Note: Descriptions are shown in the official language in which they were submitted.
CA 02466411 2004-05-05
FUNCTIUNAL FIBRE PRODUCT FOR. Fi~OD A.FPLIC.~iTIt?N~:
This invention is in the field of oilseed refining and processi~, and in
particular the
production of a functional fiber flour product for use in foods, beverages and
nutritional
supplements for standard and special diets for human and animal consumption.
The composition of processed foods is an ongoing concern, both for
professional
dietitians, and the general public alike. Chazxges in lifestyle and eating
habits have meant
that mare and more of the foods consuztzed by eoz~sumers are commercially
processed
rather than freshly prepared. Because of this, there is increasing concern and
attention
paid to the comgosition of pFOCessed foods, in order that foods meet
requ~rexnez~ts iua
terms ofnuiritional value and digesiibility.
There are as well different dietary philosophies. Most of the published food
guides
available in Wcstcm countries recommend a diet higP~ in complex carbohydrates
and
fiber,1ow in fat and with modest amounts of protein. Typical.ty, it is
recommended that
individuals derive most of their food energy from complex carbohydrate sources
such as
. . ;
grains and fruits. These same so~rrces are also relatively high. in dietary
fiber, as well a.5
being low in saturated and traps fats, forms of fat considered to be more
harmful,
especially with respect to cardiovascular disease.
In addition to the conventionally accepted diets, there are e~ variety of
alternative diet .
regimes thax have crncrged in the last few decades, The interest in diet and
dieting is
primarily basex9 on the fact that increased affluence and decreased physical
activity in
Western society ha.s led to over consumption of food, the result of which is a
significant
rise in obesity and in health problems that are related to obesity, such as
cardiovascular
disease and diabetes. Combined with the increasing costs of providing health
care,
healthful eating is now seen as an important factor not only for individuals
concerned
1
CA 02466411 2004-05-05
with their personal health, but for tixose who pay the casts of health like
health insurers,
and the government wb,ere socialised Rxiedicine is in place.
'~Thile soiree weight loss and weight management diets adhere to the premise
that food
selection should be towards foods with low fat, and the bulk of energy be
derived from
coxziplex carbohydrates, others have su~ested that weight loss is possible by
aggressively restricting simple carbohydrate intake, and consumux~ mainly
protein and
fat. ~,egardless of the relative merits of any particular diet program, it is
clear that
modexri day consumers do make food. choices based on the perceived health and
dietary
l4 benefitsofparticularfoods.
One of the factors that have gained increasing attention recently is the role
of fiber in diet
and health. The U.S. Surgeon General recommends that a person should consume
20 -
35 gin of fiber daily. The average western diet is well below this value, and
people in
Canada and the U.S. typically canstime 10 - 15 gm. daily.
Fiber comes in two fprms, soluble and insoluble, and is di~erezitiated by both
their
i
physical characteristics and their physiological eFfects. Insoluble fiber is
comprised of
such things as cellulose and Iignaris, and is the indigesti151e portion of
foods. lnsotuble
ZO ~'ber, as the natrie suggests is fiber that does not dissolve in water.
This type of fiber adds
bulk to food, and improves the ease of movement of food through the
gastrointestinal
tract.
In contrast, soluble fiber is soluble in water. Soluble fiber comprises food
constituents
such as gums or pectin. Soluble fiber has marry physiological health benefits:
it coats the
lining of the digestive tract, delays the emptying of stomacl2 contents, and
slows the rate
of sugar absorption. The delay in stomach e.-~riptying results in a sensation
of being fut.t,
and thus provides a mechanical feedback that serves to limit appetite: Slowing
the rate of
sugar absorption reduces demand on the endocrine pancreas, the sauarce of the
hormone
2
CA 02466411 2004-05-05
insulin, which is secreted iax response to increased blood sugar levels.
Moderating insulin
levels is lcnovvni to lead to wore stable regulation of blood sugar, which in
turn moderates
appetite.
Lignans arc members of a class of phytochernicals laiown as phytoestrogens.
Lignans are
well known for their antioxidant properties, and have been shown to reduce;
the incidence
of some forms of caxiccr, as well as to produce cardio-protective effects in
humans. In
addition, they possess steroid-like properties and are considered to be
bene~eial in
reducing the adverse symptoms of menopause in women.
