Note: Descriptions are shown in the official language in which they were submitted.
2141974
ULTRA-FINE WHOLE WHEAT FLOURS
AND FOOD PRODUCTS MADE THEREFROM
Background Of The Invention
Commercial whole grain wheat flours, commonly
referred to as whole wheat flours or graham flours, are
most commonly produced by the conventional roller
milling process. Roller milling is a process whereby
cleaned wheat is passed between metal rolls. These
rolls generally have corrugated surfaces, and they are
rotated at differential speeds to produce a shearing-
type grinding action. In the case of stoneground whole
wheat flours, mill stones are incorporated into the
process to achieve part of the grinding action. In
rare cases mill stones are used exclusively to produce
a stoneground whole wheat flour. Commercial whole
wheat flours are typically classified into grades of
coarse, medium, and fine based on granulation size.
Fine whole wheat flour is significantly coarser in
granulation as compared with conventional patent
flours.
Unlike whole wheat flours, patent flours have
the majority of the bran and germ removed from the
endosperm by repeated grinding and sifting which
results in coarse endosperm particles (middlings).
Middlings are then further reduced in particle size by
smooth metal rolls rotating at differential speeds. In
commercial patent flours, 100% of the particles will
typically pass through an opening of 150 microns (U.S.
2141974
standard 100 wire sieve). Commercially available whole
wheat flours are substantially coarser. For example,
the weight percentage of whole wheat flour that will
not pass through a 150 micron opening is generally more
than 20~ for fine whole wheat flour.
Due to the presence of bran, germ and
aleurone, and the lack of refinement of the endosperm,
conventional whole wheat flour is functionally less
desirable than patent flour in baking applications.
The undesirable characteristics associated with
conventional whole wheat flours include both processing
characteristics and finished product characteristics.
Doughs made from conventional fine whole
wheat flours have poor tolerance to mixing and
fermentation as well as poor gas retention properties
during proofing and baking. The deficiencies of
conventional whole wheat flours can be overcome to some
extent by supplementing the flour with vital wheat
gluten and by using dough strengthening surfactants.
It is generally recognized that when whole wheat flour
granulation size is reduced from coarse to fine,
tolerance and gas retention properties in a dough
system improve for a given lot of wheat. Absorptive
properties of whole wheat flours also become more rapid
and uniform as the granulation size is reduced. In
many baking applications a nonuniform rate of water
absorption results in doughs that have poor processing
characteristics. The bran and germ particles in whole
wheat flours tend to produce doughs that are not as
smooth and extensible as patent flour doughs and tend
to cause processing problems in certain baking
applications. The bran and germ portions of the whole
wheat flour also tend to produce a dough with less of a
continuous gluten network. Because such bran and germ
portions are generally irregular in shape, they tend to
cut into the gluten network during proofing and the
2141974
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-- 3
early oven stage of baking. This results in poor gas
retention properties and lower baked volumes.
Many food products made with conventional
100% whole wheat flour tend to have undesirable
organoleptic properties as compared to food products
made with patent flours. Many people find the gritty
texture associated with conventional 100% whole wheat
based foods undesirable and therefore the market for
such products is limited to a relatively small
percentage of consumers. Because of the well known
nutritional advantages of whole wheat flour, increasing
the acceptability of whole wheat food products would be
beneficial to the nutrition of the general population.
8ummary Of The Invention
The present invention relates to ultra-fine
whole wheat flours which have been milled to an
unusually small particle size to eliminate or minimize
processing and organoleptic problems associated with
conventional whole wheat flours.
According to this invention, an ultra-fine
whole wheat flour is provided having a granulation
profile characterized in that at least 98 wt% of the
flour has a particle size of 150 microns or less. The
preferred granulation profile is as follows:
over 150 micron 0-2 wt%;
over 75 micron 0-30 wt%;
over 38 micron 10-65 wt~;
through 38 micron 10-80 wt%.
This invention is also directed to such
ultra-fine whole wheat flour having a low level of
starch damage, preferably no greater than about 10%,
and to specific products made from this flour.
This invention is also directed to a method
for making the ultra-fine whole wheat flour described
above with an air attrition mill.
2141974
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Brief Description Of The Drawings
Figure 1 is a flow diagram for a milling
process for making a preferred embodiment of the flour
of this invention.
Figure 2 is a cross-sectional view of an
attrition mill suitable for use in the process of
Figure 1.
Detailed Description Of The
Presently Preferred Embodiments
Ultra-fine whole wheat flours represent a
distinct grade of whole wheat flour which is
significantly different from the current commercially
available grades. In terms of water absorption rate,
gas retention properties and other processing
characteristics, ultra-fine whole wheat flours perform
significantly better than conventionally milled fine
whole wheat flours in many applications. In addition,
the organoleptic properties of many food products made
with ultra-fine whole wheat flours are superior to
those made with conventional fine whole wheat flours.
The following discussion will first provide
definitions, and will then turn to a general descrip-
tion of a preferred method for making the ultra-fine
whole wheat flour of this invention. It will conclude
with examples of the use of this ultra-fine whole wheat
flour in various applications.
