder is preferred.
Additionally, there are a wide range of operator
controllable variables including screw speed, screw profile,
temperature, moisture, feed rate, and die size/shape, which
may be manipulated when an extruder is utilized. One
skilled in the art will know to select operating parameters
necessary to achieve the desired product characteristics. A
more complete discussion on design factors and operating
variable selection can be found in the article '°FUndamental
and Practical Aspects of Twin Screw Extrusion'°, J. Fichtali
and F. R. van de Voort, Cereal Foods World, Vol. 34, No. 11,
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CA 02095172 1999-12-13
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. 16
pages 921-929 (1989),
The amount of water added in the initial cooking and
forming step will depend upon the type of cereal grain used
to prepare the dry mix, but will typically range from about
3 % to about 36%, preferably from about 8% to about 25 % by
weight of the total dry mix. When the preferred oat/wheat
cereal grain combination is used to prepare the dry mix, the
amount of water added in the initial cooking and forming
step will typically be in the range of from about 10% to
about 25% by weight of the dry mix. The moisture level of
the cooked cereal dough product resulting from the initial
cooking and forming step ranges from about 25% to about 35%,
preferably from about 28% to about 32% by weight.
The water may be combined with the dry mix prior to
introduction to the initial extruder, or may be directly
injected into the initial extruder at any point along the
screw mechanism. When combined with the dry mix prior to
introduction to the initial extruder, the cereal grain will
be substantially fully hydrated and gelatinized at the
completion of the initial cooking and forming step.
The cooking temperature of the dry mix/water
combination in the initial cooking and forming step is
typically in the range of from about 120°C to about 205°C,
preferably from about 135oC to about 160oC, and is
'9
CA 02095172 1999-12-13 I
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. 17
' maintained for a corresponding time of from about 15 seconds
to about 75 seconds, preferably from about 20 seconds to
about 45 seconds.
When an initial extruder is utilized in the process of
the present invention, the throughput necessary to produce a
product having given characteristics will be based upon the
geometry of the extruder, and will be apparent to one
skilled in the art. For the present invention, throughput
of the initial extruder typically ranges from about 22.5 to
about 2,720 kg. cooked cereal dough per hour.
The cooked cereal dough product formed in the initial
cooking and forming step is subjected, in conjunction with
edible particulate matter, to a secondary forming step under
conditions sufficient to form a secondary cereal dough
product having particulate matter dispersed therein.
The secondary forming step may take place in the same
initial extruder used for preparing the cooked cereal dough
product, although in a later and preferably separate
chamber, or may take place in a separate, secondary forming
device. Examples of such separate, secondary forming
devices include, but are not limited to: a forming extruder;
a meat grinder, and a Readco Extructor or ~trud-0-Mix (R.T.M. ),
(available from the Bepex Corporation, located in Rolling
Meadows, IL), with the forming extruder being preferred. As
with the initial extruder, the selection of the type of
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forming extruder and its operating variables will depend
upon the desired properties of the final product, and will
be known to those skilled in the art. A single-screw
forming extruder is most preferred in the present invention.
The secondary forming step acts to mix the cooked
cereal dough product and particulate matter, deaerate and
compress the cooked cereal dough product, and additionally
allows for a number of other desirable properties in the
final cereal flake product, such as lowered dough viscosity,
which provides far improved dough cutting when necessary far
further processing, such as flaking, etc. The mixing action
. in the secondary forming step aids in the preparation of a
product wherein the edible particulate matter is distributed
throughout the flake in a substantially uniform manner,
which in turn provides for unique and desirable flavor and
texture properties in the final flake product.
The edible particulate matter introduced into the
secondary forming step is of the type already described
herein. The amount of such edible particulate matter
introduced to the secondary forming step is dependent upon
factors such as the type of particulate matter, the desired
percentage of embedded particulate matter in the final
product, the size of the flake to be produced, and so on.