1~
In recent years, there has also became more popular; a variety of diets based
on a general
theme of law carbohydrate and high protein as well as relatively high fat
intake. In
general each of these diets work by switching the body's metabolism from sugax
burning
to fat-burning. The typical sources of low carbohydrate foods include meat,
eggs, cheese
and other similar animal derived proteins, which also have very little dietary
fiber
content. These protein sources are relatively expensive as compared to plant
Toads
sources malting these diets more costly than the conventional diet. In
addi'on, there is
i
cancern about the potential adverse side effects of a prolonged diet lower in
dietary fiber
and higher in fat than what is customarily recommended by the U.S. Surgeon
General and
24 the American Dietetic Association. As a result, there is a market need and
a consumer
desire for foods that are relatively low in carbohydrates arnl fats as well,
while
maintaining the desirable charactEristics of high fiber and protein per the
new weight loss .
diets.
Those who arc health conscious are concerned nat just about their dietary
energy sources,
but also of their dietary micronutrient profiles. The vitamin and mineral
contents of
foods are frequently published on labels (publication is mandatory in The
CT.S.) iv order to
allow consumers to make more fully infarmed choices as to their food
selections. One
class of nutrients of note is the ameba-3 fatty acid group (O~As). Typically
found at
3
CA 02466411 2004-05-05
high levels in fish, OFAs have been shown in clinical. studies to reduce tl~e
risk of
cardiovascular disease, decrease the risks ofblood clotting, decrease
triglyceride levels in
the blood, decrease the growth of atherosclerntic plaque and help lower blood
pressure.
The American Heart Association recommends that people eat fish three tinges a
week if
possible; because of their naturall y high levels of OFAs. There are several
disadvantages
to fish serving as the primary sQU~cce of OFAs. First, fi8h is relatively
expensive as a
protein source, since iz~ rmany land locked parts of the world the source of
marine hsh is
fairy distant. In addition, it is known that some types of fish concentrate
mercury, which
makes repeated and prolonged consumption of fish a potential health risk.
Mercury
toxicity in humans is well documented, and includes symptoms such as
neurological and
renal damage, as well as developmental defects in fetuses. As a result, xt
would be
desirable to have a food product relatively high in (7fA content, but oz~e
which is not
derived from a fish source and tlxus avoids the problems associated with
consumption of
fish.
A further issue with many foods is their instability. Stable food products
which do not
degrade in quality arc highly desirable in modern times because many foals are
now
stored for extended periods and shipped over long distances. instability ix~
foods includes
the development of off flavors or odors due to claernical reactions such as
oxidation,
which can render foods unpalatable azzd unfit for consumption. Spoilage due to
the effect
of enzymes or microorganisms ran also adversely affect the nutritional value,
palatability, and safety of foods. Food products derived from oilseeds are
especially
vulnerable to degradation due to oxidation of the oils over time, and the
oxidation
byproducts may render a food product either unpalatable or unsuitable for use.
A problem
in prior art processes for producing oilseed products such as functional fiber
flax flour
has been their inability to produce a product will x~ot undergo oxidative
rancidity spoilage
during normal storage periods.
4
CA 02466411 2004-05-05
Palatability is of primary importance for all food products. Humans are very
discriminating in their food preferences with regard to taste, color and
texture. Therefore,
notwithstanding the nutritional benefits of a food, products quite simply have
to be
agreeable to the consumer's palate. A problem in prior art processes for
producing
S oilseed products such as functional fiber flax flour has been their
inability to produce a
product that can be substituted in any significant proportion for wheat flr
other traditional
flours in baked products such as bread, pizza crust, muffins, and the like
without
adversely affecting the taste, aroma, color and texture of the finished
products.
The prior art flax flour, also commonly referred to as defatted flax meal,
adv~;rsely affects .
taste, color, and texture of the finished baked product, and also adversely
affects binding .
properties (how the flax flour binds to other baking ingrediezzts such as
salt, sugar,
skzorte~~.~ag, bakizag powder, s,~das, flavorings, milk and whey powders),
baking
performance (leavings, oven jump and spread), and baking equipment performance
(gumming of eduipment, bowl pull away, and machinability of the product).