Definitions:
"Bread" is meant to encompass bread and bread-like
products made with a yeast leavened dough, including
products made from fresh, frozen, and refrigerated
(retarded) dough as well as from mixes. Pizza, bagels,
buns, breadsticks, danish and the like are included in
the category of bread.
"Cake" is intended to refer to cake and cake-like
products such as muffins, doughnuts and the like.
"Cookies" is intended to refer to cookies,
crackers and the like.
21A lg7~
"Pastry" is intended to cover pastry such as pie
crusts, toaster pastry, and the like.
"Extruded Snack Foods" is intended to cover snack
foods which are extruded during preparation, such as
pretzels .
"Pancakes" is intended to cover pancakes and
related products such as waf f les and waf f le cones .
"Pasta" is intended to cover all types of pasta
including noodles and other shapes.
"Biscuits" is intended to cover biscuits and all
purpose baking mix.
"Tortillas" is intended to cover tortillas and
tortilla-like products.
"Extruded cereal" is intended to cover breakfast
cereals which are extruded during preparation.
"Product Mix" is intended to cover a mix for
making any of the above identif ied food products,
including bread mix, cake mix, cookie mix, pastry mix,
extruded snack food mix, pancake mix, pasta mix,
biscuit mix, noodle mix, tortilla mix, and extruded
cereal mix.
"Whole Wheat Flour" is intended to cover wheat
flour milled from and including the whole portion of
the wheat kernel of the cleaned wheat. During
cleaning, up to about 3 wt% of the wheat can be removed
in a scouring step.
General Discussion
This invention specif ically relates to an
ultra-f ine whole wheat f lour and to the use of such
f lours for the production of wheat f lour based food
products .
The ultra-f ine whole wheat f lours described
below were produced by an air attrition milling
process. It is believed that there are other grinding
techniques available that can produce ultra-f ine whole
wheat f lours, but at present the process described
2~41974
,_
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below is preferred to traditional milling techniques
used in the flour milling industry such as pin milling,
impact milling, and disc milling.
Air attrition milling refers to a process by
which an air stream causes particles to collide with
each other thereby reducing the size of the particles.
Air attrition milling differs from impact milling in
that it relies on interparticle collision versus
particle collision with a hard surface. Block et al
(U.S. Patent No. 3,001,727) outlines a milling process
which involves air attrition; however, the process
involves the further processing of endosperm fragments
after the removal of germ and bran fractions of the
wheat kernels and does not deal with the production of
an ultra-fine whole wheat flour.
The air attrition grinding technique
described below was found to produce whole wheat flours
with an average particle size much finer than
conventionally milled fine whole wheat flours and with
a particle size distribution within the same range as
patent wheat flours. In addition, the flours produced
by this technique were found to have starch damage
levels within the range typically found for commercial
patent flours.
Figure 1 shows a milling flow diagram for a
preferred process for producing the ultra-fine whole
wheat flour described here.
Cleaned wheat is introduced via an airlock
10, and then pneumatically conveyed to a cyclone
separator 12, which separates the wheat from the
process air and supplies the wheat to an air attrition
mill 14. The mill 14 grinds the wheat to flour.
To obtain the desired particle size profile
for ultra-fine whole wheat flour, the finely ground
wheat flour leaving the mill 14 is conveyed
pneumatically to a collection cyclone separator 16 for
separation of the ground product from the process air.
21AIQ74
-- 7
The ground material from the collection cyclone
separator 16 is then sifted by a vibro sifter 18
(Buhler Type MKVA-5212M) with a 135 mesh sieve size.
The overtails from the sifter 18 are then recycled to
the intake port of the air attrition mill 14 for
regrinding. The sifted flour is then pneumatically
conveyed via a second airlock 20 to a flour bin (not
shown). Note that the flour retains all of the
original constituents of the cleaned wheat, and is
therefore a whole wheat flour as defined above. Though
one air attrition mill is shown, multiple such mills
can be used in parallel or in series if desired.
The cleaned wheat supplied to the airlock 10
is preferably untempered, and it is cleaned by
conventional methods (not shown). A Millerator removes
rough waste and then Carter disc separators remove
foreign kernels, weed seeds and other foreign material.
An aspirator then removes light dust-like material.
The kernels are then given a scouring to further clean
the surface of the kernel. The cleaned wheat is then
transferred to a surge bin where it is held prior to
being fed to the air attrition mill 14. By way of
example, suitable cleaning can be accomplished by
passing the wheat through a grain cleaner to remove
dust and foreign material, a gravity selector, and a
scouring device of the type described in U.S. Patent
5,158,237. Approximately 0.5-3 wt% of the wheat is
preferably removed in this scouring device, depending
on the type of wheat. At present it is preferred to
remove no more than about 1 wt% in the scouring step.
Scouring of this type has been found to remove most or
all of the wheat kernel brush (or wheat beard), and
therefore to improve the baking characteristics of the
resulting ultra-fine whole wheat flour. The scouring
also removes most or all of the epidermis (cuticle)
layer of the bran and thereby very thoroughly cleans
the outside of the wheat kernel.