Generally, from about 0.10 to about 0.40 kg., preferably
from about 0.25 to about 0.35 kg. edible particulate matter
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per kg. cooked cereal dough product is introduced into the
secondary forming step. Examples of typical amounts for
specific types of edible particulate matter added to the
secondary forming step include, but are not limited to, the
following: from about 0.20 to about 0.40 kg., preferably
from about 0.25 to about 0.35 kg. of granola per kg. cooked
cereal dough product; from about 0.10 to about 0.25 kg.,
preferably from about 0.10 to about 0.15 kg. of fruit and
fruit pieces per kg. cooked cereal dough product; from about
0.10 to about 0.35 kg., preferably from about 0.10 to about
0.20 kg. of dehydrated fruit pieces per kg. cooked cereal
dough product; from about 0.10 to about 0.30 kg., preferably
from about 0.20 to about 0.30 kg. of nut pieces per kg. of
cooked cereal dough product: and from about 0.10 to about
0.40 kg., preferably from about 0.25 to about 0.35 kg. of
raw and/or cooked cereal grain, preferably raw oats, per kg.
cooked cereal dough product.
The edible particulate matter is not necessarily cooked
prior to introduction to the secondary forming step, and
will not be substantially cooked therein. In the secondary
forming step, the cooked cereal dough product/edible
particulate matter mixture typically reaches a temperature
in the range of from about 25oC to about 100oC, preferably
from about 65°C to about 100oC, and is maintained at such
temperature for a corresponding period typically ranging
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from about 0.5 minutes to about 5 minutes, preferably from
about 0.75 minutes to about 2 minutes. Additional
ingredients as already described herein, such as sweeteners,
flavoring agents, preservatives, salts, etc., can
additionally be incorporated into the final flake product
via addition in the secondary forming step, in lieu of being
added at other points in the process.
When the forming extruder is utilized, the secondary
cereal dough product preferably exits the forming extruder
in the form of a continuous strand, similar to a rope,
through a die head. The selection of the type of die head
. used will depend upon the desired physical characteristics
of the secondary cereal dough product and can be determined
by one skilled in the art. Examples of desired physical
characteristics influencing selection of the die head
include, but are not limited to, land length, flow
characteristics and temperatures of the secondary cereal
dough product, size of the.particulate matter contained in
the secondary cereal dough product, pressure in the forming
extruder, screw torque, etc. One skilled in the art will be
able to select a die head based on these various parameters w .
and the characteristics of a desired product.
While not intending to be bound by theory, it is
unexpected and surprising that a cooked cereal dough product
having as high a moisture content as the dough prepared
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using the preferred oat/wheat cereal grain combination
(i.e., up to about 30% by weight moisture) could be flaked.
One would normally expect that a dough having a high
moisture content would be difficult or impossible to cut or
pelletize and would adhere to any flaking rolls. It is
believed that the flaking of this high moisture content
dough is achieved through the use of the secondary forming
step following the initial cooking and forming step, as
described below.
After exiting the secondary forming step, the secondary
cereal dough product is converted into flakes. This may be
accomplished by methods known to those skilled in the art,
and is typically accomplished by dividing, preferably by
cutting, the secondary cereal dough product into separate
pellets and then conveying the pellets to a flaking
operation for conversion into flakes.
The pellets are preferably cut into discrete lengths in
the range of from about 3.0 mm. to about 9.5 mm., preferably
from about 5.0 mm. to about 7.0 mm. The cuts are typically
perpendicular to the longitudinal axis of the secondary
cereal dough product as it exits the cold. former, although
they may also be angular to the longitudinal axis. The
cutting device typically comprises a single knife edge,
which is preferred, although multiple knife edges and other
CA 02095172 1999-12-13
22
cutting devices such as vertical or horizontal cutters may
be used as well.
The conveyance of the pellets to the flaking step may
be achieved by any method known to those skilled in the art,
including, but not limited to, a pneumatic conveyor, a belt
conveyor, buckets, etc. A pneumatic conveyor is the
preferred method wherein the air used to convey the pellets
also acts to cool and extract a negligible amount of
moisture from the pellet surface, which renders the pellet
surface no longer "sticky". This aids in the flaking of the
pellets. If conveying methods other than pneumatic
conveying are utilized, it is preferred that ambient air be
directed across the pellet surface to extract a minimal
amount of moisture from the pellet surface, thereby
providing the already described benefits of the pneumatic
conveying process.