Given the nutritional advantages of using flour products derived from flax,
the issue of
i
palatability presents problems for the food pmduct industxy seeking wheat
flour
sulastitutes that lave high fiber, high prptein, low saturated and tratxs
fatty acids and low
digestible carbohydrate contents. in order to be functional, flax flour must
be able to
substitute for traditional cereal-derived flours to enhance nutritional
.composition
significantly but without adversely affecting the traditional appearance,
taste and texture .
characteristics and the palatability of the finished extruded, baked, flied,
roasted, or
cooked food produce. It is also most desirable that the inclusion of
functional fiber flax
flour product not change the handling properties of dough, batter, or slurry
(e.g.
maehinability orbaking performance) ifit is to be accepted for use in
cornmereial baking
processes, otherwise specialized equipment may be required that would increase
the cost
of production. Therefore, a functipnal fiber flax flour proc~uct will behave
in a manner
analogous to traditional flours, such that wl~ez~ ela fuzzctionai fiber flax
flour is used Lo
5
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CA 02466411 2004-05-05
rcpiaee a portaon of the traditional flour, existing processing techniques and
conditions
may still be employed to produce finished products that will be accepted by
consumers.
An additional reduirement for a functional fiber flax product is that it
should have
relatively low oil content. Extraction methods often use a solvent extraction
step to
remove residual oil remaining after crushing. However, the use of many
solvents
precludes certification of the resulting product as an "organic" product. E1s
the demand
for eerti$ed organic food products increases, a higher valuE flax flour
product would be
one processed without the use of solvents. While it is possible to use
alcohols that have
la been certified as "organic", the use of alcohol increases the casts of
pre>duction. A
problem in prior art processes for producing oilseed pz~oducts such as
functional fiber flax
fl~au~c has been theiuc inability to produce a product with low levels of oils
atad which are
not highly susceptible to oxidative rancidity and spoilage.
It is an abject of the present invention to provide an altered functional
fiber float flour
product that overcomes problems in the prior art. It is a further object of
the present
invention to provide such an altered functional fiber flax flour product such
that it can be
substi'h~ted in significant proportions for conventional cereal-derived flours
without
advez~sely affecting palatability, baking performance rsr the appearance and
palatability of
the finished foot! product. It is a further abject of the present invention to
provide such
an altered functional fiber flax flour product with extended stability and
shelf life in
ambient storage conditions.
It is a further object of the present invention to provide an altered
fianctional fiber flax
flour product with high levels of salable and insoluble dietary fibers, omega-
~ fatty acids,
protein, and lignans, and low Levels of digestible carbohydrate, saturated
arid traps fats.
It is a further object of the present iztvention to provide a process that
comprises a high
pressure and high temperature exttvding step between two separate oil
expelling steps for
b
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CA 02466411 2004-05-05
producing the altered functional fiber flax flour product.
In one embodiment, the iztvention provides a stable high fber altered
functional fiber flax
flour product that has useful and superior qualities with respect to
palatability,
S rnachinability, and handling characterisiacs when used in baking, extrusion,
and cooking
processes. The raw material feed stock used is golden flax seed, rather than
the
traditional brown flax seed. 'fhe functional fiber flax seed flour product it
thus light in
color, and has reduced off flavors. The altered functional fiber flax flour
product has a
reduced content of omega-3 fatty acids and net carbohydrate compared to prior
art flax
flours, and increased levels of lignans, protein and fiber compared to prior
art flax flours.
The functional fiber flax flour product is stable, with an extended shclflife
under ambient
storage and handling conditions compared to prior art flax flour, and can be
used in
significant proportions as a substitute for wheat and other flours, without
adversely
affecting palatability, machinability, and handling characteristics to produce
baked and
extruded foods with increased fiber, increased protein, and decreased
carbohydrate levels.
Such processed food prpductfi also contain nutritionally desirable and
elevated levels of
omega-3 and lignans not found in most conventional baked and processed food
products.
i
The process used to obtain the functional fiber altered flax flour product of
the invention
includes an extrusion step after the flax has been through a ~~rst expetler
pre;;s. Extrusion
involves subjecting the initial flax seed cake exiting the fars~t expeller
press to high
pressures 30 - 40 bar in a screw extreider which raises the temperature of the
product to as
high as 130 ° C and forcing the ,product out through a die, forming
pellets. In conventional
food processing, such extruders are used for that purpose, palletizing
material into a final
form for salt as dog food and the like. lrt the present process the high
temperatures and
pressures in the extruder appear to fiucture the oil cells andlor perhaps
alter the fiber in
such a way that the benefits of the product are achieved.
7
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CA 02466411 2004-05-05
The pelletized flax seed cake them is pressed again itx a second cxpcller
press where more
oil is removed, such that the final altered flax cake has an ail content of
about 1 U%.
Depending on the situation the final altered flax cake then can be micronized
to further kill
microorganisms although the high temperatures in the extruder do substantially
kill all
S bactcxia and the like that rxai$bt be present The double pressed frnal
altered flax seed cak~c
in any event is then milled into the final altered functional fiber flax flour
product of the
invention.