~ _ - 8 - 2 1 4 1 974
The presently preferred air attrition mill 14
is referred to as a turbo rotor mill, as shown in Fig-
ure 2. A vertical rotor 22 which has a fan 24 at the
bottom provides air flow to accelerate the wheat going
into the grinding chamber and provides air flow for the
grinding chamber. The rate at which wheat is fed into
the grinding chamber is controlled by an integral
feeder 26. Disc shaped vanes 28 are attached to the
rotor 22 above the fan 24 and are enclosed in a housing
32. The rotor 22 spins the vanes 24 at high speeds and
further accelerates the air stream which contains the
wheat. The accelerated air reacts with the grooved
inner wall 30 of the chamber housing 32 to produce
small vortexes of air rotating at high velocities. The
turbulence produced in the vortexes results in sharp
changes in the speed and direction of the wheat and
causes interparticle attrition of the wheat. Pulsation
of the rotational air stream and ultra sonic vibrations
increase the efficiency of the attrition process. At
the upper portion of the rotor 22 above the vanes 28 is
the classifying section 34 where rotating blades allow
finely ground material to pass through a sifter 36 for
collection. Larger particles are forced out of a
recycle port 38 and are reintroduced into the chamber
for regrinding. The degree of attrition (i.e. the
fineness of the flour) is controlled by adjusting the
recycle setting for the recycle port 38 as well as by
adjusting the clearance of the rotor vanes 28 from the
inner wall 30 of the grinding chamber, and by
regulating airflow through the grinding chamber via the
damper 40.
One suitable air attrition mill is identified
as a "TurboRotor"*type FG1 air attrition mill
manufactured by Mahltechnik Gorgens GmbH (Kurfurstenstr
4, D-4047 Dormagen 5, Germany). Preferred settings and
components for this air attrition mill are as follows:
1. Separation between vanes 28 and grooved inner
wall 30: 2 mm;
* a trademark
21~1974
g
2. Recycling unit valve position: opened as
necessary to achieve desired flour fineness
(valve adjustment rod opened by 1 inch has
been found suitable);
3. Air damper 40 position: closed as necessary
to achieve desired flour fineness (damper
setting of one-half open has been found
suitable);
4. Sifter 36 screen - heavy-duty ASTM-3-160
Nitex, having 160 micron openings;
5. Feed Rate - 1200 pounds of wheat per hour.
Other air attrition mills such as the
Rotomill*supplied by the International Process
Equipment Company of Pennsauken, N.J. are believed to
be suitable in practicing this invention.
The process described above produces an
ultra-fine whole wheat flour with a particle size such
that a minimum of 98% will pass through a screen with
openings of 150 microns in diameter. The flour has
been found to exhibit a starch damage level of 3-9% as
determined by the MegaZyme*Assay (An enzymatic assay
kit based on the method developed by Gibson et al.
(1992) supplied by MegaZyme Pty Ltd., North Rocks,
Australia). The particle size distribution of the
resulting ultra-fine whole wheat flour falls within the
following ranges when tested on a jet sieve Alpine Air
Jet Sieve A 200 LS, Alpine AG Machines, D-8900
Augsburg, Germany:
Over 150 microns (100 U.S. Std sieve) 0%-2%;
Thru 150 microns over 75 microns (U.S. 200 sieve)0-30%;
Thru 75 microns over 38 microns (U.S. 400 sieve)10-65%;
Thru 38 microns (U.S. 400 sieve) 10-80%.
The process described above is capable of
producing ultra-fine whole wheat flours from any class
or subclass of wheat or admixtures of wheats including
but not limited to the following:
hard red winter;
hard red spring;
hard white winter;
* a trademark
2~1374
-
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hard white spring;
durum;
soft white winter;
soft red winter.
The specific particle size distribution and
starch damage level of ultra-fine whole wheat flours
will depend on the type of wheat being milled. As with
conventional milling, soft wheats tend to produce finer
particle distributions and lower starch damage levels
as compared to hard wheats. Starch damage in ultra-
fine whole wheat flours produced as described above
generally ranges from 5-8% starch damage for hard
wheats, 3-6% for soft wheats, and 6-9% for durum
wheats. For a given wheat type, class, or admixture,
the amount of flour less than 38 microns in diameter
will be significantly higher for ultra-fine whole wheat
flour as compared to conventional fine whole wheat
flour.
Just as with patent flours, different
classes, sub-classes, or admixtures of wheat can be
selected for milling into ultra-fine whole wheat,
depending on the requirements of the specific food
application. The following examples demonstrate the
unique processing and finished product characteristics
that can be achieved with ultra-fine whole wheat flour
as compared with conventional fine whole wheat flour.
It should be noted that wheats with a white bran coat
are generally preferred for the production of 100%
whole wheat food products from ultra-fine whole wheat
flour. Finished food products made from white bran
coat wheats tend to have a lighter color and an
improved flavor due to the lower level of bitter
tasting phenolic compounds in the white bran coat. It
has been found that the characteristic color and bitter
taste of whole wheat flour made from red bran coat
wheats can be improved by ultra-fine milling as
described above.