Flaking of the pellets can be accomplished by any
method known to those skilled in the art. A detailed
description of flaking processes and devices can be found in
the article "Flaking Ready-to-Eat Breakfast Cereals", P.
Fast, G. Lauhoff, D. Tayler, S. Getgood, Cereal Foods World,
Vol 25. No. 3, pp. 295-298 (1990),
Flaking is typically accomplished
by a device which passes the pellets between a pair of
rollers moving in either a counter direction or in the same
CA 02095172 1999-12-13
~.
23
- direction at differing speeds, or between a roller and a
flat surface. In any of the aforementioned methods the
rollers or the roller and flat surface are spaced apart by a
distance sufficient to produce the desired flake thickness.
In accordance with the present invention a typical flake
thickness ranges from about 0.10 mm to about 0.65 mm,
preferably from about 0.20 mm to about 0.40 mm.
Following flaking, the flakes are preferably toasted.
In the toasting step the flakes may also be coincidentally
dried by the toasting action. Toasting may be done by any
means known to those skilled in the art, such as those
described in the article "Toasting and Toasting Ovens for
Breakfast Cereals", R. Fast, F. Shouldice, W. Thomson, D.
Taylor, S. Getgood, Cereal Foods World, Vol. 35, No. 3, pp.
299-310 (1990),
Examples of toasting methods useful in the present
invention include, but are not limited to, infra-red lamps,
an oven, etc. It is preferred to maintain a toasting
temperature in the range of from about 120oC to about 260°C,
more preferably from about 130°C to about 195°C, for a
period of time ranging from about 0.2 to about 15 minutes,
preferably from about 3 to about 9 minutes, respectively.
The rate of toasting may be increased by spreading the
flakes on an extended surface, such as in shallow pans or on
a conveyer belt. After leaving the toasting device, the
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flakes typically have a moisture level ranging from about
0. 5% to about 6%, preferably from about 1 % to about 3 % by
weight. Following toasting, the flakes are typically
allowed to cool and then are packaged and shipped.
In a preferred embodiment, the flakes are subjected to
a coating step following flaking and prior to toasting. In
the coating step the 'flake is coated with syrup to form a
substantially continuous and discrete film thereon. The
syrup is used in an amount ranging from about 20%'to about
40%, preferably from about 25% to about 35% dry solids
weight basis as a portion of the total flake weight. The
syrup can be formed from any mono- or disaccharide, or
mixtures thereof, including, but not limited to honey, brown
sugar, corn syrup, sucrose, fructose and the like, and may
include optional ingredients such as flavoring agents, salt,
etc. The syrup preferably comprises from about 40% to about
60%, more preferably from about 45% to about 55% by weight
sweetener, preferably brown sugar; from about 15% to about
30%, more preferably from about 20% to about 25% by weight
corn syrup solids; from about 20% to about 40%, more
preferably from about 25% to about 35% by weight water; from
about 0.01% to about 0.10%, more preferably from about
0.025% to about 0.075% flavoring agents, preferably natural
coconut flavor; and from about 1.0% to about 2.5%, more
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preferably from about 1.25% to about 1.75% by weight salt,
preferably sodium chloride.
In a more preferred embodiment, the flakes prepared by
the process of the present invention are dried immediately
after coating. The flakes can be dried by any means known
to those skilled in the art. In a typical drying operation,
the flakes are subjected to a temperature ranging from about
121 degrees C to about 260 degrees C, for a corresponding
period of from about 0.2 to about 15 minutes. As~with the
toasting step, it is preferred that the flakes be spread on
an extended surface, such as shallow pans or on a conveyor
belt, during drying. Following drying, the flake typically
has a moisture content ranging from about 0.5% to about 6%,
preferably from about 1% to about 3% by weight.
The present invention further comprises a process for
preparing ready-to-eat cereal flakes having edible
particulate matter embedded therein and attached thereto.
