Note: Descriptions are shown in the official language in which they were submitted.
CA 02226766 1998-01-13
FILLED CEREAL PRODUCT
FIELD OF THE INVENTION
The instant invention generally relates to a cerea! product having a plurality of
5 tastes, sweetness and textures and more specifically to a dough-filled, shelf-stable,
ready-to-eat cereal product having a plurality of tastes, sweetness and textures and
method for making the same.
BACKGROUND OF THE INVENTION
With the demise of the traditional "bacon and eggs" breakfast, hot or cold cereal
probably represents the most favored alternative repast. Given its popularity, and the
increased competition for "market share", cold cereals have undergone a marked
change from cornflakes and puffed wheat, rice or corn, and shredded wheat biscuits to
various colored and flavored cereal bits. Cartoon and whimsical characters have been
15 coupled with cereals to add to their appeal to children. Still others advertise vitamin or
fiber content. Given the myriad number of cereals available to, and the inherent fickle
nature of the consumer, manufacturers constantly strive to produce a cereal product
that will be the "next favorite".
It should also be noted that cereals have transcended the breakfast table to
20 become snack food. Therefore, when offered as a snack, the cereal product must
stand on its own without the further accouterments of sugar or milk.
In addition, one can clearly ascertain the trends in flavoring of cereals. The trend
spans the gulf from plain and sugar coated to fruit, chocolate and combinations of
flavors. Texture has also endured both subtle and overt changes. Variations from25 bland to crispy texture has given way to dual-textures within the same cereal bit. By
example, cereals with soft fruit interiors or cereal combined with fruit and nut pieces
offer the consumer further texture and taste choices.
Notwithstanding the advances in cereal technology relating to taste and texture,cereal products must display certain physical qualities. The cereal must retain its flavor
30 over time, resist sogginess when exposed to milk and provide the consumer with a
unique taste and texture. Taste and texture are the most difficult parameters to
I
CA 02226766 1998-01-13
~ achieve Hence there is a longstanding need to provide the consumer with a cereal
product with unique texture and taste.
One approach in striving to provide the consumer with a unique texture has been
to employ conventional shredding systems in new ways. Conventional shredding
5 systems used in the production of shredded wheat are disclosed in U.S. Pat. Nos.
502,378; 2,008,024; 2,013,003, 2,693,419; 4,004,035; and Canadian Pat. No. 674,046.
A conventional shredding mill comprises a pair of closely spaced rolls or rollers that
rotate in opposite directions, with at least one of the rolls having circumferential
grooves. Upon passing between the rolls, the wheat is deformed into long individual
10 strings or shreds. The circumferentially grooved roll can also be grooved transversely
to the circumferential grooves for the production of net-like sheets. A conventional 6
inch diameter roller for producing net-like sheets has 60 transverse grooves equally
spaced about the circumference which produce cross-hatchings in the netted product.
When the rollers are held to roll in mutual contact, the shreds or filaments will be fairly
15 separate from each other, though more or less contacting, but when the rollers are
sprung slightly apart, under pressure, the adjacent filaments may be united to each
other by very thin translucent, almost transparent, webs or fins between them.
The shredding mills are typically arranged in a linear series along a common
conveyor, with the shreds running longitudinally or in parallel with the direction of
20 movement of the conveyor. The sheets or layers of filaments are deposited on the
convey~r in super-imposed position, with their filaments running in the same direction.
A typical biscuit, for example, may contain up to 21 individual layers of shreds. Upon
obtaining the requisite thickness, the multiple layer web can be cut transversely and
longitudinally into multiple lines of biscuits in known manner.
U.S. Patents Nos. 4,696,825 and 4,795,647 issued to Leibfred report shelf-stablepaste-filled shredded cereal biscuits. The paste may be a fruit paste filling (including a
fruit dough filling which comprises a fruit paste and glycerin), a meat filling, a cheese
filling or the like.
CA 02226766 1998-01-13
U.S. Patent No. 4,588,596 issued to Bone et a/. describes a ready-to-eat cereal
produced from a cookie dough. A fatty acid or fatty acid salt is added to the cookie
dough formulation to improve the bowl life of the cereal.
U.S. Patent No. 5,093,146 issued to Calandro et a/. describes a ready-to-eat
5 cereal prepared from a cookie formulation. The cereal may optionally be coated with a
sugar-like glaze. The purpose of this invention is to provide a cookie-like cereal having
an improved bowl life.
It is an object of the present invention to provide a new cereal bit.
Another object of the present invention is to provide a means of adding nut
10 pieces and /or fruit pieces to a shredded cereal bit.