214~ 974
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It is speculated that the reduced particlesize of the ultra fine whole wheat flour described
above may allow for increased bioavailability of
nutrients as well as minimized irritation of the
intestinal wall. Preliminary studies indicate that
ultra-fine whole wheat flours have a greater degree of
separation between the alurone and pericap portions of
the wheat kernel as compared to conventionally milled
whole wheat flours.
EXAMPLE 1: 100% Whole Wheat Bread Using Ultra-fine
Whole Wheat Flour Milled From Hard Red
Spring Wheat
A sample of hard red spring wheat was divided
into two portions. The first portion was milled in the
conventional manner to produce conventional fine whole
wheat flour. The second portion was milled as
described above to produce ultra-fine whole wheat
flour. The properties of the two flours were measured,
and then the following comparative bake evaluations was
performed.
- 2~4~91~
- 12 -
Flour Properties Conventional Ultra-Fine
Fine Whole Whole Wheat
Wheat
Moisture 11.4 9.7
Ash 1.586 1.378
Protein 14.5 14.4
Total Dietary Fiber 9.7 9.35
Falling Number 297 293
Starch Damage 5.70 6.94
Granulation (microns)
Over 150 28.1 0.0
Over 75 thru 150 26.5 12.3
Over 45 thru 75 22.733.8
over 38 thru 45 2.310.7
Thru 38 20.4 43.2
Farinograph
Absorption 76.5 78.5
Peak 5-7 5-7
Stability 6.1 6.2
MTI 40 30
Bake Evaluation:
100% Whole Wheat Bread by Sponge and Dough Process
Formulation: Grams:
Sponge
Whole Wheat Flour (14% m.b.) 455.0
Water 314.0
Bakers Compressed Yeast 21.0
Yeast Food (bromated type) 3.5
Dough strengthener (Elasdo-70 Paniplus)* 1.4
* a trademark
~, ,
_ - 13 -
Formulation: Grams:
Dough
Whole Wheat Flour (14% m.b.) 210.0
Water Variable
Soy Oil 23.8
Granulated Sugar 70.1
Salt 16.8
Sodium Stearoyl Lactylate 3.5
Procedure:
1) Sponge ingredients were mixed in a Hobart*A-120
mixer with a McDuffy bowl and a two prong beater
for one minute on speed 1 and two minutes on speed
2 with sponge water adjusted to give a set sponge
temperature of 74-76 degrees F.
2) The sponge was placed in an open metal container
and fermented for 3 hours in a cabinet maintained
at 86 degrees F and 87% relative humidity.
3) After the fermentation period the sponge was
returned to the mixing bowl along with the dough
ingredients and mixed on speed 1 for one minute
and on speed 2 a variable amount of time according
to the test design (see below). The dough water
temperature and the mixer jacket temperature were
adjusted to give a finished mix dough temperature
of 80-82 degrees F.
4) The dough was placed in an open metal container
and placed back in the fermentation cabinet for 20
minutes.
5) The dough was then scaled to two 652 gram pieces
and sheeted on a National sheeter set at first at
5/161' and then again at l/41' prior to folding 1/3 of
the sheeted inward over the center I /3 . Then the
remaining 1/3 was folded over the top of the first
fold.
6) The folded dough piece was lightly sprinkled with
flour and allowed to rest at ambient conditions
for 10 minutes.
* a trademark
.~
2 141974
,~
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7) The rested dough piece was then molded on a Lane
straight grain molder with the top roller set at
0.3" and the bottom roll set at 0.2", the inlet of
the pressure board was set at a height of 1 7/8
and the outlet at a height of 2 I/l6''.
8) The molded dough piece was then placed in a bread
baking pan measuring 10 1/2~ X 4 5/81' (top inside) 9
I/2'' x 3 3/41' (bottom outside) and a depth of 3 I/2''
with the seam side of the dough piece down.
9) The panned dough pieces were then placed in a
cabinet maintained at 110 degrees F dry bulb and
104 degrees F wet bulb for approx. one hour, until
the dough had proofed l/411 above the top of the
pan.
10) The fully proofed doughs were then baked in a Reed
gas-fired reel type oven maintained at 400 degrees
F for 23 minutes.
11) The baked loaves were depanned and allowed to cool
on a wire rack for one hour prior to being sealed
in poly bags.
12) After 18 hours the loaves were removed from the
bags and measured for volume by rapeseed displace-
ment using a National volume measuring instrument.
The average volume for the two duplicate loaves
from each dough was recorded.
13) The loaves were then sliced and scoured according
to a standard scouring system.
Experimental Desiqn:
Three doughs were mixed for each of the two
flour types according following absorptions and mix
times:
2141974
Conventional Fine Ultra-l'me
Whole Wheat Whole Wheat
Low absorption/low rnix (LL) 62%/1 1/2 rnin 60%/2 ~/z rnin
Center point (CP) 64%/3 1/2 min 62%/4 '/z min
High absorption/high mix (HH) 66%/S 1/2 min 64%/6 1/2 min
The center point conditions were determined
by previous experimentation to give the optimum dough
development and dough handling properties for each
flour.