Simply double pressing tl,e flax seed without extruding could bring the oil
content of the
final cake down to 10%, however the flax flour resulting there from does not
have the
beneficial and improved properacs of stability, palatability, and
machinability
demonstrated by the functional fiber altered flax flour product of the
invention.
Beneficially, the extraction process does not use any solvents such as are
commonly used
when attempting to decrease oil content. This allows for the altered flax
flour product
manufactured by the present grocers to receive an "organic" certification, and
reduces the
costs of production that would be added by processing with solvents such as
alcohol that
are certified as "organic." Organic foals are becoming increasingly desirable
and foods
so certified are typically of higher value.
2b Oilseed crops such as flax are .recognized as producing seeds with several
nutritional
characteristics desirable for huxxtans and animals. These include the presence
of high
levels of fiber, both soluble and insoluble, protein, and law levels of
digestible
carbohydrates. In addition, like other giant sources, the fat content is
mainly iu the form
of unsaturated fats, which are more desirable in terms of human health. Flax
also
contains significant levels oiF omega-3 fatty acids (OFAs), which have been
shown
through medical research to lave a number of beneficial efFects on
cardiovascular health
in hurnarls, and lignans like secoisola~riczz~esizzol diglycoside (SDG). Wheil
consumed,
SDG is coirverted in the body to the man~ahiaz~ lignans enterolactane and
enterodial.
These compounds have bean shown to provide health benefits, reducing the risks
of
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CA 02466411 2004-05-05
cancer and. heart disease. lz~ woman, lignans have the potential to reduce
the, unfavorable
symptoms of menopause, as well as reduce tho incidarce of hormone-related
cancers.
In addition, dietary choices have changed over time, and with concerns about
obesity and
the role of carbohydrates, consumers are seeking out sources of food that are
low in
simple carbohydrate but high in protein. Further, the bewc:~tts of fiber arE
also wcll-
documvnied such that consumers increasingly seetc foods with fiber when making
choices
related to diet.
As a result, the present invention is directed towards producing a functional
fiber flax
seed flour product that combines the aforementioned health benefits, and which
can be
used ixt place of a portion of the wheat flour in baking processes axed as a
substitute for
other sources of fiber and protein in food products. The rxaeth~od further
provides for a
product that is stable and which has an extended shelf life, making it more
amenable to
storage and transport.
The Altered functional fiber t'lax flour product:
The ~~nal milled altered functional fiber flax flour product .has
characteristics consistent
with the ability of the flour to be used irn the production c~f batter, dough
or slurry.
Parameters that define the suitability of a flour product for such
applications include the
water holding aa~d binding properties, mixing ability, texture of the mixed
product, the
ability to withstand mixing without a loss of structural integrity' of the
flour particles, the
color, flavor and the texture that the flour product imparts to the final
baked and
processed food products in which it is included. Consistency in these
parameters is
important to commercial bakers and food processors as it permits standardised
recipes to
be u~:ed, which will yield predictable quality in finished products.
9
CA 02466411 2004-05-05
Other factors that are important in baking processes and food preparation a~
the binding
properties of a flour or fiber ingredient, i.e. how well it binds to other
ingredicmts like
salt, sugar, shortening, baking powder, sodas, flavorings, milk, whey po~rders
and the
Like, baking perforcnanca, and interaction with baking equipment. Eduipme;nt
gumming,
bawl pull away and machinabitity of the prodecct are important considerations,
especially
in cornrnercial baking operations. Water absorption is also a significant
concern in
cpmmercial processes including baking and extrusion. Bread typically achieves
water
absorption levels of 65% to 68%, while water absorption in cakes ranges above
30%_ A
functional fiber flax flour that can achieve similar or better water
absorption levels as
comparod to traditional flours will be desirable as increased water
absorption, while
maintaining taste and texture, allows a baked product to be produced at lower
cost.
An important requirement for flour products is that of palatability.
PaIaxability includes
factors such as taste, flavor and color. Additionally, for a flour to be
considered palatable
by ccxnsumers, it must also provide for a fuiishcd baked product with certain
characteristics of texture. Some of the desirable texture characteristics
include ease of
chewing, the graininess of the baked product, and the size and uniformity of
the air
spaces that develop in a product during the baking process.