Some embodiments of the present invention provide a continuous process for
the production of multi-tex~ured dough-filled shredded wheat biscuits using shredding
mills which are arranged in the conventional linear fashion wherein each shred layer is
produced from a separate pair of shredding rollers. The variation enhances the textural
15 contrast of a crisp biscuit and an essentially dry, rich tasting, crumbly solid center that in
some embodiments also includes a chewy character such as that found when the
dough filling of the present invention also includes a significant portion of fruit such as
apples. The multiple tastes and textures of the inventive cereal bit are shelf stable for
extended periods of time.
SUMMARY OF THE INVENTION
The present invention provides a process for the continuous production of a
shelf-stable farinaceous dough-filled cereal product having a plurality of tastes and
textures. The cereal product of the present invention has a farinaceous central matrix
25 that is wrapped by an outer cereal portion. The farinaceous central matrix can contain
other materials such as nut pieces, fruit pieces, or conventional pastes such as cheese
or meat pastes.
In a preferred embodiment, a first plurality of disparate cereal shred layers are
continuously laminated, followed by continuous addition of at least one dough filling
30 rope upon the first plurality of shredded layers. A second plurality of shredded cereal
CA 02226766 1998-01-13
shred layers is continuously laminated upon the dough filling rope to obtain a
sandwiched matrix. Each of the layers typically has a plurality of generally parallel
longitudinal strands and a piurality of cross-hatchings which are generally perpendicular
to the longitudinal strands. The cross-hatchings and the longitudinal strands form an
integral net-like sheet. The longitudinal strands of each layer and the dough filling
ropes are generally arrayed in a parallel conflguration. The sandwiched matrix is cut to
wrap the filling and the product is baked.
The filling is a farinaceous dough that can be prepared by creaming a sugar
component, dough conditioner, an emulsifler and a portion of the flour with a fat or
shortening. Water and an optional liquid sweetener, such as honey or high fructose
corn syrup, are added and blended to homogeneity. The remaining portion of the flour
along with any leavening agent is then added and blended with the other ingredients to
form a uniform cookie or other farinaceous dough. While some of the preferred
embodiments of the present invention use a "cookie" dough, other embodiments uselS other types of conventional doughs such as yeast and quick bread doughs. In the
practice of the present invention, the dough should substantially not run after it is
placed on the first cereal layer. Thus, flowable batter should be avoided. The cookie
dough may be allowed to set for a sufficient period of time under controlled conditions
to proof the dough and develop the proper texture for shaping and machining.
The cookie dough contains at least one flour component in the amount of about
30% to 55% by weight of the dough and preferably about 35% to 50% by weight of the
dough. In a preferred embodiment of the invention, the cookie dough contains a
mixture of pastry and bread flour. The dough typically also includes at least one type of
fat or shortening in the amount of about 5% to 25% by weight of the dough and
preferably about 10% to 18%.
Process compatible ingredients can be included to adjust the texture of the
product produced by the process of the present invention. For example, at least one
solid, crystalline, or granulated sugar, such as sucrose, may be used in the farinaceous
dough. In addition to solid or granulated sugars, liquid sweeteners may also be used.
Sweetening agents like liquid brown sugar, high fructose corn syrup and honey may be
CA 02226766 1998-01-13
operatively substituted in the practice of the present invention. In embodiments of the
invention, the sugar component may be added in an amount to provide, for example,
from about 10% to 40% by weight, and preferably from about 15% to 30% by weight
total sugar solids, based on the total weight of the farinaceous dough.
The farinaceous dough of the present invention preferably contains sufficient
water to obtain a texture or consistency suitable for extruding the dough into the desired
size. Generally, the total water content ranges from about 10% to 25%, by weight, and
more preferably about 14% to 20%.
An optional dough conditioner and/or an optional emulsifier may be added to
enhance machinability of the dough.
The dough formulation may further contain flavorings such as powdered cocoa,
chocolate liquor, vanilla extracts, almond extract, nuts or seeds (including whole,
pieces, diced or meal) such as almonds, Brazil, cashews, hazelnuts, pecans, and
walnuts, peanuts, sunflower seeds, poppy seeds, fruit flavors, fruit pieces such as fruit
granules, pastes, powders and dices from, for example, apples, pears, oranges and
dates, raisins, peaches, blueberries and cranberries, spices such as cinnamon and
nutmeg, and other flavoring agents. The amount of flavoring added is determined by
the intensity of the flavoring agent, the desired intensitv of the flavor and any textural
attribute contributed by the flavoring.
The method according to the present invention produces a ready-to-eat
breakfast cereal having a sweet, dual textured taste and which remains crispy in milk
for an extended period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a side view of a roller having a channel groove;
Fig. 2 is a top view of a roller having a channel groove; and
Fig. 3 is a side view of a roller combined with a cleaning knife.