Results:
Conventional fime whole wheat Ultra-fine whole wheat
LL CP HH LL CP HH
Volume (cc) 26752600 260028502875 2925
Volume 7 6 6 9 9 10
Crumb Grain 7 S 3 10 9 6
Body 7 7 S 10 10 9
Tolerance 6 --- --- 9 --- ---
Overall --- --- 9.5 --- ---
6.75
The ultra-fine whole wheat flour produced
bread with significantly better volume than the
conventional fine whole wheat flour, while maintaining
good crumb grain and body characteristics. The ultra-
fine whole wheat flour also produced a dough which was
more tolerant to mixing and absorption relative to the
conventional fine whole wheat flour.
Breads produced according to the above
procedure and formulation at optimum conditions were
tested by a trained sensory panel in a descriptive
sensory test. The panelists described the bread made
with conventional fine whole wheat flour as having a
gritty, firm texture, whereas the bread made with
ultra-fine whole wheat flour was described as being
7 ~
- 16 -
smooth and soft and was considered to have a texture
very similar to that of bread made from patent wheat
flour.
Example 2: Reduced Calorie Whole Wheat Bread Using
Ultra-fine Whole Wheat Flour Milled From
Hard Red Spring Wheat
The same flours utilized in Example 1 were
evaluated by the following formulation and procedure:
Formulation:
Sponge Grams
Whole Wheat Flour 406.0
Vital Wheat Gluten 84.0
Water 404.0
Bakers Compressed Yeast 21.0
Yeast Food (non-bromated type) 3.5
Sodium Stearoyl Lactylate 3.5
Dough strengthener (Elaso-70)* 5.3
Ascorbic Acid 0.084
Dough
Whole Wheat Flour 210.0
Oat Fiber (Snowite*'CHUSA) 105.0
Water 264.0
Whey 21.0
Salt 15.8
Granulated Sugar 77.0
Molasses 7.0
Gum (Ticaloid*lite TIC Gums) 2.6
Procedure:
The procedure of Example 1 was used with the
following exceptions:
1) Doughs were mixed on speed 1 for 1 minute and
speed 2 for 3 minutes for the fine whole wheat
flour and 4 minutes for the ultra-fine whole wheat
flour;
2) Fermentation time was 2 hours;
3) Doughs were scaled at 552 grams;
4) Doughs were proofed to l/2~1 above the pan.
The bread made with the ultra-fine whole
flour had a slice height of 4 I/2~1 ~ which is the size
desired for commercial reduced calorie breads. The
bread made with the conventional fine whole wheat flour
* a trademark
2~974
_
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had a slice height Of 3 7/81~ ~ which is unacceptable for
many commercial reduced calorie breads. The bread made
with the ultra-fine whole wheat flour had a close crumb
grain and a good crumb body, whereas the bread made
with the conventional fine whole wheat had a coarse,
open crumb grain and a wet, weak body.
Example 3: 100% Whole Wheat Pizza Crust Using
Ultra-fine Whole Wheat Flour Milled From
Hard White Winter Wheat and Hard Red
Spring Wheat
Flour Properties of Hard White Winter Ultra-Fine Whole
Wheat Flour:
Moisture 8.1
Ash 1.420
Protein 12.3
Total Dietary Fiber 9.2
Falling Number 699
Starch Damage 6.87
Granulation (microns)
Over 150 0%
over 75 thru 150 9%
over 45 thru 75 27%
over 38 thru 45 6%
thru 38 58%
Farinograph
Absorption 69.1%
Peak 4.5
Stability 4.8
MTI 50
The above ultra-fine whole wheat flour milled
from hard white winter wheat and the ultra-fine whole
wheat flour milled from hard red spring wheat of
Example 1, along with the conventional fine whole wheat
flour listed in Example 1, were evaluated for the
production of a pizza crust by the formulation and
procedure shown below.
~I41914
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Formulation: Grams:
Whole Wheat Flour 1000.0
Water 500.0
Instant Active Dry Yeast (Red Star)7.5
Soy Oil 40.0
Salt 17.5
Procedure:
1) The dough was mixed to three-quarters of full
development on a Hobart A-120 mixer with a McDuffy
bowl and a two prong beater (3 minutes on speed 1
and 2 minutes on speed 2). The water temperature
was adjusted to give a finished dough temperature
of 75 degrees F.
2) 340 gram dough pieces were scaled and rounded by
hand and coated with a small amount of soy oil.
3) The rounded dough balls were placed on a metal
tray with a paper liner and then retarded in a
refrigerator for 24 hours.
4) The retarded doughs were removed from the
refrigerator and allowed to sit at room tempera-
ture until they reached 68-70 degrees F (approx. 2
hours).
5) The dough balls were then flattened by hand and
then sheeted to a 12" diameter using an ACME
sheeter.