Xrit tk~e present case, the altered functional fiber flax flour product
produced by the
described process from golden flax seed yields a flour product with properties
that make
it useful in the production of products such as baked goods, pasta, and other
processed
foods. Golden flax seed feed stcxk, as opposed to the more common brown flax
seed,
producev a light colored flour product without the taste associated with brawn
flax seed.
~elxt~azz~ary tests with the functional fiber flax seed flour product have
shown that it is
possible to replace about 25% of the wheat flour that would normally be used
in bread
with the altered fuxlctional fiber flax flour product of the invention,
without sigruiflcantly
affecti~ the taste or appearance of the finished product. In some foods it
kuzs been
possible to replace up to 40% of the wheat flour with the altered functional
fiber flax
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CA 02466411 2004-05-05
flour product, while in other foods like piaza crust, cuzxently the upper
limit appears to be
substaxitially less than 25°fo.
While golden flax seed is the preferred feedstock, it is also contemplated
that a range of
S altered functional fiber flax flour products can be obtained by using
feedstock of varying
proportions of golden and brown flax seeds. The product could be tailored in
color and
taste to suit the preferences of the end user.
The altered functional fiber flax flour product of the present invention
advaxitageously
has a higher water absorption capacity than wheat four does, and so increased
water is
used nx~ foxz~aulations when the functional fiber flax seed flour is blended
with wheat
flour. To achieve the same consistency of dough, approximately l.Wto 2 times
as much
water must be added for each part of functional fiber flax seed flour product
as would be
used far the similar amount of wheat flour. Where 25% of the wheat flour is
replaced
with flax seed flour, this would allow an additional 10-25°1°
water be added as compared
to a recipe wlxere oxaly wheat flour was used The ability to absorb more water
allows for
a greater annount of a baked product cozxtaaxuiz~g the functional fber flax
seed flour
roduct to be aced from the same amount of startin i
p prod g dry materials.
Aithough the changes arc presently undefuzed, the processing method including
high
pressure and high temperature extrusion has apparently caused changes in the
crushed
flax seed cake, such that the functional fiber flax seed flour produced from
the cake has
novel properties that permit its use a flour replacement .in baking, extrusion
and
processing without significantly affecting the taste or agpearance of the
finished products,
and without adversely affecting baking, extrusion or processing performance.
Thus, the prv;sent invention provides a stable altered fcnctional fibrr flaxx
flour product
that can be used to produce, in a conventional baking process, baked goods
vcrith the
~nutritidnal advantages of flax such as increased levels of fiber, protein,
and. increased
11
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CA 02466411 2004-05-05
li.gyan arid decreased Levels of digestible carbohydrate. lYhilc the omega-3
fatty acid
content of the product of the invention is less than that of conventional flax
flour, the
product allows the production of finished baked, extnaded, and processed
floods vuith a
significant level of barc~ncial omega-3 fatty acid. Prior art baked, extruded,
and
processed foods contained na omega-3 fatty acids.
It is anticipated that the method of the invention could be practised using
oilseeds other
than flax seed to obtain some advantage.
! 0 The functional fiber flax seed flour prnduced by the present method has
beers further
characterized. The results of these analyses show that a functional f'ber flax
seed flour
can be produced witb~ lower level of digestible carbohydrate, Itigher level of
fiber, and
In addition to the features listed above, the functional fiber flax seed flour
product
I S produced by the process of the invention contains significant amounts of
nutrients such as
calcium, copper, iron, magnesium, niacin, potassium, phosphorous, riboflavin,
thiamine
and zinc, and is relatively low in sodium.
20 DES~RII''x'XtJT~ t~lF "X'~ DRAGS:
While the invention is claimed in the concludii2g portions hereoy preferred
embodiments
are provided in the accornparlying detailed description which may be best
understood in
conianction with the accalnpanying diagrams where like parts in each of the
se~reral
25 diagrams are labeled with like numbers, and where:
k'i,g. 1 is a flowchart representation of the method of the invention of
producixag a
stable oilseed functional fiber flt~urproduct_
12
CA 02466411 2004-05-05
A Stable Altered functional fiber flax flour product with 1'~Tovel Properties
ThE functional fiber flax flour product composition of the invention comprises
a dietary
fiber component comprising: a) soluble fiber, b) insoluble fiber, c} prebiotic
agent, and d)
lignans. The functional fiber flax flour product coiociposition also comprises
a
carbohydrate component, which includes the dietary fiber material. The
functional lhber
flax flour product composition further comprises a fat component comprising:
a) poly-
unsaturated fatty acids, b) omega-3 fatty acids, c) omega-fi fatty acids, and
d) saturated
fatty acids, and iv) lignan precursors.