This preparation process comprises (a) initially preparing a
dry mix comprising cereal grain and a plasticizes; (b)
introducing the dry mix and water into an initial cooking
and forming step under conditions sufficient to produce a
cooked cereal dough product; (c) introducing edible
particulate matter and the cooked cereal dough product into
a secondary forming step under conditions sufficient to form
a secondary cereal dough product having particulate matter
~~ tI '.~ 1. ~ iJ
26
dispersed therein; (d) converting the secondary cereal dough
product to flakes; and (e) enrobing the flakes with edible
particulate matter and a vehicle for attaching said edible
particulate matter.
Steps (a) - (d) of this process are carried out in the
same manner as already described herein for preparing the
cereal flake having edible particulate matter embedded
therein.
In step (e), the cereal flake is coated with edible
particulate matter and a vehicle for attaching said
particulate matter to the flake. The edible particulate
matter attached to the flake is of the type already
described herein. However, the particulate matter attached
to the flake surface need not be the same as the particulate
matter embedded therein. For example, granola could be
embedded in the flakes while nuts are attached to the
flakes.
The attachment vehicle coats the flake to form a
substantially continuous and discrete film thereon and is
typically in liquid form. It can be selected from any
edible vehicle known to be useful to those skilled in the
art. Examples of suitable attachment vehicles include, but
are not limited to, syrups, gels and hydrated starches, with
syrups being preferred. Such syrups preferably are the same
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as those already described herein as being useful for
enrobing the embedded cereal flake.
The edible particulate matter which is attached to the
flake surface is added in the enrobing step in an amount
ranging from about 15% to about 35%, preferably from about
20% to about 30% by weight of the cereal flake weight. The
attachment vehicle is used in an amount ranging fram about
15% to about 35%, preferably from about 20% to about 30%, an
a dry solids weight basis, of the cereal flake weight. .
A preferred enrobing process comprises introducing the
embedded cereal flake and edible particulate matter into a
rotary drum which coincidentally transports said flakes and
edible particulate matter in an axial direction. As the
drum rotates, the flakes and particulate matter are mixed
through a tumbling action. The attachment vehicle is
concurrently sprayed onto the flakes and particulate matter,
preferably from spray nozzles located axially at or near the
top of the drum. When the sprayed flakes and particulate
matter come in contact, they tend to stick together, thereby
attaching said particulate matter to the flake surface. In
such an enrobing process, the flakes which are enrobed are
typically retained in the drum for a period of from about
0.5 to about 6 minutes, preferably from about 1 to about 2.5
minutes. The drum rotation speed is dictated by product
density and flight width, and typically falls in the range
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of from about 7 RPM to about 30 RPM, preferably from about
13 RPM to about 20 RPM. The average bed thickness in such a
drum is typically in the range of from about 1% to about 25%
fill, preferably from about 5% to about 10% fill.
In a preferred embodiment, this process for preparing a
cereal flake having edible particulate matter embedded
therein and attached thereto comprises either an additional
toasting step or drying step. The toasting step follows
flaking and precedes enrobing, and is as already described
herein for the process for preparing the embedded cereal
flake. The drying step follows enrobing and is also as
already described herein. Tn a most preferred embodiment,
both the toasting and drying steps are included in the
process of the present invention.
The present invention is further illustrated, but not
limited by, the following examples.
EXAMP7LE8
EBAMPLE 1
A flake cereal which incorporates particulate matter into
the cooked dough matrix of the flake is manufactured as
described herein. The following process steps are required.
A. Base formula batch mixing
B. Extrusion/Cooking
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CA 02095172 1999-12-13.
. 29
' C. Particulate additions
D. Pellet forming
E. Flaking
F. Toasting
A. Base Formula Batch Mixing
The following ingredients are mixed and fed into an
extruder/cooker to provide a cooked dough of the proper
characteristics. These ingredients are preconditioned
prior to introduction into the extruder/cooker.