6) The dough was then placed on a 12" pizza pan and
topped with sauce and cheese.
7) The topped crusts were then baked in a Reed Gas
fired reel oven at 400 degrees F for 10 minutes.
Evaluation:
The pizza crusts produced with the ultra-fine
whole wheat flours were judged to have textural
characteristics and degree of rise similar to a pizza
crust made with patent wheat flour. The pizza crust
made with the conventional fine whole wheat flour was
judged to be unacceptable due to a lack of rise
219191~
.
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(denseness), a poor color (too dark), a gritty texture,bitter flavor and aftertaste, and poor strength
(ability to hold sauce and cheese). The color and
flavor of the crust made with ultra-fine whole wheat
flour from hard red spring wheat was slightly less
bitter and lighter in color than the crust made from
the conventional fine whole wheat flour. The crust
made from the ultra-fine whole wheat flour from hard
white winter wheat was much lighter in color and much
less bitter in flavor compared to the crust made with
the conventional hard red spring wheat fine whole wheat
flour.
Example 4: 100~ Whole Wheat Heat Tortilla Using
Ultra-Fine Whole Wheat Flour Milled From
Hard White Winter Wheat And Hard Red
Spring Wheat
The same ultra-fine whole wheat flours evalu-
ated in Examples 1 and 3 as well as the conventional
fine whole wheat flour listed in Example 1 were
evaluated on a pilot scale heat pressed tortilla line
using a standard formulation for heat pressed wheat
flour tortillas. The only adjustment necessary was an
increase in water utilized for the whole wheat flours
relative to the patent wheat flour normally utilized.
The tortillas produced with the ultra-fine
whole wheat flours were judged to be similar in texture
to tortillas produced with patent wheat flour. The
tortillas produced with the hard red spring wheat
ultra-fine whole wheat flour were slightly lighter in
color and slightly less bitter in flavor as compared
with the tortillas produced with the conventional fine
whole wheat flour. The tortillas produced with the
ultra-fine whole wheat flour milled from hard white
winter wheat were much lighter in color and much less
bitter in flavor than the tortillas made from the
conventional fine whole wheat flour. The tortillas
produced with the conventional fine whole wheat flour
2~41~7~
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were dark in color and had a gritty texture and a
bitter flavor and aftertaste.
Example 5: 100% Whole Wheat Chocolate Chip Cookies
With Ultra-Fine Whole Wheat Flour Milled
From Soft White Winter Wheat
The following ultra-fine whole wheat flour
was evaluated in comparison with a patent soft white
winter wheat flour in the following cookie formulation
and procedure.
Flour Properties:
Moisture 10.0
Ash 1.397
Protein 8.4
Total Dietary Fiber 9.5
Falling Number 393
Starch Damage 5.9
Granulation (microns)
Over 150 microns 0.4
over 75 thru 150 0.8
over 45 thru 75 18.4
over 38 thru 45 4.7
thru 38 75.7
Formulation: Grams:
Flour 250.0
All-Purpose Vegetable Shortening175.0
Granulated Sugar 75.0
Brown Sugar 100.0
High Fructose Corn Syrup (42%) 50.0
Eggs (Liquid whole) 50.0
Vanilla Extract 5.0
Baking Soda 1.3
Salt 1.3
Chocolate Chips 100.0
Procedure:
1) The shortening, granulated sugar, brown sugar,
H.F.C.S. 42%, whole egg, and vanilla were creamed
together in a Hobart n-150 mixer with a paddle
attachment for two minutes on medium speed.
2) The flour, baking soda and salt were then added to
the mixing bowl with the creamed ingredients from
2~ 41~4
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step 1 above and mixed on medium speed for 1
minute.
3) The chocolate chips were then blended into the
cookie dough by mixing for 30 seconds on medium
speed.
4) A small scoop was utilized to deposit
approximately 30 grams of dough for each cookie
onto a lightly greased cookie sheet.
5) The cookies were baked for 12 minutes at 375
degrees F.
Evaluation:
The cookies made with the ultra-fine whole
wheat flour had an external appearance that was
indistinguishable from that of the cookies made from
the patent wheat flour. The spread and height
characteristics of the cookies made the ultra-fine
flour were similar to those of the cookies made with
patent wheat flour. The internal crumb of the cookies
made with the ultra-fine whole wheat flour were
slightly darker than that of the cookies made patent
wheat flour; however, with the exception of color the
internal appearance and crumb structure were identical.
The flavor and texture of the cookies made with the
ultra-fine whole wheat flour were very similar to those
of cookies made with the patent wheat flour.
Example 6: 100% Whole Wheat Cake Muffins Using
Ultra-fine Whole Wheat Flour Milled From
Soft White Winter Wheat
The ultra-fine whole wheat flour listed in
Example 5 as well as a patent soft white winter wheat
flour were evaluated in the following formulation and
procedure.