The fiber component generally comprises more than 3D% by weight and comprises:
a)
soluble ~.ber, b) insoluble fiber, c) prebiotic agent, and d) ligmans. The
soluble fiber
component generally comprises one-third of the fiber component and the
majority of
which is mucilage gum. The soluble fiber component generally further comprises
a pre-
biotic agent. The insoluble fiber component genez~ally comprises two-thirds of
the fiber
component and is primarily composed of non-starch polysaccharides - cellulose
and
lignans. The ratio of soluble to insoluble dietary fiber is geanerally about
1:2 to i:3. The
i
average particle size of the dietary fiber is less than about 250 microns, and
can be less
than 25 microns.
In the ftmctYOnaI fiber flax flour product compasition of the invention the
protein
component gerlcrally comprises more than 3~J% by weight and has a composition
sixz~.ilar
to that of soy protein, and is gluten free.
In the functional fibex flax flour product composition. of the i~aventxoz~ the
fat component
generally comprises less than 15% by weight, and campri.ses: i}
polyunsaturated fats: a)
omega-3 fatty acids, b) omega-6 fatty acids, ii) manaunsaturated fats; and
iii) saturated
fats. The polyunsaturated fats generally comprise more than 7.5% by weight and
include
omega-~ fatty acid - alpha-Iinolenic acid (alL,.A), and omega-6 fatty acid -
linolenic acid.
13
CA 02466411 2004-05-05
The monotussaturated fats generally eaLnprise maze than 1 fo by weight, and
comprise
linoleic acid. The saturated. fats generally comprise less than 2°!o by
weight, aztd
carnprisc oleic acid. The ratio of omega.3 to omega-6 fatty acids is generally
about 3:1
to 4:1.
In the functional fiber flax flour product composition of the itxvention a
lignan precursor
component generally comprises more than I.5°t° by weight, and
the lignan component
generally comprises the Iignart precursor secoisolariciresiz~ol diE;lycoside
(SL7G).
In the functional fiber flax flour product composition of the invention the
carbohydrate
component is generally one of digestible carbohydrate material, non-digestibEe
carbohydrate material, or mixtures thereof, and the non-digestible
earbohycliatE material
is one of dietary fiber, non-absorbent carbohydrate material, or mixtures
thereof.
The functional her flax flour product composition of the az~vezztiaz~
generally has a water
absorption value of ?00% or higher as deternaitxed by the farinograph method,
AACC
Method 54-21A, and a viscosity of 6U0 centipoise or more, as determined on a
IS%
solution with a l3rookheId® viscometer at 25 ° C and a shear rate
of 10 scc-1.
The composition can be mixed with ac~cal flours in various combinations along
with
water, $alt, fat, and yeast to rrcake a bread dough which may be baked into a
bread, pizza,
car facaccia product generally having less than 7.t? grazrxs of digestible
carbohydrate per
28.35 gtu serving, and as low as less than 3.U grams of digestible
carbohydrate per 28.35
gm serving. The hread, piaza, or faeaccia product generally has the cell
srn~.cture and
?5 prganaleptic properties comparable to conventional bread, pizza, or
focaceia, comprising,
per 28.35 gm of bread, pizza, or focaccia product: a) at least 5 grn protein;
b) about 7.0
gm and less of digestible carbohydrate; c) up to I.fi gm of omega-3 fatty
acids and the
bread, pir.T,a, or focaccia ha:, a water activity (aW) of more than about
11.80 and Iess than
about 0.95.
i
' 14
i
CA 02466411 2004-05-05
Tfze composition can be mixed wits, cereal flours in. various
cozxzbi.zaati.ans along witlB egg,
water, salt, fat, and baking powder to make a batter which may he baked into a
cake,
muffin, pancake, waffle or crepe product generally l~avang less than 7.0 grams
of
digestible carbohydrate per 28.35 gm serving, and as low as less than 3.0
grams of
digestible carbohydrate per 28.35 #~cn serving. The cake, muffin, pancalte,
waffle or
crepe product generally has the cell structure and organoleptic properties
comparable to
conventional cake, nawffin, pancake, waffle or crepe, zespectively,
comprising, per 2$.35
gm of said cake, znufFn. pancake, waffle or crepe product: a) at least 5 gna
protein; b)
1 U about 7.0 ,gm and less of digestible carbohydrate; a) up to 1.5 gvn of
omega-3 fatty acids;
and the cake, muffin, pancake, waffle ar crepe has a water activity (aW) of
more than
about 0.$0 and less than about 0.95.