~ ( CA 02226766 1998-01-13
DETAILED DESCRIPTION OF THE INVENTION
The ready-to-eat farinaceous dough-filled cereal products of the present
invention are shelf-stable and possess a plurality of textures. The dough filling is
wrapped in a cereal layer which provides a textural contrast thereto. Typically, the
outer cereal layer has a crisp dry texture and is generally compressible, whereas the
central matrix has an essentially dry, crumbly texture, being preferably solid, being
typically rigid and fracturing when bitten.
Moreover, the cereal product of the present invention exhibits a mouth feel thatdiffers from conventional cereals. For example, when the outer portion is a plurality of
cereal shreds, the outer portion shreds are dry, bland, crisp and filamentous, while the
central matrix is rich, solid and crumbly when the consumer chews the cereal morsel.
Both the shred layer and the central matrix have a water content of from about 1 to
8.5%.
As used herein the term "wrapped" does not require a complete covering,
although such is preferred. Desirably, the covering is at least substantially complete
along each cut edge of the biscuit and complete across the major dimensions of the
biscuit. Accordingly, a filling is considered to be wrapped by a cereal layer where the
filling is exposed along portions of one or more cut edges.
A shredded layer embodiment typically uses a plurality of layers, each of which
has a plurality of generally parallel longitudinal strands and a plurality of cross-
hatchings generally perpendicular to the longitudinal strands. The cross-hatchings and
the longitudinal strands form an integral net-like sheet. The use of an open space
within the area formed by the longitudinal strands and the cross-hatchings in the outer
layers provides a more attractive product.
In preparing a shredded filled biscuit embodiment of the present invention, the
cereal grains are cooked and tempered in a known manner to obtain particles which are
suitable for shredding on shredding rolls. Suitable moisture contents of the cereal
grains for shredding range from about 28% to 50%, more typically from about 42% to
46% by weight, based upon the weight of the cereal grains. The cooked and tempered
cereal grains are transferred, suitably by means of belt conveyors to a hopper which
CA 02226766 1998-01-13
feeds a screw conveyor. The latter transfers the cereal grain to a series of shredding
rolls or mills via flow tubes or hoppers.
The shredding mills, to form the shreds, may comprise a pair of rolls that rotate
in opposite directions. While the rolls typically have circumferential grooves, desirably
S at least one of the rolls has both circumferential and cross-hatching grooves which are
transverse to the circumferential grooves for the production of an integral net-like sheet.
Upon passing between the roll, the cereal grain is deformed into the circumferential
grooves and the cross-hatching grooves. Each pair of rolls produces a cereal shred
layer having a plurality of generally parallel longitudinal strands and a plurality of cross-
hatchings generally perpendicular to the strands. The longitudinal strands are
produced by the circumferential grooves and run in parallel with the direction of
movement of an underlying conveyor. The cross-hatchings of the shred layer are
produced by the cross-hatching grooves and run generally perpendicular to the
direction of movement of the conveyor.
By arranging the shredding mills in a linear series along a common underlying
conveyor, the shreds may be positioned as desired. Each of the shredded shred layers
or sheets are deposited on the conveyor in super-imposed position, with their
longitudinal strands running in the same direction. The shred formed thereby form a
series of positioned laminae (individaul laminate layers)
A first plurality of shredded cereal shred layers are continuously laminated. Atleast one dough filling is then continuously deposited upon the first plurality of shred
layers. Each dough rope is typically deposited generally parallel to, or in the same
direction as, the longitudinal strands. A second plurality of shred layers is then
continuously deposited on the one or more dough rope fillings in super-imposed
position to the first plurality of shred layers to obtain a sandwiched matrix of shred over-
wrapping the central matrix.
The number of shredded cereal layers or net-like shredded sheets in the first
plurality of shred layers may be the same or different from the number in the second
plurality of shred layers. It is generally preferable to provide about the same total
-
CA 02226766 1998-01-l3
n~lmber of shredded shred layers in the first plurality as in the second plurality so as to
provide a pleasing symmetrical appearance.
In other embodiments of the present invention, other conventional cereal layers
are substituted for one or more shredded cereal layers described above.
The dough filling is deposited by means of an apparatus placed between
adjacent pairs of shredding rolls. The dough filling is suitably applied by extrusion
through a nozle so as to form an dough rope which is continuously deposited upon the
first plurality of shred layers. The apparatus should have a means for controlling and
directing the flow of the filling so as to provide a straight and uniform dough upon a
substrate which moves at substantially the same linear rate as the dough rope.
Alternatively, the dough filling can be deposited using a channel roll such as
shown in FlGs 1, 2 and 3. Cylindrical roller 10 has one or more grooves 230 running
about its circumference. Typically, groove 230 has a semi-circular cross-section with a
diameter between about 1/8 to 3/8 of an inch. Cylindrical roller 10 with its groove (or
grooves) is combined with a smooth cylindrical roller, each of which rotates in the
opposite direction. The dough filling is fed in via the nip above where the two rollers
abut and the dough filling exits the rollers as rope at the bottom of the rollers. The
dough filling rope is then laid upon the cereal wrapping. Desirably, a wire is employed
to peel the dough out of the channel roller groove after the dough passes throùgh the
nip.