2~41974
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Formulation:
Flour 172.0
Water 165.0
Granulated Sugar 90.0
All Purpose Vegetable Shortening 20.0
Oat Bran 10.0
Rice Bran 10.0
Dry Molasses 10.0
Nonfat Dry Milk 8.0
Instant Clear Jel Starch (National Starch) 5.0
Salt 2.5
Baking Soda 2.4
Sodium Aluminum Phosphate 1.75
Levair (Rhone-Plonce) 0.8
Natural Maple Flavor 1.6
Ground Cloves 0.3
Natural Butter Flavor 0.65
Procedure:
1) The dry ingredients were scaled and placed in a 5
quart mixing bowl.
2) The water was added and a batter was formed by
mixing with a paddle attachment for 1 minute on
low speed and 30 seconds on medium speed.
3) The batter was scaled into paper muffin cup liners
at 60 grams per muffin and baked at 400 degrees F
for 15 minutes.
Evaluation:
The volume and general appearance of the
muffins made with the ultra-fine whole wheat flour were
similar to that of the muffins made with the patent
wheat flour. The only significant difference in
appearance of the muffins from the two flours was a
slightly darker color for the muffins made with the
ultra-fine whole wheat flour. In terms of flavor and
texture there was no significant difference in the
muffins made from the ultra-fine whole wheat flour and
the muffins made from the patent wheat flour.
2 ~ 7 4
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Example 7: 100% Whole Wheat Pancake/Waffle Using
Ultra-Fine Whole Wheat Flour Milled From
Hard White 8pring Wheat
The ultra-fine whole wheat flour described
below was utilized to produce a pancake/waffle mix
according to the following formulation. The mix was
evaluated in pancakes and waffles along with a mix made
with a conventional fine whole wheat flour milled from
hard white spring wheat and a patent wheat flour milled
from a hard red winter wheat flour.
Flour Properties:
Moisture 8.6
Ash 1.540
Protein 11.2
Total Dietary Fiber 9.7
Falling Number 485
Starch Damage 5.7
Granulation (microns)
Over 150 0.0
Over 75 and Thru 150 11.5
Over 45 and Thru 75 17.9
over 38 and Thru 45 7.1
over 38 63.5
Formulation: % Total Mix:
Flour 75.2
Whey 8.0
All Purpose Vegetable Shortening 5.0
Baking Soda 1.15
Sodium Aluminum Phosphate o.g
Monocalcium Phosphate (anhydrous) 0.25
Sugar 5 0
Salt 1.5
Dried Whole Eggs 3.0
Procedure:
1) 250 grams of premix was preweighed.
2) 250 grams of 68-72 degree F water was scaled into
a 5 quart mixing bowl.
3) With the wire whip attached to the mixer, the
mixer was set on low speed and the premix was
added over a period of 1 minute. The bowl was
then scraped and then mixed for 30 seconds on
2~1914
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Medium speed, scraped, and then mixed for another
30 seconds on medium speed.
4) The batter was deposited on the waffle maker and
baked for 2.5 minutes and removed.
Evaluation:
The waffles made with the ultra-fine whole
wheat flour were found to have a texture and flavor
similar to the waffles made with patent wheat flour.
The waffles made with the conventional fine whole wheat
flour were judged to be gritty compared to the ultra-
fine whole wheat flour waffles and the patent wheat
flour waffle. In terms of appearance the ultra-fine
whole wheat waffles were slightly darker than the
patent wheat flour waffles, but did not have the
visible bran specs seen in the waffles made with the
conventional whole wheat flour.
~xample 8: 100% Whole Wheat Pretzels Using Ultra-
fine Whole Wheat Flour Milled From Hard
White Spring Wheat
The ultra-fine whole wheat flour listed above
in Example 5 was utilized to produce pretzels using a
commercial formula on a commercial extrusion-type
pretzel line. A soft red winter wheat patent flour was
also evaluated for comparison. The ultra-fine flour
produced a pretzel with good external appearance and
symmetry but with a slightly darker color than the
pretzels from the patent wheat flour. The texture of
the pretzels made with whole wheat flour was judged to
be slightly harder and crisper than the pretzels made
with patent wheat flour. Overall, the pretzels made
with ultra fine whole wheat flour were judged to be
acceptable. Attempts to make pretzels with
conventional fine whole wheat flour were not successful
due to processing problems not experienced with the
ultra-fine whole wheat flour.
L q74
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Example 9: 100% Whole Wheat Pasta Using Ultra-Fine
Whole Wheat Flour Milled From Durum
Wheat
The ultra-fine whole wheat flour described
below was evaluated in long goods pasta along with a
patent durum flour and conventional whole wheat durum
flour for comparison. A laboratory pasta press was
used on a formulation consisting of flour and water.
The following water levels were utilized:
Patent durum flour 32%
Conventional whole wheat durum flour 39%
Ultra-fine whole wheat durum flour 39%
The extruded long goods were hung on a wooden
pole in a drying cabinet which was programmed for
gradual drying cycle over an 18 hour period.