The composition can also be mixed with cereal flours ixz various combinations
along with
IS water, salt, fat, and yeast to make a pliable dough which zzzay be boiled
and baked into a
bagel or bialy product generally having less than ?.0 grams of digestible
carbohydrate per
2$.35 gtn serving, and as low as less than 3.0 grams of digestible
carbohydrate per 2$.35
grn serving. The bagel or bialy product generally has the cell structure and
organoleptic
properties comparable to conventional bread, comprising, per 28.35 g7.n of
bagel or bialy
20 product: a) at least 5 gm protein; b) about 7.0 gn and less of digestible
carbohydrate; c)
up to 1.6 gm of omega.-3 fatty acids; and the bagel or bialy has a water
activity (aw) of
mere than about 4.80 and less than about 0.95.
The composition can be mixed with cereal flours in various combinations along
with
25 water, egg, vegetable powders, and fat to make a mixture which may be
extruded and
dried to form a stable pasta or noodle product generally having less than 7.0
grams of
diSestible carbohydrate per 28.35 gm serving, and as low as less than 3.0
grates of
digestible carbohydrate per 28.35 gm serving. The pasta or noodle product
generally has
the cell structure and organoleptic properi:ies comparable to conventional
pasta ar noodle,
CA 02466411 2004-05-05
comprising, per 25.35 grrl of pasta or noodle product: aj at least S gtn
protein; b) about
7.0 gn2 and less of digestible carbohydrate; c) up to I.6 ~n of omega-3 fatty
acids; and
the pasta or noadlc has a water activity (aw) of more than about 0.80 and less
than about
0.95.
Production of ~t Stable .AlCered fut~ctidnal fiber flax flour produ4-t with
Novel
Prpperties
Fig. I provides a flowchart illustration of the steps comprisit2g the process
of the
invention. The individual steps are as follows.
Step 1 -Flax Feedstoc_l~: Light colored or golden flax seed from storage bins
is weighed,
and then fed via a rate controlled auger into a seed conditionr~. If the flax
seed has
1 S moisture content greater than I O°I° it is first dried in a
conventional heated-air seed dryer.
A control mechanism regulates the speed of the auger, such that a continuous
flow
process is achieved.
i
Step ~ - Conditioning: The flax seed feedstack is then passed throw a seed
cQnditipner
where the rnaisturE content is reduced to approximately 8% by stirring and
heating the
flax seed to about 3S - SO°C. Such seed conditioners are known in the
oilseed processing
art.
Step 3 - First Pressin tea expel a first portion of oil:
2S
Typically flax seed has oiI content of about 40°I°. After
conditionins, the flax seed is
pressed in a first expeller press, as is known in the art, to remove a first
portion of rail
from the flax seed. The oil is collected for conventional use, and the initial
flax cake
exiting the fiizst expeller press has oil content of about 1 G -18% by weight.
The pressure
16
CA 02466411 2004-05-05
and friciiozz of the first expeller presser raises tk~e ternperatuse of the
initial flax cake to
about GO°C.
Conventional flax flour or meal is typically made by grinding this initial
flax cake into
flour, however further steps are required to produce the altered functional
flbcr flax flour
product of the invention,
Step 4 - Extruding:
The initial flax cake exiting the first expeller gress is then passed through
an extruder to
produce pellets. xt~e extruder used by the present inventor is an- Insta
pModel
2000RC Extruder manufactured by insta-Prod International, a division of Tniple
"F", Imo,
of Des Moines, Iovsra, U.S.A. The manufacl~r advertises that the extruder is
capable of
cooking, expanding, sterilizing, dehydrating and texturizing a wide range of
products,
t5 and states that by creating heat thmugh friction, the lLusta-Pro dry
extrusion process
allows for high heat, shoat-coolE tizn$ producing high quality fend and food.
The Insta-Frog Model 20a0RC Extruder is a rotathlg screw t~r-pe extruder with
a 5%a inch
screw rotating in a 5 5116 inch barrel. The Model 2000RC Extruder can raise
the
temperature of the product being extruded to well over 200 ° C. The
screw rotates at
about 615 rpm. The cake leaves the extruder through the exit orihcc as an
altered flax
cake in the form of pellets.