48.72% oat flakes
43.90% wheat flakes
5.00% brown sugar
1.50% sodium chloride
0.50% vitamins
0.38% preservative
B. Extrusion/Cookin
The extruder/cooker is a Baker Perkins ,Twin Screw (R.T.M. )
of 50 mm barrel size having nine barrel sections, each
barrel section having a heating element and cooling
means. The proper cook is achieved under controlled
temperature and pressure conditions using the following
extruder operating parameters. A back pressure valve
is used at the exit of the extruder/cooker to maintain
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baz'rel pressure and residence time in the
extruder/cooker.
Operating Conditions
Dry feed rate: 68 kg/hr.
Water rate: 27 kg/hr
Moisture content: 34%
Barrel Temperature (C)
Section 1 68
Section 2 99
Section 3 127
Section 4 135
Section 5 141
Section 6 166
Section 7 177
Section 8 182
Section 9 182
Screw RPI4 160
Specific Mechanical
Energy (HP hr/lb) 0.020
Exit Pressure (gauge) 28.5 atm
Dough Temperature 146C
C. particulate Matter
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In this example granola is used as the particulate
matter. The granola comprises (on a wet basis) 21.6%
wheat flakes, 37.8% oat flakes, 0.35% sodium chloride,
5.2% non-fat dry milk, 2.3% flavoring agents and 23.2%
brown sugar. The granola is sized by passing through a
3/8" round hole perforated screen and collecting the
material which remains on a #8 mesh U.S. Standard
screen.
D. Forming 8te
Upon exiting the extruder/cooker, excess steam flashes
off the cooked dough product, which is then introduced
into the inlet of a 4.25 inch (10.8 cmj Bonnot forming
extruder in conjunction with the granola. The granola
is added to the forming extruder using a screw feeder
at a feed rate of 27.25 kg/hr. A secondary cereal
dough product comprising the cooked cereal dough and
granola is formed in the forming extruder. This
secondary cereal dough product is deaerated and formed
in the forming extruder under a temperature of 100
degrees C and a gauge pressure of 0.5 atm. The dough
is forced through a die plate at the exit of the
forming' extruder, where it is cut into gelatinized
pellets by a rotating knife. The die plate for this
product is configured with 12 holes of 11/64 inch (0.44
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CA 02095172 1999-12-13 . .
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32
cm) diameter each arranged in a single circle. The
speed of the rotating knife controls the length of the
pellets, which drop~into a pellet transfer system. The
resulting pellets have an average length of 0.3 cm. and
a moisture content of approximately 23%.
E , Flakinct
The pellets are conveyed to a Ross/Ferrel (R.T.M. ) flaking
device where they are converted into flakes via a
vibratory pan feeder. During conveyance the pellets
cool from 88°C to 43°C. The operating conditions of
the flaking device are:
Pellet/flakes.Moisture content 23%
Roll gap 0.125 cm
Roll speed 100 RPM
Roll temperature 36°C
Roll pressure (gauge) 91.5 atm
Feed rate 123 kg/hr
F, Toasting
The flakes are toasted in a three stage dump Proctor &
Schwartz (R..T'.I~I. ) oven. ' Toasfiing is carried out under the
following conditions:
Residence time
Zone 1 0.6 min.
l ~i .~ :~ i ~l ~'
33
Zone 2 1.3 min.
Zone 3 0.8 min.
Temperature
Zone 1 199C
Zone 2 199C
Zone 3 163oC
Air Flow Direction
Zone 1 up
Zone 2 up
Zone 3 down .
Flake Moisture Profile
Zone 1 - entrance 23%
Zone 2 - entrance 15%
Zone 3 - entrance 7%
Zone 3 - exit 1.0%
Bed Depth
Zone 1 2.5 cm
Zone 2 5.1 cm
Zone 3 3.8 cm
Following toasting the flakes are packaged and shipped
1X~MPLE 2
An oat bran flake cereal which incorporates apple pieces
into the cooked dough matrix of the flake is prepared in the
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34
same manner as the process described in Example 1, including
utilizing the same ingredients and equipment, except as
noted herein.
Base Formula Batch Mixing
The following ingredients comprise the base mix, which
is fed into an extruder/cooker to provide a cooked
cereal dough having the desired characteristics. These
ingredients are preconditioned prior to introduction
into the extruder.