Flour Properties:
Moisture 8.8
Ash 1.440
Protein 13.3
Total Dietary Fiber 9.12
Falling Number 490
Starch Damage 8.5
Granulation (microns)
Over 150 1.1
Over 75 thru 150 25.5
Over 45 thru 75 44.3
Over 38 thru 45 18.8
thru 38 10.3
Evaluation:
The dried pastas were evaluated in a cooking
test to determine the optimum cooking time. The pastas
were then cooked to the optimum cooking time and the
percentage cooking loss and percentage weight gain were
determined. The appearance and eating characteristics
of the pastas were also evaluated.
2~41974
~ 26 --
Cookin~ Time
In MinutesCookin~ LossWei~ht Gain
Patent durum flour 10 8.1 385
Durum whole wheat 5 11.5 310
Ultra-fine durum whole wheat 8 9.6 345
The appearance of the cooked pasta made with
the ultra-fine whole wheat was slightly dark golden
amber color whereas the cooked pasta made from the
whole wheat durum flour was a very dark brown color
with visible bran specs. The eating characteristics of
the pasta made from ultra-fine whole wheat flour were
judged to be very similar to the pasta made from the
patent Durum flour. The texture of the pasta made from
the whole wheat Durum flour was judged to be poor due
to a gritty texture.
~xample 10: 100% Whole Wheat Pastry Using Ultra-Fine
Whole Wheat Flour Nilled From 8Oft White
Winter Wheat
An ultra-fine whole wheat flour was milled as
described above from soft white winter wheat and used
to make a pie crust pastry. For comparison purposes a
conventional fine whole wheat flour milled from soft
white winter wheat was also used in the same
formulation.
Formulation:
Flour 200 grams
Salt 3 grams
A/P shortening 70 grams
Water 6 0 grams
Procedure:
The shortening was cut into the flour with a
shortening cutter until subdivided into pea size
pieces. The water and salt were then added and a dough
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was formed by mixing in a Hobart N-50 Mixer for 30
seconds with a paddle at low speed. The dough was
sheeted using a rolling pin and placed into an aluminum
pie tin and formed into place by hand. The pie crusts
were baked without filling for ten minutes at 375~ F.
Evaluation:
The pie crust made with ultra-fine whole
wheat flour as described above had textural eating
properties comparable to those of a crust made from
patent flour. The crust made with the fine whole wheat
flour had a gritty eating character and did not have
the flakiness noted in the crust made with the patent
flour and the ultra-fine whole wheat flour.
Example 11: 100% Whole Wheat Biscuit Using Ultra-
Fine Whole Wheat Flour Nilled From Hard
White Spring Wheat
The following formulation and procedure used
to evaluate ultra-fine whole wheat flour milled as
described above from hard white spring wheat:
Formulation:
Flour 250.0 grams
All-Purpose Shortening 32.0 grams
Salt 9.0 grams
Actif-8 6.3 grams
Sodium Bicarbonate 6.0 grams
Dried Buttermilk 3.1 grams
Granulated Sugar 3.1 grams
Water 180.0 grams
Procedure:
Dry ingredients were pre-blended and then
water was added and blended with a Hobart N-50 mixer on
low speed until a dough formed. The dough was gently
kneaded by hand on a floured surface, rolled out to a
thickness of 1/2 inch, and then cut with a biscuit
cutter and placed on a baking sheet. The biscuits were
h ~ ~ 1 9 7 4
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baked in a gas-fired reel oven at 425~ F for 10
minutes.
Example 12: 100% Whole Wheat ~YpAn~ed Ring-Type
Breakfast Cereal Using Ultra-Fine Whole
Wheat Flour Milled From Hard White
Spring Wheat
The fine particle size of ultra-fine whole
wheat flour indicates that a 100% whole wheat expanded
ring type breakfast cereal having acceptable appearance
and texture is producible. It is proposed that the
following formula can be utilized:
Formulation:
Ultra-Fine Whole Wheat Flour 64.0%
Pregelatinized Wheat Starch 20.0%
Sugar 10.0%
Malt Syrup 4.2%
Salt 1.0%
Trisodium Phosphate 0.4%
Calcium Carbonate 0.4%
This formulation can be dry blended and then
fed into a conditioning cylinder where water is added
to form a dough which is introduced into a twin screw
extruder chamber where shear and heat are applied. The
product is extruded out a die and cut by a rotating
blade. The extruded and cut rings are then dried on a
band type dryer to a moisture content less than 10%.
Example 13: Product Nixes Using Ultra-Fine Whole
Wheat Flour
Product mixes for breads, cakes, cookies,
pastries, snack foods, pancakes, pasta, biscuits,
noodles, and tortillas can readily be made using the
ultra-fine whole wheat flour of this invention. In
general, the formulation for such product mixes will be
similar to standard product mixes that use patent
flour, adjusted as necessary to accommodate the
h 1 4 ~ ~ 7 ~
-- 29 --
increased fiber and germ of ultra-fine whole wheat
flour.
Conclusion
The foregoing examples should make it clear
that the ultra-fine whole wheat flour of this invention
provides important advantages in many applications. It
is of course intended that the foregoing examples be
regarded as illustrative rather than limiting. It is
the following claims, including all equivalents, which
are intended to define the scope of this invention.