Instead of using a wire to peel the dough out of the channel roller groove, a knife
blade 5 such as shown in Fig. 3, can be used to remove the dough. Knife blade 5 is
mounted in blade holder 3 through blade insertion slot 4 by mounting means 7 and 8, in
this illustration, screws, and the blade holder 3 is in turn mounted to the roller apparatus
via connect means 2 and mounting means 9.
A further alternate means of placing the dough filling on the cereal wrapping isvia a conventional wire cut dough extrusion device.
The number of ropes which are deposited generally ranges from about one to
five or more, depending upon the width of the shredding roll and the desired biscuit
~0 size. A conventional 6 inch diameter shredding roll typically has a width of between
CA 02226766 1998-01-13
about 5 to 6 inches. Typically, about 5 spoon size or bite size biscuits may be produced
within this width thereby calling for the deposition of five dough ropes.
The mass flow rate of the dough rope from the apparatus forming the rope
should be sufficient to provide typically at least about 15% by weight filling in the biscuit,
S based upon the weight of the final product. Preferably, the products contains between
about 18 and 36 % filing or central matrix.
The sandwiched matrix is cut transversely and longitudinally to the direction offlow of the product into multiple lines of filled biscuit preforms using known cutting
devices. The sandwiched matrix is suitably first cut transversely and then longitudinally
lO with respect to the longitudinal strands of each shredded shred layer. In producing
rectangularly shaped biscuits, it is preferable to cut the biscuit so that its longest
dimension is transverse to the longitudinal strands and the dough rope. This provides
greater tolerance for cutting between the dough rope without cutting through the dough
rope. The longitudinal cuts are suitably made about midpoint between adjacent dough
1 S ropes.
As a result of cutting completely through the sandwiched matrix one forms
individual biscuit shapes prior to baking. However, cutting partially through the
sandwiched matrix to form biscuit shapes, followed by baking and separating the baked
partially cut laminate into individual biscuits in a known manner is preferred. This
20 procedure provides easier control of the orientation of a cut product as it passes
through the oven.
The cutting edges of the transverse and longitudinal cutters should preferably be
blunt so as to form at least substantially integral seam along each edge of the biscuit
preform. The cutting should be such so as to at least substantially prevent the
'5 appearance of the dough filling in the baked, final product.
Baking the shred covered matrix forms a mechanical structure that has a strong
bond between the two layers. The resulting structure also retards the entry of milk into
the cereal thereby delaying sogginess.
The fillings used in the filled shredded biscuits of the present invention may be a
;0 cookie-like formulation which is incorporated into a shredded cereal matrix that is baked
CA 02226766 1998-01-13
to produce a ready-to-eat cereal. The combination is formed into pieces and baked
preferably in an oven to leaven the cereal pieces and to produce a leavened cookie-like
- crumb structure in part of the cereal piece. The resulting cereal pieces have a
sufhciently low moisture to be shelf stable.
S In alternative embodiments of the present invention, the layers of shreds are
replaced with any other conventional sheet of cooked cereal material. For example an
extruded sheet of an oat based formulation could form the first layer upon which a filling
is deposited. Thereafter, a sheet of a corn based formulation could be layered over the
filling. Such a product would then typically be cut and baked in a conventional manner.
Such a product could be in the form of a sandwich, a puff, a pillow, a biscuit or the like.
In alternate embodiments of the invention, a cookie or other farinaceous dough
formulation is prepared by first creaming sugar and a portion of the flour with the fat or
shortening, a dough conditioner and an optional emulsifier. Liquid components, such
as liquid sweeteners, flavors and water, are then blended into the creamed ingredients.
All the remaining dry ingredients, such as any remaining flour, leavening agents and the
bowl-life extending ingredients are blended to form a homogeneous dough. The dough
is optionally allowed to stand and proof for a period of time to develop proper texture.
The cookie dough is then added to a wrapping and the combination is baked. The
baked pieces generally have a final moisture content of about 2% to 5.5% by weight.
An optional sugar glaze may be applied to the baked pieces to provide added
sweetness and a glossy appearance. The optional sugar glaze may also alter the
mouth-feel of the cereal product of the present invention.
The cookie or farinaceous dough contains at least one flour component in the
amount of about 30% to 70% by weight of the dough and preferably about 30% to 55%
by weight of the dough. In a preferred embodiment of the invention, the cookie dough
contains about 10% to 25% pastry flour based on the total weight of the dough.