The temperature of the initial flax cake may fall somewhat when movin;~ from
the first
2~ cxpcllcr press to the extruder, but the screw extruder raises the
temperature of the flays
cake in the extruder to about IOU°C. No oil is removed during the
extrusion step,
however it appears that same structural changes take place in the flax cake
during this
step that beneficially alter the properties of the flax cake. It appears Chat
extrusit~n
fracttu~es the ail cells, alters the strr~cture of the fiber, or induces some
sirailar alterations
17
CA 02466411 2004-05-05
in the cake. In any event; the product produced from the extruded sc;ed cake
has a longer
shelf life than conventional flax flour, and exhibits improved baking
perforntance.
While the above described lnsta-Frog M~el 2000RC Extntder has been used to
carry out
the process, it is contemplated other extnzders could as vsiell be utilized to
carry out the
extruding step. xt is also contemplated extruding such that the temperature of
the flax
cake in the extruder is raised to between 80 and 134 ° C could ysrovide
satisfactory results.
Ste~S - Second fL'e55ir~~to ex~?el a second portion of o 1:
1Q
The flax cake pelIe~ are then passed through a second expeller press, where a
second
portion of oil is expelled. The oil content oftt~e ~tzial altered flax cake
exiting the second
expeller press is about 10% by weight 1t is cox<templated that further
pressing, or
pzsessizxg under higher pressures could reduce the oil content of the final
altered flax cake
t 5 to about ~% or less.
Stcn 6 - Milline_
i
'The anal altered flax cake can then be micronized with infrared ovens or the
like, as is
2Q laaown in the art The high temperatures of the extrusion process however
kills
substantially all bacteria and the like, so for many applications
micronization may not be
required. Similarly other prior art operations such as providing a 104%
nitrogen
atmosphere during expelling or like operations to reduce oxidation could also
be
incorporated.
Iu any event, whether micranized or not, the final altered flax cake is then
milled
conventionally into the altered flax ffaur product of the invention. for most
applications,
the finished functional h'ber flax seed flour product will be rr~illed so that
at least 90% of
the altered fimctionat fiber flax flour product passes thxough a USA mesh size
of 2Q.
18
CA 02466411 2004-05-05
~eSLlltS
It appears that the cozubination of high pressure and high temperature in the
extrusion
S process is effective to produce c.Exaz~es iz~ the resulting flax seed cake.
While the precise
chemical and structural changes that occur during processing are not fully
understood, it
is clear that the process results in modification of the functionality of the
fiber and
perhaps of other constituents. These modifications result in an altered
functional fiber
flax seed flour product with z~ovet properties that are amenable for use as a
substitute for
wheat and other cereal-derived flours in baked goods and other processed food
products,
and tbat has a snba~tantialIy larger shelf life stability than prior art
milled flax flours. As
a result, an altered functional fiber flax flour product can be produced which
reins tlxe
nutritional benefits of flax seed, while acquiring novel properties that
peTTt~at the
funetioxial fiber flax seed flour so produced m be useful in baking
operations, or for use
in other flour-eontaizzi~ng processed food products including pasta and
cerealt~. Flax seed
meal or flour produced by prior art cnishing methods do not have the necessary
properties required to function as an adequate substitute for traditional
cereal-derived
flours, and do not allow the nutritional benefits of flax seed to be readily
enjoyed in
common foods.
It is expected that the reduced levels of omega-3 fatty acids in the altered
functional fiber
flax flour product of tile pz~esent invention result from more cornpIete
extraction of the oiI
from the flax seed, as cozxxpared to a tz-aditional.ly milled flax seed meal
or flour (Table 1).
In addition, it is thought that the enhancement of the lignan content of the
finished
product contributes to tl~e stability o.f tk~e pzoduct, as lignans are well
known as
antioxidants. An advantage lxere is that no artificial additives are necessary
to produce a
stable prnduct with the desired functional characteristics, atad sa the
praduet is capable of
desilmation as an "organic" food product, increasing tlxe value of the
fux~ctionaJ fiber fa.ax
flour so produced.
I9
,. .,m . ~"..-~ ,~x~c....~" . ~... _ ... _ _ _.. , . .,._, ~~, ,, ._ . . .~_.
.~~~~~, .-,~...~...._ ... . . ..~..m.~._ m ..
CA 02466411 2004-05-05
The foregoing is considered as illustrative orsly of the p~rineiples of the
invention.
Further, since numerous changes and modifications wil! readily occccr to those
skilled in
the art, it is not desired to limit the invention to the exact construction
a~td operation
shown and descn-bed, and accordingly, alI such suitable changes or
modifications in
structure or operation which rna,y be resorted to are iaxtended to fall within
the scope of
the claimed invention.