70.00% oat bran
6.00% oat bran concentrate
10.18% wheat flour
2.00% malted barley flour
11.00% brown sugar
0.62% salt
0.20% vitamins
B. Extrusion,/Cool~inct
The same equipment described in Example 1 is used,
except the barrel section of the extrusion cooker is
shortened and only five barrel sections are necessary.
The processing conditions are:
Operating Conditions
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Dry feed rate: 68 kg/hr
Water rate: 27.2 kg/hr
Moisture content: 34%
Barrel Temperature (C)
Section 1 66
Section 2 93
Section 3 121
Section 4 149
Section 5 177
Screw RPM: 160
Specific Mechanical
Energy (HP hr/lb): 0.016
Exit Pressure (gauge) 27.2 atm
Dough Temperature: 146°C
C. Particulate Matter
Low moisture dehydrated apple pieces are used for the
particulate matter. They are sized through a #12 US
Standard mesh. The apple pieces are added to the
forming extruder at a rate of 17 kg/hr using a screw
feeder.
D. Forming BteQ
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A 4.25 inch (10.8 cm) Bonnot forming extruder is used
to incorporate the apple pieces into the cooked dough
matrix and is used to form pellets. The apple pieces
are added to the forming extruder in conjunction with
the cooked cereal dough from the extrusion cooker using
a screw feeder at a rate of 26 kg/hr. The forming
extruder is operated at a temperature of 100oC and a
gauge pressure of 0.5 atm. As described in Example 1
above, the dough is deaerated, formed, and cut into
pellets at the die face. The speed of a rotating knife
controls the length of the pellets, which are 0.6 cm.
in length. The die plate is configured as described in
Example 1. The resulting pellet has a moisture content
of approximately 26%. The pellets are then conveyed to
a flaking device, as described in Example 1.
E. Flaking
The same flaking system is used as in Example 1 and is
operated under the following conditions:
Moisture content 26%
Roll gap 0.125 cm
Roll speed 105 RPM
Roll temperature 36°C
Roll pressure (gauge) 91.5 atm.
Feed rate 107 kg/hr
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37
F. Taastina
The cereal flakes are toasted in the
equipment
described in Example 1 under the following conditions:
Residence Time
Zone 1 0.6 min.
Zone 2 1.3 min.
Zone 3 0.8 min.
Temperature
Zone 1 199oC
Zone 2 199C
Zone 3 135oC
Air Flow Direction
Zone 1 up
Zone 2 up
Zone 3 down
Flake Moisture Profile
Zone 1 - entrance 26%
Zone 2 - entrance 15%
Zone 3 - entrance 8%
Zone 3 - exit 1.0%
Bad Depth
' Zone 1 2.5 cm
Zone 2 5.1 cm
Zone 3 3.8 cm
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The toasted flakes are packaged and shipped.
EXAMPLE 3
A cereal flake prepared in accordance with Example 1 is
further processed to attach relatively large-size edible
particulate matter to the surface of the flake using a
relatively small amount of adhesive material.
The flakes prepared in Example 1 are metered into a flow-
through type enrober using a weight belt feeder. In the
enrober two atomizing nozzles are used to spray 844
grams/min of syrup onto 1498 grams/min toasted flakes and
568 grams/min of instantized rolled oats. The instantized
oats are sized such that all oats are above a #8 mesh US
Standard screen. The syrup system is comprised of the
following ingredients and is held at a temperature of 74-
79oC.
Water 28.80%
Corn syrup solids 21.73%
Brown sugar 23.90%
Table Sugar 23.90%
Salt 1.51%
Natural Coconut Flavor 0.16%
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CA 02095172 1999-12-13
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39
The enrobed flakes are dried using a three-stage Proctor &
S chwart z (R.T.M.) single flat bed oven. The oven is operated under
the following parameters:
Residence Time 11 min.
Temperature
Zone 1 143°C
Zone 2 143°C
Zone 3 121°C
Air Flow Direction
Zone 1 up
Zone 2 down
Zone 3 up
Following drying the flakes are packaged and shipped.