In both the wrapping layer and in the filling, any cereal grain or mixture thereof
may be used. Exemplary cereal grains are wheat, corn, oat, barley. rye, rice, and
mixtures thereof
CA 02226766 1998-01-13
In the filling, the cereal grain includes a flour which may be bleached or
unbleached. Wheat fi'our, and in particular bread flour and/or pastry flour, and mixtures
of wheat flour with other grain flours are generally preferred.
Corn bran, wheat bran, oat bran, rice bran, and mixtures thereof may be used to
S replace the flour in whole or in part to produce a fiber-enriched product, to enhance
color, or to affect texture. The bran may be included, for example, in amounts of up to
about 20% by weight, based upon the weight of the dough. Generally the bran
component will be included in amounts of about 1% to 10% by weight, and preferably
from about 2% to 5% by weight, based upon the weight of the dough.
The preferred fat or shortening in the present invention may be any food grade
fat or shortening suitable for baking applications. The fats which may be used generally
include vegetable fats, lard, tallow and mixtures thereof. The fat may be fractionated,
partially hydrogenated, and/or inter-esterified. Edible reduced- or low-calorie, or non-
digestible fats, fat substitutes, or synthetic fats, such as sucrose polyesters which are
15 process compatible, may also be used. The shortenings or fats may be solid or semi-
solid at room temperature of about 75~F to 90~F. The use of fats which are solid or
semi-solid at room temperature is generally preferred over liquid oils to reduce oil
separation from the finished product during storage.
The fat or shortening is generally included in amounts of about 0% to 25% by
20 weight, based on the total weight of the ingredients. Preferably, the fat or shortening is
included in amounts of about 10% to 18% by weight.
Exemplary emulsifiers which can be used include lecithin, sorbitan
monostearate, mono- and/or di-glycerides and polyoxyethylene sorbitan fatty acidesters, such as polysorbates (e.g., polyoxyethylene (20) sorbitan monostearate).25 Emulsifiers are often added to cookie doughs to enhance the formation of the emulsion
with the fat component and to reduce the amount of mixing required. Generally,
emulsifiers are included in cookie doughs to reduce the amount of work needed to form
the emulsion.
A dough conditioner and/or emulsifier such as sodium stearoyl lactylate, non-fat30 milk, whole eggs, lecithin and salt may be added to the dough formulation. For
CA 02226766 1998-01-13
example, a dough conditioner can be used to produce a machinable dough consistency
for extended periods of time. When used, a dough conditioner and/or emulsifier is
generally included in the dough in the amount of about 0.05% to 3% by weight.
The ready-to-eat cereal of the present invention may also contain process-
S compatible ingredients to modify the texture of the products, such as sucrose, fructose,lactose, dextrose, galactose, maltodextrins, corn syrup solids, hydrogenated starch
hydrolysates, protein hydrolysates and mixtures thereof. Reducing sugars, such as
fructose, maltose, lactose, and dextrose or mixtures of reducing sugars may be used to
promote browning during the baking stage. Fructose is the preferred reducing sugar,
lO because of its ready availability and its generally more enhanced browning effect. The
source of fructose may include invert syrup, corn syrup, high fructose corn syrup,
molasses, brown sugar, maple syrup and mixtures thereof. The sugar may be admixed
with other ingredients in either solid form or crystalline form.
Crystalline or granulated sucrose alone or with other sugars is preferred in thelS present invention. The sucrose content may, for example, be at least about 80% by
weight, based upon the total sugar solids content of the dough. The balance of the
sugar solids may comprise, for example fructose, dextrose, lactose, or mixtures thereof.
In embodiments of the present invention, the total sugar solids content of the
farinaceous dough of the present invention is, for example, at least about 10% by
20 weight, and may, for example, go up to about 40% by weight, based upon the total
weight of the cookie dough. The sugar solids content preferably ranges from about
15% to 40%, by weight, based upon the weight of the cookie dough.
The total moisture content of the farinaceous dough is generally in the range ofabout 10% to 25% by weight. The preferred moisture content is from about 14% to
25 20% by weight. The amount of added water is generally in the amount of about 5% to
17% by weight. The amount of moisture in the farinaceous dough should be sufficient
to provide the desired consistency to enable proper processing of the dough. The total
moisture content of the dough will include any water added as a separate ingredient, as
well as the moisture from the flour, which is usually 10% to 14% by weight of the flour
30 and the moisture from other ingredients, including, for example, high fructose corn
CA 02226766 1998-01-13
syrups, honey, invert syrups, or liquid humectants. Generally, the amount of water
present in the farinaceous dough is sufficient to produce a consistency which can be
extruded using conventional equipment. If the water content is too low, the dough may
be too stiff and cannot be machined. The addition of too much water may cause the
S dough to become sticky and too soft to hold its shape.
The formulation of the present invention may contain up to about 3% by weight
of a yeast or chemical leavening system, based on the total weight of the farinaceous
dough. The amount of the leavening agent used is selected to control the rise and
spread of the dough and to adjust the pH of the finished cereal. Exemplary optional
chemical leavening agents include sodium bicarbonate, ammonium bicarbonate,
sodium phosphate, cream of tartar (also known as potassium bitartrate) and mixtures
thereof. In the preferred embodiments of the invention, the leavening agent is provided
in amounts of about 0.2% to 1% by weight based on the weight of the dough.
In embodiments of the invention, a dry multi-vitamin premix may be included in
the farinaceous dough. Dry vitamin compositions are preferred to avoid the addition of
the carrier liquid to the farinaceous dough. Dry multi-vitamin premixes suitable for the
invention may, for example, be such as those supplied by Hoffman LaRoche Company.
In one form of the invention, the vitamin premix is dry blended with the sugar
component before admixing with the remaining ingredients.
A vitamin premix may be included in an amount of up to about 0.5% by weight,
based on the total weight of the farinaceous dough. The preferred range for the vitamin
premix may be about 0.05% to 0.3% by weight, based on the total weight of the
farinaceous dough. The amount of vitamin premix used can be altered to meet any
level of vitamin concentration desired.
An exemplary multi-vitamin premix that may be used in this invention includes
one or more vitamins, such as vitamin E, biotin, vitamin A, vitamin D, niacin, vitamin B6,
vitamin B2, folic acid and minerals, such as calcium, iron, and zinc.
Alternatively, the optional vitamin premix may be added as a coating in any
conventional cereal coating.
CA 02226766 1998-01-13
The farinaceous dough preferably contains at least one flavoring component.
Suitable flavorings include, for example, powdered cocoa, chocolate liquor, vanilla
extract, nuts or seeds (including whole, pieces, diced or meal) such as almonds, Brazil,
cashews, hazelnuts, pecans, and walnuts, peanuts, sunflower seeds, poppy seeds, fruit
S flavors, fruit pieces such as fruit granules, pastes, powders and dices from, for
example, apples, pears, oranges and dates, raisins, peaches, blueberries and
cranberries, spices such as cinnamon ancl nutmeg, and other flavoring agents. The
amount of the flavoring added is determined by the intensity of the flavoring agent, the
desired intensity of the flavor and any textural attribute contributed by the flavoring.
10 Generally, the amount of flavoring included in the dough formulation is less than about
70% and preferably between about 1% to 50%, by weight. Typically, a nut containing
farinaceous dough used in the present invention contains between about 0% and 50%
nuts whereas a fruit containing farinaceous dough used in the present invention
contains between about 0% and 50% fruit pieces. Moreover, a farinaceous dough used
15 in the present invention typically contains between about 0 and 15% of other flavoring
material. It is preferred that a nut containing farinaceous dough used in the present
invention contains between about 0 and 35% nuts, a fruit containing farinaceous dough
used in the present invention contains between about 0% and 35% fruit pieces, and
that the farinaceous dough used in the present invention contains less than about 5%
20 of other flavoring material.
In a preferred process of the present invention, the ingredients of the
farinaceous dough are selected to produce a leavened, cookie-like filling. The
ingredients generally comprise at least one flour, sugar, fat or shortening, a dough
conditioner, emulsifier, leavening and a flavoring. The flour, sugar, dough conditioner,
25 emulsifier and fat or shortening are preferably creamed in a suitable mixing device,
such as a Hobart mixer. The ingredients are blended for a sufficient period of time to
form a uniform mixture. The mixing time may vary, depending on temperature
conditions, mixing speed, and the proportions of the respective ingredients. Mixing is
generally carried out at room temperature or slightly above room temperature. The
14
CA 02226766 1998-01-13
mixing speed is preferably set at a low speed for about three minutes to ten minutes. A
uniform mixture is generally achieved in about five minutes.
After the flour, sugar and fat or shortening are blended, the liquid ingredients,
such as liquid sweeteners. water, aqueous leavening systems, and flavors are mixed
5 for about one to five minutes, generally about two minutes, to uniformly disperse the
ingredients and form a homogeneous mixture. The remaining dry ingredients are then
added and blended for about two minutes.
Desirably, the homogeneous mixture is optionally allowed to set for about thirtyto ninety minutes before extruding into a cereal wrapping.
The cereal grains which are used in preparing the outer cereal portion may be
wheat, oats, rice, corn, barley, rye, combinations thereof, and the like.
The cut, filled product may be dried, baked and toasted in conventional
equipment. Suitable ovens for drying, baking and toasting the cut filled product include
Proctor & Schwartz, Werner-Lehara, Wolverine and Spooner ovens containing forced15 air and gàs fired burners and a conveyor.
Temperature profiles used in the oven for drying, baking and toasting of the
biscuit preforms are generally within the range of about 200 ~F to 600 ~F. The total
time for drying, baking and toasting should be such so as to produce light to moderate
browning. It depends upon the number of shred layers, the size of the shredded
20 product, the filling, and the type of oven. In a continuous system, the typical total time
for drying, baking and toasting typically ranges from about 5 minutes to 15 minutes
whereas in a batch oven system, the typical total time for drying, baking and toasting
typically ranges from about 10 to 20 minutes.
In a preferred form of the invention, a confectionery glazing solution is applied
25 over the cereal pieces to provide a sweet taste. The glaze is generally a sugar solution
which is heated to completely disperse the sugar. A suitable sugar may be, for
example, about 85% by weight sucrose and about 15% by weight high fructose corn
syrup or invert sugar. The sugar is dissolved in water at about 180 ~F and mixed to
form a homogeneous cloudy mixture. The glaze is held at a temperature of between~0 about 155 ~F to 165 ~F and applied. The glaze is preferably applied by spraying. The
CA 02226766 1998-01-13
glaze is preferably applied as a coating comprising about 10% to 15% by weight, based
on the total weight of the cereal pieces.
Alternatively, or in addition, any other conventional cereal coating such as a
frosting, an icing, tack-ons. a fondant or other su~ar, flavoring or spray oil may be
S applied to the cereal pieces at conventional levels in a conventional manner.
The coated cereal pieces are then dried to about 3% to 4% by weight moisture
and packaged.
The hnal product suitably has an average moisture content of about 1.5% to
6.5%, more preferably from about 2.5% to 5.5% by weight, based upon the weight of
lO the final product, as determined by a vacuum oven moisture analysis.
Desirably, the baked product of the present invention has a water activity of less
than about 0.74 and more desirably less than about 0.45. The Decagon CX-1 water
activity monitor is a useful way to determine the water activities of the products of the
present invention. Preferredly, if the product after baking has a water activity of more
15 than about 0.45, it is dried. A useful method of drying the product is by putting the
product in a 250~F oven for about 20 minutes.
The color of the hnal baked product desirably is a substantially uniform off-white
to light golden tan color.
The cereal shreds may contain one or more additives at the usual levels of
20 concentration.' Exemplary thereof is a sugar such as sucrose, salt, malt, flavoring, food
colorant, emulsifier such as a blend of distilled monoglycerides, vitamins and/or
minerals.
The present invention is further illustrated in the following examples. All
percentages, parts, and proportions are by weight and all temperatures are in ~F,
25 unless indicated otherwise:
Typically the ratio of dry solids in the dough filling to the dry solids in the
wrapping material is between about 1:1 and 1:7, although it is preferred that the ratio is
- between about 1:2 and 1:5 and it is more preferred that the ratio dry solids in the filling
to the dry solids in the wrapping material is between about 1:2.5 to 1:4.
I6
CA 02226766 1998-01-13
EXAMPLE I
Using a conventional shredded wheat production system, four layers of
conventional wheat shreds were laid down. A web layer was placed on top of the four
layers of shreds and a 3/16" strip of Pillsbury Refrigerated Sugar Cookie Dough was
S extruded on the web layer. A second web layer was placed on top of the cookie dough
and three more layers of shreds were laid on the second web layer.
Next, the seven layers of shreds, the two web layers and the cookie dough were
flattened with a large stainless steel sheet so as to slightly compact the plurality of
layers. The plurality of layers was then cut into biscuits of about 28/32" by 30/~~ and
baked at about 450~F for about fifteen and a half minutes. After baking, the product
was dried in a 250~F oven for about twenty minutes.
COMPARATIVE EXAMPLE I
Example I was repeated, except that no filling was added to the layers of wheat
shreds. These biscuits were baked for about ten minutes at 450~F.
EXAMPLE ll
Example I was repeated, except that before the second web layer was placed on
the cookie dough, pecan meal or pecan pieces were sprinkled on the cookie dough.Additionally, the biscuits were baked for about fourteen minutes.
EXAMPLE lll
Example I was repeated, except that before the second web layer was placed on
the cookie dough, either a small or a large nut mixture was sprinkled on the cookie
dough.
The small nut mixture consisted of an equal mass of each of walnut fluff, fine
diced almonds and pecan meal whereas the large nut mixture consisted of an equalmass of each of 3/16" walnut pieces, small diced almonds and midget cut pecan
pieces. The biscuits were baked for about fourteen minutes.
COMPARATIVE EXAMPLE ll
Apple granola granules were placed in the center of a shredded wheat matrix at
a level of about 20% of the total product. This combination was baked, however, it
lacked structural integrity and fell apart upon removal from the oven.
'~ ! CA 02226766 1998-01-13
EXAMPLE IV
Example I was repeated, except that before the second web layer was placed on
the cookie dough, 12 mesh apple granules were sprinkled on the cookie dough, and in
some instances, cinnamon was sprinkled on the apple granules. These biscuits were
5 baked for about fourteen minutes.
The products of Examples I - IV and Comparative Example I were evaluated as
follows:
Example Qrganoleptic Evaluation
Comparative Example I Crisp biscuit, good wheat taste
Example I Crisp texture, sweet flavor with dual texture (crispouter layer and crumbly inner layer)
Example ll - pecan pieces Sweet with nuts and dual texture
Example ll - pecan meal Crisp with dual texture, sweet with a nutty taste
Example lll - small nut pieces Dual textured, sweet with nuts
lS Example lll - large nut pieces Dual textured, sweet with nuts
Example IV - apple granules Dual textured, very slight apple flavor
Example IV - apple granules with
cinnamon Dual textured with an apple cinnamon flavor
Each of the products of the present invention was able to maintain a structural
20integrity.
EXAMPLE V
Example I was repeated, except that a mixture of 3 parts, by weight, cookie
dough combined with 4 parts, by weight, 12 mesh apple granules was used instead of
the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
25In addition to the crisp, crumbly texture, the apple granules also provided the
product with a chewy texture.
EXAMPLE Vl
Example I was repeated, except that a mixture of 5 parts, by weight, cookie
dough combined with 2 parts, by weight, 12 mesh apple granules was used instead of
30the cookie dough of Example 1. These biscuits were baked for about fourteen minutes.
18
~I CA 02226766 l998-0l-l3
EXAMPLE Vll
Example I was repeated. except that a mixture of 3 parts, by weight, cookie
dough combined with 4 parts, by weight, pecan meal was used instead of the cookie
dough of Example 1. These biscuits were baked for about fourteen minutes.
E>~AMPLE Vlll
Example I was repeated, except that a mixture of 5 parts, by weight, cookie
dough combined with 2 parts, by weight, pecan meal was used instead of the cookie
dough of Example 1. These biscuits were baked for about fourteen minutes.
E)CAMPLE IX
Separately, a conventional cooked wheat berries, a conventional cookie dough,
a conventional cereal coating and a conventional cereal frosting were prepared. The
cookie dough consisted about 32 % wheat flour, about 21 % sugar, about 10 % of an all
purpose partially hydrogenated cotton seed and soybean oil shortening, about 0.2%
sodium bicarbonate, about 0.2% cream of tartar, about 0.4 % salt, about 0.8 %
cinnamon, about 24% 1/8" chopped evaporated apple pieces, about 0.8% non-fat drymilk, about 0.8% lecithin, about 0.2% of a dry vitamin and mineral blend and natural
and artificial flavors. The cereal coating was a mixture of sugar and corn syrup and had
about 77 % solids. The cereal frosting was a white fondant of about 79% sugar, about-
1.6 % of an partially hydrogenated cotton seed and soybean oil shortening in a hard fat
flake form, and about 0.5% gelatin, the frosting had about 80 % solids, the balance
being water.
Using an about 6 inch wide conventional shredded wheat production system,
four layers of conventional wheat shreds were laid down. Five approximately 3/16"
strips of cookie dough, at between about 45 and 85~F, were deposited using a channel
roll on top of the four layers of shreds, each strip was spaced about an inch from any
neighboring cookie dough strips. Three additional layers of shreds were laid on the five
strips of cookie dough. The sandwiched cookie dough was partially cut into
approximately rectangular shapes prior to baking.
The shred layers with the sandwiched cookie dough was baked in a pilot plant
Wolverine continuous multi-zone dryer with a first zone temperature of about 480~F
19
CA 02226766 1998-01-13
and an exit zone temperature of about 330~F for about 9 minutes. After exiting the
oven, the edges were trimmed off and the sheets were broken into individual biscuits.
Any fines were removed by screening.
Next, using a pilot plant batch reel, the baked biscuits were coated with the
5 conventional cereal coating and dried at about 225~F. Again, any fines present were
removed by screening.
The dried, coated biscuits were then arranged in a monolayer in a large tray andiced with the conventional icing. The icing is pumped through a tube with holes so as to
coat the dried, coated biscuits with the icing. The iced biscuits were stored at room
10 temperature at least until the icing started to turn white. Thereafter, the biscuits were
packaged and stored.
The finished product was roughly 53% shreds, 20% cookie dough filling, 13 %
coating and 14 % icing and had a moisture content of between 5 and 5.5 %.
Before packaging, any fines present were again removed by screening. The
I S biscuits were then packaged, desirably in an odor barrier material that is an effective to
retain the flavors in the packaging.
